HP LaserJet 5200/5200L Series Printers Service Manual

HP LaserJet 5200/5200L Series printers
Service Manual
HP LaserJet 5200 Series printers
Service Manual
Copyright and license
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© 2006 Copyright Hewlett-Packard
Development Company, L.P.
Microsoft®, Windows®, and Windows NT®
are U.S. registered trademarks of Microsoft
Corporation.
Reproduction, adaptation, or translation
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except as allowed under the copyright laws.
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The information contained herein is subject
to change without notice.
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Systems Incorporated.
The only warranties for HP products and
services are set forth in the express warranty
statements accompanying such products
and services. Nothing herein should be
construed as constituting an additional
warranty. HP shall not be liable for technical
or editorial errors or omissions contained
herein.
UNIX® is a registered trademark of The
Open Group.
Edition 1, 3/2006
Part number Q7543-90934
Energy Star® and the Energy Star® logo are
U.S. registered marks of the United States
Environmental Protection Agency.
Table of contents
1 Product information
Quick access to printer information ...................................................................................................... 2
Printers at a glance .............................................................................................................................. 3
HP LaserJet 5200 Series printers ........................................................................................ 3
Features at a glance ............................................................................................................................. 4
Walkaround .......................................................................................................................................... 6
Control-panel overview ......................................................................................................................... 8
Printer software .................................................................................................................................. 10
Printer drivers .................................................................................................................... 10
Driver Autoconfiguration .................................................................................... 10
Update Now ...................................................................................................... 11
HP Driver Preconfiguration ............................................................................... 11
Additional drivers ............................................................................................................... 11
Opening the printer drivers ................................................................................................ 12
Software for Macintosh computers .................................................................................... 12
Installing Macintosh printing system software for networks .............................. 13
Installing Macintosh printing system software for direct connections
(USB) ................................................................................................................ 13
To remove software from Macintosh operating systems ................................... 14
Software for networks ........................................................................................................ 14
HP Web Jetadmin ............................................................................................. 14
UNIX .................................................................................................................. 14
Linux .................................................................................................................. 15
Utilities ............................................................................................................................... 15
HP Easy Printer Care Software ......................................................................... 15
Embedded Web server ..................................................................................... 15
Other components and utilities .......................................................................... 15
Selecting print media .......................................................................................................................... 16
Supported media sizes ...................................................................................................... 16
Supported media types ...................................................................................................... 18
2 Installation and configuration
What is in the box ............................................................................................................................... 20
Identification ....................................................................................................................................... 21
Model and serial numbers ................................................................................................. 21
Site requirements ............................................................................................................................... 22
Physical specifications ....................................................................................................... 22
Space requirements ........................................................................................................... 22
Input/Output (I/O) configuration .......................................................................................................... 23
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Parallel configuration ......................................................................................................... 23
USB configuration .............................................................................................................. 23
Connecting the USB cable ................................................................................ 23
Network configuration ........................................................................................................ 24
Manually configuring TCP/IP parameters from the control panel ...................... 24
Setting an IP address ....................................................................... 24
Setting the subnet mask ................................................................... 25
Setting the default gateway .............................................................. 25
Disabling network protocols (optional) .............................................................. 26
To enable or disable IPX/SPX .......................................................... 26
To enable or disable AppleTalk ........................................................ 26
To disable DLC/LLC ......................................................................... 27
Enhanced I/O (EIO) configuration ..................................................................... 27
HP Jetdirect EIO print servers .......................................................... 27
Connecting to a network or a computer ............................................................................. 27
Installing printer memory .................................................................................................................... 30
To install printer memory ................................................................................................... 30
Checking DIMM installation ............................................................................................... 34
Installing CompactFlash cards ........................................................................................................... 35
Checking CompactFlash installation .................................................................................................. 39
Enabling memory (Windows only) ...................................................................................................... 40
3 Maintenance
Managing supplies ............................................................................................................................. 42
Approximate print-cartridge replacement intervals ............................................................ 42
Managing the print cartridge .............................................................................................. 42
Print-cartridge life expectancy ........................................................................... 42
Print-cartridge storage ....................................................................................... 42
HP print cartridges ............................................................................................ 42
HP policy on non-HP print cartridges ................................................................ 42
Print-cartridge authentication ............................................................................ 43
HP fraud hotline and Web site .......................................................................... 43
Checking supply levels ...................................................................................................... 43
To check supplies by using the control panel ................................................... 43
To check supplies by using HP Web Jetadmin ................................................. 43
To check supplies using the embedded Web server ........................................ 43
