HP 5100 Service Manual
HP 5100 - LaserJet B/W Laser Printer Manual
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HP 5100 manual content summary:
- HP 5100 | Service Manual - Page 1
service hp LaserJet 5100 5100tn 5100dtn 5100Le - HP 5100 | Service Manual - Page 2
- HP 5100 | Service Manual - Page 3
hp LaserJet 5100 series printers service - HP 5100 | Service Manual - Page 4
both 32 and 64-bit configurations) on all HP 9000 computers are Open Group UNIX 95 branded products. Microsoft, Windows®, MS-DOS, and Windows NT, are U.S. registered trademarks of Microsoft Corporation. TrueType™ is a U.S. trademark of Apple Computer, Inc. UNIX® is a registered trademark of The Open - HP 5100 | Service Manual - Page 5
32 Laser statement for Finland 33 Luokan 1 laserlaite 33 Material Safety Data Sheet 33 Environmental product stewardship 34 2 Service approach Regulatory information 36 Service approach 36 Parts and supplies 36 Warranty 36 Limited warranty for the print cartridge 36 Service and support 37 - HP 5100 | Service Manual - Page 6
menu 47 Paper-handling menu 48 Print-quality menu 50 Printing menu 51 Configuration menu 53 I/O menu 55 EIO menu (HP LaserJet 5100tn and 5100dtn printers 56 Resets menu 58 Service mode 59 Service menu 59 Setting the page count, maintenance count, and serial number 60 Cold reset paper size - HP 5100 | Service Manual - Page 7
78 Resolution Enhancement technology 78 EconoMode 79 Input/output 79 CPU 79 Printer memory 80 Memory Enhancement technology 80 Page protect 81 PJL 81 PML 81 Control panel 81 Image-formation system 82 Toner cartridge 83 Photosensitive drum 84 Writing the image 86 Developing the image - HP 5100 | Service Manual - Page 8
memory installation 109 Installing EIO cards or mass-storage devices 110 Paper-handling accessories 110 Before you begin 111 Replacing printer parts 111 Removing loose toner 111 Required tools 111 Parts removal order 112 Covers 113 Rear door and rear output bin 113 Fuser Paper guide 155 - HP 5100 | Service Manual - Page 9
Power on 188 Engine test 190 Display 190 Event log 191 Printer messages 193 General paper-path troubleshooting 202 Information pages 204 Image quality 207 Image system troubleshooting 224 Interface troubleshooting 225 Reference diagrams 227 Locations of components 227 Sensors and signals - HP 5100 | Service Manual - Page 10
8 Q1860-90918 - HP 5100 | Service Manual - Page 11
49. Figure 50. Figure 51. Figure 52. Sample identification labels 19 Printer dimensions-HP LaserJet 5100 printer and HP LaserJet 5100Le printer . . . . 21 Printer dimensions-HP LaserJet 5100tn printer and HP LaserJet 5100dtn printer . . 22 Printer dimensions, HP LaserJet 5100 series printer with - HP 5100 | Service Manual - Page 12
printer 125 Figure 54. Corner covers removal 126 Figure 55. Internal assemblies 127 Figure 56. Transfer-roller assembly removal (1 of 3 128 Figure 57 Laser/scanner assembly removal (top, inside view of printer 164 Figure 98. Main motor removal (rear view 165 Figure 99. Toner cartridge guide - HP 5100 | Service Manual - Page 13
page 205 Figure 126. Repetitive defect ruler 223 Figure 127. Jetdirect configuration page 226 Figure 128. Paper path (sensors and switches 227 Printer switches 240 Figure 144. 250-sheet feeder switches 240 Figure 145. 500-sheet feeder switches 241 Figure 146. Motors, fans, and fuser - HP 5100 | Service Manual - Page 14
277 Figure 174. Main gear assembly 278 Figure 175. Pickup gear assembly 279 Figure 176. PCA assembly locations 280 Figure 177. Printer controller assembly 281 Figure 178. Fuser 282 Figure 179. 250-sheet feeder 283 Figure 180. PCA assembly locations, 250-sheet feeder 284 Figure 181. 500-sheet - HP 5100 | Service Manual - Page 15
48. Table 49. Table 50. Table 51. Table 52. Printer features 16 Comparison of HP LaserJet 5100 Series printers 18 Power requirements 20 Gray background 218 Loose toner or toner smear 219 Repetitive defects 220 Skew 220 Smudged lines (either direction 221 Toner specks 221 White lines - HP 5100 | Service Manual - Page 16
Jetdirect configuration page categories 225 Sensors, switches, clutches, and solenoids 237 Motors, fans, and fuser heaters 243 PCAs 248 Clutches and solenoids 250 Paper-size detection 251 Technical support websites 259 Accessories and supplies 260 Screws used in the printer 261 Replaceable - HP 5100 | Service Manual - Page 17
Site requirements 20 Space requirements 21 Paper specifications 25 Supported types of paper 26 Guidelines for using paper 27 Labels 29 Transparencies 29 Vellum 29 Envelopes 29 Card stock and heavy paper 31 Safety information 32 Laser safety statement 32 Canadian DOC regulations 32 FCC - HP 5100 | Service Manual - Page 18
(PCL) fonts, 80 internal PostScript® fonts Processor 300 MHz Memory options HP LaserJet 5100 printer and HP LaserJet 5100 Le printer: 16 MB, expandable to 192 MB through three industry-standard dual inline memory module (DIMM) slots HP LaserJet 5100tn printer and HP LaserJet 5100dtn printer - HP 5100 | Service Manual - Page 19
inches (279 by 432 mm). HP LaserJet 5100tn printer The HP LaserJet 5100tn printer (product number: Q1861A) is a 22 ppm laser printer that comes standard with a 100-sheet multipurpose Tray 1, a 250-sheet Tray 2, a 500-sheet feeder, 32 MB of memory, and an HP Jetdirect print server for connecting to - HP 5100 | Service Manual - Page 20
Table 2. Comparison of HP LaserJet 5100 Series printers HP LaserJet 5100 (Q1860A) HP LaserJet 5100tn (Q1861A) Ethernet 10-T/ 10-2 optional standard Input bins (standard/ optional optional Processor 300 MHz 300 MHz HP LaserJet 5100dtn HP LaserJet 5100 LE (Q1862A) (Q1863A) standard not - HP 5100 | Service Manual - Page 21
number is alphanumeric, such as USB0000146 for the HP LaserJet 5100 series printer. The serial number contains information about the origin location, as well as the revision level, the production code, and the production number of the printer. The labels also contain power rating and regulatory - HP 5100 | Service Manual - Page 22
Install the printer away from direct sunlight, open flames, or ammonia fumes. If the printer is placed near a window, make sure the window has short-term based on HP LaserJet 5100dtn current) printer) 100 to 127 Vac 50 to 60 Hz (+/-10%) (+/-3 Hz) 5.4 amps 6 amps 220 to 240 Vac 50 to 60 Hz - HP 5100 | Service Manual - Page 23
.9 in) 47.5 cm (18.7 in) 47.0 cm (18.5 in) 27.0 cm (10.6 in) 47.3 cm (18.6 in) Figure 2. 47.0 cm (18.5 in) 11.0 cm (4.3 in) Printer dimensions-HP LaserJet 5100 printer and HP LaserJet 5100Le printer Q1860-90918 Chapter 1 Printer description 21 - HP 5100 | Service Manual - Page 24
139.8 cm (55 in) 62.5 cm (24.6 in) 30.3 cm (11.9 in) 47.0 cm (18.5 in) 27.0 cm (10.6 in) 62.0 cm (24.4 in) Figure 3. 15.5 cm (6.1 in) Printer dimensions-HP LaserJet 5100tn printer and HP LaserJet 5100dtn printer 22 Printer description Q1860-90918 - HP 5100 | Service Manual - Page 25
dimensions, HP LaserJet 5100 series printer with accessories Printer weight (without toner cartridge) HP LaserJet 5100 printer: 23 kg (50 lb) HP LaserJet 5100tn printer with optional 500-sheet feeder: 34 kg (75 lb) HP LaserJet 5100dtn printer with duplexer and optional 500-sheet feeder: 52 kg - HP 5100 | Service Manual - Page 26
PowerSave LWAd= 6.8 bels (A) LWAd= 6.4 bels (A) LWAd= 4.4 bels (A) Bystander position LpAm=53 dB LpAm=50 dB LpAm=32 dB Operator position LpAm=60 dB maximum* LpAm=56 dB maximum* LpAm=37 dB maximum* *Maximum values are based on the HP LaserJet 5100dtn printer. 24 Printer description Q1860-90918 - HP 5100 | Service Manual - Page 27
0.007 in) 75 to 105 g/m2 (20 to 28 lb) 75 transparencies 50 labels 10 envelopes 1. The printer supports a wide range of paper sizes. Check the printer software for supported sizes. To print custom-size paper see the user's guide. 2. Capacity might vary depending on paper weight and thickness, and - HP 5100 | Service Manual - Page 28
. 4. To print custom-size paper, see the user's guide. Table 9. Paper specifications, duplexer Minimum Dimensions1 148 by 210 mm (5.8 by 8.3 inches) Weight 60 to 105 g/m2 (16 to 28 lb) Maximum 297 by 432 mm (11.7 by 17 inches) 1. The printer supports a wide range of media sizes. Check the - HP 5100 | Service Manual - Page 29
or perforations. Problems with feeding. Ragged edges. Use higher quality paper. Do not use letterhead paper that is printed with low-temperature inks, such as those used in some types of thermography. Do not use raised letterhead. The printer uses heat and pressure to fuse toner to the paper - HP 5100 | Service Manual - Page 30
49 58 65 105 9 32 80 44 55 67 74 120 10 34 86 47 58 71 79 128 11 36 90 50 62 75 83 135 12 .18 39 100 55 67 82 91 148 13 .19 42 107 58 72 87 97 157 weight (g/m2) 60 64 75 80 81 90 100 105 120 128 135 148 157 163 176 199 28 Printer description Q1860-90918 - HP 5100 | Service Manual - Page 31
output bin to print transparencies to the top output bin. To avoid damaging the printer, use only transparencies that are recommended for use in monochrome laser printers. If you have problems printing on transparencies, use Tray 1. Vellum Vellum is typically a special lightweight paper similar to - HP 5100 | Service Manual - Page 32
that have adhesive strips or flaps Envelopes that have a peel-off adhesive strip or more than one flap that folds over to seal must use adhesives that are compatible with the heat and pressure in the printer. The extra flaps and strips might cause wrinkling, creasing, or jams. Envelope margins The - HP 5100 | Service Manual - Page 33
is better suited for feeding through a laser printer. 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, paper jams, poor toner fusing, poor print quality, or - HP 5100 | Service Manual - Page 34
printer is completely confined within protective housings and external covers, the laser beam cannot escape during any phase of normal user operation. Using controls, making adjustments, or performing procedures other than those specified in this service manual instructions interference by one or more - HP 5100 | Service Manual - Page 35
laitteessa käytettävän laserdiodin säteilyominaisuuksista: Aallonpituus 775-795 nm Teho 5 mW Luokan 3B laser Material Safety Data Sheet Material Safety Data Sheets can be obtained from the HP LaserJet Supplies website at http://www.hp.com/go/msds. Q1860-90918 Chapter 1 Printer description 33 - HP 5100 | Service Manual - Page 36
in the toner cartridge and in the print engine. Energy consumption This HP LaserJet printer design reduces: Power usage drops significantly while in PowerSave mode, which saves natural resources and saves money without affecting the high performance of this printer. This printer qualifies for - HP 5100 | Service Manual - Page 37
2 Service approach Overview Regulatory information 36 Service approach 36 Parts and supplies 36 Warranty 36 Limited warranty for the print cartridge 36 Service and support 37 Worldwide service and support offices 38 Q1860-90918 Chapter 2 Service approach 35 - HP 5100 | Service Manual - Page 38
