HP LaserJet 4000 and 4050 Series Printers - 7M Tech Assist, Troubleshooting 41.5 Errors and Blank Pages ___________________________________________________ ISSUE: The HP LaserJet 4000 or 4050 series printer displays a 41.5 error and has intermittent blank pages. NOTE: The 41.5 error is not related to the laser/scanner although the manual suggests replacing the laser/scanner and engine controller board. It is a paper feed issue. SOLUTION: The 41.5 error on HP LaserJet 4000 and 4050 series printers is a media feed issue, not a laser/scanner issue. The paper does not reach the sensor in time for the laser/scanner to be activated. Follow the steps below to verify proper movement of paper in the printer. 1. Check the condition of separation roller in the tray(s). Clean the rollers. Replace if worn or damaged. 2. Check the Torque limiter in the tray(s). Remove the torque limiter and run a paper path test. 3. Adjust the spring on the underside of the tray, next to the torque limiter, to a different notch. Run a paper path test. 4. Check separation roller mounting assembly including the drive gear, bushing, coupler, and spring for damage or offset. 5. Check the paper guide in tray(s) for warp, burrs or other damage that could cause paper to hang in tray. 6. Check transport rollers that move paper from optional Trays 3 and 4 for proper operation. Replace if worn or damaged. 7. Check pickup rollers for wear. If rollers are worn they will not push the paper into the paper path quickly enough for sensors to register the paper and activate the laser/scanner. Replace if worn or damaged. 8. Check registration, feed sensors, and the flags for damage and proper operation. Defeat one sensor at a time, power cycling after checking each sensor, to verify sensor is not damaged or stuck. 9. If the error still persists after performing the previous steps, replace the Paper Feed Assembly. HP LaserJet 4000 and 4050 Series Printers - 41.5 Error Message ___________________________________________________ In this document: Parts needed (Part numbers are subject to change) Instructions Procedures Adjust Tray 1 default paper size if associated with error Inspect tray guide adjustments Replace the paper tray Replace the registration assembly Removal and replacement procedures Parts needed (Part numbers are subject to change) Alternate part Part descriptions Part numbers numbers Feed and Separation Rollers RF5-1885-000CN N/A Tension Spring RS5-2622-020CN N/A Registration and Feed Sensor RG5-2642-000CN N/A Assembly Paper Feed Assembly RG5-2651-010CN N/A Paper Trays: C4124A* N/A Optional 500-Sheet Tray* C4125A* C4125-67901* Universal 500-Sheet Tray* C4126A* C4126-67901* 250-Sheet Replacement Tray* RG5-2652- Registration Assembly* N/A 070CN* *Optional, unless determined to be otherwise during the troubleshooting process Instructions The 41.5 error refers to a media feed error. To fix this error: 1. Inspect and clean the paper path with a water-dampened, lint-free clothe to eliminate obstructions and paper dust. 2. Print and review the event log. The event log retains the last 30 error messages. Use the event log to diagnose and troubleshoot intermittent failures. o Error log results: 41.5 errors point to media that has reached the PS102 or PS103 sensor too early. NOTE: The printer should display Ready on the Control Panel in order to print. If unable to print an event log, configuration page or menu map from a lower tray(s), attempt to print with Tray 1 set to First. 3. Print and review the configuration page. NOTE: A configuration page can be used to view printer settings and determine what options are installed on the printer. If an HP Jetdirect printer server EIO card is installed, an HP Jetdirect configuration page will print out as well. 4. Print and review the menu map, which lists paper tray configuration settings and sizes. 5. Print a paper path test from all trays to recreate and isolate the issue. 6. Identify the location of the issue within the paper path. NOTE: Paper motion from lower trays and roller rotation may be viewed from the back of the printer. Take note where sheets exhibit irregular media movement. 7. Identify with which tray(s) the 41.5 error occurs. 8. Inspect the paper path and all paper path mechanical assemblies in the location where the issue can be isolated. 9. Eliminate paper and tray adjustment issues. 10. Check sensors PS102 and PS103 to see if they flag the correct error messages and return to READY. 