COLOR LASERJET ENTERPRISE CP4020/CP4520 SERIES PRINTER Service Manual CP4025n CP4025dn CP4525n CP4525dn CP4525xh
HP Color LaserJet Enterprise CP4020CP4520 Series Printers Service Manual
Copyright and License Trademark Credits © 2009 Copyright Hewlett-Packard Development Company, L.P. Adobe®, Acrobat®, and PostScript® are trademarks of Adobe Systems Incorporated. Reproduction, adaptation, or translation without prior written permission is prohibited, except as allowed under the copyright laws. Corel® is a trademark or registered trademark of Corel Corporation or Corel Corporation Limited. The information contained herein is subject to change without notice.
Conventions used in this guide TIP: Tips provide helpful hints or shortcuts. NOTE: Notes provide important information to explain a concept or to complete a task. CAUTION: Cautions indicate procedures that you should follow to avoid losing data or damaging the product. WARNING! Warnings alert you to specific procedures that you should follow to avoid personal injury, catastrophic loss of data, or extensive damage to the product.
iv Conventions used in this guide ENWW
Table of contents 1 Theory of operation Basic operation ..................................................................................................................................... 2 Sequence of operation ......................................................................................................... 3 Engine-control system .......................................................................................................................... 4 DC controller ............................
Step 6: Secondary transfer ............................................................................... 26 Step 7: Separation ............................................................................................ 27 Step 8: Fusing ................................................................................................... 27 Step 9: ITB cleaning .......................................................................................... 28 Step 10: Drum cleaning ...............................
Before performing service .................................................................................................................. 70 After performing service ..................................................................................................................... 70 Post-service test ................................................................................................................................. 71 Print-quality test ....................................................
Cassette feed guide ......................................................................................................... 118 Secondary transfer assembly .......................................................................................... 119 Reinstall the secondary transfer assembly ..................................................... 120 Separation pad (Tray 1) ...................................................................................................
Lifter-drive assembly ........................................................................................................ 173 Remove the lifter-drive assembly .................................................................... 173 Lifter base assembly ........................................................................................................ 175 Remove the lifter base assembly .................................................................... 175 Reinstall the lifter base assembly .....
Lifter-drive assembly (optional paper feeder) .................................................................. 230 Remove the lifter-drive assembly (optional paper feeder) .............................. 230 Pickup motor assembly (optional paper feeder) ............................................................. 231 Remove the pickup motor (optional paper feeder) assembly .......................... 231 Controller PCA (optional paper feeder) ................................................................
S Tray 3 paper present sensor ....................................................... 265 T Tray 3 feed sensor ...................................................................... 265 U Tray 3 paper surface 1 and 2 sensors ........................................ 265 V Tray 3 paper size switches .......................................................... 265 W Tray 4 paper present sensor ...................................................... 265 X Tray 4 feed sensor ........................................
Repetitive defects ruler ................................................................................... 312 Calibrate the product ....................................................................................... 313 Control panel menus ........................................................................................................ 314 Control panel menus ....................................................................................... 314 Show Me How menu ...........................
Envelopes jam or will not feed in the product .................................................................. 405 Output is curled or wrinkled ............................................................................................. 406 Product will not duplex or duplexes incorrectly ................................................................ 406 Use manual print modes ..................................................................................................................
Internal components (7 of 7) ............................................................................................ 450 Cassettes 2-5 ................................................................................................................... 452 Paper pickup assembly .................................................................................................... 454 Tray 1 paper pickup assembly .........................................................................................
Return and recycling instructions ..................................................................................... 508 United States and Puerto Rico ........................................................................ 508 Multiple returns (more than one cartridge) ..................................... 508 Single returns ................................................................................. 508 Shipping ......................................................................................
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List of tables Table 1-1 Table 1-2 Table 1-3 Table 1-4 Table 1-5 Table 1-6 Table 1-7 Table 1-8 Table 1-9 Table 1-10 Table 1-11 Table 1-12 Table 1-13 Table 1-14 Table 1-15 Table 1-16 Table 1-17 Table 1-18 Table 3-1 Table 3-2 Table 3-3 Table 3-4 Table 3-5 Table 3-6 Table 3-7 Table 3-8 Table 3-9 Table 3-10 Table 3-11 Table 3-12 Table 3-13 Table 3-14 Table 3-15 Table 3-16 ENWW Sequence of operation ...............................................................................................................
Table 3-17 Table 3-18 Table 3-19 Table 3-20 Table 3-21 Table 3-22 Table 3-23 Table 3-24 Table 3-25 Table 3-26 Table 3-27 Table 3-28 Table 3-29 Table 3-30 Table 3-31 Table 4-1 Table 4-2 Table 4-3 Table 4-4 Table 4-5 Table 4-6 Table 4-7 Table 4-8 Table 4-9 Table 4-10 Table 4-11 Table 4-12 Table 4-13 Table 4-14 Table 4-15 Table 4-16 Table 4-17 Table 4-18 Table 4-19 Table 4-20 Table 4-21 Table 4-22 Table 4-23 Table 4-24 Table 4-25 Table 4-26 Table 4-27 Table 4-28 Table B-1 xviii Causes and solutions for fuser
Table B-2 Product dimensions, with all doors and trays fully opened ............................................................ 502 Table B-3 Power requirements ....................................................................................................................... 503 Table B-4 Power consumption (average, in watts)1246 .................................................................................... 503 Table B-5 HP Color LaserJet Enterprise CP4020-CP4520 Series13 .......................
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List of figures Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 1-6 Figure 1-7 Figure 1-8 Figure 1-9 Figure 1-10 Figure 1-11 Figure 1-12 Figure 1-13 Figure 1-14 Figure 1-15 Figure 1-16 Figure 1-17 Figure 1-18 Figure 1-19 Figure 1-20 Figure 1-21 Figure 1-22 Figure 1-23 Figure 1-24 Figure 1-25 Figure 1-26 Figure 1-27 Figure 1-28 Figure 1-29 Figure 1-30 Figure 1-31 Figure 1-32 Figure 1-33 Figure 1-34 ENWW Relationship between the main product systems ...........................................
Figure 1-35 Figure 1-36 Figure 1-37 Figure 1-38 Figure 1-39 Figure 1-40 Figure 1-41 Figure 1-42 Figure 1-43 Figure 1-44 Figure 1-45 Figure 1-46 Figure 1-47 Figure 1-48 Figure 1-49 Figure 1-50 Figure 1-51 Figure 1-52 Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5 Figure 2-6 Figure 2-7 Figure 2-8 Figure 2-9 Figure 2-10 Figure 2-11 Figure 2-12 Figure 2-13 Figure 2-14 Figure 2-15 Figure 2-16 Figure 2-17 Figure 2-18 Figure 2-19 Figure 2-20 Figure 2-21 Figure 2-22 Figure 2-23 Figure 2-24 Figure 2-25 Figur
Figure 2-27 Remove the transfer roller (2 of 3) ................................................................................................ 90 Figure 2-28 Remove the transfer roller (3 of 3) ................................................................................................ 91 Figure 2-29 Reinstall the transfer roller ............................................................................................................ 91 Figure 2-30 Remove the intermediate transfer belt (1 of 4) ...
Figure 2-71 Figure 2-72 Figure 2-73 Figure 2-74 Figure 2-75 Figure 2-76 Figure 2-77 Figure 2-78 Figure 2-79 Figure 2-80 Figure 2-81 Figure 2-82 Figure 2-83 Figure 2-84 Figure 2-85 Figure 2-86 Figure 2-87 Figure 2-88 Figure 2-89 Figure 2-90 Figure 2-91 Figure 2-92 Figure 2-93 Figure 2-94 Figure 2-95 Figure 2-96 Figure 2-97 Figure 2-98 Figure 2-99 Figure 2-100 Figure 2-101 Figure 2-102 Figure 2-103 Figure 2-104 Figure 2-105 Figure 2-106 Figure 2-107 Figure 2-108 Figure 2-109 Figure 2-110 Figure 2-111 Figure 2
Figure 2-115 Figure 2-116 Figure 2-117 Figure 2-118 Figure 2-119 Figure 2-120 Figure 2-121 Figure 2-122 Figure 2-123 Figure 2-124 Figure 2-125 Figure 2-126 Figure 2-127 Figure 2-128 Figure 2-129 Figure 2-130 Figure 2-131 Figure 2-132 Figure 2-133 Figure 2-134 Figure 2-135 Figure 2-136 Figure 2-137 Figure 2-138 Figure 2-139 Figure 2-140 Figure 2-141 Figure 2-142 Figure 2-143 Figure 2-144 Figure 2-145 Figure 2-146 Figure 2-147 Figure 2-148 Figure 2-149 Figure 2-150 Figure 2-151 Figure 2-152 Figure 2-153 Figur
Figure 2-159 Figure 2-160 Figure 2-161 Figure 2-162 Figure 2-163 Figure 2-164 Figure 2-165 Figure 2-166 Figure 2-167 Figure 2-168 Figure 2-169 Figure 2-170 Figure 2-171 Figure 2-172 Figure 2-173 Figure 2-174 Figure 2-175 Figure 2-176 Figure 2-177 Figure 2-178 Figure 2-179 Figure 2-180 Figure 2-181 Figure 2-182 Figure 2-183 Figure 2-184 Figure 2-185 Figure 2-186 Figure 2-187 Figure 2-188 Figure 2-189 Figure 2-190 Figure 2-191 Figure 2-192 Figure 2-193 Figure 2-194 Figure 2-195 Figure 2-196 Figure 2-197 Figur
Figure 2-203 Reinstall the main-drive assembly (2 of 7) ................................................................................ 207 Figure 2-204 Reinstall the main-drive assembly (3 of 7) ................................................................................ 208 Figure 2-205 Reinstall the main-drive assembly (4 of 7) ................................................................................ 209 Figure 2-206 Reinstall the main-drive assembly (5 of 7) .................................
Figure 3-6 Figure 3-7 Figure 3-8 Figure 3-9 Figure 3-10 Figure 3-11 Figure 3-12 Figure 3-13 Figure 3-14 Figure 3-15 Figure 3-16 Figure 3-17 Figure 3-18 Figure 3-19 Figure 3-20 Figure 3-21 Figure 3-22 Figure 3-23 Figure 3-24 Figure 3-25 Figure 3-26 Figure 3-27 Figure 3-28 Figure 3-29 Figure 3-30 Figure 3-31 Figure 3-32 Figure 3-33 Figure 3-34 Figure 3-35 Figure 3-36 Figure 3-37 Figure 3-38 Figure 3-39 Figure 3-40 Figure 3-41 Figure 3-42 Figure 3-43 Figure 3-44 Figure 3-45 Figure 3-46 Figure 3-47 Figure 3-48
Figure 3-50 Figure 3-51 Figure 3-52 Figure 3-53 Figure 3-54 Figure 3-55 Figure 3-56 Figure 3-57 Figure 3-58 Figure 4-1 Figure 4-2 Figure 4-3 Figure 4-4 Figure 4-5 Figure 4-6 Figure 4-7 Figure 4-8 Figure 4-9 Figure 4-10 Figure 4-11 Figure 4-12 Figure 4-13 Figure 4-14 Figure 4-15 Figure 4-16 Figure 4-17 Figure 4-18 Figure 4-19 Figure 4-20 Figure 4-21 Figure 4-22 ENWW Yellow comparison page .............................................................................................................