(FRU) and replacement part numbers. Replacement parts can be ordered from the HP Customer Support (HPCS) organization. Chapter 8 of this manual also contains information about products specifically designed for this printer. Order accessories from HPCS. See "Worldwide service and support offices" on - HP 5100 | Service Manual - Page 39
Service and support World Wide Web Print drivers, updated HP MFP firmware, and product and support information can be obtained from the following URLs: U.S., http://www.hp.com/support/lj5100 Europe, http://www.hp.com/support/lj5100 China, ftp://www.hp.com.cn/support/lj5100 Japan, ftp://www. - HP 5100 | Service Manual - Page 40
Worldwide service and support offices For the U.S., call (1) ( 52 02 Israel: +972 (0)9 9524848 South Africa Inside RSA: 086 000 1030 Outside RSA: +27-11 258 9301 United Arab Emirates, Bahrain, Jordan, Kuwait, Lebanon, Oman, Palestine, Qatar, Saudi Arabia, and Yemen: 971 4 883 8454 38 Service - HP 5100 | Service Manual - Page 41
Brazil Greater Sao Paulo: (11) 3747-7799 Outside Greater São Paulo: 0800-157751 Chile: 800-22-5547 Guatemala: 800-999-5305 Mexico Mexico City: 52-58-9922 Outside Mexico City: 01-800-472-6684 Peru: 0-0800-10111 Puerto Rico: 1-877-2320-589 Venezuela Caracas: 207 8488 Outside Caracas: 800 - HP 5100 | Service Manual - Page 42
40 Service approach Q1860-90918 - HP 5100 | Service Manual - Page 43
menu 47 Paper-handling menu 48 Print-quality menu 50 Printing menu 51 Configuration menu 53 I/O menu 55 EIO menu (HP LaserJet 5100tn and 5100dtn printers 56 Resets menu 58 Service mode 59 Service menu 59 Setting the page count, maintenance count, and serial number 60 Cold reset paper size - HP 5100 | Service Manual - Page 44
Cancel Job - Value + Select Figure 6. Control panel layout Control panel lights Table 12. Interpreting 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. 42 - HP 5100 | Service Manual - Page 45
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 - HP 5100 | Service Manual - Page 46
set for the current print job by the software application or driver. 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 - HP 5100 | Service Manual - Page 47
indicating that it is now the default. 5 Press [GO] to exit the menu. Settings in the printer driver and software application override control panel settings. (Software application settings override printer-driver settings.) If you cannot gain access to a menu or item, it is either not an option for - HP 5100 | Service Manual - Page 48
enter the personal identification number (PIN) assigned to the job in the driver. COPIES=X DELETE: The number of copies the user wants to print. 1-999: Prints the requested number of copies of the job. Deletes the job from the printer's hard disk or RAM memory. 46 Printer operation Q1860-90918 - HP 5100 | Service Manual - Page 49
The configuration page shows the printer's current configuration. If an HP Jetdirect print server card is installed (HP LaserJet 5100tn and 5100dtn printers), a Jetdirect configuration page will print out as well. PRINT PCL FONT LIST The PCL font list shows all the PCL fonts currently available to - HP 5100 | Service Manual - Page 50
software application. Some items in this menu (such as duplex and manual feed) can be opened 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 17. Paper-handling - HP 5100 | Service Manual - Page 51
Values [TYPE]= NORMAL NORMAL LOW HIGH VELLUM Explanation This item appears only when CONFIGURE FUSER MODE MENU=YES. Most paper types are set to NORMAL by default. ROUGH=HIGH VELLUM=VELLUM For a complete list of supported paper types, see page 26. Q1860-90918 Chapter 3 Printer operation 49 - HP 5100 | Service Manual - Page 52
50 percent. 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: It is best to turn EconoMode on or off from the printer driver Follow the instructions on the - HP 5100 | Service Manual - Page 53
set the number of copies from the printer driver or software application. (Driver and software settings override control panel settings.) PAPER=LETTER (110 V printers) or PAPER=A4 (220 V printers and ENVELOPE=COM10 (110 V printers) ENVELOPE=DL (220 V printers) For supported paper sizes see page 25 - HP 5100 | Service Manual - Page 54
for line-draw characters. See the user guide for more information about symbol-set charts. COURIER=REGULAR REGULAR DARK Select the version of Courier font to use: REGULAR: The internal Courier font that is available on the HP LaserJet 4 series printers. DARK: The internal Courier font that is - HP 5100 | Service Manual - Page 55
= AUTO AUTO PCL PS RESOURCE SAVE= OFF OFF AUTO ON PAGE PROTECT= AUTO AUTO ON Explanation Set the printer to change to printer language, the printer will not automatically switch from one language to another unless specific software commands are sent to the printer. Dedicate printer memory - HP 5100 | Service Manual - Page 56
the required maintenance is not performed, the printer's performance will decline. Sets the speed with which smaller-sized media passes through the printer. This item allows the user to tell the printer that a new print cartridge has been installed. Setting this item to YES resets the HP TonerGauge - HP 5100 | Service Manual - Page 57
appears (see the following information in this table). Specify the amount of memory to be used for I/O buffering. OFF: I/O buffering is not performed and the I/O BUFFER SIZE item does not appear. When the I/O buffer setting is changed, any downloaded resources (such as fonts or macros) have to be - HP 5100 | Service Manual - Page 58
HP LaserJet 5100tn and 5100dtn printers) EIO (enhanced input/output) menus depend on the particular accessory product that is installed in an EIO slot of the printer. If the printer contains an HP Jetdirect set and limit the frame type to the one detected. For Ethernet cards, frame-type selections - HP 5100 | Service Manual - Page 59
22. EIO menu for networked printers Item Values Explanation CFG LINK=NO NO YES NO: The 10/100Base-TX link configuration menu is not used. YES: You can use and manually set 10/100Base-TX link 100 Mbps, full-duplex operation on the print server. Q1860-90918 Chapter 3 Printer operation 57 - HP 5100 | Service Manual - Page 60
printer's default settings. Communication between the printer and computer has been interrupted. You are using multiple I/O ports, and one of the ports is having problems. The items in the resets menu clear all memory in the printer the printer control panel. RESET ACTIVE I/O This item performs - HP 5100 | Service Manual - Page 61
only). Clear the event log. Set the page interval at which the next PERFORM PRINTER MAINTENANCE message appears on the control panel. To use service mode 1 Hold down [SELECT] and [CANCEL JOB] while turning on the printer. (If the control panel reads INITIALIZING, you released the keys too soon - HP 5100 | Service Manual - Page 62
counts and serial numbers are stored in nonvolatile random-access memory (NVRAM). If it is necessary to replace the formatter PCA, the page counts should be set to the current value to reflect the age of the print engine and maintenance items. The procedure for setting the serial number is similar - HP 5100 | Service Manual - Page 63
example, 150,000 pages), then set the maintenance count equal to the page 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 appears after another 150,000 pages have - HP 5100 | Service Manual - Page 64
size The default paper size is stored in NVRAM. When the printer is cold reset, the default paper size is set to the factory setting. Possible values are COLD RESET PAPER=LETTER and COLD RESET PAPER=A4. When you replace the formatter in countries/regions that use A4 rather than letter size - HP 5100 | Service Manual - Page 65
CAUTION Cold reset A cold reset clears all data from the printer memory and sets all of the control panel menu settings back to the initial factory default settings. Performing a cold reset resets the Jetdirect and other EIO configurations. To avoid making changes to your configuration, remove - HP 5100 | Service Manual - Page 66
that came with the printer contain drivers and other useful applications for use with current Microsoft Windows and other popular operating systems, networks, and applications. See the HP Web site-http://www.hp.com-for updated drivers, utilities, and applications. 64 Printer operation Q1860-90918 - HP 5100 | Service Manual - Page 67
4 Printer maintenance Overview Cleaning the printer and accessories 66 Cleaning spilled toner 67 Preventive maintenance 68 Reset maintenance count 68 Expected life of components 68 Q1860-90918 Chapter 4 Printer maintenance 65 - HP 5100 | Service Manual - Page 68
To maintain high-quality printing and performance, thoroughly clean the printer and the paperhandling accessories: every time you change the toner cartridge (run a cleaning page). after printing approximately 15,000 pages. whenever print quality problems occur. Clean the outside surfaces with - HP 5100 | Service Manual - Page 69
time the toner cartridge is replaced. If the cleaning page is needed frequently, try a different type of paper. Cleaning spilled toner Defective toner cartridges can develop leaks. Also, after a paper jam has occurred, some toner might remain on the rollers and guides inside the printer. The pages - HP 5100 | Service Manual - Page 70
two 500-sheet tray feed/separation rollers. See the instructions included in the kit for detailed replacement procedures. Reset maintenance count After the printer maintenance kit has been installed, reset the maintenance count. 1 Turn the printer off. 2 While pressing [-ITEM] and [-VALUE], turn the - HP 5100 | Service Manual - Page 71
75 Laser and scanner drive 76 Paper-motion monitoring and control 76 Solenoids, sensors, clutches, and switches 76 Engine test 76 Motors 77 Formatter system 78 PowerSave 78 Resolution Enhancement technology 78 EconoMode 79 Input/output 79 CPU 79 Printer memory 80 Read-only memory and - HP 5100 | Service Manual - Page 72
70 Functional information Q1860-90918 - HP 5100 | Service Manual - Page 73
Printer subsystems This chapter presents a generalized functional overview of the printer and the printing processes. Figure 9. Paper-feed subsystem Q1860-90918 Chapter 5 Functional information 71 - HP 5100 | Service Manual - Page 74
Ac/dc power distribution The ac line voltage for the printer is applied through the main switch (SW101) and on the formatter, the dc controller PCA, and the BD PCA. +5 Vdc is supplied to the laser driver PCA and sensors. +24 Vdc is supplied to the high-voltage power supply circuitry on the dc - HP 5100 | Service Manual - Page 75
is necessary to turn the power off, correct the problem in the faulty load, then turn the printer on again. The circuit has two fuses that break and thermistor voltage. If it is abnormal, the CPU identifies the fusing-roller heater error, turns the relay (RL1) off, and reports it to the formatter. - HP 5100 | Service Manual - Page 76
High-voltage power distribution Figure 11. High-voltage power supply circuit In response to the instructions from the microprocessor (CPU) on the dc controller, this circuit applies the superimposed voltage of dc voltage and ac voltage to the primary charging roller - HP 5100 | Service Manual - Page 77