Replacing supplies and parts ............................................................................................................. 44
Supply replacement guidelines .......................................................................................... 44
Life expectancy of consumable parts ................................................................................ 44
Changing the print cartridge .............................................................................................. 44
To change the print cartridge ............................................................................ 45
Cleaning the printer ............................................................................................................................ 48
Cleaning the printer manually ............................................................................................ 49
Cleaning the paper path using the printer control panel .................................................... 49
Cleaning spilled toner ........................................................................................................ 50
Vacuum specifications ...................................................................................... 50
4 Theory of operation
Engine control system ........................................................................................................................ 52
Power-on sequence ........................................................................................................... 53
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Motors, fans, and solenoids ............................................................................................... 53
Laser/scanner system ........................................................................................................................ 55
Pickup-and-feed-system ..................................................................................................................... 56
Cassette (tray 2) pickup mechanism ................................................................................. 57
Multipurpose-tray (tray 1) pickup mechanism .................................................................... 58
Jam detection .................................................................................................................... 58
Image-formation system ..................................................................................................................... 59
Image-formation process ................................................................................................... 60
Latent-image formation block ............................................................................................ 60
Step 1: primary charging ................................................................................... 60
Step 2: laser-beam exposure ............................................................................ 61
Development block ............................................................................................................ 61
Step 3: developing ............................................................................................ 61
Transfer block .................................................................................................................... 61
Step 4: image transfer ....................................................................................... 61
Step 5: separation from the drum ...................................................................... 62
Fixing block ........................................................................................................................ 62
Step 6: fusing .................................................................................................... 62
Drum-cleaning block .......................................................................................................... 62
Step 7: drum cleaning ....................................................................................... 62
Print cartridge .................................................................................................................... 63
Print-cartridge activation .................................................................................................... 63
5 Removal and replacement
Removal and replacement strategy .................................................................................................... 66
Introduction ........................................................................................................................ 66
Required tools .................................................................................................................... 66
Types of screws ................................................................................................................. 67
Service approach ............................................................................................................... 67
Before performing service .................................................................................................. 68
After performing service ..................................................................................................... 68
Parts removal order ........................................................................................................... 68
Customer self-repair parts .................................................................................................................. 70
Tray 1 pickup roller ............................................................................................................ 70
Tray 2 pickup roller ............................................................................................................ 72
Tray 2 separation pad ........................................................................................................ 73
Tray 3 retard roller ............................................................................................................. 74
Tray 3 pickup and feed rollers ........................................................................................... 75
Formatter ........................................................................................................................... 76
CompactFlash cards .......................................................................................................... 77
DIMMs ............................................................................................................................... 80
Control-panel overlay ......................................................................................................... 84
Duplexer ............................................................................................................................ 84
External doors, covers, and panels .................................................................................................... 86
Right cover ......................................................................................................................... 86
Lower back cover ............................................................................................................... 86
Face-up bin ........................................................................................................................ 87
Top cover ........................................................................................................................... 89
Left cover ........................................................................................................................... 92
Left front cover ................................................................................................................... 94
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Face-down cover ............................................................................................................... 95
Tray 2 ................................................................................................................................. 96
Right front cover ................................................................................................................ 96
Right lower cover ............................................................................................................... 97
DC controller cover .......................................................................................................... 100
Cartridge door unit ........................................................................................................... 100
Control panel ................................................................................................................... 108
Internal assemblies .......................................................................................................................... 110
Laser/scanner .................................................................................................................. 110
Formatter ......................................................................................................................... 111
Fuser ................................................................................................................................ 112
Cassette-paper pickup unit .............................................................................................. 113
Face-down delivery unit ................................................................................................... 118
Main motor ....................................................................................................................... 120
