HP Color LaserJet 5500, 5500n, 5500dn, 5500dtn, 5500hdn series printer Service Repair Manual

Service HP color LaserJet 5500/5550 Printers

HP Color LaserJet 5500/5550 Printers Service Manual

© 2005 Copyright Hewlett-Packard Development Company, L.P. Reproduction, adaptation or translation without prior written permission is prohibited, except as allowed under the copyright laws. The information contained herein is subject to change without notice. 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. Part number: Q3713-90965 Edition 1, 1/2005 Trademark Credits Adobe and Adobe Photoshop are trademarks of Adobe Systems Incorporated. CorelDRAW™ is a trademark of Corel Corporation or Corel Corporation Limited. Microsoft® is a U.S. registered trademark of Microsoft Corporation. Netscape is a U.S trademark of Netscape Communications Corporation. PANTONE® Pantone, Inc.’s check- standard trademark for color. PostScript is a trademark of Adobe Systems, Incorporated, which may be registered in certain jurisdictions. TrueType is a U.S. trademark of Apple Computer, Inc. UNIX is a registered trademark of the Open Group. Windows, MS Windows, and Windows NT are U.S. registered trademarks of Microsoft Corporation.

Table of contents 1 Printer description Model Configurations ................................................................................................................3 The HP Color LaserJet 5500 series printer ........................................................................ 3 Performance, memory, and other printer features .................................................................... 6 Identification ..............................................................................................................................9 Model and serial numbers ..................................................................................................9 HP Color LaserJet 5500 models ......................................................................................11 HP Color LaserJet 5550 models ......................................................................................12 Printer specifications ............................................................................................................... 13 Supply storage requirements (HP Color LaserJet 5500 series) ...................................... 15 Product information ................................................................................................................. 16 Product information ..........................................................................................................16 Electrical specifications (HP Color LaserJet 5500 models) .............................................16 Electrical specifications (HP Color LaserJet 5550 models) .............................................17 Media requirements ................................................................................................................19 Selecting print media ........................................................................................................19 Media specifications .........................................................................................................19 Supported media weights and sizes (HP Color LaserJet 5500 models) .......................... 19 Supported paper weights and sizes (HP Color LaserJet 5550 models) ..........................22 Media specifications for 2-sided (duplex) printing ............................................................25 Media to avoid ..................................................................................................................25 Media that may cause damage to the printer ................................................................... 26 Printing on special media .................................................................................................26 Transparencies ................................................................................................................. 26 Printing on transparencies ................................................................................................ 26 Glossy paper .....................................................................................................................27 Colored paper ................................................................................................................... 27 Heavy paper .....................................................................................................................27 Printing images (HP Color LaserJet 5550 models) ..........................................................28 Envelopes ......................................................................................................................... 28 Labels ...............................................................................................................................29 HP LaserJet Tough paper ................................................................................................29 Preprinted forms and letterhead ...................................................................................... 29 Recycled paper .................................................................................................................30 Weight equivalence table .................................................................................................30 Hewlett-Packard warranty statement ...................................................................................... 32 Limited warranty for print cartridge life .................................................................................... 33 HP's Premium Protection Warranty. Color LaserJet Image Fuser Kit and Image Transfer Kit Limited Warranty Statement ............................................................................34 Declaration of Conformity ........................................................................................................35 Safety information ...................................................................................................................37 Laser safety statement .....................................................................................................37 Canadian DOC regulations ...............................................................................................37 EMI statement (Korea) .....................................................................................................38 VCCI statement (Japan) ................................................................................................... 38 Laser Statement for Finland .............................................................................................39 ENWW iii

