Replacement of the PS-5 Assembly

Replacement of the PS-5 sensor can be done without removing the connector holder assembly from the printer. First, it is necessary to verify that this is the correct sensor to replace. The printer will probably display a Clear Paper Jam message on the Control Panel. By taking the printer into Service mode and executing the sensor monitor test, all the sensors can be checked to determine which one is causing the error. This specifically addresses how to replace PS-5. This is the sensor and the plastic flag right before the fuser in the paper path. The sensor can be damaged, or the flag may be broken or bent. This normally happens as the result of paper jams and in the way the jammed media is removed from the printer. If the transfer charger assembly (also called the static charge eliminator) is installed incorrectly, the flag can get broken or damaged.

How to put the printer into service mode and test the sensors

NOTE: For a more detailed explanation of the SERVICE MODE tests see BPL90098 - Performing the Service Mode Diagnostic Tests

Push the MENU key until SERVICE MENU appears on the control panel.

Simultaneously push the left side of the VALUE and ITEM keys; NVRAM SETTING should appear on the control panel. It may take several tries to do this.

Push the MENU key until SENSOR MONITOR appears on the control panel.

The push the ITEM key once. The message EXECUTE TEST should appear.

Push SELECT.

Two rows of digits will appear on the control panel. See Figure 1, call-outs 1 and 2.

Figure 1: Sensor test on display 1-Sensor number row 2-Sensor status row 3-PS-5 sensor and status

Understanding the sensor monitor display on the Control Panel

The digits in the top row each identify a sensor. Figure 1, call-out 1, shows this.

The bottom row shows the status of each sensor. This value is either a 1 or a 0. The 0 value means the sensor is off and a 1 means the sensor is on.

The way the sensor monitor test works is that a sensor that is working correctly should display a 0, and when manually pushed or tripped should display a 1.

NOTE: Numbers 6 and 7 are the Tray 2 and Tray 3 sensors. With the trays closed, they should display 1, and when the trays are opened they should display 0.

PS-5 is highlighted in Figure 1, call-out 3; it is Sensor Number 2. In this example, it has a value of 1, which means it is on. If it is not being manually pushed down or tripped, it indicates a stuck sensor. This will cause a CLEAR PAPER JAM error to appear on the control panel.

Using the example in Figure 1, the flag or the sensor could be damaged. PS-5 needs to be replaced.

Exiting service mode

Push the ITEM key until NVRAM SETTINGS appears on the control panel.

Push the MENU key until EXIT SERVICE MODE appears on the control panel.

Push the SELECT key; SERVICE MODE will appear on the control panel.

Push the GO button; READY should appear on the control panel.

How to replace PS-5

This involves removing just the part of the connector holder assembly containing the PS-5 sensor.

Turn the printer off, and unplug it.

Remove the duplexer (if equipped) and the fuser.

The assembly containing PS-5 is shown inside the printer in Figure 2. By gently prying and unclipping it, the piece will come out looking like the example in Figure 3. The sensor must be popped out of this assembly before the connector can be disconnected.

Figure 2: PS-5 assembly before being removed 1-PS-5 sensor flag 2-Assembly to be removed

Figure 3: The PS-5 assembly removed from the connector holder assembly 1-The assembly unclipped from the connector holder assembly 2-The opening it was removed from in the connector holder assembly

Figure 4 shows the PS-5 sensor out of the assembly. Call-out 1 shows the two clips that must be released before the sensor will come out. Then it can be disconnected. There is not much slack in the wires. Opening the other doors of the printer, removing the transfer drum to get some additional light into the printer and using a flashlight will help to make the job easier.

Figure 4: PS-5 sensor 1-Clips that need to be released first

Remove the PS-5 assembly from the new connector holder assembly, pop the sensor out, attach the connector and pop it back into the new assembly.

The PS-5 assembly will snap back into place when reinstalled correctly.

Power up the printer and test the printer to verify the error has been cleared.

© 2005 Hewlett-Packard