Fuser motor ..................................................................................................................... 125
Main fan ........................................................................................................................... 126
Sub fan ............................................................................................................................ 129
Registration unit ............................................................................................................... 134
Transfer roller .................................................................................................................. 135
Paper-feed unit ................................................................................................................ 136
Printed circuit assemblies (PCAs) .................................................................................................... 139
DC controller .................................................................................................................... 139
High-voltage power supply .............................................................................................. 142
Low-voltage power supply PCA ....................................................................................... 151
Duplexer ........................................................................................................................................... 155
Duplexer .......................................................................................................................... 155
Duplexer left cover ........................................................................................................... 156
Duplexer right cover ......................................................................................................... 157
Duplexer top cover ........................................................................................................... 158
Duplexer back cover ........................................................................................................ 159
Duplexer feed motor ........................................................................................................ 161
Duplexer fan .................................................................................................................... 164
Duplexer PCA .................................................................................................................. 167
500-sheet feeder .............................................................................................................................. 169
500-sheet feeder front cover ............................................................................................ 169
500-sheet feeder left front cover ...................................................................................... 170
500-sheet feeder left cover .............................................................................................. 170
500-sheet feeder right front cover .................................................................................... 172
500-sheet feeder right cover ............................................................................................ 173
500-sheet feeder rear dust cover ..................................................................................... 175
500-sheet feeder paper-pickup unit ................................................................................. 176
500-sheet feeder lifter drive unit ...................................................................................... 180
500-sheet feeder drive unit .............................................................................................. 182
500-sheet feeder drive PCA ............................................................................................ 186
500-sheet feeder pickup motor ........................................................................................ 186
6 Troubleshooting
Introduction ....................................................................................................................................... 191
Basic troubleshooting checklist ........................................................................................................ 192
Factors that affect printer performance ............................................................................ 192
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Troubleshooting flowchart ................................................................................................................ 193
Step 1: Does READY appear on the control-panel display? ........................................... 193
Step 2: Can you print a configuration page? ................................................................... 193
Step 3: Can you print from a program? .......................................................................... 194
Step 4: Does the job print as expected? .......................................................................... 195
Step 5: Does the printer select the trays? ........................................................................ 196
Solving general printing problems .................................................................................................... 198
Control-panel message types ........................................................................................................... 201
Control-panel messages .................................................................................................................. 202
Replacement-parts configuration ..................................................................................................... 220
Formatter and DC controller ............................................................................................ 220
Formatter (new) ............................................................................................................... 220
DC controller (new or previously installed in another printer) .......................................... 220
Formatter ......................................................................................................................... 220
Guidelines for using paper ............................................................................................................... 221
Printing special pages ...................................................................................................................... 222
Data collection .................................................................................................................................. 223
General paper-path troubleshooting ................................................................................................. 224
Paper-path checklist ........................................................................................................ 224
Jams in tray 1 .................................................................................................................. 225
Jams in tray 2 or the optional 500-sheet feeder .............................................................. 225
Common causes of jams .................................................................................................................. 226
Jam locations ................................................................................................................................... 227
Jam recovery ................................................................................................................... 229
Clearing jams ................................................................................................................................... 230
Clearing jams from the input-tray areas ........................................................................... 230
Clearing jams from the print-cartridge area ..................................................................... 231
Clearing jams from the output-bin areas .......................................................................... 233
Clearing jams from the optional duplexer ........................................................................ 235
Solving repeated jams ..................................................................................................... 236
Troubleshooting print-quality problems ............................................................................................ 238
Print-quality problems associated with media .................................................................. 238
Print-quality problems associated with the environment .................................................. 238
Print-quality problems associated with jams .................................................................... 238
Image-defect examples ................................................................................................... 238
Light print (partial page) .................................................................................................. 240
Light print (entire page) .................................................................................................... 240
Specks ............................................................................................................................. 241
Dropouts .......................................................................................................................... 241
Lines ................................................................................................................................ 242
Gray background ............................................................................................................. 242