Toner safety ............................................................................................................................40 2 Service approach Chapter contents ..................................................................................................................... 41 Service approach ....................................................................................................................42 Parts and supplies ...................................................................................................................43 Ordering parts ...................................................................................................................43 By phone: ..........................................................................................................................43 By mail: ............................................................................................................................. 43 Ordering supplies ..............................................................................................................43 Ordering parts, supplies, and accessories over the Internet ............................................ 43 Ordering directly through the embedded Web server (for printers with network connections) ..................................................................................................................43 Ordering directly through the HP Toolbox software (HP Color LaserJet 5550 model only) .................................................................................................................... 44 Exchange program ...........................................................................................................44 Supplies ............................................................................................................................ 44 World Wide Web ...............................................................................................................44 HP service parts information compact disc ......................................................................45 HP support assistant compact disc ..................................................................................45 Customer care reseller sales and service support center ................................................45 HP service agreements ....................................................................................................45 Other areas .......................................................................................................................45 HP customer care ............................................................................................................. 45 Ordering related documentation and software .................................................................46 HP maintenance agreements .................................................................................................48 On-site service agreements ..............................................................................................48 Priority on-site service ......................................................................................................48 Next-day on-site service ................................................................................................... 48 Weekly (volume) on-site service ......................................................................................48 3 Installation and configuration Site requirements .................................................................................................................... 51 Space requirements ................................................................................................................ 52 500-sheet paper feeder dimensions ................................................................................. 52 Printer stand dimensions .................................................................................................. 52 Unpack the printer ................................................................................................................... 53 Package contents .............................................................................................................53 Unpacking the HP Color LaserJet 5500 series printer (for base models 5500n and 5500dn) ..................................................................................................................54 Unpacking the HP Color LaserJet 5500/5550dtn and 5500/5550hdn models .......................58 Installing print cartridges for HP Color LaserJet 5500 series printers ....................................62 Installing print cartridges (HP Color LaserJet 5500 series models) .................................62 Installing paper trays (HP Color LaserJet 5500 series printers) ......................................64 Installing accessories (HP Color LaserJet 5500 series printers) .....................................66 Installing optional printer stand (HP Color LaserJet 5500 series printers) ....................... 69 Installing a new overlay (HP Color LaserJet 5500 models) .............................................70 Installing a new control panel label (HP Color LaserJet 5550 models) ...........................71 Testing the printer operation .............................................................................................73 Using PowerSave .............................................................................................................73 Connecting to a computer ....................................................................................................... 75 Parallel connections .........................................................................................................75 USB configuration (HP Color LaserJet 5550 models) ...................................................... 76 Auxiliary connection configuration (HP Color LaserJet 5550 models) .............................76 Network connections ........................................................................................................77 iv ENWW

Enhanced I/O (EIO) configuration ........................................................................................... 79 HP Jetdirect print servers .................................................................................................79 Available enhanced I/O interfaces ....................................................................................79 NetWare networks ............................................................................................................79 Windows and Windows NT networks ...............................................................................80 AppleTalk networks ..........................................................................................................80 LocalTalk configuration .....................................................................................................80 LocalTalk network configuration ....................................................................................... 80 UNIX/Linux networks ........................................................................................................80 Wireless printing ......................................................................................................................81 IEEE 802.11b standard ....................................................................................................81 Bluetooth ...........................................................................................................................81 Printer drivers .......................................................................................................................... 82 Available drivers ...............................................................................................................82 Additional drivers ..............................................................................................................83 Select the right printer driver for your needs ....................................................................83 Printer driver Help .............................................................................................................84 Software for Macintosh computers .........................................................................................85 PPDs .................................................................................................................................85 HP LaserJet Utility ............................................................................................................85 Installing the printing system software .................................................................................... 86 Installing Windows printing system software for direct connections ................................86 Installing Windows printing system software for networks ...............................................87 To set up Windows-sharing to use the printer on a network ............................................ 87 Installing Macintosh printing system software for networks .............................................88 Installing Macintosh printing system software for direct connections (USB, HP Color LaserJet 5550 models) ..................................................................................89 Installing the software after the parallel or USB cable has been connected .................... 90 Network configuration .............................................................................................................92 Configuring Novell NetWare frame type parameters .......................................................92 HP Web Jetadmin .............................................................................................................93 UNIX .................................................................................................................................93 Utilities ..............................................................................................................................93 Embedded Web server ..................................................................................................... 94 Configuring TCP/IP parameters .......................................................................................96 Setting network security on the printer .................................................................................102 Locking the control panel ................................................................................................102 Using an ASCII PJL escape sequence to set network security .....................................103 4 Printer maintenance Cleaning the printer and accessories ..................................................................................106 Cleaning spilled toner ..................................................................................................... 106 Vacuum specifications .................................................................................................... 106 Periodic cleaning ................................................................................................................... 108 Cleaning the static discharge comb ...............................................................................108 Cleaning the OHT sensor ............................................................................................... 109 Approximate replacement intervals for supply items ............................................................111 ETB life under different circumstances ...........................................................................113 Locating supplies ..................................................................................................................114 Replacing supply items .........................................................................................................115 Changing print cartridges ...............................................................................................115 Replacing the transfer unit (ETB) ...................................................................................117 Replacing the transfer unit when it is not at end of life ..................................................118 Replacing the fuser .........................................................................................................119 Replacing the fuser when it is not at end of life ..............................................................120 ENWW v