11. Inspect the feed/separation rollers. o Verify that the feed/separation rollers are in place and not missing. o Ensure that these rollers are clipped properly in place. o Ensure the tension spring is not missing that holds the feed/separation rollers in place. (The tension spring is located on the bottom of the tray, directly below the feed/separation roller.) 12. Inspect the paper feed assembly, replacing if damaged. 13. Inspect the registration assembly, replacing if damaged. 14. Recheck the connections. Procedures Identifying the location of the issue within the paper path A paper path test combined with the results of the event log and configuration page will help isolate problem areas. Performing a paper path test 1. Press MENU until Information Menu appears in the printer display. 2. Press ITEM until Print Paper Path Test appears in the printer display. 3. Press SELECT. 4. Press [+] to cycle selections until the desired paper trays appear. 5. Press SELECT. 6. Press [+] until the desired output bin appears (open the Rear Output Bin to print to it). 7. Press SELECT. 8. Press [+] until the desired duplex mode (on or off) appears. 9. Press SELECT 10. Press [+] to cycle selections until the desired number of copies appear. 11. Press SELECT to perform the paper path test. Eliminating paper and tray adjustment issues Paper that is pre-printed has perforations, and/or rough edges can cause paper jams, misfeeds, and multi-feeds. Paper with incorrect fiber content, thickness, weight, grain, smoothness (Sheffield) and moisture content, can also cause similar problems. NOTE: Do not fan paper. To separate a ream, bow it into a U shape. 1. Inspect trays for proper paper loading. Be sure the paper is stacked loosely under the paper guide to ensure that over filling is not the issue. 2. Inspect the tray guide adjustments to ensure they are set correctly. Tray guides should be adjusted snugly to the correct paper size. The paper size notches should be aligned. 3. Determine if the paper is multi-feeding. Test with paper from a new, unopened package. 4. Switch paper trays (from this printer or from a similar model) to determine if jams are tray related. Checking sensors 1. Trip, tape down, or insert paper to engage the sensor flag, then open and close the printer's top cover. When activated, sensor PS102 should indicate a 13.1 error and PS103 should indicate a 13.2 error. 2. Replace the Registration/Feed Sensor Assembly if tripping the sensors does not result in the correct error messages or if the printer does not return to READY. Inspecting, removing, and replacing the feed roller 1. Turn the printer off. 2. Unplug the power cable. 3. Remove the paper tray(s) from the printer. 4. Inspect the feed roller (located in the printer) and verify if it is correctly seated or damaged. If damaged, replace it. To remove the feed roller, pinch the release at the left side of the roller and slide it off the shaft. See Figure 1. Figure 1: Removing the feed roller Inspecting, removing, and replacing the separation roller NOTE: Blank pages will also print out with a 41.5 error. Reseating the separation roller clutch and feed separation roller should fix this issue. 1. Release the latch and lift the cover inside the tray. 2. Pinch the release tab at the left side of the roller and slide it off the shaft. 3. Replace the separation roller and verify that it is positioned correctly and locked in place. 4. Print a test page to see if the roller replacement resolved the media feed error. If not, continue with the repair steps. NOTE: Ensure that the separation roller access panel is closed correctly before inserting the tray back into the printer. Failure to latch the access panel correctly may cause the tray to become lodged into the printer. Adjust Tray 1 default paper size if associated with error 1. Press the MENU key until Paper Handling Menu appears on the Control Panel. 2. Press the ITEM key until Tray 1 size = appears. 3. Press the VALUE key to change the size that the tray equals if it does not match the desired setting. 