is applied to the developing cylinder. The level of remaining toner is always detected when the developing bias is applied. The presence this printer. When the printer power switch is turned on and the printer enters the standby mode, the CPU sends the signals to drive the loads (such as laser diode - HP 5100 | Service Manual - Page 78
scanner drive Based on information received from the formatter, the dc controller board sends signals to the laser/scanner assembly to modulate the laser diode on and off and to drive the laser/scanner motor. See "Image-formation system" on page 82 for more information. Paper-motion monitoring and - HP 5100 | Service Manual - Page 79
unit along with the motor drive circuit. When the printer turns on, the CPU on the dc controller PCA initially causes the fan motor to run for one-half second. The CPU controls the half-speed/full-speed rotations according to the target fuser roller temperature when the CPU receives the /PRNT signal - HP 5100 | Service Manual - Page 80
EIO cards and additional memory DIMMs. PowerSave This feature (accessed from the configuration menu) conserves power by shutting down the fuser and exhaust fans after the printer has been idle for an adjustable period of time. The printer retains all printer settings, downloaded fonts, and macros - HP 5100 | Service Manual - Page 81
They provide automatic I/O switching between multiple computers or networks connected to the printer. The network version printers include the HP Jetdirect Print Server with Ethernet 10/100Base-TX support. Flash Flash is provided in optional 2- and 4-MB flash memory DIMMs for storage of forms, fonts - HP 5100 | Service Manual - Page 82
version; the HP LaserJet 5100tn and HP LaserJet 5100dtn printers use a 4MB Flash/ROM and 32 MB SDRAM version. DIMMs and SIMMS are not compatible. Only one type of DRAM DIMM is supported-SDRAM DIMMs that are 32-bit, 100-pin, 100 MHz (PC100). Read-only memory and random-access memory (RAM) Besides - HP 5100 | Service Manual - Page 83
of configuration, in addition to the standard printer command language (PCL). With standard cabling, PJL allows the printer to perform the following functions: Two-way communication with the host computer through a bidirectional parallel connection. The printer can tell the host such things as - HP 5100 | Service Manual - Page 84
is the main part of the printer, and consists of six stages: on the surface of the photosensitive drum. The laser beam modulated by the video signal is illuminated fuser. The cartridge has a toner sensor that detects the level of remaining toner and the presence of the cartridge. If the toner - HP 5100 | Service Manual - Page 85
components that wear, degrade, or are consumed in the replaceable toner cartridge eliminates the need for a service call when replacement is required. The printer also has a cartridge drive system that minimizes banding. Figure 15. Toner cartridge Q1860-90918 Chapter 5 Functional information 83 - HP 5100 | Service Manual - Page 86
16. Aluminum Base Photosensitive Drum Cleaning the drum In the transfer stage, not all the toner is transferred to the paper, but some remains on the photosensitive drum. In this stage, the residual toner is cleaned so that the next print image will be clear and distinct. Figure 17. Cleaning - HP 5100 | Service Manual - Page 87
Conditioning the drum After the drum is cleaned, it must be conditioned. This 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 - HP 5100 | Service Manual - Page 88
place a dot of light every 1/1200th of an inch. This is how the printer achieves its 1200x1200 dpi resolution. After the writing process, the drum surface has an VDO) for one sweep (scan line) and to diagnose problems with the laser diode or scanner motor. 86 Functional information Q1860-90918 - HP 5100 | Service Manual - Page 89
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 20. Developing the image The print density control in the control panel menu adjusts the dc - HP 5100 | Service Manual - Page 90
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 - HP 5100 | Service Manual - Page 91
heated fusing roller and a soft pressure roller. This melts the toner and presses it into the paper. The fusing roller contains a a relay opens, interrupting power to the fusing heater, causing a fuser error message (50.X FUSER ERROR). If the fusing system exceeds 464° F (240° C), the thermal - HP 5100 | Service Manual - Page 92
Fusing temperature control Variable fusing temperature is a feature that gives the user or service technician the ability to adjust the fusing temperature profile based on the media being used in the printer. The default fuser mode is Normal for most types of paper, which should be optimal for most - HP 5100 | Service Manual - Page 93
pickup roller and the feed roller start rotating to feed a sheet of paper into the printer. When the paper is fed from Tray 1, the Tray 1 pickup solenoid (SL404) fed. The paper then passes through the transfer area, feed belt, fuser, and delivery unit and is output onto the rear output bin or the - HP 5100 | Service Manual - Page 94
full circle to feed one sheet of paper. Extra sheets are removed with the separation pad, and only one sheet is fed into the printer as the Tray 1 feed feeds the paper through the transfer area, the feed belt, the fuser, and the delivery unit, and outputs it to the top output bin. Figure - HP 5100 | Service Manual - Page 95
2 pickup solenoid (SL306) and picks up one sheet of paper from the tray. The paper is fed into the printer as the feed rollers rotate. The paper passes becomes ready and feeds the paper through the transfer area, feed belt, fuser, and delivery unit and outputs it to the top output bin. Figure - HP 5100 | Service Manual - Page 96
Figure 27. Paper skew correction 94 Functional information Q1860-90918 - HP 5100 | Service Manual - Page 97
. The feeder control PCA has an 8-bit microcomputer, and controls the serial communications between the feeder(s) and the dc controller PCA of the printer. The feeder control PCA drives motors and solenoids with various commands from the dc controller PCA. The feeder control PCA sends the status of - HP 5100 | Service Manual - Page 98
Figure 29. 500-sheet paper feeder 96 Functional information Q1860-90918 - HP 5100 | Service Manual - Page 99
whether the paper has been correctly fed, the following paper sensors are installed: Registration roller paper sensor (PS403) Top of page sensor (PS402) Fuser paper delivery sensor (PS1306) If the paper does not reach or pass through any of the sensors within the specified period of time, the - HP 5100 | Service Manual - Page 100
Duplexer This function is to reverse the one side printed paper from the printer and refeed it into the printer. The duplexer operation sequence is controlled by the duplexing driver PCA. The duplexing driver PCA has an 8-bit microcomputer, which controls the serial communications between the - HP 5100 | Service Manual - Page 101
printer then starts to send the paper into the duplexer. Within a specified period of time after receiving the command, the duplexing driver The duplexing driver PCA then switches the reversing motor (PM1701) to reverse rotation. As the the leading edge of the paper is fed into the feed guide, it - HP 5100 | Service Manual - Page 102
Figure 32. Duplexer Paper jam in the duplexer The following sensors are located to detect the presence of paper and to determine whether the paper is correctly fed. reversing unit paper sensor (PS1701) refeed paper sensor (PS1703) If the paper does not reach or pass through any of the sensors - HP 5100 | Service Manual - Page 103
until the main motor completes the initial drive. Clears the drum surface potential and cleans the transfer charging roller. During this period, the printer detects the toner level and the presence of the cartridge. STBY (standby) From the end of the WAIT period until the /PRNT signal is input - HP 5100 | Service Manual - Page 104
Figure 33. Timing diagram, two consecutive prints on A4 paper (600 dpi, face-down tray delivery) 102 Functional information Q1860-90918 - HP 5100 | Service Manual - Page 105
Figure 34. Timing diagram, two consecutive prints on A4 paper (1200 dpi, face-down tray delivery) Q1860-90918 Chapter 5 Functional information 103 - HP 5100 | Service Manual - Page 106
104 Functional information Q1860-90918 - HP 5100 | Service Manual - Page 107
memory installation 109 Installing EIO cards or mass-storage devices 110 Before you begin 111 Replacing printer parts 111 Removing loose toner 111 Required tools 111 Covers 113 Rear door and rear output bin 113 Fuser 152 Tray 1 lift plate 154 Paper guide 155 Top-of-page sensor 156 Face- - HP 5100 | Service Manual - Page 108
Laser/scanner assembly 164 Main motor 165 Toner cartridge guides 166 Optional 500-sheet feeder 174 Power inlet assembly 167 Tray indicator assembly 176 Left front 180 500-sheet feeder power connector 181 500-sheet feeder separation roller 182 106 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 109
not already done so, print a configuration page to find out how much memory is installed in the printer before you add more memory. 1 Turn the printer off. Unplug the power cord and disconnect any cables. Note If an a DIMM, the locks must be open.) Q1860-90918 6 Removing and replacing parts 107 - HP 5100 | Service Manual - Page 110
tray and the rear section of the duplexer. Reattach any interface cables and the power cord. Turn the printer on and test the DIMM (see page 109). If an optional duplexer is installed: 1 Slide the rear section and the cables are routed through the left side. 108 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 111
control panel shows the READY message when the printer is turned on. If an error message appears, a DIMM might have been incorrectly installed. Check the printer messages. 2 Print a new configuration page. 3 Check the memory section on the configuration page and compare it to the configuration - HP 5100 | Service Manual - Page 112
are not available for the HP LaserJet 5100Le printer. Turn off the printer before installing the EIO card or the mass-storage device. See figure 35 for the orientation and location of the EIO card or optional mass-storage device, such as a hard disk. Use HP Jetdirect to delete files from a mass - HP 5100 | Service Manual - Page 113
-hole becomes stripped, then repair of the screw-hole or replacement of the affected assembly is required. CAUTION CAUTION Removing loose toner Loose toner might be present inside the printer, on printer parts, or on the toner cartridge. If toner gets on your clothing, wipe it off with a dry cloth - HP 5100 | Service Manual - Page 114
inner cover Tray 1 lift plate Paper guide Left and right corner covers Rear Fuser Paper-feed belt assembly Top cover and toner cartridge Control panel overlay and control panel Toner cartridge door assembly Face-down cover Laser guide Tray 1 pickup solenoid Power inlet assembly Toner cartridge guides - HP 5100 | Service Manual - Page 115