Printer memory (HP Color LaserJet 5500 models) ............................................................... 122 To print a configuration page ..........................................................................................122 Installing memory and font DIMMs (for HP Color LaserJet 5500 models) ..................... 122 Installing DDR memory DIMMs (for HP Color LaserJet 5550 models) ..........................125 Enabling memory (HP Color LaserJet 5500 models) ..................................................... 128 Enabling the language font DIMM (HP Color LaserJet 5550 models) ...........................128 Enabling the language font DIMM (HP Color LaserJet 5500 models) ...........................129 Checking DIMM installation (HP Color LaserJet 5500 models) .....................................129 Installing an HP Jetdirect print server card ....................................................................129 5 Theory of operation Basic operation .....................................................................................................................135 Operation sequence .......................................................................................................135 Engine control system ...........................................................................................................137 DC controller circuit ........................................................................................................137 Motors and fans .............................................................................................................. 139 Fuser power supply circuit .............................................................................................. 141 Heater temperature control .............................................................................................142 Heater temperature control (HP Color LaserJet 5550 models) ...................................... 143 Failure detection (HP Color LaserJet 5550 models) ......................................................144 High-voltage power supply .............................................................................................144 Low-voltage power supply .............................................................................................. 145 Formatter system ............................................................................................................146 PowerSave .....................................................................................................................146 Input/Output .................................................................................................................... 147 Printer memory ...............................................................................................................148 Read-only memory .........................................................................................................148 Random-access memory ................................................................................................148 Firmware DIMM (HP Color LaserJet 5500 models) .......................................................148 Firmware compact flash (HP Color LaserJet 5550 models) ..........................................148 Nonvolatile memory ........................................................................................................ 148 PJL overview ..................................................................................................................149 PML .................................................................................................................................149 Control panel ..................................................................................................................149 Laser/scanner system ........................................................................................................... 150 Scanner motor control ....................................................................................................151 Image formation system ........................................................................................................152 Image formation process ................................................................................................ 153 Print cartridges ................................................................................................................155 Toner level detection ......................................................................................................156 Electrostatic transfer/transport belt (ETB) unit ...............................................................160 Electrostatic latent image formation block ...................................................................... 161 Development block .........................................................................................................163 Transfer block ................................................................................................................. 164 Fusing block ....................................................................................................................165 Fuser motor speed control ..............................................................................................166 Cleaning block ................................................................................................................166 Calibration and cleaning ................................................................................................. 167 Color plane registration calibration ................................................................................. 171 Drum phase calibration ...................................................................................................172 Image stabilization control .............................................................................................. 172 Pickup/feed system ............................................................................................................... 175 Pickup/feed unit ..............................................................................................................178 Fuser/delivery unit ..........................................................................................................185 Duplex feed unit ..............................................................................................................186 vi ENWW