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1 ENWW Theory of operation ● Basic operation ● Engine-control system ● Laser/scanner system ● Image-formation system ● Pickup, feed, and delivery system ● Jam detection ● Optional paper feeder 1
Basic operation The product routes all high-level processes through the formatter, which stores font information, processes the print image, and communicates with the host computer.
Sequence of operation The DC controller PCA controls the operating sequence, as described in the following table.
Engine-control system The engine-control system receives commands from the formatter and interacts with the other main systems to coordinate all product functions.
DC controller The DC controller controls the operational sequence of the product.
Clutches Component abbreviation Component name CL1 Duplex re-pickup clutch (HP Color LaserJet CP4525dn, HP Color LaserJet CP4025dn, and HP Color LaserJet CP4525xh only) Switches Table 1-3 Switches Component abbreviation Component name SW1 5V interlock switch SW2 24V interlock switch SW3 Power switch SW4 Cassette media size switch SW5 Front door switch SW6 Right door switch Test print switch 6 Chapter 1 Theory of operation ENWW
Sensors Table 1-4 Sensors Component abbreviation Component name NPLED Media sensor SR1 Yellow drum home position sensor SR2 Magenta drum home position sensor SR3 Cyan drum home position sensor SR4 Black drum home position sensor SR5 Fuser delivery sensor SR6 Output bin full sensor SR7 Fuser pressure release sensor SR8 MP-tray-media-presence sensor SR9 Primary-transfer-roller disengagement sensor SR10 New ITB sensor SR11 Developer alienation sensor SR14 Loop sensor 1 SR15 Loop se
Motors The product has 13 motors. The motors drive the components in the paper-feed and image-formation systems.
The DC controller determines if a motor has failed and notifies the formatter when it encounters the following conditions: ● Startup failure: the motor does not reach a specified speed within a specified time from when the motor starts. ● Rotational failure: the rotational speed of the motor is not in the specified range for a specified time after the motor reaches a specified speed.
High-voltage power supply The DC controller controls the high-voltage power supply to generate biases.
Table 1-7 High-voltage power supply circuits (continued) ENWW Circuit Description Primary-transfer-bias generation The primary transfer bias transfers the toner from each photosensitive drum onto the ITB. The primary transfer bias circuit in the high-voltage power supply generates the biases for each color. Secondary-transfer-bias generation The secondary transfer bias transfers the toner image from the ITB onto the paper.
Low-voltage power supply The low-voltage power-supply circuit converts the AC power from the wall receptacle into the DC voltage that the product components use. The product has two low-voltage power-supplies for 110 Volt or 220 Volt input.
Table 1-8 Converted DC voltages (continued) Main DC voltage +5 V +3.3 V Sub-voltage Behavior +24 VB Interrupted when the front door or right door open +5 VB Constantly supplied +5 VC Interrupted when the front door or right door open 3.3 V Constantly supplied 3.
Fuser control The fuser heater-control circuit and the fuser heater safety circuit control the fuser temperature according to commands from the DC controller.
Fuser temperature control The fuser temperature control maintains the target surface temperature of the fuser sleeve.
● ● ◦ Current detection circuit ◦ Thermoswitch DC controller: The DC controller monitors the detected temperature of the main thermistor and sub thermistors.
turned on, or if the detected temperature of the thermistors does not rise to a specified temperature for a specified time after the fuser motor is turned on. ● ● ● Thermistor open: The DC controller determines a thermistor open if: ◦ The detected temperature of TH1 is kept at 12° C (53° F) or lower for a specified time after the fuser motor is turned on. ◦ The detected temperature of TH2 is kept at 4° C (39° F) or lower for a specified time.
Laser/scanner system The laser/scanner system forms the latent electrostatic image on the photosensitive drums according to the VIDEO signals sent from the formatter. The product has two laser/scanners: one for yellow and magenta and the other for cyan and black. The main components of the laser/scanner system are the laser unit and the scanner motor unit, which are controlled by the signals sent from the DC controller.
Laser/scanner failure The DC controller determines that a laser/scanner has failed when any of the following conditions occurs: ● Laser failure: The detected laser intensity does not match a specified value when the product initializes. ● Scanner motor startup failure: The scanner motor does not reach a specified rotation within a specified period from when the laser scanner starts driving.
Figure 1-9 Protective-glass cleaners (PGCs) 20 Chapter 1 Theory of operation ENWW
Image-formation system The image-formation system creates the printed image on the paper. The system consists of the following components: ● Print cartridges ● ITB ● Secondary transfer roller ● Fuser ● Laser /scanner units The DC controller controls the laser scanner unit and each of the high-voltage power supplies to form the toner image on the photosensitive drum surface, according to the VIDEO signals. The toner image is then transferred to the print-media and fused.
Figure 1-11 Image-formation drive system M2 Fuser motor Primary charging roller Developing roller Primary charging roller Developing roller Primary charging roller Developing roller Primary charging roller Developing roller M4 M3 Y drum motor 22 M drum motor Chapter 1 Theory of operation M5 C drum motor M6 Bk drum motor M1 ITB motor ENWW
Image-formation process The image-formation system consists of ten steps divided into six functional blocks. Figure 1-12 Image-formation process : Media path : Direction of drum rotation Delivery : Block : Step 8. Fusing Fuser ITB cleaning Transfer 7. Separation 9. ITB cleaning 6. Secondary transfer 5. Primary transfer 10. Drum cleaning Drum cleaning 4. Developing 1. Pre-exposure Developing Registration 2. Primary charging 3.
Step 1: Pre-exposure Light from the pre-exposure LED strikes the surface of the photosensitive drum to remove any residual electrical charges from the drum surface. Figure 1-13 Pre-exposure LED Photosensitive drum Step 2: Primary charging The primary-charging roller contacts the photosensitive drum and charges the drum with negative potential.
Step 3: Laser-beam exposure The laser beam strikes the surface of the photosensitive drum in the areas where the image will form. The negative charge neutralizes in those areas, which are then ready to accept toner. Figure 1-15 Laser-beam exposure Laser beam Step 4: Development Toner acquires a negative charge as the developing cylinder contacts the developing blade.
Step 5: Primary transfer The positively charged primary-transfer rollers contact the ITB, giving the ITB a positive charge. The ITB attracts the negatively charged toner from the surface of each photosensitive drum, and the complete toner image transfers onto the ITB.
Step 7: Separation The stiffness of the paper causes it to separate from the ITB as the ITB bends. The static-charge eliminator removes excess charge from the paper to make sure that the toner fuses correctly. Figure 1-19 Separation Secondary transfer opposed roller ITB Paper Static charge eliminator Secondary transfer roller Step 8: Fusing To create the permanent image, the paper passes through heated, pressurized rollers to melt the toner onto the page.
Step 9: ITB cleaning The cleaning blade scrapes the residual toner off the surface of the ITB. The residual toner feed screw deposits residual toner in the toner collection box. Figure 1-21 ITB cleaning Residual toner feed screw ITB Cleaning blade Step 10: Drum cleaning The cleaning blade scrapes the residual toner off the surface of the photosensitive drum, and toner is deposited in the toner collection box in the cartridge.
The DC controller rotates the drum motor to drive the photosensitive drum, developing roller, and the primary-charging roller. Figure 1-23 Print-cartridge system DC controller M10 Developing disengagement motor SR11: Developing disengagement sensor Developing unit SR1/SR2/SR3/SR4: Drum home position sensor M3/M4/M5/M6: Drum motor Primary charging roller Memory tag Developing roller The DC controller rotates the drum motor to drive the photosensitive drum, developing unit, and primary charging roller.
The DC controller determines a memory tag error and notifies the formatter when it fails to either read from or write to the memory tag. ● Cartridge presence detection: The DC controller detects the presence of the cartridges by monitoring the memory tag. The DC controller notifies the formatter when a cartridge is missing or installed in the incorrect slot.
The developing-roller engagement and disengagement control operates as follows: When the product is turned on and when each print job is completed, all four of the developing units are disengaged from the photosensitive drums. ● The drive of the developing disengagement motor rotates the developing disengagement cam. ● As the cam rotates, the developing unit engages with or separates from the photosensitive drum. When the print mode is full color, the developing units engage with the drums.
Primary-transfer-roller engagement and disengagement The sequence of the primary-transfer-roller engagement and disengagement control is as follows: 1. The fuser motor turns on the primary-transfer disengagement solenoid and rotates the primarytransfer-roller disengagement cam. 2. As the cam rotates, the Y/M/C primary-transfer-roller slide plate or the Bk primary-transfer-roller slide plate moves to the right or left, which causes the primary-transfer roller to move up or down. 3.
Figure 1-26 Three states of primary-transfer-roller engagement and disengagement DC controller M2 ITB SR9: Primary transfer disengagement sensor Fuser motor SL1 Primary transfer disengagement solenoid Photosensitive drum Primary transfer roller Primary transfer roller disengagement cam YMC primary transfer roller slide plate Bk primary transfer roller slide plate ENWW Image-formation system 33
ITB cleaning The cleaning blade in the ITB cleaner scrapes the residual toner off the ITB surface. The residual toner feed screw deposits the residual toner to the residual toner feed unit. The ITB motor and the residual toner feed motor drive the screw. The DC control detects whether the toner collection box is full, using the residual-toner full sensor, and then notifies the formatter.
Color-misregistration control Internal variations in the laser/scanners can cause the toner images to become misaligned. The colormisregistration control corrects the following problems: ● Horizontal scanning start position ● Horizontal scanning magnification ● Vertical scanning start position The DC controller forms a pattern of toner on the surface of the ITB and measures a misaligned length with the RD sensor.
Environmental changes or deterioration of the photosensitive drums and toner can cause variations in the image density. The image-stabilization control reduces these fluctuations. Table 1-11 Image-stabilization controls Image density control (DMAX) This control corrects variations in image density related to deterioration of the photosensitive drum or the toner.
Pickup, feed, and delivery system The pickup, feed, and delivery system uses a series of rollers to move the paper through the product.