door and rear output bin removal (1 of 2) 2 The plastic support strap is located on the left side of the printer. To release the strap, pinch the top of the strap the left, and then remove it from the printer. For reassembly, insert the pin on the left side of the cover first. Q1860-90918 6 - HP 5100 | Service Manual - Page 116
to disengage the fuser assembly detents. 4 Grasp the green pressure-release handles (callout 3) and pull the fuser out of the chassis. The fuser power connection is on the left side of the assembly. 32 2 12 Figure 39. Fuser removal (rear view of printer) 114 Removing and replacing parts Q1860 - HP 5100 | Service Manual - Page 117
on the end of the shaft, and slide the shaft through the ring. Figure 40. CAUTION Top cover removal (1 of 3) It is critical that you perform step 1 before you attempt to remove the top cover. If you damage the arm, the printer will not operate. Q1860-90918 6 Removing and replacing parts 115 - HP 5100 | Service Manual - Page 118
on the top portion of the back of the printer (callout 2). The rear cover needs to be opened The cable that connects the control panel to the printer chassis is on the left side of the cover. 5 Disconnect the control panel cable from the printer chassis by grasping the wires and gently pulling the - HP 5100 | Service Manual - Page 119
tabs on the outside of the cover. 3 Lift the overlay off of the control panel. Figure 43. Control panel overlay removal Q1860-90918 6 Removing and replacing parts 117 - HP 5100 | Service Manual - Page 120
free the control panel. 6 Grasp the control panel by its metal frame and remove it from the underside of the top cover. 118 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 121
(see page 115). 2 Remove the control panel from the top cover (see page 117). The control panel must be removed before you can separate the toner cartridge door from the top cover. 3 Disengage the pins (callout 1) by pressing them outward. 12 Figure 45 - HP 5100 | Service Manual - Page 122
will separate from each other. 3 Press the Tray 1 guide (callout 3) against the printer. 32 Figure 46. 12 2 Front cover removal 4 Tray 1 guide by allowing the guide to slide off the keyed pins at its lowest position. Figure 47. Tray 1 guide removal 120 Removing and replacing parts Q1860- - HP 5100 | Service Manual - Page 123
Front cover pins 1 Remove the front cover and Tray 1 (see page 120). 2 Remove two screws (callout 1) to free the front cover pins. 12 Figure 48. Front cover pins removal Q1860-90918 6 Removing and replacing parts 121 - HP 5100 | Service Manual - Page 124
of the printer. 3 Squeeze the locking tabs (callout 1) inward, one side laser/scanner, removing it with a rolling motion away from you. Be careful not to break the two locator pins (callout 2) on the front of the assembly. 2 Figure 50. Face-down cover removal (2 of 2) 122 Removing and replacing - HP 5100 | Service Manual - Page 125
by pushing down on it. 3 Grab the side cover at the top and pull it toward the front of the printer to release the tabs. With your other hand, grab the lower, back edge. Rock the cover gently until it cover first. Then snap on the top of the cover. Q1860-90918 6 Removing and replacing parts 123 - HP 5100 | Service Manual - Page 126
1 inner cover is a plastic tray located at the top front of the printer. See figure 53. 1 Remove the top cover (see page 115), the in a cutout in the left side of the chassis and is easily broken. In figure 52, the paper-handling PCA is removed to make identification of the left end of the paper - HP 5100 | Service Manual - Page 127
front of the chassis. 2 Figure 53. Note Tray 1 inner cover removal (2 of 2, front of printer) 3 Facing the front of the printer, slip the cover off of the locator pins by tilting it to the right and then sliding it in the left side of the chassis. Q1860-90918 6 Removing and replacing parts 125 - HP 5100 | Service Manual - Page 128
Right and left corner covers Each cover is secured by one self-tapping screw (callout 1). Remove the screw, and then lift off the cover. 12 Figure 54. Corner covers removal 126 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 129
printer, unless otherwise specified. 12 2 Figure 55. 62 52 32 42 Internal assemblies Item 1 2 3 4 5 6 Explanation Upper delivery assembly Laser/scanner Registration assembly Tray 1 paper-guide plate assembly Paper-handling PCA Main gear assembly Q1860-90918 6 Removing and replacing parts - HP 5100 | Service Manual - Page 130
and replace the transfer roller. Roll the transfer roller into a clean sheet of paper to protect it after removal. 1 Face the front of the printer, open the top cover, and lift the small green handle on the right side of the registration assembly to expose the transfer guide (callout - HP 5100 | Service Manual - Page 131
to lift the transfer roller straight up to free the transfer roller from the hinged clip. 32 Figure 57. Transfer-roller assembly removal (2 of 3) 4 Free the left side of the transfer roller by lifting 58. Transfer-roller assembly removal (3 of 3) Q1860-90918 6 Removing and replacing parts 129 - HP 5100 | Service Manual - Page 132
To reinstall Before reinstalling the transfer roller, make sure that the hinged clip (callout 4) is up. 42 Figure 59. Reinstalling the transfer roller 130 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 133
(see page 115) and the left side cover (page 123). 2 Facing the left side of the printer, disconnect the cable (callout 1) from the PCA. 3 Remove two self-tapping screws (callout 2) and Readjust the top margin after you replace the paper-handling PCA (see page 132). Q1860-90918 6 Removing and - HP 5100 | Service Manual - Page 134
top margin of test prints that are made after laser/scanner or dc controller replacement is not 2.0 mm. The following steps comprise the the difference is 0.8 mm; turn the VR401 clockwise for one scale. 4 Make several test prints again, and perform step 2. Make sure that the top margin is 2.0 mm - HP 5100 | Service Manual - Page 135
Test print Figure 62. Location of VR401 on the paper-handling PCA Q1860-90918 6 Removing and replacing parts 133 - HP 5100 | Service Manual - Page 136
grounding screw (callout 3) that hold the gear assembly to the chassis. 12 2 32 Figure 63. Main gear assembly removal (1 of 2, left side) 134 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 137
the locating tab (callout 4) and remove the main gear assembly. Be careful when you remove the assembly. The toner cartridge engagement arm (callout 5) can break if it is not handled carefully. 42 52 Figure 64. Note Main gear assembly removal (2 of 2) Remember to reconnect the cable at the top of - HP 5100 | Service Manual - Page 138
chassis. Be careful not to damage the tray-size sensor springs when removing or replacing the pickup gear assembly. 12 2 Figure 65. Note 32 Pickup gear assembly removal (left side of printer) Before replacing the pickup gear assembly, route the cables through the wire clip (callout 3) that is - HP 5100 | Service Manual - Page 139
Tray 1 pickup solenoid 1 Remove the paper-handling PCA (see page 131). 2 Remove the Tray 1 solenoid by removing one black machine screw (callout 1) and sliding the solenoid assembly away from the pickup gear assembly. 12 Figure 66. Tray 1 pickup solenoid removal Q1860-90918 6 Removing - HP 5100 | Service Manual - Page 140
self-tapping screws (callout 2) that secure the fan to the chassis. 4 Remove the fan from the chassis. 2 Figure 67. 12 Fan removal (right side of printer) 138 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 141
out. 4 Remove any DIMMs from the DIMM slots. 12 Figure 68. Note Formatter assembly removal After you reinstall the formatter, update the printer configuration, if necessary, using the pages that you printed in step 1 (see "Service mode" on page 59). Q1860-90918 6 Removing and replacing parts 139 - HP 5100 | Service Manual - Page 142
Open the top cover and remove the toner cartridge. 2 Facing the front of the printer, raise the green center handle of roller removal To reinstall If the Tray 1 separation pad should be replaced, replace the separation pad before you replace the pickup roller (see "Tray 1 separation pad" on page 141 - HP 5100 | Service Manual - Page 143
the separation pad (callout 2). 2 Figure 71. Tray 1 separation pad removal (2 of 2) To reinstall Make sure that the silver clip faces the front of the printer, and firmly press the new separation pad into the holder until it clicks into place. Q1860-90918 6 Removing and replacing parts 141 - HP 5100 | Service Manual - Page 144
sheet tray. 1 Remove the 250-sheet tray. 2 For Tray 2, carefully tilt the printer onto its left side. -OrFor an optional 250-sheet tray, set the feeder upside- removal (bottom of the printer) To reinstall Orient the pin on the roller so that it lines up with the hole in one of the side bushings. - HP 5100 | Service Manual - Page 145
74. Tray 2 separation pad removal (2 of 2) 3 Pull the spring off of the old separation pad, and then insert the spring onto the new separation pad. 4 Replace the separation pad. Q1860-90918 6 Removing and - HP 5100 | Service Manual - Page 146
on the inside of the chassis, behind the left corner cover (callout 2). 12 2 Figure 75. Paper-feed roller assembly removal (1 of 3, left side view of printer) 144 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 147
printer and under the registration assembly roller guide. 12 Figure 76. Paper-feed roller assembly removal (2 of 3, location of two screws inside the printer) 5 Remove the paper tray, and tilt the printer printer. 2 Figure 77. Paper-feed roller assembly removal (3 of 3, bottom view of printer) - HP 5100 | Service Manual - Page 148
the bottom of the dc controller assembly. 6 Remove one machine screw (callout 3) and its lock washer, printer (see figure 63 on page 134, callout 3). 12 Figure 78. Note 32 2 Dc controller assembly removal (1 of 3, rear view of printer) You might have to readjust the top margin after you replace - HP 5100 | Service Manual - Page 149
held on the tray by four screws each. 10 Carefully remove the ribbon cable, and loosen the screws on the board you want to remove. 52 62 72 Figure 80. CAUTION Dc controller assembly removal (3 of 3) To prevent damage to the high-voltage contacts, the paper-feed belt assembly needs to - HP 5100 | Service Manual - Page 150
), the fuser (page 114), the main gear assembly (page 134), and the dc controller (page 146). 2 Facing the front of the printer, remove two machine screws (callout 1), one on each side of the belt assembly. 12 Figure 81. Paper-feed belt assembly removal (1 of 2) 148 Removing and replacing parts - HP 5100 | Service Manual - Page 151
assembly by grasping the small green handle, and lift out the belt assembly. 4 Remove the plastic guide (callout 2) and replace the belts if necessary. The guide snaps back in after the belt replacement. The edge (callout 3) has a metal ridge with sharp teeth. Avoid contact with the edge. . 2 32 - HP 5100 | Service Manual - Page 152