500-sheet paper feeder .........................................................................................................187 Pickup and feed operations ............................................................................................ 187 6 Removal and replacement Introduction ............................................................................................................................191 Removal and replacement strategy ................................................................................191 Repair notices .................................................................................................................191 Caution regarding electrostatic discharge (ESD) ...........................................................191 Required tools .................................................................................................................191 Types of screws ..............................................................................................................192 Supplies .................................................................................................................................194 Print cartridges and ETB ................................................................................................194 Covers and external components .........................................................................................196 Rear cover ......................................................................................................................196 Top cover ........................................................................................................................196 Rear top cover ................................................................................................................197 Left cover ........................................................................................................................ 198 Right cover ......................................................................................................................199 Reinstallation tip .............................................................................................................200 Multi-purpose tray (Tray 1) .............................................................................................200 Front cover ......................................................................................................................201 Control panel ..................................................................................................................202 Cassette cover ................................................................................................................204 Internal components (front) ................................................................................................... 205 Paper pickup unit ............................................................................................................ 205 Cassette sensor PCB .....................................................................................................206 Multi-purpose tray sensor PCB ......................................................................................206 Paper pickup drive unit ................................................................................................. 207 Lifter drive unit ..............................................................................................................208 Cassette (Tray 2) paper pickup and feed rollers ............................................................210 Solenoid and clutch ........................................................................................................211 Cassette separation roller .............................................................................................212 Multi-purpose tray pickup roller ......................................................................................213 Multi-purpose tray separation pad ................................................................................. 214 Color registration detection unit ......................................................................................214 Internal components (left side) ..............................................................................................216 DC controller shield ........................................................................................................216 Environment sensor (HP Color LaserJet 5550 models) ................................................. 216 Memory tag antenna PCBs ............................................................................................217 E-label memory controller PCB ......................................................................................223 DC controller PCB ..........................................................................................................224 Cassette paper size detection switches .........................................................................225 Power supply fan ............................................................................................................226 Internal components (rear) .................................................................................................... 228 Formatter ........................................................................................................................228 Low-voltage power supply .............................................................................................. 229 Formatter case ................................................................................................................ 231 Laser/scanner units ........................................................................................................233 Internal components (right side) ...........................................................................................239 High-voltage power supply PCB .....................................................................................239 Toner level detection PCB .............................................................................................. 240 High-voltage contact blocks ............................................................................................241 Door switch ..................................................................................................................... 242 Internal components (top) .....................................................................................................244 Discharging PCB ............................................................................................................244 ENWW vii

Fuser power supply PCB ................................................................................................ 245 Fuser drive unit ............................................................................................................... 246 Fuser inlet paper sensor ................................................................................................. 249 Fuser delivery sensor and output bin full sensor ............................................................250 Static discharge comb ....................................................................................................252 Formatter fan ..................................................................................................................253 Cartridge fan ................................................................................................................... 253 Optional 500-sheet paper feeder ..........................................................................................255 Paper feeder left cover ...................................................................................................255 Paper feeder right cover ................................................................................................. 256 Paper feeder pickup and feed rollers .............................................................................257 Paper feeder separation roller ........................................................................................ 257 Paper feeder pickup unit .................................................................................................257 Paper feeder lifter drive unit .........................................................................................259 Paper feeder length and width detection switches ....................................................... 260 Paper feeder pickup clutch ............................................................................................. 261 Paper feeder PCB ..........................................................................................................262 7 Troubleshooting Introduction ............................................................................................................................266 Troubleshooting process .......................................................................................................267 Pre-troubleshooting checklist .........................................................................................267 Troubleshooting flowchart ..............................................................................................268 Troubleshooting flowchart (continued) ...........................................................................270 Troubleshooting power-on .............................................................................................. 270 Printer error troubleshooting .................................................................................................272 Status messages ............................................................................................................272 Warning messages ......................................................................................................... 272 Error messages ..............................................................................................................272 Critical error messages ...................................................................................................272 Alphabetical printer messages .............................................................................................. 273 Numerical printer messages .................................................................................................302 Replacement parts configuration (HP Color LaserJet 5550 models) ...................................341 Both the formatter and DC controller ..............................................................................341 Formatter (new or previously installed in another printer) .............................................. 341 DC controller (new or previously installed in another printer) ........................................342 Paper path troubleshooting ................................................................................................... 343 Jams ...............................................................................................................................343 Jam locations ..................................................................................................................343 Jam locations by error message ....................................................................................343 Jam recovery ..................................................................................................................345 Avoiding paper jams ....................................................................................................... 346 Persistent jams ...............................................................................................................347 Basic troubleshooting for paper jams .............................................................................347 Data collection ................................................................................................................347 General paper path troubleshooting ............................................................................... 348 Paper path checklist .......................................................................................................348 Paper transport troubleshooting ............................................................................................354 Paper is wrinkled or folded .............................................................................................354 Image formation troubleshooting ..........................................................................................356 Print quality problems associated with media ................................................................356 Overhead transparency defects .....................................................................................356 Print quality problems associated with the environment ................................................357 Print quality problems associated with jams ..................................................................357 Print quality troubleshooting pages ................................................................................357 viii ENWW

HP Color LaserJet 5500, 5500n, 5500dn, 5500dtn, 5500hdn series printer Service Repair Manual

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