Figure 1-30 Switches and sensors for the pickup, feed, and delivery system Duplex model only SR6 SR5 SR14 SR15 SR22 SR20 Media sensor SR8 SW4 SR25 SR23 SR24 Table 1-12 Switches and sensors for the pickup, feed, and delivery system Abbreviation Component SR5 Fuser delivery sensor SR6 Delivery tray media full sensor SR8 MP tray media presence sensor SR14 Loop sensor 1 SR15 Loop sensor 2 SR20 TOP (top of page) sensor SR21 MP tray media-presence sensor SR22 Duplex re-pickup sensor (dupl
Figure 1-31 Motors and solenoids for the pickup, feed, and delivery system M2 M11 Duplex model only SL2 Duplex flapper M1 Pickup arm SL4 Lifter CL1 SL3 M7 M13 Table 1-13 Motors and solenoids for the pickup, feed, and delivery system ENWW Abbreviation Component M1 ITB motor M2 Fuser motor M7 Lifter motor M11 Duplex reverse motor (duplex models only) M13 Pickup motor CL1 Duplex re-pickup clutch (duplex models only) SL2 Duplex reverse solenoid (duplex models only) SL3 Multipurpose
The pickup, feed, and delivery system is divided into the following three blocks: ● Pickup-and-feed block: From each pickup source to the fuser inlet ● Fuser-and-delivery block: From the fuser to the delivery destination ● Duplex block: From the duplex reverse unit to duplex re-pickup unit (for duplex models only) Figure 1-32 Three main units of the pickup, feed, and delivery system Fusing-and-delivery block Duplex block Pickup-and-feed block 40 Chapter 1 Theory of operation ENWW
Pickup-and-feed unit The pickup-and-feed unit picks an individual sheet of paper from the multipurpose tray or the cassettes, carries it through the secondary-transfer unit, and feeds it into the fuser. Figure 1-33 Pickup-and-feed unit Simplex media path Duplex media path Pickup-and-feed block Cassette pickup The sequence of steps for the cassette-tray pickup operation is the following: ENWW 1. The product is turned on or the cassette is inserted. 2.
7. As the pickup arm lowers, the cassette pickup roller touches the surface of the paper stack. 8. One sheet of paper feeds into the product.
Cassette lift operation and cassette paper-presence detection The product keeps the paper stack surface at the correct pickup position.
The low friction force between the sheets weakens the driving force from the cassette feed roller. Therefore, the separation roller is driven by its own driving force and holds back any multiple-fed sheets from the cassette.
The MP-tray media-presence sensor (SR8) detects whether paper is present in the MP tray. Figure 1-37 Multipurpose tray pickup mechanism DC controller Pickup motor M13 SL2 MP tray pickup solenoid MP tray media presence sensor SR8 MP tray pickup roller Lifting plate MP tray separation pad Paper feed After the pickup operation, the paper feeds through the product and into the fuser. ENWW 1. The paper picked up from the cassette is fed to the registration unit as the pickup motor rotates.
The DC controller notifies the formatter of a paper size mismatch error when the paper length detected by the TOP sensor does not match the paper size specified by the formatter.
Skew-feed prevention The product can straighten the paper without slowing the feed operation. 1. The leading edge of paper strikes the registration shutter, and the leading edge is aligned with the shutter. 2. As the feed rollers keep pushing the paper, the paper warps. 3.
glossy film, or overhead transparency) and switches to the correct print mode. The DC controller determines a media mismatch error and notifies the formatter under the following condition: Simplex printing ● The specified print mode is overhead transparency (OHT), but the media sensor detects another paper type. ● The specified print mode is not auto or OHT, but the media sensor detects OHT. Duplex printing ● The media sensor detects OHT.
The face-down tray media full sensor on the output bin detects whether the tray is full of printed pages. The DC controller notifies the formatter when the sensor is on for a specified time. Figure 1-40 Fuser and delivery unit Simplex media path Fusing-and-delivery block Duplex media path SR6 Face-down tray media full sensor Loop control The loop control stabilizes the paper feed operation before the paper enters the fuser.
sensor 2 is for heavy media. The DC controller slows the fuser motor when the sensor is off and speeds up the sensor when the sensor is on.
Pressure-roller pressurization control To prevent excessive wear on the pressure roller and help with jam-clearing procedures, the pressure roller pressurizes only during printing and standby. The DC controller reverses the fuser motor. The fuser motor rotates the fuser pressure-release cam.
Duplexing unit (HP Color LaserJet CP4525dn, HP Color LaserJet CP4025dn, and HP Color LaserJet CP4525xh only) For supported models, the duplexing unit reverses the paper and feeds it through the paper path to print the second side. Figure 1-43 Duplexing unit Simplex media path Duplex media path Duplex block Duplexing reverse and feed control The duplex reverse control reverses the paper after the first side is printed and feeds it to the duplex repickup position to print the second side of the page.
5. The duplex reverse motor and the duplex feed clutch stop, and the paper feed operation pauses. 6. After a specified period of time, the duplex reverse motor rotates, and the duplex feed clutch is turned on. The paper is then picked up again.
The formatter specifies the duplex-media-feed mode for each two-sided print job. Duplex printable media size (A4, Letter, B5, Legal and Executive) and designated print mode (Auto, Normal, Heavy media 1, Heavy media 2 (120 g/m2 or lighter), Glossy media 1, Glossy media 2, Glossy media 3, Glossy film, Designated media 1, and Designated media 2) must be specified.
Jam detection The product uses the following sensors to detect the paper as it moves through the paper path and to report to the DC controller if the paper has jammed.
Table 1-16 Jams that the product detects Jam Description Pickup delay jam The TOP sensor does not detect the leading edge of the paper within a specified time (including two retries) after the pickup operation from the cassette, multipurpose tray, or optional paper feeder starts. Pickup stationary jam The TOP sensor does not detect the trailing edge of the paper within a specified time from when it detects the leading edge.
Optional paper feeder The 1 x 500-sheet paper feeder is optionally installed at bottom of the product. The paper feeder picks up the print media and feeds it to the product. There are two types of paper feeders: 1 x 500-sheet paper feeder and 3 x 500-sheet paper feeder. The operational sequence of the paper feeders is controlled by the paper feeder controller.
Figure 1-47 3 x 500-sheet optional paper feeder PD feed roller PD pickup roller PD separation roller Figure 1-48 Signals for the paper feeder Paper deck Motor +3.3V Solenoid DC controller +24V Paper deck controller Photointerrupter Switch The input trays contain several motors, solenoids, sensors, and switches, as described in the following table.
Table 1-17 Electrical components for the paper feeder Component type Abbreviation Component name Motors M1 PD lifter motor 1 M2 PD pickup motor M3 PD lifter motor 2 (3 x 500-sheet paper feeder only) M4 PD lifter motor 3 (3 x 500-sheet paper feeder only) SL1 PD pickup solenoid 1 SL2 PD pickup solenoid 2 (3 x 500-sheet paper feeder only) SL3 PD pickup solenoid 3 (3 x 500-sheet paper feeder only) SR1 Tray 3 paper surface sensor 1 SR2 Tray 3 paper surface sensor 2 SR3 Tray 3 paper present
Component Drives Failure detection PD lifter motor 3 (3 x 500-sheet paper feeder only) M4 Lifter of the lower cassette No PD pickup motor M2 PD pickup roller, PD feed roller, and PD separation roller No Paper-feeder pickup and feed operation The paper feeder picks up one sheet from the paper-feeder cassette and feeds it to the product.
Table 1-18 Pickup feed components (1 x 500-sheet paper feeder) (continued) Component SR3 Tray 3 paper presence sensor SR4 Tray 3 paper present sensor SW2 Tray 3 paper size switches M2 Pickup arm SR2 SR3 SW2 SR1 SR4 SL1 SR7 SR8 M1 SR6 SW3 SR5 SW1 SL2 SR10 SR9 M3 SR11 SW4 SR12 SL3 M4 Components ENWW M1 PD lifter motor 1 M2 PD pickup motor M3 PD lifter motor 2 (3 x 500-sheet paper feeder only) M4 PD lifter motor 3 (3 x 500-sheet paper feeder only) SL1 PD pickup solenoid 1 SL2 PD
SR5 Tray 4 paper surface sensor 1 (3 x 500-sheet paper feeder only) SR6 Tray 4 paper surface sensor 2 (3 x 500-sheet paper feeder only) SR7 Tray 4 feed sensor (3 x 500-sheet paper feeder only) SR8 Tray 4 media-stack-surface sensor (3 x 500-sheet paper feeder only) SR9 Tray 5 paper surface sensor 1 (3 x 500-sheet paper feeder only) SR10 Tray 5 feed sensor (3 x 500-sheet paper feeder only) SR11 Tray 5 paper present sensor (3 x 500-sheet paper feeder only) SR12 Tray 5 media-stack-surface sensor
Paper-feeder cassette lift operation The paper feeder keeps the paper stack surface at the correct pickup position. The cassette lift operation occurs under the following conditions: ● The product is turned on. ● The cassette is inserted. ● The paper stack surface of the cassette lowers. The sequence occurs as follows: 1. The PD lifter motor rotates and the lifter moves up. 2. When the tray media-stack-surface sensor detects the stack surface of the paper, the PD lifter motor stops. 3.
Paper feeder jam detection The 1 x 500-sheet paper feeder uses the tray 3 paper presence sensor (SR4) to detect the presence of paper and to check whether paper has jammed. Figure 1-51 Jam detection (1 x 500-sheet paper feeder) SR4 The 1 x 500-sheet paper feeder detects the following jams: ● 1 x 500-sheet PD pickup delay jam: Tray 3 feed sensor does not detect the leading edge of paper within a specified time (including two retries) after the pickup operation starts.
Figure 1-52 Jam detection (3 x 500-sheet paper feeder) SR4 SR7 SR10 The 3 x 500-sheet paper feeder detects the following jams: ENWW ● 3 x 500-sheet PD pickup delay jam: One of the tray feed sensors does not detect the leading edge of paper within a specified time (including two retries) after the pickup operation starts.
66 Chapter 1 Theory of operation ENWW
2 ENWW Removal and replacement ● Introduction ● Removal and replacement strategy ● Electrostatic discharge ● Required tools ● Before performing service ● After performing service ● Post-service test ● Parts removal order ● Customer self repair (CSR) components ● External panels, covers, and doors ● Internal assemblies ● Optional paper feeder assemblies (1 x 500-sheet and 3 x 500-sheet) 67
Introduction This chapter describes the removal and replacement of field-replaceable units (FRUs) only. Replacing FRUs is generally the reverse of removal. Occasionally, notes and tips are included to provide directions for difficult or critical replacement procedures. HP does not support repairing individual subassemblies or troubleshooting to the component level. Note the length, diameter, color, type, and location of each screw. Be sure to return each screw to its original location during reassembly.