4. Press the SELECT key to make this change the new printer default. Inspect tray guide adjustments Verify that all of the tray guides are aligned to the desired size setting and are not damaged. Replace the paper tray If no trouble is found with the feed/separation rollers, remove and replace the tray that is located where the issue occurs. If the tray guides, and/or paper size dial are non-functional, replace the paper tray. Replace the registration assembly If this error occurs from all trays, replace the registration assembly. NOTE: Do not replace the registration assembly if the error only occurs with the lower trays. If the error can be isolated to the lower trays, replace the paper feed assembly. Removal and replacement procedures Removing and replacing the Control Panel, covers, and Tray 1 1. Turn the printer off and Figure 3: Removing the rear right-side cover unplug the power cable along with any other cables that may be attached. 2. Remove the print cartridge. 3. Remove the rear, right-side cover by grasping the cover by the rear lip and pulling firmly toward the rear of the printer until it stops. 4. Remove the Control Panel Figure 4: Removing the Control Panel overlay overlay. Using a flat-blade screwdriver, gently pry upward on the right side of the Control Panel overlay to loosen it. 5. Remove the Control Panel overlay from the tabs on the left and lift it upward, off of the printer. 6. Remove the Figure 5: Removing the Control Panel Control Panel. a. Use a flat- blade screwdriver to pry each side of the Control Panel upward. b. Remove the top of the Control Panel from the tab. c. Disconnect the ribbon cable from the Control Panel 7. Remove the print cartridge drive arm a. Locate the print cartridge drive arm to the Figure 6: Removing the print cartridge drive arm right of the top cover hinge. b. Remove the print cartridge drive arm by using needle- nose pliers to pinch the pin from its hinge on the top cover. Note: Be sure to reconnect the print cartridge drive arm when replacing the top cover, or the print cartridge will not seat properly. Figure 7: Removing the top cover 8. Remove the top cover. a. Remove the four screws holding the top cover. Two are behind the rear output bin, near the top, and two are on top of the printer under the top cover. 1- Four screws holding the top cover 9. Squeeze the right front side of the top cover to remove it. It may be necessary to use Figure 8: Releasing tabs to lift the top cover a small flat- blade screwdriver to release the tab inside the small hole. a. Hold the output assembly (located toward the rear of the printer) in place. b. Remove the top cover. 10. Remove the Figure 9: Removing left-side cover left-side cover a. Open Tray 1 b. Release the latch on the left side cover from the inside of the printer. c. Release the latches on the front side of the cover. d. Lift the cover upward to release the front topside of the 1- Latch cover, and then pull the cover 2- Catch away from the printer. 11. Remove the right-side cover a. Release the Figure 10: Removing the right side cover latch at the top center of the cover. b. Lift the cover straight up until it is free of the tabs at the bottom and from the power switch rod, then, pull it away from the printer. Note: Be sure to reconnect the power switch rod when reinstalling the front right side cover. 1- Latch at the top center of the cover 12. Remove Tray 1 a. Open Tray 1 b. Push outward Figure 11: Removing Tray 1 from the front cover on the two slot hinges to release the pins on Tray 1. c. Slide the front cover to the right, and remove it from the three hinges on the bottom. d. Firmly pull both sides of the Tray 1 sensor arm cover away from the printer until it releases from the shaft. e. Rotate Tray 1 downward, and remove it from the two hinges . Note: Be sure that the sensor arms move freely when reinstalling the Tray 1 sensor arm cover. Removing the Tray 1 pickup assembly 1. Remove the top cover. 2. Remove the left-side cover. Figure 12: Removing the Tray 1 pickup assembly 3. Remove the front right-side cover. 4. Remove Tray1 5. Flip down or remove the envelope feeder connector cover. 6. Remove the envelope entrance cover 7. Remove the black self- tapping screw at 1- Envelope feeder connector cover the bottom of the envelope 2- Envelope feeder gear cover feeder gear cover. 3- Black self-tapping screw 8. Remove the 4- Long screw long screw 116mm (4.8 inches) on the right side of the Tray 1 pickup assembly. 9. Disconnect the solenoid Figure 13: Tray 1 pickup assembly cable (white square plastic piece) on the right side of the Tray 1 pickup assembly (Note the way that the cables are routed for replacement). 10. Unplug the connector to the engine controller board on the left side of the Tray 1 pickup assembly. 