pulling up on the release tab (callout 1), and sliding the collar to the left. 12 Figure 83. Tray 1 shaft removal (1 of 2, right side view of printer) 150 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 153
plate, and must be installed on top of it. Also make sure that the shaft is reinstalled in the correct orientation. Q1860-90918 6 Removing and replacing parts 151 - HP 5100 | Service Manual - Page 154
to align the solenoid arm (callout 1) with the gap in the gear (on the left side of the printer). 4 Press the release tabs (callout 2) outward, and slide the gear off of the shaft. 5 Remove Figure 85. Tray 2 shaft removal (left side view of printer) 152 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 155
, and push until the tab locks in the indentation on the shaft. 4 Facing the left side of the printer, orient the shaft so that the open end of the shaft (callout 3) points away from the solenoid arm. . 32 Figure 86. Reinstallation of Tray 2 shaft Q1860-90918 6 Removing and replacing parts 153 - HP 5100 | Service Manual - Page 156
120), the left and right side covers (page 123), and the Tray 1 shaft (page 150). 2 Rotate the Tray 1 lift plate to the front of the printer, and then carefully pry down each hook (callout 1) until the hook is released from the pivot pin. When you remove the lift plate, be careful - HP 5100 | Service Manual - Page 157
Paper guide 1 Lift the green handle (callout 1) in the middle of the registration assembly. 2 Release the guide by freeing the end pins (callout 2), and then lift the paper guide out. 12 2 Figure 88. Paper guide removal Q1860-90918 6 Removing and replacing parts 155 - HP 5100 | Service Manual - Page 158
shaft to the right. 4 Remove the screw (callout 1) that secures the sensor to the chassis. 12 Figure 89. Top-of-page sensor removal (bottom of printer) 5 Remove the sensor, feeding the cable through the opening in the chassis. 156 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 159
(callout 1), and slide the sensor to the right to remove it. 12 Figure 90. Face-down bin-full sensor lever removal Q1860-90918 6 Removing and replacing parts 157 - HP 5100 | Service Manual - Page 160
). 2 Disconnect the two cables (callout 1) from the connector. 3 Remove the two self-tapping screws (callout 2). 12 Figure 91. 2 2 Accessory interface connector removal (left side of printer) 4 Remove the connector. 158 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 161
pickup gear assembly (page 136), the main gear assembly (page 134), and the transfer guide (page 128, steps 1 and 2). 2 Release the e-ring (callout 1) that is (1 of 2) 3 Remove two screws in the top, middle of the printer (see figure 76 on page 145, callout 1). These screws are already removed - HP 5100 | Service Manual - Page 162
in the shaft with the clutch. When you slide the clutch on the shaft, make sure that the metal alignment tab is seated on the printer frame. Also make sure that the cable is situated away from the registration assembly. 160 Removing and - HP 5100 | Service Manual - Page 163
and the main gear assembly (page 134). 2 Face the left side of the printer. 3 The delivery assembly is secured by three tabs on each side. Use the on each side, and then lift the assembly out. After you release one tab, lift the assembly only slightly until you release the tab on replacing parts 161 - HP 5100 | Service Manual - Page 164
the main gear assembly (page 134). 2 Facing the left side of the printer, insert a flat-blade screwdriver and twist gently to release the tab on roller (callout 1). The lower delivery rollers might fall out. When you replace them, make sure they align with the indentations in the chassis. 12 Figure - HP 5100 | Service Manual - Page 165
of the spring. 2 32 Figure 96. Note Delivery roller removal (2 of 2) As you reinstall the roller, realign the lower delivery rollers. Q1860-90918 6 Removing and replacing parts 163 - HP 5100 | Service Manual - Page 166
3 Disconnect three cables (callout 2). 4 Lift the laser/scanner assembly out of the chassis. 12 2 2 Figure 97. Note Laser/scanner assembly removal (top, inside view of printer) You might have to readjust the top margin after you replace the laser/scanner assembly (see page 132). 164 Removing and - HP 5100 | Service Manual - Page 167
of the main gear assembly. 12 Figure 98. Main motor removal (rear view) 3 Carefully separate the motor from the gear assembly. Q1860-90918 6 Removing and replacing parts 165 - HP 5100 | Service Manual - Page 168
reinstall the guide, insert the two "non-leading" tabs (callout 2) first. Twist the right guide counterclockwise and the left guide clockwise to lock the guides. Gently flex the "leading" tab so that it will fit into the slot easily. Then snap the guide into place. 166 Removing and replacing parts - HP 5100 | Service Manual - Page 169
cable from the frame. 6 Press down the top of the line-voltage connector to release it from the power-supply PCA. Q1860-90918 6 Removing and replacing parts 167 - HP 5100 | Service Manual - Page 170
(2 of 2) 3 If necessary, pull the spring off of the old separation pad, and then insert the spring onto the new separation pad. 168 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 171
shaft. 12 2 32 42 Figure 103. Optional 250-sheet feeder pickup roller removal (bottom of the printer) To reinstall Orient the pin on the roller so that it lines up with the hole in one of the side bushings. Slide the cam toward the roller until the tab snaps into place. Q1860 - HP 5100 | Service Manual - Page 172
to the right. 4 Lift the paper-sensing flag (callout 2) from the assembly. 2 Figure 105. Optional 250-sheet feeder sensing flag removal (2 of 2) 170 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 173
, and then lift the frame off of the feeder assembly. 42 Figure 107. Optional 250-sheet feeder control PCA removal (2 of 3) Q1860-90918 6 Removing and replacing parts 171 - HP 5100 | Service Manual - Page 174
to the feeder control PCA. 9 Remove the two screws (callout 5) that secure the PCA to the frame and lift the PCA off of the frame. 52 Figure 108. Optional 250-sheet feeder control PCA removal (3 of 3) 172 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 175
the frame and lift the spring from the frame. 2 Figure 110. Optional 250-sheet feeder paper-size spring assembly removal (2 of 2) Q1860-90918 6 Removing and replacing parts 173 - HP 5100 | Service Manual - Page 176
you, one end at a time. 2 2 12 32 Figure 111. 42 500-sheet feeder removal (1 of 2, top view) 3 Remove the paper-size sensing springs (callout 5) by disengaging the locking tabs from the left frame assembly. 52 Figure 112. Paper-size spring assembly removal 174 Removing and replacing parts - HP 5100 | Service Manual - Page 177
4 Remove the five self-tapping screws (callout 6). 62 52 Figure 113. 500-sheet feeder removal (2 of 2, top view with covers removed) Q1860-90918 6 Removing and replacing parts 175 - HP 5100 | Service Manual - Page 178
1). 3 Remove the cover. 4 Remove the top self-tapping screw. 5 Remove the tray indicator assembly (callout 2). 2 12 Figure 114. Tray indicator assembly removal 176 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 179
reinstall the cover. Make sure that the tray indicator operates correctly. 2 32 12 Figure 115. Installing the left front corner cover Q1860-90918 6 Removing and replacing parts 177 - HP 5100 | Service Manual - Page 180
500-sheet feeder feed roller 1 Place the feeder upside down on the work surface. 2 Pinch the feed roller tab and slide the feed roller (callout 1) off of the shaft. 12 Figure 116. 500-sheet feeder feed roller removal 178 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 181
500-sheet feeder pickup roller 1 Place the feeder upside down on the work surface. 2 With one hand, rotate the pickup roller shaft (callout 1) 90 degrees. 3 With the other hand, press the . Figure 118. 500-sheet feeder pickup roller removal (2 of 2) Q1860-90918 6 Removing and replacing parts 179 - HP 5100 | Service Manual - Page 182
then lift the PCA from the frame. 12 2 Figure 119. Gear assembly, 500-sheet feeder PCA, and paper-size switch PCA removal 180 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 183
-sheet feeder power connector 1 Remove the left cover from the 500-sheet feeder (see page 174). 2 Remove the two screws (callout 1). 3 Disconnect one cable (callout 2). 12 Figure 120. 2 Power connector removal 4 Lift the connector off of the frame. Q1860-90918 6 Removing and replacing parts 181 - HP 5100 | Service Manual - Page 184
Note 500-sheet feeder separation roller 1 With one hand, lift the return cover (callout 1) on the 500-sheet tray. 2 With the other hand, pinch the separation sure that the torque limiter remains in position. 12 2 Figure 121. Separation roller removal 182 Removing and replacing parts Q1860-90918 - HP 5100 | Service Manual - Page 185
operating checks 187 Power on 188 Engine test 190 Display 190 Event log 191 Printer messages 193 General paper-path troubleshooting 202 Information pages 204 Image quality 207 Interface troubleshooting 225 Reference diagrams 227 Locations of components 227 Sensors and signals 236 Dc - HP 5100 | Service Manual - Page 186
you quickly define the problem(s). Use the process flow on page 185 to investigate printer malfunctions and errors more carefully and then pursue the best approach to troubleshooting. Table 28. Major steps for troubleshooting Power on (page 188) Does the printer perform the initialization and - HP 5100 | Service Manual - Page 187
step. (page 188) A. See "Printer messages" on page 193 to understand the message and correct the problem. A. For error messages encountered printing the event log, see printer messages. If the event log does not print, see "Engine test" on page 190. Q1860-90918 Chapter 7 Troubleshooting 185 - HP 5100 | Service Manual - Page 188
A. For error messages encountered printing the configuration page, see printer messages. If the page does not print, see "Engine test" on page 190. A. See "Image quality" on page 207 and compare pages to samples. A. See "Interface troubleshooting" on page 225. 186 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 189
troubleshooting a specific printer problem, make sure that the following conditions are met: The printer is being maintained on a regular basis and in accordance with the procedures described in chapter 4. The customer is using acceptable print media as specified in the HP LaserJet Printer - HP 5100 | Service Manual - Page 190
Power on 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 29. Power on defect or blank display Problem Action Is the power cord plugged Verify that power - HP 5100 | Service Manual - Page 191
is turned OFF. If resistance does not meet these thresholds, replace the printer power supply. Defective ac receptacle or Check the printer's ac receptacle and wiring for the ac power line. If no printer power supply. problem is found, replace the power supply. Table 31. No dc power Cause - HP 5100 | Service Manual - Page 192