Electrostatic discharge CAUTION: Some parts are sensitive to electrostatic discharge (ESD). Look for the ESD reminder when removing product parts. Always perform service work at an ESD-protected workstation or mat, or use an ESD strap. If an ESD workstation, mat, or strap is not available, ground yourself by touching the sheet-metal chassis before touching an ESD-sensitive part. Protect the ESD-sensitive parts by placing them in ESD pouches when they are out of the product.
Before performing service ● Remove all media from the product. ● Turn off the power using the power switch. ● Unplug the power cable and interface cable or cables. ● Place the product on an ESD workstation or mat, or use an ESD strap (if one is available). If an ESD workstation, mat, or strap is not available, ground yourself by touching the sheet-metal chassis before touching an ESD-sensitive part. ● Remove the print cartridges. See Print cartridges on page 74.
Post-service test Perform the following test to verify that the repair or replacement was successful. Print-quality test ENWW 1. Verify that you have completed the necessary reassembly steps. 2. Make sure that the tray contains clean, unmarked paper. 3. Attach the power cord and interface cable or interface cables, and then turn on the product. 4. Verify that the expected startup sounds occur. 5. Print a configuration page, and then verify that the expected printing sounds occur. 6.
Parts removal order Figure 2-2 Parts removal order (1 of 2) 72 Chapter 2 Removal and replacement ENWW
Figure 2-3 Parts removal order (2 of 2) DCCA 2T assembly DCCA HVPS-upper DCCA DCCA ENWW HVPS-upper HVPS-upper DCCA HVPS-upper DCCA HVPS-upper Parts removal order 73
Customer self repair (CSR) components Print cartridges CAUTION: If toner gets on your clothing, wipe it off with a dry cloth and wash clothing in cold water. Hot water sets toner into fabric. 1. Open the front door. Make sure that the door is completely open.
2. Grasp the print-cartridge handle and pull out to remove. CAUTION: Do not touch the green roller. Doing so can damage the cartridge. Do not expose the cartridge to strong light. Cover the cartridge with a sheet of paper to protect it from light. Reinstallation tip Align the print cartridge with its slot and insert the print cartridge until it clicks into place.
Toner-collection unit NOTE: The toner-collection unit is designed for a single use. Do not try to empty the toner-collection unit and reuse it. Doing so could cause toner to spill inside the product and result in reduced print quality. For recycling information, see the product user guide. 1. Open the front door. Make sure that the door is completely open. Figure 2-6 Remove the toner-collection unit (1 of 4) 2. Grasp the top of the toner-collection unit and remove it from the product.
3. To prevent toner spills, place the blue cap (callout 1) over the blue opening at the top of the unit (callout 2).
Formatter PCA CAUTION: ESD sensitive component. 1. Turn the product off and disconnect the power and interface cable or interface cables. 2. Unscrew the formatter thumb screws, and then firmly pull the formatter from the product. Place the formatter on a clean, flat, grounded surface. Figure 2-10 Remove the formatter NOTE: When reinstalling the formatter, push firmly on the right side to make sure the formatter is seated.
Hard drive Before proceeding, remove the following components: ● Formatter PCA. See Formatter PCA on page 78. Remove the hard drive CAUTION: 1. ESD sensitive component. Disconnect two connectors. Figure 2-11 Remove the hard drive (1 of 3) 2. Release one tab.
3. Rotate the hard drive assembly away from the formatter until the slots in the hinges are aligned with the elongated hinge pins, and then slide the hard drive assembly off the hinge pins.
Memory DIMM Before proceeding, remove the following components: ● Formatter PCA. See Formatter PCA on page 78. Remove the memory DIMM CAUTION: ESD sensitive component. NOTE: See Enable memory on page 82 after installing a new memory DIMM. 1. Place the formatter on a clean, flat, grounded surface, and then spread the latches apart on each side of the DIMM slot.
2. Lift the DIMM up at an angle, and pull it out. Reinstallation tip Hold the DIMM by the edges. Align the notch on the DIMM with the bar in the DIMM slot at an angle and firmly press the DIMM into the slot until it is fully seated. When installed correctly, the metal contacts are not visible. Push down on the DIMM until both latches engage the DIMM. Figure 2-15 Remove the memory DIMM (2 of 2) Enable memory Windows XP, Windows Server 2003, Windows Server 2008, and Windows Vista 1. Click Start. 2.
Windows 7 1. Click Start. 2. Click Devices and Printers. 3. Right-click the product driver icon, and then select Printer properties. 4. Click the Device Settings tab. 5. Expand the area for Installable Options. 6. Next to Automatic Configuration, select Update Now. 7. Click OK. NOTE: If the memory is not updated correctly after using the Update Now option, you can manually select the total amount of memory installed in the product in the Installable Options area.
Tray NOTE: Use this procedure to remove Tray 2 and the optional Trays 3, 4, and 5. 1. Pull the tray straight out of the product until it stops. Figure 2-16 Remove the tray (1 of 2) 2. Carefully lift up on the tray to release it, and then remove the tray.
Fuser CAUTION: The fuser might be hot. Allow enough time after turning off the product power for the fuser to cool. NOTE: The product detects a new fuser using a fusible link that blows after 100 pages have been printed. If a new fuser is installed for troubleshooting purposes, be sure to remove it before printing 100 pages. 1. Open the right-door assembly. Figure 2-18 Remove the fuser (1 of 2) 2. Grasp the handles and squeeze the blue release levers.
Feed and separation rollers (Trays 2-5) CAUTION: Do not touch the spongy roller surface unless you are replacing the roller. Skin oils on the roller can cause paper pickup problems. 1. Locate the feed and separation rollers for the tray. TIP: You do not have to separate the product from the feeder to remove these rollers. Remove the cassette, and then reach up into the cavity to remove the rollers. 2. Release two tabs, and then remove the rollers.
Pickup roller (Tray 1) CAUTION: Do not touch the spongy roller surface unless you are replacing the roller. Skin oils on the roller can cause paper pickup problems. 1. Open Tray 1. Figure 2-21 Remove the pickup roller (Tray 1) (1 of 5) 2. Push the top edge of the cover to release the tabs.
3. Open the right-door assembly, and then remove the cover. Figure 2-23 Remove the pickup roller (Tray 1) (3 of 5) 4. Release the two blue tabs.
5. Rotate the roller body away from the product to remove it.
Secondary transfer roller CAUTION: Do not touch the spongy roller surface unless you are replacing the roller. Skin oils on the roller can cause image quality problems. 1. Open the right-door assembly. Figure 2-26 Remove the transfer roller (1 of 3) 2. Use the blue lever to lower the secondary transfer assembly.
3. Grasp the roller shaft collars, and lift the transfer roller off of the product. Figure 2-28 Remove the transfer roller (3 of 3) Reinstall the transfer roller When you reinstall the transfer roller, make sure that the pins on the shaft collars align with the holes in the mounting assembly. After installing the new transfer roller, remove the protective cover.
Intermediate transfer belt (ITB) CAUTION: Do not touch the black-plastic belt. Skin oils and fingerprints on the belt can cause printquality problems. Always place the ITB on a flat surface in a safe and protected location. 1. Open the right-door assembly. Figure 2-30 Remove the intermediate transfer belt (1 of 4) 2. Use the blue lever to lower the secondary transfer assembly.
3. Grasp the small handles on the ITB and then pull the ITB out of the product until two large handles expand along the right- and left-side of the ITB.
4. Grasp the large handles on the ITB and then pull the ITB straight out of the product to remove it. CAUTION: The ITB is a sensitive component. Be careful when handling the ITB so that it is not damaged. Always place the ITB in a safe and protected location. Figure 2-33 Remove the intermediate transfer belt (4 of 4) Reinstallation tip If you are installing a replacement ITB, make sure that you remove the packing tape (callout 1) and the protective cover sheet (callout 2).
External panels, covers, and doors Identification and location Figure 2-34 External panels, covers, and doors; identification and location 1 12 2 11 3 10 4 9 5 8 6 7 ENWW Item Description Item Description 1 Rear-top cover (see Rear-top cover on page 102) 7 Power-supply cover (see Power-supply cover on page 98) 2 Right-door assembly (see Right-door assembly on page 113) 8 Rear cover (see Rear cover on page 112) 3 Right-rear cover (see Right-rear cover on page 110) 9 Tray cassette (see
Upper-left cover 1. Open the front-door assembly. Figure 2-35 Remove the upper-left cover (1 of 3) 2. Remove one screw.
3. Release two tabs, slightly push the cover upward and toward the rear of the product, pull outward on the rear corner, and then remove the upper-left cover.
Power-supply cover ▲ Remove one screw (callout 1), release one tab (callout 2), and then remove the power-supply cover (callout 3).
Left cover Before proceeding, remove the following components: ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. Remove the left cover 1. Open the front-door assembly. 2. Remove four screws. Figure 2-39 Remove the left cover (1 of 2) 3. Slide the left cover toward the rear of the product, and then remove.
Front-top cover Before proceeding, remove the following components: ● Upper-left cover. See Upper-left cover on page 96. Remove the front-top cover 1. Open the front-door assembly. 2. Remove three screws. Figure 2-41 Remove the front-top cover (1 of 3) 3. Flex the back left corner of the cover and lift to release the pin.
4. Remove the cover.
Rear-top cover Before proceeding, remove the following components: ● Upper-left cover. See Upper-left cover on page 96. ● Front-top cover. See Front-top cover on page 100. Remove the rear-top cover 1. Remove two screws. Figure 2-44 Remove the rear-top cover (1 of 2) 2. Open the right-door assembly. 3. Release three tabs (callout 1) and then remove the cover (callout 2).
Right-front cover Before proceeding, remove the following components: ● Upper-left cover. See Upper-left cover on page 96. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. Remove the right-front cover NOTE: Be careful. When removing the cover, do not dislodge the power button. If the button is dislodged, see Reinstall the power button on page 104 to reinstall it. 1. Open the right-door assembly.
2. Release two tabs, and then remove the right-front cover. Figure 2-48 Remove the right-front cover (3 of 3) Reinstall the power button Snap the power button into the holders on the cover. Make sure that the spring is correctly installed.
Control-panel assembly Before proceeding, remove the following components: ● Upper-left cover. See Upper-left cover on page 96. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Right-front cover. See Right-front cover on page 103. Remove the control-panel assembly 1. Remove two screws.
2. Disconnect one connector, and then remove the control-panel assembly.
Front-door assembly Before proceeding, remove the following components: ● Upper-left cover. See Upper-left cover on page 96. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102 ● Right-front cover. See Right-front cover on page 103 Remove the front-door assembly 1. Open the front-door assembly. 2. Release the right link arm by pushing the two segments together and then releasing.