Toner smear .................................................................................................................... 243
Loose toner ...................................................................................................................... 243
Repeating defects ............................................................................................................ 244
Repeating image .............................................................................................................. 244
Misformed characters ...................................................................................................... 244
Page skew ....................................................................................................................... 245
Curl or wave ..................................................................................................................... 245
Wrinkles or creases ........................................................................................................ 246
Vertical white lines ........................................................................................................... 246
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Tire tracks ........................................................................................................................ 247
White spots on black ....................................................................................................... 247
Scattered lines ................................................................................................................. 247
Blurred print ..................................................................................................................... 248
Random image repetition ................................................................................................ 248
Interface troubleshooting .................................................................................................................. 250
Communication checks .................................................................................................... 250
AUTOEXEC.BAT standard configurations ....................................................................... 250
Parallel MS-DOS commands .......................................................................... 250
Printer Job Language (PJL) commands .......................................................................... 250
@PJL [Enter] ................................................................................................... 250
UEL ................................................................................................................. 251
@PJL COMMENT ........................................................................................... 251
@PJL INFO CONFIG ...................................................................................... 251
@PJL INFO ID ................................................................................................ 251
@PJL INFO USTATUS ................................................................................... 251
@PJL INFO PAGECOUNT ............................................................................. 251
@PJL JOB ...................................................................................................... 251
@PJL EOJ ...................................................................................................... 252
@PJL ECHO ................................................................................................... 252
@PJL USTATUS JOB=ON/OFF ..................................................................... 252
@PJL USTATUSOFF ..................................................................................... 252
Changing printer-control-panel configuration settings ...................................................................... 253
Changing control-panel settings ...................................................................................... 253
To change a control-panel setting ................................................................... 253
Show address .................................................................................................................. 253
Tray-behavior options ...................................................................................................... 254
Sleep Delay ..................................................................................................................... 255
Personality ....................................................................................................................... 256
Clearable warnings .......................................................................................................... 256
Auto continue ................................................................................................................... 257
Cartridge low .................................................................................................................... 257
Cartridge-out response .................................................................................................... 257
Jam recovery ................................................................................................................... 258
RAM disk ......................................................................................................................... 258
Language ......................................................................................................................... 259
Fuser modes .................................................................................................................... 259
Using the control-panel menus ......................................................................................................... 261
To use the menus ............................................................................................................ 261
Show Me How menu ........................................................................................................................ 262
Retrieve Job menu .......................................................................................................................... 263
Information menu ............................................................................................................................. 264
Paper Handling menu ....................................................................................................................... 265
Configure Device menu .................................................................................................................... 266
Printing submenu ............................................................................................................. 266
Print Quality submenu ..................................................................................................... 268
System Setup submenu ................................................................................................... 271
I/O submenu .................................................................................................................... 275
Resets submenu .............................................................................................................. 276
Diagnostics menu ............................................................................................................................. 277
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Service menu ................................................................................................................................... 278
Tools for troubleshooting .................................................................................................................. 279
Using the configuration page ........................................................................................... 279
Using the embedded Web server .................................................................................... 280
Accessing the embedded Web server ............................................................ 281
Information tab ................................................................................................ 281
Settings tab ..................................................................................................... 281
Setting the real-time clock ............................................................................... 282
Networking tabs .............................................................................................. 282
Other links ....................................................................................................... 282
Configuration pages ......................................................................................................... 283
Configuration page .......................................................................................... 283
HP embedded Jetdirect page .......................................................................... 283
Paper-handling configuration page ................................................................. 284
Finding important information on the configuration page ................................ 284
Print the supplies status page .......................................................................................... 285
Print the usage page ........................................................................................................ 286
Print the file directory page .............................................................................................. 288
Print the PCL font list page .............................................................................................. 289