problems. Because the engine test prints a full page of lines across the entire printable area, it is also useful for checking and adjusting registration. Make sure that the toner cartridge is installed in the printer before you perform an engine test. The engine test prints either from Tray 2 (the - HP 5100 | Service Manual - Page 193
information about correcting event log messages on the printer. The event log codes and the error message that appears on the control panel do by one digit. For example, 13.1 on the control panel appears as 13.01 in the event log. Figure 123. Event log page Q1860-90918 Chapter 7 Troubleshooting - HP 5100 | Service Manual - Page 194
log stores the last 30 errors. To print the event log: Press [MENU] until INFORMATION MENU appears. Press [ITEM] until PRINT EVENT LOG appears. Press [SELECT] to print the event log. Interpret the event log The event log is the key tool for troubleshooting printer problems. Figure 123 shows - HP 5100 | Service Manual - Page 195
will not print and will be cleared from memory. Print the job using a driver for a different printer language, or add the requested language to the printer, if it is available. Note: PostScript is not available for the HP LaserJet 5100Le printer. Press [GO] to continue. CLOSE TOP COVER The - HP 5100 | Service Manual - Page 196
could not be performed. You might have attempted an OPERATION FAILED illegal operation, such as trying to download a file to a non-existent directory. FLASH FILE SYSTEM IS FULL Delete files from the flash DIMM or add another one. Download or delete files using HP Jetdirect, and download or delete - HP 5100 | Service Manual - Page 197
PRINTER MAINTENANCE Hewlett-Packard recommends that only HP-authorized service technicians perform service on the printer. However, you can perform most routine maintenance. When the PERFORM PRINTER MAINTENANCE message appears on the control panel, you need to purchase a printer maintenance kit - HP 5100 | Service Manual - Page 198
are operating and can feed media. 2. Check the paper path for obstructions at the transfer roller and toner cartridge, at the paper-feed guide, and at the fuser. 3. Check PS1306 for correct operation. Replace any defective sensors or flags. For the locations of sensors, see page 236. 13.10 PAPER - HP 5100 | Service Manual - Page 199
is correctly configured (see page 48). After performing the actions above, press [GO]. The page that contains the error will automatically be reprinted. (Or, you might want to press [CANCEL JOB] to clear the job from the printer's memory.) If the problem persists: 1. Make sure that only a single - HP 5100 | Service Manual - Page 200
3) and J1308-1 (callout 4) with the fuser removed. If no continuity exists, replace the fuser. 6. If the problem persists, replace the power supply, and then replace the dc controller, if necessary. 42 12 32 2 51.x PRINTER ERROR 52.x PRINTER ERROR A beam-detect error occurred. 1. Press [GO]. The - HP 5100 | Service Manual - Page 201
the error persists, replace the motor, and then replace the dc controller, if necessary. 62.x PRINTER ERROR A problem exists in the printer's memory. x= location 0-internal memory 1 to 4-DIMM slots 1, 2, 3, or 4 Reseat or replace the specified DIMM. Q1860-90918 Chapter 7 Troubleshooting 199 - HP 5100 | Service Manual - Page 202
www.hp.com and use HP Jetdirect or another appropriate utility to update the printer. 4. Remove the DIMMs one at a time and cycle the power. 5. Try using the parallel interface, if possible. 6. Remove the EIO cards from the printer and then perform a cold reset. 7. If the error persists, replace the - HP 5100 | Service Manual - Page 203
the EIO card detected an error. The EIO card might be defective. 7-EIO slot 2: the EIO card detected an error. The EIO card might be defective. 1. Turn the printer off, and then turn the printer back on. 2. Reseat, if necessary, or replace the EIO board. Q1860-90918 Chapter 7 Troubleshooting 201 - HP 5100 | Service Manual - Page 204
cleaning procedures in chapter 4. When was the user Determine from the PCL configuration page the number of pages since the maintenance performed on last maintenance (page 205). The Printer Maintenance Kit should be the printer? installed every 150,000 images. 202 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 205
Paper-path test To perform a paper-path test: 1 Press [MENU] until INFORMATION MENU appears 2 Press [ cycle selections until the appropriate number of copies appears. Choose 1, 10, 50, 100, or 500 copies. 11 Press [SELECT] to perform the paper-path test. Q1860-90918 Chapter 7 Troubleshooting 203 - HP 5100 | Service Manual - Page 206
print the menu map. The content of the menu map varies, depending on other menu settings and the options that are currently installed in the printer. (Many of these values can be overridden from the printer driver or software application.) Figure 124. Menu map 204 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 207
page Use the configuration page to view the current printer settings, to help troubleshoot printer problems, or to verify correct installation and functionality of optional accessories, such as memory (DIMMs), paper trays, and printer languages. If an HP Jetdirect print server EIO card is installed - HP 5100 | Service Manual - Page 208
printer. 2 Installed Personalities Lists all printer languages that are installed (such as PCL the last three entries. 4 Memory Lists printer memory, PCL Driver Work Space (DWS), I/O buffering options that are installed in your printer are listed on the configuration page. If an - HP 5100 | Service Manual - Page 209
the fuser, then a problem might exist in the fuser. Check the toner cartridge Image-formation defects are often the result of problems with the toner cartridge. If you suspect that the toner cartridge is the source of the problem, replace the toner cartridge before troubleshooting image defects - HP 5100 | Service Manual - Page 210
reducing the amount of toner on the printed page by up to 50%. Advise the customer to turn EconoMode on or off from the printer driver or software application, because used, it is likely that the toner supply will outlast the mechanical parts in the toner cartridge. 208 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 211
The quality of the printer's output is subject to user judgment. This section of the manual helps you define print lines (either direction) (table 50 on page 221) Toner specks (see also "Dots" on page 216) (table 51 on page 221) White lines (in the paper-path direction) (table 52 on page 221) - HP 5100 | Service Manual - Page 212
. Perform the half self-test functional check (see page 224). If the defect develops on the print drum, replace the toner cartridge. Worn or dirty fuser rollers. Clean the fuser using the cleaning page procedure on page 67. Several pages might be required if the fuser is very dirty. If the problem - HP 5100 | Service Manual - Page 213
Replace the laser/scanner assembly. faulty (it is turning the laser on continuously). Connectors between the laser/scanner unit and dc controller are not seated correctly or are defective. Inspect and reseat the connectors. Replace the cables as necessary. Q1860-90918 Chapter 7 Troubleshooting - HP 5100 | Service Manual - Page 214
. Check with the network administrator. Multiple feeds. The printer might be feeding two or more pages at once ( replace the laser/scanner assembly. No transfer-roller voltage. Without transfer-roller voltage, toner does not transfer correctly from the surface of the drum to the paper. Perform - HP 5100 | Service Manual - Page 215
Transparencies can have this problem because they are not designed for proper toner adhesion. Use HP-approved transparencies for monochrome LaserJet printers (see the HP LaserJet Printer Family Paper Specification Guide). Printer's operating Make sure that the printer's operating environment (and - HP 5100 | Service Manual - Page 216
. Wrong output bin. Print to a different output bin (top or rear output bin). Wrong fuser setting for the From the paper-handling menu on the control panel, change the fuser mode media type. setting or choose another media type from the printer driver. 214 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 217
laser/scanner. Replace the laser/scanner. Defective high-voltage circuitry. Replace the dc controller. Table 42. Dirt on back of page Possible cause Action Dirt inside printer (on tray separation pad or roller, feed roller, transfer roller, fuser, toner cartridge, feed belt, feed guide - HP 5100 | Service Manual - Page 218
, if they are dirty. If the problem remains after cleaning, or if the contacts are damaged or deformed, replace them. Deformed or deteriorated Replace the transfer roller. transfer roller. Defective dc controller assembly. Replace the dc controller assembly. 216 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 219
toner cartridge. 2. Check the laser/scanner shutter door for proper operation. If it is defective, replace the laser/scanner assembly. The dc controller is defective. The dc controller contains the high-voltage circuitry. Action 8 Replace the dc controller. Q1860-90918 Chapter 7 Troubleshooting - HP 5100 | Service Manual - Page 220
high-voltage connectors are mounted on and above the dc controller and protrude into the toner cartridge cavity. Check the springs for functionality. Clean if dirty, replace if defective or missing. High-voltage circuitry is defective. Replace the dc controller. 218 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 221
the fuser. will smear if the fuser is not heated sufficiently to bond the toner image to the paper. The dc controller is defective. The dc controller regulates fuser roller temperature. If a new fuser does not resolve the problem, replace the dc controller. Q1860-90918 Chapter 7 Troubleshooting - HP 5100 | Service Manual - Page 222
a repetitive print defect. Fuser is dirty or defective. Clean the fuser by running a cleaning page through the printer (see page The circumferences of the 67). Several pages might be required if the fuser is very dirty. If the problem rollers used in the fuser are persists, replace the fuser. 75 mm - HP 5100 | Service Manual - Page 223
fuser rollers. Replace the fuser. Table 52. White lines (in the paper-path direction) Possible cause Action Lack of toner or faulty toner Redistribute the toner in the toner cartridge. If the problem continues, cartridge. replace the toner cartridge. Dirt in the laser path. Clean the laser - HP 5100 | Service Manual - Page 224
printer (see page 67). If the problem persists, replace the fuser. Unstable laser beam or beam control circuitry. Replace the following in the order indicated: 1. Laser/scanner assembly. 2. Dc controller. 3. Cables between the dc controller and the laser/scanner. 4. Formatter. 222 Troubleshooting - HP 5100 | Service Manual - Page 225