3. Squeeze the tab on the left link arm using needle nose pliers to release it from the front door assembly. NOTE: Hold the link arm firmly when releasing to prevent it from snapping against the front of the product. Figure 2-53 Remove the front-door assembly (2 of 5) 4. Remove two screws (callout 1).
5. Remove two screws. Figure 2-55 Remove the front-door assembly (4 of 5) 6. Remove the front-door assembly.
Right-rear cover Before proceeding, remove the following components: ● Upper-left cover. See Upper-left cover on page 96. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. Remove the right-rear cover 1. Open the right-door assembly. 2. Release one tab.
3. Lift the cover to remove.
Rear cover Before proceeding, remove the following components: ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98, ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. Remove the rear cover ▲ Remove two screws (callout 1), release three tabs (callout 2), and then remove the rear cover (callout 3).
Right-door assembly 1. Open the right-door assembly. Figure 2-60 Remove the right-door assembly (1 of 9) 2. Carefully remove the hinge cover (callout 1).
3. Remove three screws. Figure 2-62 Remove the right-door assembly (3 of 9) 4. Remove the hinge assembly. Reinstallation tip When the hinge is reinstalled, make sure that the tab (callout 1) is correctly positioned on the door.
5. Release one pin, and then release the link arm (callout 1). CAUTION: The link arm is spring loaded. Hold the arm securely (as shown) to prevent the spring from abruptly retracting. Figure 2-64 Remove the right-door assembly (5 of 9) 1 6. Release one tab, and then remove the cover (callout 1). TIP: Lift up on the secondary transfer assembly to make removing the cover easier.
7. Disconnect two connectors. Figure 2-66 Remove the right-door assembly (7 of 9) 8. Lift two link arms to release.
9. Slide the right-door assembly toward the front of the product and remove.
Internal assemblies TIP: For clarity, some photos in this chapter show components removed that would not be removed to service the product. If necessary, remove the components listed at the beginning of a procedure before proceeding to service the product. Cassette feed guide TIP: If a page is jammed in the product, you might be able to access it by removing this guide. 1. Open the right-door assembly. Figure 2-69 Remove the cassette feed guide (1 of 2) 2.
Secondary transfer assembly The secondary transfer assembly includes the transfer roller. 1. Open the right-door assembly. Figure 2-71 Remove the secondary transfer assembly (1 of 3) 2. Release one tab and carefully remove the stopper. NOTE: You might have to slightly lift up on the corner of the assembly to release the stopper pin from the hole in the chassis.
3. Remove the secondary transfer assembly. CAUTION: Do not damage the blue release lever when removing the assembly. Figure 2-73 Remove the secondary transfer assembly (3 of 3) Reinstall the secondary transfer assembly Press and hold the blue release lever when you reinstall the assembly.
Separation pad (Tray 1) Before proceeding, remove the following components: ● Pickup roller. See Pickup roller (Tray 1) on page 87. ● Right door assembly. See Right-door assembly on page 113. Remove the separation pad (Tray 1) 1. Remove two screws (callout 1) and the cover (callout 2). Figure 2-75 Remove the separation pad (1 of 6) 1 2 2. Remove two screws (callout 1) and separate Tray 1 (callout 2) from the door assembly.
3. Release two tabs (callout 1) and slide the locking cap and sub roller toward the edge of the tray. Figure 2-77 Remove the separation pad (3 of 6) 1 4. Release two tabs (callout 1) and slide the locking cap and sub roller toward the edge of the tray. CAUTION: Do not damage the flag (callout 2).
5. Release one tab (callout 1) and slide the pickup-roller holder toward the edge of the tray. CAUTION: Do not damage the flag (callout 2). Figure 2-79 Remove the separation pad (5 of 6) 2 6. 1 Release one tab (callout 1) and remove the separation pad.
Registration density (RD) sensor assembly Before proceeding, remove the following components: ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 92. ● Secondary transfer assembly. See Secondary transfer assembly on page 119. Remove the RD sensor assembly 1. Release one tab (callout 1), and then remove the cover (callout 2). Figure 2-81 Remove the RD sensor assembly (1 of 7) 1 2 NOTE: When reinstalling the cover, make sure that the tabs are seated correctly.
2. Release one tab, and then remove the wire-harness cover. TIP: Open the front door to make it easier to remove the cover. Figure 2-83 Remove the RD sensor assembly (3 of 7) 3. Disconnect three connectors.
4. Remove two screws. Figure 2-85 Remove the RD sensor assembly (5 of 7) 5. Slide the shutter toward the back side of the product. Keep the shutter in this position for the following step.
6. Carefully remove the assembly from the product. CAUTION: Do not damage the shutter as it passes through the chassis.
Registration assembly Before proceeding, remove the following components: ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 92. ● Secondary transfer assembly. See Secondary transfer assembly on page 119.
Remove the registration assembly NOTE: If a replacement registration assembly is installed, you must use the control-panel menus to reset the registration-roller count and input the media sensor value. See Service menu on page 420 and Service menu on page 420. 1. Release one tab (callout 1), and then remove the cover (callout 2). Figure 2-88 Remove the registration assembly (1 of 8) 1 2 NOTE: When reinstalling the cover, be sure that the tabs are seated correctly.
2. Release one tab, and then remove the wire-harness cover. TIP: To make the cover easier to remove, open the front-door assembly to close the RD-sensor shutter. Figure 2-90 Remove the registration assembly (3 of 8) 3. Disconnect two connectors.
4. Remove two screws (callout 1), and then remove the cassette feed guide (callout 2). Figure 2-92 Remove the registration assembly (5 of 8) 2 1 5. Remove four screws.
6. Release two pins and the front of the assembly. Figure 2-94 Remove the registration assembly (7 of 8) 7. Remove the assembly from the product. Reinstallation tip When you reinstall the registration assembly, make sure that it is correctly positioned in the product. The tabs on the assembly must fit into the slots in the product chassis and the assembly fits securely up against the product chassis.
Residual-toner-feed motor Before proceeding, remove the following components: ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 92. ● Upper-left cover. See Upper-left cover on page 96. Remove the residual-toner-feed motor Remove one screw (callout 1), disconnect one connector (callout 2), and them remove the residualtoner-feed motor (callout 3).
Residual-toner duct and feed assembly Before proceeding, remove the following components: ● Toner-collection unit. See Toner-collection unit on page 76. ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 92. ● Upper-left cover. See Upper-left cover on page 96. ● Residual-toner-feed motor. See Residual-toner-feed motor on page 133. Remove the residual-toner duct and feed assembly 1. Remove one screw.
2. Release one tab, and then remove the waste toner duct. Figure 2-98 Remove the residual-toner duct and feed assembly (2 of 4) 3. Remove one screw.
4. Push the residual-toner feed assembly into the product and then remove through the print cartridge cavity. CAUTION: The waste toner feed assembly contains toner. Place a cloth below the work area to catch any spilled toner.
Cartridge fan and environmental sensor Before proceeding, remove the following components: ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. Remove the cartridge fan and environmental sensor 1. Remove four screws (callout 1), and then remove the sheet-metal plate (callout 2).
2. Release one spring. TIP: Close the front-door assembly to reduce tension in the spring. Figure 2-102 Remove the cartridge fan and environmental sensor (2 of 7) 3. Release one tab and then slide the fan assembly toward the back of the product.
4. Pull the fan assembly out of the product, and then disconnect two connectors. TIP: One connector is below the sponge. Figure 2-104 Remove the cartridge fan and environmental sensor (4 of 7) 5. Release two tabs (callout 1), and then remove the cover (callout 2).
6. Disconnect one connector (callout 1), and then remove the fan (callout 2). Figure 2-106 Remove the cartridge fan and environmental sensor (6 of 7) 2 1 7. Carefully release one tab, and then remove the environmental sensor. CAUTION: ESD-sensitive part.
Toner-collection sensor and scanner-thermistor assembly Before proceeding, remove the following components: ● Toner-collection unit. See Toner-collection unit on page 76. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. Remove the toner-collection sensor and scanner-thermistor assembly 1. Remove four screws (callout 1), and then remove the sheet-metal plate (callout 2).
2. Open the front-door assembly, and then remove one screw. Figure 2-109 Remove the toner-collection sensor and scanner-thermistor assembly (2 of 3) 3. Disconnect two connectors (callout 1), and then remove the toner-collection sensor and scannerthermistor assembly (callout 2).
Delivery fan Before proceeding, remove the following components: ● Upper-left cover. See Upper-left cover on page 96. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. Remove the delivery fan 1. Remove one screw (callout 1), disconnect one connector (callout 2), and release one wire retainer (callout 3). Figure 2-111 Remove the delivery fan (1 of 2) 2 1 3 TIP: When the fan is reinstalled, the air must flow into the product.
2. Release one tab (callout 1), and then remove the delivery fan (callout 2).
Delivery assembly Before proceeding, remove the following components: ● Fuser. See Fuser on page 85. ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 92. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Right-front cover. See Right-front cover on page 103. ● Control-panel assembly.
2. Remove two screws (callout 1), and then remove the paper guide (callout 2). NOTE: Duplex models only: press the duplex solenoid (callout 3) to create enough clearance to remove the paper guide (callout 2). TIP: The fuser delivery sensor is installed on the rear of the paper guide. Leave the sensor attached to the guide, and rotate the paper guide toward the rear of the product to access the delivery assembly. Figure 2-114 Remove the delivery assembly (2 of 7) 2 3 1 3.
4. Remove two screws. Figure 2-116 Remove the delivery assembly (4 of 7) 5. Pull one tab out, and then push the tab down to release the bushing.
6. Remove two screws. Figure 2-118 Remove the delivery assembly (6 of 7) 7. Remove the assembly.
Reinstall the delivery assembly NOTE: For duplex models, the solenoid plunger must be removed from the discarded assembly, and then installed on the replacement assembly. For all models, the output-bin full sensor must be removed from the discarded assembly, and then installed on the replacement assembly. 1. Duplex models only: Make sure that the solenoid plunger is correctly installed on the replacement assembly. Figure 2-120 Reinstall the delivery assembly (1 of 4) 2. For all models: Do the following.
b. Hold the delivery assembly with the diverter (callout 1) in the depressed position to move the sensor flag (callout 2) away from the sensor. Release one tab (callout 3). Figure 2-122 Reinstall the delivery assembly (3 of 4) 1 2 3 c. Slide the sensor up toward the top of the delivery assembly to release two hooks (callout 1), and then carefully remove the sensor from the assembly. CAUTION: Do not damage the sensor holder or sensor flag when removing the sensor from the delivery assembly.