Print the PS font list page ................................................................................................ 290
Diagnostics ....................................................................................................................................... 291
Embedded HP Jetdirect LEDs ......................................................................................... 291
Heartbeat LED ................................................................................................................. 292
Printer resets .................................................................................................................................... 293
Cold reset ........................................................................................................................ 293
To perform a cold reset ................................................................................... 293
NVRAM initialization ........................................................................................................ 293
To initialize NVRAM ........................................................................................ 294
Perform the self test ......................................................................................................... 294
Save + Restore ................................................................................................................ 294
Replacing the formatter and the DC controller ................................................ 295
Replacing the formatter only ........................................................................... 295
Replacing the DC controller only ..................................................................... 296
Service menu (service PIN codes) .................................................................................. 296
Service ID ........................................................................................................ 297
Restoring the Service ID ................................................................................. 297
Converting the Service ID to an actual date .................................................... 297
Test pages ........................................................................................................................................ 298
Engine-test page .............................................................................................................. 298
Formatter-test page ......................................................................................................... 298
Troubleshooting network printing problems ..................................................................................... 299
Troubleshooting common Windows problems ................................................................................ 300
Troubleshooting common Macintosh problems ................................................................................ 301
Troubleshooting Linux problems ...................................................................................................... 303
Troubleshooting common PostScript problems ................................................................................ 304
General problems ............................................................................................................ 304
7 Parts and diagrams
Parts ................................................................................................................................................. 310
How to use the parts lists and diagrams .......................................................................................... 311
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Types of screws ............................................................................................................................... 311
Related documentation and software ............................................................................................... 312
Accessories and supplies ................................................................................................................. 312
External panels and covers .............................................................................................................. 316
Internal components ......................................................................................................................... 320
Paper-feed assembly ....................................................................................................................... 326
Face-up delivery assembly ............................................................................................................... 328
Face-down delivery assembly .......................................................................................................... 330
PCAs ................................................................................................................................................ 332
Fuser ................................................................................................................................................ 334
Cassette (tray 2) ............................................................................................................................... 336
Cassette (tray 2) paper-pickup assembly ......................................................................................... 338
500-sheet feeder cassette (tray 3) ................................................................................................... 340
500-sheet feeder, cassette, external panels and covers .................................................................. 342
500-sheet feeder internal components ............................................................................................. 344
500-sheet feeder paper-pickup assembly ........................................................................................ 346
500-sheet feeder drive assembly ..................................................................................................... 348
500-sheet feeder lifter-drive assembly ............................................................................................. 350
500-sheet feeder PCA ...................................................................................................................... 352
Duplexer ........................................................................................................................................... 354
Duplexing PCA assembly ................................................................................................................. 358
Duplexing-feed drive assembly ........................................................................................................ 360
Alphabetical parts list ....................................................................................................................... 362
Numerical parts list ........................................................................................................................... 369
Appendix A Printer specifications
Electrical specifications .................................................................................................................... 378
Power-consumption specifications ................................................................................................... 379
Acoustic specifications ..................................................................................................................... 380
Operating-environment specifications .............................................................................................. 381
Appendix B Product warranty
Hewlett-Packard Limited Warranty Statement ................................................................................. 384
Availability of support and service .................................................................................................... 385
HP maintenance agreements ........................................................................................................... 386
Next-Day Onsite Service ................................................................................................. 386
Appendix C Regulatory statements
FCC regulations ............................................................................................................................... 388
Declaration of conformity .................................................................................................................. 389
Safety statements ............................................................................................................................. 390
Laser safety ..................................................................................................................... 390
Canadian DOC regulations .............................................................................................. 390
EMI statement (Korea) ..................................................................................................... 390
VCCI statement (Japan) .................................................................................................. 390
Power cord statement (Japan) ......................................................................................... 390
Laser statement for Finland ............................................................................................. 391
Index ................................................................................................................................................................. 393
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