printer or the toner replace the appropriate roller. First occurrence of print defect Toner cartridge primary charging roller-44 mm (1-3/4 in) Toner cartridge developing cylinder or registration roller-50 mm (2 in) Feed roller - 52 mm (2-1/16 in) Transfer charging roller - 55 mm (2-3/16 in) Fuser - HP 5100 | Service Manual - Page 226
, conditioning, writing, and developing), and troubleshoot the failure as a transfer or fusing problem. If no image is present on the photosensitive drum, perform the following check. Drum rotation functional check The photosensitive drum, located in the toner cartridge, must rotate for the print - HP 5100 | Service Manual - Page 227
troubleshooting network problems. If the printer is not connected to an MS-DOS-based host, see "EIO troubleshooting" on page 225. PC direct connect (parallel) test After the printer is installed, verify communications (bypassing the Windows driver) between the printer and the IBM-compatible computer - HP 5100 | Service Manual - Page 228
Table 54. HP Jetdirect configuration page categories (continued) 4 Novell/NetWare This block should state the Novell printer server name to which the printer is connected. If the node name reads " be appropriate. 1 4 2 3 Figure 127. Jetdirect configuration page 226 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 229
Reference diagrams Locations of components Figure 128. Paper path (sensors and switches) Q1860-90918 Chapter 7 Troubleshooting 227 - HP 5100 | Service Manual - Page 230
Figure 129. Paper path (clutches, solenoids, and motors) 228 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 231
Figure 130. 250-sheet paper feeder Q1860-90918 Chapter 7 Troubleshooting 229 - HP 5100 | Service Manual - Page 232
Figure 131. 250-sheet paper feeder 230 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 233
Figure 132. 500-sheet paper feeder Q1860-90918 Chapter 7 Troubleshooting 231 - HP 5100 | Service Manual - Page 234
Figure 133. 500-sheet paper feeder 232 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 235
Figure 134. Duplexer Q1860-90918 Chapter 7 Troubleshooting 233 - HP 5100 | Service Manual - Page 236
Figure 135. Duplexer 234 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 237
Figure 136. Duplexer Q1860-90918 Chapter 7 Troubleshooting 235 - HP 5100 | Service Manual - Page 238
55 on page 237 shows the name of each sensor, switch, clutch, and solenoid in the printer. Delivery rollers Photosensitive drum Registration roller Tray 1 pickup roller PS1306 Feed belt Fuser Transfer roller Tray 2 pickup roller Feed roller Optional 250-sheet tray Optional 500-sheet tray - HP 5100 | Service Manual - Page 239
PS1701 Duplexer reversing-unit paper sensor PS1702 Duplexer side-registration guide home-position sensor PS1703 Duplexer refeed paper sensor PS2001 500 500-sheet feeder paper-size switch 4 TSW1 Fuser thermal switch TH1301 Fuser roller thermistor Q1860-90918 Chapter 7 Troubleshooting 237 - HP 5100 | Service Manual - Page 240
Figure 139. Printer sensors Figure 140. 250-sheet feeder sensors 238 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 241
Figure 141. 500-sheet feeder sensors Figure 142. Duplexer sensors Q1860-90918 Chapter 7 Troubleshooting 239 - HP 5100 | Service Manual - Page 242
Figure 143. Printer switches Figure 144. 250-sheet feeder switches 240 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 243
Figure 145. 500-sheet feeder switches Q1860-90918 Chapter 7 Troubleshooting 241 - HP 5100 | Service Manual - Page 244
Figure 146. Motors, fans, and fuser heaters (see table 56 on page 243) 242 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 245
pickup motor (250-sheet paper feeder) Reversing motor (duplexer) Side registration guide drive motor (duplexer) Refeed motor (duplexer) Paper feeder pickup motor (500-sheet paper feeder) Exhaust fan Fuser heater H1301 H1302 Fuser heater 1 Fuser heater 2 Q1860-90918 Chapter 7 Troubleshooting 243 - HP 5100 | Service Manual - Page 246
Figure 148. Connectors (main unit) 244 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 247
Figure 149. Connectors (duplexer and 250-sheet paper feeder) Q1860-90918 Chapter 7 Troubleshooting 245 - HP 5100 | Service Manual - Page 248
Figure 150. Connectors (500-sheet paper feeder) 246 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 249
Figure 151. PCAs Q1860-90918 Chapter 7 Troubleshooting 247 - HP 5100 | Service Manual - Page 250
control PCA 7 Feeder sensor PCA 8 Duplexer driver PCA Function Controls the print sequence Generates +24 Vdc, +5 Vdc, and +3.4 Vdc and drives the fuser heaters Relays the signals between sensors, loads, and the loads in the duplexer and monitors sensors 248 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 251
Figure 153. Clutches and solenoids Q1860-90918 Chapter 7 Troubleshooting 249 - HP 5100 | Service Manual - Page 252
and solenoids (duplexer) Table 58. Clutches and solenoids Symbol Name of symbol Code Clutch CL405 CL406 Solenoid SL306 SL404 SL1501 SL1701 SL2001 Name Registration roller clutch Feed solenoid (duplexer) Paper feeder pickup solenoid (500-sheet paper feeder) 250 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 253
OFF ON OFF Legal OFF ON ON Executive ON ON OFF Printer 250F Letter ON OFF ON 500F Letter-R Printer 250F Letter OFF OFF ON 500f Printer 250F Letter ON OFF OFF 500F Custom 250F = 250-sheet paper OFF OFF ON ON ON ON ON ON Q1860-90918 Chapter 7 Troubleshooting 251 - HP 5100 | Service Manual - Page 254
Dc controller inputs and outputs Figure 155. Dc controller I/O (1 of 4) 252 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 255
Figure 156. Dc controller I/O (2 of 4) Q1860-90918 Chapter 7 Troubleshooting 253 - HP 5100 | Service Manual - Page 256
Figure 157. Dc controller I/O (3 of 4) 254 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 257
Figure 158. Dc controller I/O (4 of 4) Q1860-90918 Chapter 7 Troubleshooting 255 - HP 5100 | Service Manual - Page 258
256 Troubleshooting Q1860-90918 - HP 5100 | Service Manual - Page 259
in this chapter identify and locate the printer's major subassemblies and replacement parts. This chapter discusses the following: Ordering parts and supplies, and getting support 259 Related documentation and software 259 Support 259 Ordering parts 259 Ordering consumables 259 Accessories - HP 5100 | Service Manual - Page 260
258 Parts and diagrams Q1860-90918 - HP 5100 | Service Manual - Page 261
and software To order documentation, drivers, updated HP printer software, and product and support information, see the information in chapter 2. Support Table 60. Technical support websites HP Connect Online (for HP partners) http://www.connect-online.hp.com HP Connect Online is an Internet - HP 5100 | Service Manual - Page 262
replacement tray RG5-7188-030CN 500-sheet replacement tray RG5-7164-000CN C4117-69001 HP multi-purpose paper HP LaserJet paper Toner cartridge (10,000 pages) SDRAM dual in-line memory -69001 J3111-69001 J4167-69001 J6058-69002 Maintenance Kit 110V 220V Q1860-67902 Q1860-67903 Q1860-69002 - HP 5100 | Service Manual - Page 263
Common hardware and replacement cables Table 62. Screws used in the printer Description Screw, M4x10 pan head tapping XA9-0974-000CN Table 63. Replaceable cables Description Part Number Cable, display, accessory power, photo sensor RG5-7073-000CN Cable, fuser ac RG5-3561-000CN Cable, - HP 5100 | Service Manual - Page 264
Diagrams and parts lists Upper delivery assembly Figure 159. Paper feed belt assembly Assembly locations (1 of 3) Formatter Main gear assembly Figure 160. Assembly locations (2 of 3) Paper feed roller assembly Power supply Dc controller Pickup gear assembly 262 Parts and diagrams Q1860- - HP 5100 | Service Manual - Page 265
Q1860-69005 Firmware DIMM, HPLJ 5100 (base) Q2449-67901 Firmware DIMM, HPLJ 5100Le Q2467-67901 Firmware DIMM, HPLJ 5100tn, 5100dtn Q2451-67901 Formatter (HPLJ base, 5100tn, 5100dtn) Q1860-67901 Q1860-69001 Formatter (HPLJ 5100Le) Q1863-67901 Q1863-69001 Fuser, 110V RG5-7060-000CN Q1850 - HP 5100 | Service Manual - Page 266
-040CN 1 1A RB1-6134-030CN 1 2 RG5-3548-000CN 1 3 Q1860-67904 1 4 RG5-3550-000CN 1 5 RG5-3551-040CN 1 Description Cover, front inner Tray 1 sensor arm Tray 1 paper guide Cover, front Cover, left side Cover, rear 264 Parts and diagrams Q1860-90918 - HP 5100 | Service Manual - Page 267
number Quantity Description 5E RB2-1977-000CN 1 Strap, rear output support 5Q RG5-3552-000CN 1 Face-up tray assembly 6 RB2-1745 Description Cover, top Control panel leaf spring Cable, control panel Toner cartridge door assembly Control panel assembly Cover, control panel LED Q1860- - HP 5100 | Service Manual - Page 268
1 See figure 175 Figure 164. Internal components (1 of 4) 266 Parts and diagrams See figure 171 Q1860-90918 - HP 5100 | Service Manual - Page 269
WG8-5362-000CN 1 38 RG5-3523-000CN 1 501 XB4-7401-007CN 14 502 XD2-1100-322CN 1 Description Tray 1 separation pad Tray 1 paper guide plate assembly Sensor, rear door Cable, paper sensor (PS307) Cable, paper sensor (PS402) Roller, lower delivery Bushing, right lower delivery roller Bushing - HP 5100 | Service Manual - Page 270
Figure 165. See figure 169 Internal components (2 of 4) 268 Parts and diagrams Q1860-90918 - HP 5100 | Service Manual - Page 271
Description Pickup roller assembly, Tray 1 Roller, Tray 1 pickup Power inlet assembly Pickup shaft bushing-trays 1 and 2 Shutter lever On/off switch Paper guide Tray 1 and 2 pickup shaft left bushing Tray 2 spring Gear, pickup, Tray 1 Pickup shaft bushing-trays 1 and 2 Switch rod Grounding plate/fan - HP 5100 | Service Manual - Page 272
12 RG9-1337-000CN 4 13 RS5-2225-020CN 4 17 RB2-1998-000CN 4 22 RG5-4916-000CN 1 502 XD2-1100-322CN 1 Description Transfer guide assembly Pad assembly Door switch Door switch spring Roller, lower-back delivery Roller spring, lower-back delivery Clutch, feed rollers Roller holder, top - HP 5100 | Service Manual - Page 273
components (4 of 4) Item number Part number Quantity 1 RG9-1542-000CN 1 3 RG5-3561-000CN 1 4 RG5-7072-000CN 1 5 Q1860-69004 1 6 XA9-0838-000CN 4 Description Transfer roller Cable (fuser ac) Cable (scanner) Laser/scanner assembly Screw, M4x16, with washer 8 Parts and diagrams 271 - HP 5100 | Service Manual - Page 274
Figure 168. Upper delivery assembly Table 71. Upper delivery assembly Item number Part number Quantity RG5-3542-090CN 1 3 RB2-1980-000CN 1 8 RS6-0357-000CN 1 Description Upper delivery assembly Lever, bin-full Gear, delivery roller 272 Parts and diagrams Q1860-90918 - HP 5100 | Service Manual - Page 275
Figure 169. Tray 2 paper pickup roller assembly Table 72. Tray 2 paper pickup roller assembly Item number Part number Quantity RG5-3521-020CN 1 4 RB2-1821-020CN 1 Description Paper pick up roller assembly (Tray 2) Pickup roller 250-sheet trays Q1860-90918 8 Parts and diagrams 273 - HP 5100 | Service Manual - Page 276
Figure 170. Paper feed belt assembly Table 73. Paper feed belt assembly Item number Part number Quantity RG5-4914-000CN 1 13 RB2-1887-000CN 1 14 RB2-1888-000CN 2 31 RB2-1905-000CN 1 Description Paper feed belt assembly Large feed belt Small paper feed belts Transfer roller bushing - HP 5100 | Service Manual - Page 277