Duplex-drive assembly Before proceeding, remove the following components: ● Fuser. See Fuser on page 85. ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 92. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Right-front cover. See Right-front cover on page 103. ● Control-panel assembly.
Power-supply fan Before proceeding, remove the following components: ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Right-rear cover. See Right-rear cover on page 110. ● Rear cover. See Rear cover on page 112. Remove the power-supply fan ▲ Release two tabs, and then remove the fan from the fan duct.
Interconnect board (ICB) Before proceeding, remove the following components: ● Formatter. See Formatter PCA on page 78. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Rear cover. See Rear cover on page 112. Remove the ICB WARNING! Do not remove the ICB from a product and then install it into a different product.
2. Carefully rotate and slide the ICB up and away from the chassis, disconnect one connector, and then remove the ICB.
DC controller PCA only NOTE: Use the following procedure to replace only the DC controller PCA. To access components behind the DC controller, remove the PCA and the sheet-metal backing tray. See DC controller PCA and tray on page 161. Before proceeding, remove the following components: ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Rear-top cover. See Rear-top cover on page 102. ● Rear cover. See Rear cover on page 112.
2. Remove four screws (callout 1), and then remove the DC controller PCA.
Low-voltage power supply (LVPS) Before proceeding, remove the following components: ● Formatter. See Formatter PCA on page 78. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Rear cover. See Rear cover on page 112. ● Interconnect board (ICB). See Interconnect board (ICB) on page 153.
2. Disconnect five connectors, and then release the wire harnesses from the guides as necessary. NOTE: To locate DC controller connector locations, see DC controller connector locations on page 281. Figure 2-131 Remove the low-voltage power supply (1 of 6) 3. Disconnect one connector, and then release the wire harness from the guide. Reinstallation tip Make sure that you reconnect this connector when the power supply is reinstalled.
4. Remove three screws. Figure 2-133 Remove the low-voltage power supply (3 of 6) 5. Remove three screws. Reinstallation tip When the low-voltage power supply is reinstalled, make sure the tab on the mounting bracket behind the bottom screw (callout 1), is inserted in the slot in the product chassis. When correctly installed, the mounting bracket must be flat against the product chassis.
6. Slide the bottom of the assembly away from the product, tip the top of the assembly away from the product, and then remove the assembly. Figure 2-135 Remove the low-voltage power supply (5 of 6) 2 1 7. Place the assembly on a flat surface. Remove two screws (callout 1), and then separate the formatter cage (callout 2) from the low-voltage power supply (callout 3).
DC controller PCA and tray Before proceeding, remove the following components: ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Rear cover. See Rear cover on page 112. ● Interconnect board (ICB). See Interconnect board (ICB) on page 153. ● Low-voltage power supply. See Low-voltage power supply (LVPS) on page 157.
2. Remove two screws. Figure 2-138 Remove the DC controller PCA and tray (2 of 3) 3. Disengage three tabs (two along the left edge of the PCA and one at the top-right corner of the PCA).
High-voltage power supply lower (HVPS-D) Before proceeding, remove the following components: ● Formatter. See Formatter PCA on page 78. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Rear cover. See Rear cover on page 112. ● Interconnect board (ICB).
2. Remove three screws.
3. Release four locking clips. NOTE: Squeeze each locking clip to remove.
4. Release five tabs. Figure 2-144 Remove the high-voltage power supply lower (5 of 7) 5. Rotate the top of the power supply away from the chassis, and then disconnect two connectors on the back of the power supply. NOTE: Remove the FFC (callout 1) with the high-voltage power supply PCA. Do not disconnect this FFC.
6. Disconnect one FFC (callout 1). Release only the wire harnesses from the guide (callout 2) and then remove the power supply. NOTE: Remove the FFC (callout 1) and guide (callout 2) with the PCA. Replacement high-voltage power supply PCAs have the FFC and guide installed.
Developing-disengagement motor Before proceeding, remove the following components: ● Formatter. See Formatter PCA on page 78. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Rear cover. See Rear cover on page 112. ● Interconnect board (ICB). See Interconnect board (ICB) on page 153.
Exhaust fan and fan duct Before proceeding, remove the following components: ● Formatter. See Formatter PCA on page 78. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Rear cover. See Rear cover on page 112. ● Interconnect board (ICB). See Interconnect board (ICB) on page 153.
2. Release five tabs (callout 1) and remove the cover (callout 2). Figure 2-150 Remove the exhaust fan and fan duct (2 of 3) 2 1 3. Disconnect one connector, and then remove the fan from the duct.
Reinstall the exhaust fan and fan duct Be sure that the toroid (callout 1) is correctly aligned in the FFC cable guide before attempting to reinstall the exhaust fan and duct.
Pickup motor Before proceeding, remove the following components: ● Formatter. See Formatter PCA on page 78. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Rear cover. See Rear cover on page 112. ● Right-rear cover. See Right-rear cover on page 110. ● Power-supply fan.
Lifter-drive assembly Before proceeding, remove the following components: ● Formatter. See Formatter PCA on page 78. ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 92. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Rear cover. See Rear cover on page 112.
2. Disconnect one connector (callout 1), and then remove two screws (callout 2). Figure 2-155 Remove the lifter-drive assembly (2 of 3) 1 3. 2 Remove the lifter-drive assembly from the product. CAUTION: The spring on the assembly is not captive. Do not lose the spring when the assembly is removed. Figure 2-156 Remove the lifter-drive assembly (3 of 3) NOTE: Make sure that the lifter-drive assembly moves up and down easily after reinstalling.
Lifter base assembly Before proceeding, remove the following components: ● Formatter. See Formatter PCA on page 78 ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. ● Front-top cover. See Front-top cover on page 100 ● Right-rear cover. See Right-rear cover on page 110. ● Rear cover. See Rear cover on page 112. ● Interconnect board (ICB). See Interconnect board (ICB) on page 153.
2. From inside the Tray 2 cavity, remove four screws, and then remove the lifter base assembly. NOTE: Pull the assembly straight from the product without tipping to prevent the spring from falling from the assembly. Reinstallation tip If the tray does not completely close when reinstalled, push on the lever in the opening (callout 1) with a flat blade screwdriver to reset the spring in the closing mechanism.
2. Place the spring in the lifter before installing the assembly on the product.
Tray-pickup drive assembly Before proceeding, remove the following components: ● Formatter. See Formatter PCA on page 78. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Right-front cover. See Right-front cover on page 103. ● Rear cover. See Rear cover on page 112. ● Right-rear cover.
2. Remove two screws (callout 1), disconnect one connector (callout 2), and then remove the pickup motor (callout 35). Figure 2-162 Remove the tray-pickup drive assembly (2 of 3) 2 3 1 3. Remove three screws, and then remove the tray-pickup drive assembly. NOTE: The cams on the main-drive assembly can prevent the tray-pickup drive assembly from releasing from the product. If you cannot remove the assembly, remove the DC controller and tray to provide additional space.
Tray-pickup assembly Before proceeding, remove the following components: ● Formatter. See Formatter PCA on page 78. ● Secondary transfer assembly. See Secondary transfer assembly on page 119. ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 92. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover.
2. From the front of the product, remove one screw (callout 1), and then remove one tray rail (callout 2). Figure 2-165 Remove the tray-pickup assembly (2 of 11) 1 2 3. From the right side of the product, remove two screws (callout 1) and one cover (callout 2).
4. Close the right-door assembly. Push in and then push up on the stopper to release. Figure 2-167 Remove the tray-pickup assembly (4 of 11) 5. Open the right-door assembly. Lift the two link arms (callout 1) to release from the product, and then remove the paper guide (callout 2).
6. Close the right-door assembly. Push the two tabs toward each other, and then push up to release the feed guide. Figure 2-169 Remove the tray-pickup assembly (6 of 11) 7. Open the right-door assembly, and then remove the feed guide.
8. Remove two screws (callout 1), and then remove two brackets (callout 2). Figure 2-171 Remove the tray-pickup assembly (8 of 11) 2 1 9. Release one tab (callout 1), and then slide the feed guide (callout 2) toward the front of the product to remove.
10. Remove one screw. Figure 2-173 Remove the tray-pickup assembly (10 of 11) 11. Remove the tray-pickup assembly.
Laser/scanner assembly (Y/M) Before proceeding, remove the following components: ● Toner collection unit. See Toner-collection unit on page 76. ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 92. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Rear cover.
Remove the laser/scanner assembly (Y/M) NOTE: After installing a new laser/scanner assembly, be sure to calibrate the product. See Calibrate the product on page 313. 1. Release one spring. CAUTION: The spring is not captive. Do not lose the spring when it is removed. Use a pair of needle-nose pliers to safely retain the spring when it is removed. Do not use a flat blade screwdriver to remove the spring; the spring could forcibly leave the product and strike you.
3. Release one spring (callout 1), and then disconnect one FFC (callout 2). Reinstallation tip When reinstalled, the toroid (callout 3) must be correctly positioned on the wire guide (in the provided slots) so that the fan duct will fully seat in the product when it is reinstalled. Figure 2-177 Remove the laser/scanner assembly (Y/M) (3 of 5) 1 2 3 CAUTION: The spring is not captive. Do not lose the spring when it is removed.
4. Rotate the front of the laser/scanner assembly down (callout 1), and then slide it toward the right (callout 2). Lower the left corner, and then rotate the left corner out of the product (callout 3). Reinstallation tip When the scanner is reinstalled, make sure that the tab on the front of the laser/scanner is inserted in the alignment hole in the product chassis.
Laser/scanner assembly (C/Bk) Before proceeding, remove the following components: ● Toner collection unit. See Toner-collection unit on page 76. ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 92. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Rear cover.
Remove the laser/scanner assembly (C/Bk) NOTE: After installing a new laser/scanner assembly, be sure to calibrate the product. See Calibrate the product on page 313. 1. Release one spring (callout 1), and then disconnect one FFC (callout 2). CAUTION: The spring is not captive. Do not lose the spring when it is removed. Use a pair of needle-nose pliers to safely retain the spring when it is removed.
3. Remove five screws (callout 1), and then remove the cover (callout 2). CAUTION: Be careful. The PGC actuators are easily dislodged when the cover is removed. See Figure 2-185 Reinstall the PGC actuators (1 of 5) on page 193. To reinstall the actuators, see Reinstall the protective glass cleaner (PGC) actuators on page 193. Figure 2-182 Remove the laser/scanner assembly (C/Bk) (3 of 5) 1 2 4. Release one spring. CAUTION: The spring is not captive. Do not lose the spring when it is removed.
5. Rotate the corner of the assembly away from the product until you can see the PCA, and then remove the assembly from the product. Reinstallation tip When the laser/scanner is correctly positioned in the chassis, the plastic parts which protrude at the front and rear of the product will be firmly seated against the locator tabs on the chassis. Verify that the assembly is correctly seated, and then install the spring.