1- Solenoid cable connector Figure 14: Tray 1 pickup assembly - left side 11. Remove the long screw 116mm (4.8 inches) from the left side of the assembly. 12. Remove the self-tapping screw located about a quarter of the way down from the head of the long screw on the printer side of the long 1- Connector to the engine controller board screw. 2- Long screw 3- Self-tapping screw 13. Remove the three screws Figure 15: Tray 1 pickup assembly - front side located on the front side of the assembly. Note: The assembly should be loose, but is prevented from removal by the print cartridge guide on the right-hand side. This guide can be lifted aside out of the way. 14. Pull the assembly straight out of the printer. 1- Three screws 2- print cartridge guide Removing the Registration Assembly Note: If replacing Figure 16: Three black self-tapping screws on the registration Registration Assembly assembly, check for serial numbers, USMA thru-Z, USNA thru-Z, and USEA thru-Z. (Refer to Service Note # C4118A- 06A for information on the importance of also replacing the Tray 1 pickup assembly when replacing the registration assembly.) 15. Remove the Tray 1 pickup assembly as shown above. 16. Remove the three, black self- tapping screws on the Registration Assembly. Figure 17: Looking down at the Registration Assembly 17. Lift the green handle and remove three more screws. Caution: Do not remove the silver screw in Figure 17, call- out 2. Note: If the anti- static bar becomes displaced, reinstall it with the left end in the slot, or 1- Green handle paper may jam in this area. 2- Silver screw that is not to be removed Removing the paper feed assembly 1. Unplug and unroute the connector from the right side of the paper feed assembly. The wire runs across Figure 18: Unplugging the connector to the paper feed the lower right- assembly front section, below the white gears and over, then up toward the middle rear of the assembly, ending in a square white plastic connector. Caution: For replacement of the paper feed assembly, note the way the wires are routed to the connector. If a wire is routed improperly, it can be damaged. 1- Wire that runs across the lower right-front section. Figure 19: Removing the upper screws from the paper feed assembly 2. Remove the two black upper screws from the paper feed assembly. These are located above each end of the upper silver rod. The silver rod has black rubber pads on it, and it is stacked above another similar rod. 3. To replace the paper feed assembly, orient the clutch, which is located just Figure 20: Detail of the paper feed clutch inside the dual gears, into the slot on the chassis. Note: After replacing the paper feed assembly, insert the two upper screws only. The two lower screws are for holding the Tray 1 pickup assembly in place. Separating the engine module from the paper feed module This procedure is the same for the printers with a single 500-sheet Figure 21: Unplugging the connector to the Paper Feed Tray or two 250- Module sheet Trays. 1. Remove the Rear Right Side cover. 2. Remove the Formatter Cage Assembly. 3. Remove the Formatter Pan. 4. Remove the 2 long screws from the Tray 1 Pickup Assembly. 5. Unplug the 1- connector connector to the Paper Feed Module on the right rear side of the printer (under the formatter pan). Remove the cable from its bracket. See Figure 2. Figure 22: Separating the engine from the paper feed module 6. Remove the single black, self-tapping screw from the left side of the printer, below the fan. See Figure 3. Caution: Lift the engine carefully, being sure that all cables are disconnected. 7. Lift the engine away from the Paper Feed Module. 1- single, black self-tapping screw Removing the Paper Feed Module Plate Remove the Figure 23: Removing the paper feed module plate Paper Feed Module Plate to access the Controller PCA. This procedure is the same for one 500-sheet Tray or two 250-sheet Trays. 1. Remove the 7 black self- tapping screws (one of the screws is recessed in front). 2. Remove 2 metal-to-metal screws. 3. Lift up the Paper Feed Module Plate to remove it. Removing the Paper Feed Module Gear Train Assembly Figure 24: Removing the Gear Train This procedure is the same for one 500-sheet or two 250-sheet Trays . 1. Remove the long, recessed screw. See Figure 5, call-out 1. 2. Unplug the connector. See Figure 5, call-out 2. Note the cable routing before removing it. 3. Lift the gear train upward, 1- Long, recessed screw away from the Paper Feed 2- Connector Module.