Figure 171. Paper feed roller assembly Table 74. Paper feed roller assembly Item number Part number Quantity RG5-7084-000CN 1 7 RB2-1807-000CN 1 8 RB2-1808-000CN 1 Description Paper feed roller assembly Lever, registration sensor Spring, registration sensor Q1860-90918 8 Parts and - HP 5100 | Service Manual - Page 278
Figure 172. Registration roller assembly Table 75. Registration roller assembly Item number Part number Quantity RG5-4916-000CN 1 Description Registration roller assembly 276 Parts and diagrams Q1860-90918 - HP 5100 | Service Manual - Page 279
*A15 Figure 173. 250-sheet universal tray Table 76. 250-sheet universal tray Item number Part number RG5-7188-030CN *A15 RB2-2023-000CN 1 RF5-4120-000CN 2 RS5-2439-000CN Quantity 1 1 1 1 Description 250-sheet universal tray Plate, length adjustment Separation pad (does not include - HP 5100 | Service Manual - Page 280
gear assembly Item number Part number RG5-7079-000CN 5 RB2-1856-040CN 27 XA9-0267-000CN 28 RH7-1428-000CN Quantity 1 1 3 1 Description Main gear assembly Toner cartridge engagement arm Screw, TP, M3x6 Main motor 278 Parts and diagrams Q1860-90918 - HP 5100 | Service Manual - Page 281
Figure 175. Pickup gear assembly Table 78. Pickup gear assembly Item number Part number RG9-1524-000CN 6 XA9-0815-000CN 10 RH7-5235-000CN Quantity 1 1 1 Description Pickup gear assembly Screw, tp, M3x4 Solenoid, pickup, SL404 Q1860-90918 8 Parts and diagrams 279 - HP 5100 | Service Manual - Page 282
Figure 176. PCA assembly locations Table 79. PCA assembly locations Item number Part number 1 RG5-7058-000CN 2 Q1860-69005 3 Q1860-69006 3 Q1860-69007 Quantity 1 1 1 1 Description Paper handling PCA Dc controller Power supply (100 - 120V) Power supply (220 - 240V) 280 Parts and - HP 5100 | Service Manual - Page 283
See figure 176 Figure 177. Printer controller assembly Q1860-90918 Table 80. Printer controller assembly Item number Part number Quantity 6 RB2-1790-000CN 1 7 RB2-1791-000CN 1 9 RH2-5337-000CN 1 Description Sensor mount (rear of controller pan) Sensor lever - HP 5100 | Service Manual - Page 284
Figure 178. Fuser Table 81. Fuser Item number Part number Q1860-69008 Q1860-69009 Quantity 1 1 Description Fuser, exchange (100-120V) Fuser, exchange (220-240V) 282 Parts and diagrams Q1860-90918 - HP 5100 | Service Manual - Page 285
Figure 179. 250-sheet feeder Q1860-90918 Table 82. 250-sheet feeder Item number Part number (not shown) 1 RG5-7188-030CN RG5-7184-000CN 4 RB1-7499-000CN 7 RB1-7503-000CN 9 RG5-3644-000CN 9D RB2-1821-020CN 14A RB1-7501-020CN Quantity 1 1 1 1 1 1 1 Description 250-sheet universal - HP 5100 | Service Manual - Page 286
Figure 180. PCA assembly locations, 250-sheet feeder Table 83. 250-sheet feeder Item number Part number 1 RG5-7184-000CN 2 RG5-2125-000CN Quantity 1 1 Description Feeder control PCA, 250-sheet feeder Paper-size switch PCA, 250-sheet feeder 284 Parts and diagrams Q1860-90918 - HP 5100 | Service Manual - Page 287
number (not shown) (not shown) RG5-7164-000CN C4117-69001 2 RB3-0441-000CN 4 RG5-7196-000CN Quantity 1 1 1 1 Description 500-sheet replacement tray 500-sheet replacement tray (exchange) Tray cover, rear of 500-sheet feeder Paper-size detection assembly Q1860-90918 8 Parts and diagrams 285 - HP 5100 | Service Manual - Page 288
Figure 182. 500-sheet feeder (2 of 2) 286 Parts and diagrams Q1860-90918 - HP 5100 | Service Manual - Page 289
-2632-000CN 14 RB3-0431-000CN 15 RB3-0443-000CN 16 RB3-0444-000CN 506 XB4-7301-207CN Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 Description 500-sheet replacement tray Paper pickup drive assembly Joint Upper contact cable Feed roller Tray sensor assembly Roller, feed, 500-sheet feeder Paper arm - HP 5100 | Service Manual - Page 290
Figure 183. PCA assemblies, 500-sheet feeder Table 86. 500-sheet feeder Item number Part number 1 RG5-7197-000CN 2 RG5-4212-020CN Quantity 1 1 Description Feeder controller PCA, 500-sheet feeder Paper-size switch PCA, 500-sheet feeder 288 Parts and diagrams Q1860-90918 - HP 5100 | Service Manual - Page 291
Figure 184. Duplexer Table 87. Duplexer Item number Part number Q1860-69010 Quantity Description 1 Duplexer Q1860-90918 8 Parts and diagrams 289 - HP 5100 | Service Manual - Page 292
link holder M3x12 screw, tapping, truss head 500-sheet replacement tray 500-sheet replacement tray (exchange) Tray cover, rear of 500-sheet feeder assembly Pickup roller, 250-sheet trays Lever, paper sensor Fuser, exchange (100-120V) Fuser, exchange (220-240V) Sensor mount (rear of controller - HP 5100 | Service Manual - Page 293
88. Alphabetical parts list (continued) Description Part number Toner cartridge engagement arm RB2-1856-040CN Screw, TP, Cable (fuser ac) RG5-3561-000CN Cable (scanner) RG5-7072-000CN Laser/scanner assembly Q1860-69004 Screw, M4x16, with washer XA9-0838-000CN Transfer guide assembly - HP 5100 | Service Manual - Page 294
RH7-1552-000CN Tray 2 shaft gear RS5-0695-000CN Spring RS5-2434-000CN Cartridge guide left RB2-1774-000CN Cartridge guide right RB2-1775-000CN Tray 1 separation pad RF5-4119-000CN Tray 1 paper guide plate assembly RG5-3520-060CN Sensor, rear door RG5-3553-000CN Cable, paper sensor - HP 5100 | Service Manual - Page 295
front inner RG5-3547-040CN Tray 1 sensor arm RB1-6134-030CN Tray 1 paper guide RG5-3548-000CN Cover, front Q1860-67904 Cover, left side RG5-3550-000CN Cover, rear RG5-3551-040CN Strap, rear output support RB2-1977-000CN Face-up tray assembly RG5-3552-000CN Pin, front cover RB2-1745 - HP 5100 | Service Manual - Page 296
(100-120V) Q1860-69009 Fuser, exchange (220-240V) Q1860-69004 Laser/scanner assembly Q1860-69006 Power supply (100 - 120V) Q1860-69007 Power supply (220 - 240V) C4110-40004 Overlay, English (other languages available) C4117-69001 500-sheet replacement tray (exchange) RB1-2190-000CN - HP 5100 | Service Manual - Page 297
, Tray 2 size sensor RB2-1856-040CN Toner cartridge engagement arm RB2-1887-000CN Large feed (right) RB2-1977-000CN Strap, rear output support RB2-1980-000CN Lever, bin-full RB2-1985 -4117-000CN Pad assembly RF5-4118-000CN Transfer guide assembly RF5-4119-000CN Tray 1 separation pad - HP 5100 | Service Manual - Page 298
on page 266 RG5-3556-040CN Toner cartridge door assembly Figure 163 on page 266 RG5-3561-000CN Cable (fuser ac) Figure 167 on page 271 sheet replacement tray Figure 182 on page 286 RG5-7164-000CN 500-sheet replacement tray 1337-000CN Roller 1, face-down guide Figure 166 on page 270 RG9- - HP 5100 | Service Manual - Page 299
Table 89. Numerical parts list (continued) Part number Description RS5-2439-000CN Spring, separation pad RS5-2441-000CN Spring, compression RS5-2632-000CN Spring, tension RS6-0357-000CN Gear, delivery roller RS6-0357-000CN Gear, lower delivery shaft WG8-5362-000CN Sensor, PS402 WG8- - HP 5100 | Service Manual - Page 300
298 Parts and diagrams Q1860-90918 - HP 5100 | Service Manual - Page 301
with letter paper 48 setting wider margins 52 specifications 25 A5 paper specifications 25 ac power problem 189 ac/dc power distribution process 72 and replacing 167 printer drive 262 registration roller 263 registration, removing and replacing 159 removing and replacing 127 service approach 36 - HP 5100 | Service Manual - Page 302
228 printer 249 compact disc, HP support assistant 37 component locations 227 conditioning the photosensitive drum 85 Configuration menu on control panel 53 configuration page printing 47, 205 using to troubleshoot 205 using to verify options 206 configuration page, JP Jetdirect 225 connectivity - HP 5100 | Service Manual - Page 303
5100Le printers 21 HP LaserJet 5100 with accessories 23 HP LaserJet 5100tn and 5100dtn printers 22 Q1860-90918 DIMMs caution for handling 107 checking installation 109 designating fonts 52 embedded Web server 260 flash 79 options 16 part and product numbers 260 removing and replacing 107 supported - HP 5100 | Service Manual - Page 304
. See control panel FRUs (field replaceable units) service approach 36 FRUs (field replaceable units), ordering 259 full disk 193, 195 flash device 194 memory 194 NVRAM 200 full-duplex operation, setting 57 functional overview basic sequence of operation 101 printer and printing processes 71 fuse - HP 5100 | Service Manual - Page 305
fuser 243 heavy paper 31 help service and support 36 high-voltage power distribution process 74 high-voltage power supply circuit 74 HP Connect Online website 259 HP Customer Care Online 259 HP Customer Support (HPCS) 36 HP FastRes, setting 50 HP PartnerCare 37 HP ProRes description 16 setting 50 HP - HP 5100 | Service Manual - Page 306
turning off message 54 maintenance kit 260 manual feed, turning on and off 48 304 Index manuals ordering 259 map of control panel menus. See control panel menu map margins adjusting top after paper-handling PCA replaced 132 for envelopes 30 setting wider for A4 paper 52 mass storage installing 110 - HP 5100 | Service Manual - Page 307
, 248 order of removal 112 PCL fonts printing list 47 setting 52 Perform Printer Maintenance message 195 personality (language), setting default for printer 53 phone numbers ordering parts 36 service and support 37 worldwide support 38 phone support. See support photosensitive drum 83, 84 cleaning - HP 5100 | Service Manual - Page 308
from Tray 2 93 jobs 46 PCL font list 47 PS error page 52 PS font list 47 resuming 43 selecting number to print 46 Printing menu on control panel 51 private jobs. See jobs Private/Stored Jobs menu on control panel 46 problems. See support; troubleshooting processors availability by model 18 included - HP 5100 | Service Manual - Page 309
-sheet feeder, removing and replacing 182 Tray 1, removing and replacing 140 ROM (read-only memory) 80 rotation functional check 224 rough paper, setting printer for 49 Q1860-90918 S safety statements 32, 33 saving power 53 toner 50 values on control panel 43 scalable PCL fonts 16 scanner drive 76 - HP 5100 | Service Manual - Page 310
replacing 119 toner cartridge guides, removing and replacing 166 toner cartridges description and components 83 detection process 75 image rating 207 life expectancy 79 product number 260 resetting to full 54 toner sensor 82 troubleshooting 207 toner gauge, resetting to full 54 tools for maintenance - HP 5100 | Service Manual - Page 311
191 using half self-test functional check 224 using HP Jetdirect configuration page 225 using information pages 204 using paper path test 203 using PC direct connect (parallel) test 225 using printer messages 193 See also testing troubleshooting problem areas display 190 fan 188 feeding 27 image - HP 5100 | Service Manual - Page 312
28 paper in 250-sheet feeder 25 paper in 500-sheet feeder 26 paper in duplexer 26 paper in Tray 1 25 paper in Tray 2 25 printer 23 white lines on paper 221, 222 Windows operating systems 16 worldwide service and support 38 write protected disk 193 flash device 194 310 Index Q1860-90918 - HP 5100 | Service Manual - Page 313
- HP 5100 | Service Manual - Page 314
copyright © 2002 Hewlett-Packard Company http://www.hp.com/support/lj5100
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service
hp
LaserJet 5100
5100tn
5100dtn
5100Le