2. Remove the actuator and spring from the product. Install the spring on the actuator. Figure 2-186 Reinstall the PGC actuators (2 of 5) 3. Before proceeding, take note of the following: ● Callout 1: The pin on the actuator will be installed into the slot in the chassis. ● Callout 2: The pin on the pivot arm will be installed into the slot on the actuator. ● Callout 3: The end of the spring will be installed onto the tab on the chassis.
4. Place the end of the actuator into the PGC rod, and then use a small flat blade screw driver to fasten the end of the spring on the tab on the chassis. Figure 2-188 Reinstall the PGC actuators (4 of 5) 5. Push down on the actuator to seat it into place. Verify that the actuators is correctly installed. The PGC actuator must freely move when you push in on the actuator.
High-voltage power supply upper (HVPS-T) Before proceeding, remove the following components: ● Formatter. See Formatter PCA on page 78. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Rear cover. See Rear cover on page 112. ● Interconnect board (ICB).
2. Remove three screws (callout 1), release four tabs (callout 2), and then remove the power supply.
Reinstall the high-voltage power supply upper When you reinstall the power supply, look through the holes in the PCA and make sure that the highvoltage contact springs are correctly seated against the PCA. NOTE: For a replacement power supply, remove one wire harness (callout 1) and then install it on the replacement power supply.
Yellow, magenta, cyan, and black drum motors Before proceeding, remove the following components: ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Rear cover. See Rear cover on page 112. ● Interconnect board (ICB). See Interconnect board (ICB) on page 153. ● Low-voltage power supply.
Fuser motor Before proceeding, remove the following components: ● Formatter. See Formatter PCA on page 78. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Rear cover. See Rear cover on page 112. ● Interconnect board (ICB). See Interconnect board (ICB) on page 153.
Remove the fuser motor Remove three screws (callout 1), disconnect one connector (callout 2), and then remove the motor (callout 3).
ITB motor Before proceeding, remove the following components: ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102. ● Left cover. See Left cover on page 99. ● Rear cover. See Rear cover on page 112. ● Interconnect board (ICB). See Interconnect board (ICB) on page 153. ● Low-voltage power supply.
Main-drive assembly NOTE: Removing the main-drive assembly typically requires more than 2 hours to complete. Before proceeding, remove the following components: ENWW ● Formatter. See Formatter PCA on page 78. ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 92. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. ● Front-top cover. See Front-top cover on page 100.
Remove the main-drive assembly 1. Remove eight connectors (callout 1), and then release the wire harnesses from the guides (callout 2). NOTE: Leave the wire harnesses with the product. Figure 2-196 Remove the main-drive assembly (1 of 6) 1 2 2. Remove two screws (callout 1), disconnect one connector (callout 2), and then remove the developing-disengagement motor. NOTE: When the motor is reinstalled, make sure the motor PCA is positioned at the top of the assembly.
3. Remove one screw (callout 1), and then remove the wire guide from the main-drive assembly (callout 2). NOTE: Leave the wire harnesses connected to the wire guide and attached to the product for easier reinstallation. Figure 2-198 Remove the main-drive assembly (3 of 6) 1 2 4. Remove 10 screws.
5. Separate the main-drive assembly from the product. Figure 2-200 Remove the main-drive assembly (5 of 6) 6. Release the wire harness (callout 1) from the guides, and then remove the main-drive assembly from the product. Reinstallation tip It might be easier to pass this harness over the edge of the assembly chassis after the main-drive assembly is reinstalled. Figure 2-201 Remove the main-drive assembly (6 of 6) 1 CAUTION: Be careful when you remove the assembly.
Reinstall the main-drive assembly 1. Locate the cams (callout 1) on the back side of the assembly. Figure 2-202 Reinstall the main-drive assembly (1 of 7) 1 2. Slowly rotate the shaft near the black cam. WARNING! Do not touch the plastic gears or cams. You must not wipe away any of the grease that is applied to these components. Always rotate the gears and cams by rotating the metal drive shaft.
3. Continue to rotate the shaft until the holes in the black-cam gear align as shown below. When correctly aligned, the bottom-most hole in the gear is aligned with a hole in the sheet-metal chassis. NOTE: The holes in the other cam gears have a different alignment. You must make sure that the holes in the black-cam gear are correctly aligned.
4. Verify that the cams (callout 1) align correctly. TIP: The second cam in from the right (the white cam to the left of the black cam), should have the second hole aligned with the hole in the sheet-metal chassis. The third cam in from the right, should have the third hole aligned with the hole in the sheet-metal chassis. The fourth cam in from the right (the cam nearest the developing-disengagement motor), should have the fourth hole aligned with the hole in the sheet-metal chassis.
6. When placing the assembly on the chassis, align the holes in the assembly with the holes in the chassis. Reinstallation tip If the upper-left corner of the assembly is difficult to seat, you might need to rotate the ITB motor to align the gear shaft with the hole in the chassis. Figure 2-207 Reinstall the main-drive assembly (6 of 7) 7. When the assembly is correctly installed, the tabs are flat against the chassis.
Fuser-drive assembly NOTE: Removing the fuser-drive assembly typically requires more than 2 hours to complete. Before proceeding, remove the following components: ENWW ● Formatter. See Formatter PCA on page 78. ● Fuser. See Fuser on page 85. ● Upper-left cover. See Upper-left cover on page 96. ● Power-supply cover. See Power-supply cover on page 98. ● Left cover. See Left cover on page 99. ● Front-top cover. See Front-top cover on page 100. ● Rear-top cover. See Rear-top cover on page 102.
Remove the fuser-drive assembly 1. Remove one screw (callout 1), and then remove the cover (callout 2). Figure 2-209 Remove the fuser-drive assembly (1 of 7) 2 1 2. Release the wire harness (callout 1) from the guides.
3. Remove two screws (callout 1), one static wire (callout 2), and one switch (callout 3). Figure 2-211 Remove the fuser-drive assembly (3 of 7) 1 3 2 4. Release one tab, and then slide the wire harness holder (callout 1) to release it from the fuser-drive assembly. NOTE: Releasing the wire harness provides clearance when the assembly is removed. The harness does not need to be removed.
5. Disconnect two connectors. Figure 2-213 Remove the fuser-drive assembly (5 of 7) 6. Remove three screws.
7. Carefully remove the assembly. Figure 2-215 Remove the fuser-drive assembly (7 of 7) Reinstall the fuser-drive assembly Rotate the motor until the gears align, and the assembly is flat against the chassis.
Optional paper feeder assemblies (1 x 500-sheet and 3 x 500-sheet) NOTE: For information about removing the Tray 3, 4, or 5 feed and separation rollers, see Feed and separation rollers (Trays 2-5) on page 86. For information about removing the Tray 3, 4, or 5 cassettes, see Tray on page 84.
2. Release the link arm (callout 1), and then remove the front door (callout 2).
Rear cover (optional paper feeder) ▲ Remove two screws (callout 1), and then remove the rear cover (callout 2).
Right-front cover (optional paper feeder) ▲ Open the front and right doors, remove one screw (callout 1), and then lift the right-front cover (callout 2) to remove.
Right door (optional paper feeder) 1. Open the right door, release one tab (callout 1), and then remove the stopper (callout 2) Figure 2-221 Remove the right door (optional paper feeder) (1 of 3) 1 2 2. Close the right door slightly, and then release the upper link arm.
3. Slide the door to release the lower link arm, and then remove the right door.
Left cover (optional paper feeder) Before proceeding, remove the following components: ● Front door (optional paper feeder). See Front door (optional paper feeder) on page 216. ● Right-front cover (optional paper feeder). See Right-front cover (optional paper feeder) on page 219. Remove the left cover (optional paper feeder) 1. 1 x 500 paper feeder only: Remove two screws (callout 1), and then remove two bushings (callout 2).
2. 1 x 500 paper feeder only: Remove three screws (callout 1), and then remove the storage box (callout 2). Figure 2-225 Remove the left cover (optional paper feeder) (2 of 3) 1 2 3. Release five tabs (callout 1), and then remove the left cover (callout 2).
Right cover (optional paper feeder) Before proceeding, remove the following components: ● Right door (optional paper feeder). See Right door (optional paper feeder) on page 220. Remove the right cover (optional paper feeder) ▲ Remove two screws (callout 1), release one tab (callout 2), and then remove the right cover (callout 3).
Rear-right cover (optional paper feeder) Before proceeding, remove the following components: ● Right door (optional paper feeder). See Right door (optional paper feeder) on page 220. Remove the rear-right cover (optional paper feeder) ▲ Remove one screw (callout 1), and then lift the rear-right cover (callout 2) to remove.
Pickup assembly (optional paper feeder) Before proceeding, remove the following components: ● Paper feeder right front cover. See Right-front cover (optional paper feeder) on page 219. ● Paper feeder rear cover. See Rear cover (optional paper feeder) on page 218. NOTE: The following procedure shows steps for removing the pickup assembly for Tray 3. 3 x 500sheet optional paper feeder only: The steps for removing the pickup assemblies for Tray 4 and Tray 5 are the same unless noted.
2. 1 x 500-sheet optional paper feeder only: Remove three screws (callout 1), disconnect one connector (callout 2), and then remove the motor assembly (callout 3). Figure 2-230 Remove the pickup assembly (optional paper feeder) (2 of 5) 2 3 1 3. 3 x 500-sheet optional paper feeder only: Remove four screws (callout 1), disconnect two connector (callout 2), and then remove the motor assembly (callout 3).
4. Remove one screw (callout 1), and then disconnect three connectors (callout 2). Figure 2-232 Remove the pickup assembly (optional paper feeder) (4 of 5) 2 1 5. Remove one screw (callout 1), and then remove the pickup assembly (callout 2).
Lifter assembly (optional paper feeder) Before proceeding, remove the following components: ● Rear cover (optional paper feeder). See Rear cover (optional paper feeder) on page 218. Remove the lifter assembly (optional paper feeder) 1. Disconnect one connector (callout 1). Figure 2-234 Remove the lifter assembly (optional paper feeder) (1 of 2) 1 2. Remove four screws (callout 1), and then remove the lifter assembly (callout 2).
Lifter-drive assembly (optional paper feeder) Before proceeding, remove the following components: ● Rear cover (optional paper feeder). See Rear cover (optional paper feeder) on page 218. Remove the lifter-drive assembly (optional paper feeder) 1. Disconnect one connector (callout 1), and then release the wire harnesses (callout 3) from the guides (callout 2). Figure 2-236 Remove the lifter-drive assembly (optional paper feeder) (1 of 2) 1 2 2.
Pickup motor assembly (optional paper feeder) Before proceeding, remove the following components: ● Rear cover (optional paper feeder). See Rear cover (optional paper feeder) on page 218. Remove the pickup motor (optional paper feeder) assembly 1. 1 x 500-sheet optional paper feeder only: Remove three screws (callout 1), disconnect one connector (callout 2), and then remove the motor assembly (callout 3). Figure 2-238 Remove the pickup motor assembly (optional paper feeder) (1 of 2) 2 3 1 2.
Controller PCA (optional paper feeder) Before proceeding, remove the following components: ● Rear cover (optional paper feeder). See Rear cover (optional paper feeder) on page 218. Remove the controller PCA (optional paper feeder) 1. 1 x 500-sheet optional paper feeder only: Disconnect four connector (callout 2), and then remove two screws (callout 1). Release three tabs (callout 3), and then remove the PCA (callout 4). Figure 2-240 Remove the controller PCA (optional paper feeder) (1 of 2) 2 1 3 4 2.
3 Solve problems To use the information in this chapter, you need to have a basic understanding of the HP LaserJet printing process. Explanations of each mechanical assembly, the printer systems, and the basic theory of operation are contained in Theory of operation on page 1. Do not perform any of these troubleshooting processes unless you understand the function of each product component.
Solve problems checklist If the product is not responding correctly, complete the steps in the following checklist, in order. If the product does not pass a step, follow the corresponding troubleshooting suggestions. If a step resolves the problem, you can stop without performing the other steps on the checklist. 1. Make sure that the control-panel display shows one of the following messages: Ready, PAUSED, or SLEEP MODE ON.
ENWW 8. Verify that you have installed the HP Color LaserJet Enterprise CP4020-CP4520 Series printer driver. Check the program to make sure that you are using the HP Color LaserJet Enterprise CP4020-CP4520 Series printer driver. 9. Print a short document from a different program that has worked in the past. If this solution works, the problem is with the program that you are using. If this solution does not work (the document does not print) complete these steps: a.
Menu map Print a menu map 1. Press the OK button to open the menus. 2. Use the arrow buttons to navigate to the INFORMATION submenu, and then press the OK button. 3. Use the arrow buttons to navigate to the PRINT MENU MAP submenu, and then press the OK button to print the menu structure. 4. Press the back arrow 236 Chapter 3 Solve problems to exit the menus.
Troubleshooting process Determine the problem source When the product malfunctions or encounters an unexpected situation, the product control panel alerts you to the situation. This section contains a pre-troubleshooting checklist to filter out many possible causes of the problem. A troubleshooting flowchart helps you diagnose the root cause of the problem. The remainder of this chapter provides steps for correcting problems.
Table 3-1 Pre-troubleshooting checklist (continued) ● Is the amount of media in the tray within specifications? ● Is the media correctly placed in the tray? ● Are the paper guides aligned with the stack? ● Is the paper tray correctly installed in the product? ● Is each print cartridge installed correctly? ● Are original HP print cartridges installed? ● Are the cartridges damaged? ● Are the ITB and fuser correctly installed? ● Is the ITB or fuser damaged? Covers ● Are the right and front
Troubleshooting flowchart This flowchart highlights the general processes that you can follow to quickly isolate and solve product hardware problems. Each row depicts a major troubleshooting step. A “yes” answer to a question allows you to proceed to the next major step. A “no” answer indicates that more testing is needed. Go to the appropriate section in this chapter, and follow the instructions there. After completing the instructions, go to the next major step in this troubleshooting flowchart.
Power subsystem Power-on checks The basic product functions should start up when the product is plugged into an electrical outlet and the power switch is pushed to the on position. If the product does not start, use the information in this section to isolate and solve the problem. Power-on troubleshooting overview Turn on the product power.
ENWW ● 00:36 seconds; HP logo appears on the control-panel display ● 00:60 seconds; engine noises stop (you can run engine test at this point) ● 00:83 seconds; Initializing continues ● 00:85 fans rotate at slow speed ● 00:90 seconds; product enters the Ready state Troubleshooting process 241
Tools for troubleshooting The section describes the tools that can help you solve problems with your device. Individual component diagnostics LED diagnostics LED, engine, and individual diagnostics can identify and troubleshoot product problems. Understand lights on the formatter Three LEDs on the formatter indicate that the product is functioning correctly.
4. Press the down arrow the OK button. to highlight the EMBEDDED JETDIRECT MENU option, and then press 5. Press the down arrow to highlight the LINK SPEED menu, and then press the OK button. 6. Select the appropriate link speed, and then press the OK button. Heartbeat LED The heartbeat LED indicates that the formatter is functioning correctly. While the product is initializing after you turn it on, the LED blinks rapidly, and then turns off.
3. Insert a folded piece of paper into each slot at the same time until the product is in a Ready state. Figure 3-2 Diagnostic test (2 of 2) Disable cartridge check Use this diagnostic test to print internal pages or send an external job to the product when one or more print cartridges are removed or exchanged. Consumable supply errors are ignored while the product is in this mode.
horizontal lines. The test page can use only Tray 2 as the paper source, so make sure that paper is loaded in Tray 2. Figure 3-3 Engine-test button Paper-path test This diagnostic test generates one or more test pages that you can use to isolate the cause of jams. To isolate a problem, specify which input tray to use, specify whether to use the duplex path, and specify the number of copies to print. Multiple copies can be printed to help isolate intermittent problems.
Manual sensor test (special-mode test) Use this diagnostic test to manually test the product sensors and switches. Each sensor is represented by a letter and number on the control panel display. 1. Press the Home button 2. Press the down arrow to highlight the DIAGNOSTICS menu, and then press the OK button. 3. Press the down arrow OK button. to highlight the MANUAL SENSOR TEST option, and then press the . To exit this diagnostic, press the Stop button , and then select EXIT DIAGNOSTICS.
A TOP (top of page) sensor 1. Open the right door. 2. Insert a piece of paper to activate the TOP sensor. Figure 3-4 Test the TOP sensor (1 of 2) NOTE: Open the registration shutter to verify the paper activates the sensor. Figure 3-5 Test the TOP sensor (2 of 2) ENWW 3. Check the control-panel display for sensor response. 4. If there is no response, replace the registration assembly. See Registration assembly on page 128.
B and C loop sensors 1. Open the right door. 2. Lower the secondary transfer assembly. 3. Slowly insert a piece of paper at the entrance of the fuser to activate the B and C loop sensors underneath the fuser. Figure 3-6 Test the loop sensors 4. Check the control-panel display for a sensor response. 5. If there is no response, replace fuser. See Fuser on page 85.
D fuser delivery sensor 1. Open the right-door assembly. 2. Lower the secondary transfer assembly. 3. Remove the fuser, and then verify that the sensor flag on the fuser moves freely. If the sensor flag does not move freely, replace the fuser. See Fuser on page 85. Figure 3-7 Test the fuser delivery sensor (1 of 2) 4. Insert a piece of paper to activate the fuser delivery sensor. Figure 3-8 Test the fuser delivery sensor (2 of 2) ENWW 5. Check the control-panel display for a sensor response. 6.
E duplex re-pickup sensor 1. Open the right door. 2. Lift the secondary-transfer assembly. 3. Press the flag to activate the sensor. Figure 3-9 Test the duplex re-pickup sensor 4. Check the control-panel display for sensor response. 5. If there is no response, replace the registration assembly. See Registration assembly on page 128.
F output bin full sensor NOTE: The front-top, rear-top, and right-front covers have been removed for clarity. 1. Lift the flapper on the delivery assembly to move the output-bin full sensor flag. Figure 3-10 Test the output-bin-full sensor ENWW 2. Check the control-panel display for sensor response. 3. If there is no response, remove the right-front cover (see Right-front cover on page 103) and verify that the flag is moving. If not, replace the delivery assembly. See Delivery assembly on page 145.
I developer alienation This sensor is located inside the main-drive assembly and cannot be accessed for direct manual testing. To test this sensor, do the following. 1. Access the manual-sensor test menu and select sensor test I. 2. Locate connector J112 on the DC controller PCA. CAUTION: 3. ESD sensitive component. Disconnect connector J112. The value shown on the control-panel display changes from “0” to “1” if the sensor is properly functioning.
J fuser pressure-release sensor 1. Open the right-door assembly. 2. Lower the secondary transfer assembly. 3. Remove the fuser. 4. Insert a piece of paper to activate the fuser pressure-release sensor. Figure 3-11 Test the fuser pressure-release sensor ENWW 5. Check the control-panel display for sensor response. 6. If there is no response, replace fuser pressure-release sensor.
K primary transfer-roller-disengagement sensor NOTE: The front-top, rear-top, and right-front covers have been removed for clarity. 1. Open the right-door assembly. 2. Lower the secondary transfer assembly, and then remove the fuser and ITB. 3. Rotate the gear (callout 1) to move the flag (callout 2). If the flag does not move, replace the ITB.
4. From inside the ITB cavity, press up on the primary-transfer-roller-disengagement flag to activate the sensor. Figure 3-14 Test the primary transfer-roller-disengagement sensor (3 of 4) 5. Check the control-panel display for sensor response. 6. If there is no response, remove the rear-top cover (see Rear-top cover on page 102) and verify that the flag is moving. Figure 3-15 Test the primary transfer-roller-disengagement sensor (4 of 4) 7. ENWW If the flag moves correctly, replace the sensor.
L media sensor 1. You cannot test this sensor with a manual sensor test. Test using the paper-path sensors test. See Paper-path sensors test on page 273. Figure 3-16 Media sensor 2. Access the paper-path sensors test. 3. Print a configuration page. 4. The media sensor (on the registration assembly) detects the type of media as it passes the sensor. The control-panel display changes based on the media type. NOTE: The following are examples only.
M front-door switch 1. Open the front-door assembly to disengage the front-door switch. Figure 3-17 Test the front-door switch 2. Close the front-door assembly, and then check the control panel on the product for sensor response. TIP: You can leave the front door open and use a slender blade screw driver or pencil to activate the switch. 3. ENWW If there is no response, replace the front-door switch.
N right-door switch 1. Open the right-door assembly to disengage the right-door switch. Figure 3-18 Test the right door switch 2. Close the right-door assembly, or use your finger to depress the switch flag, and check the control panel on the product for sensor response. 3. If there is no response, replace the right-door switch.
Manual sensor test 2 (special-mode test) Use this test to test paper-path sensors and the paper-size switches manually. The following illustrations and table show the locations of these sensors. 1. Press the Home button 2. Press the down arrow to highlight the DIAGNOSTICS menu, and then press the OK button. 3. Press the down arrow OK button. to highlight the MANUAL SENSOR TEST 2 option, and then press the .
Table 3-6 Default state of bits ● Label O P Q R S T U V W X Y Z a b c d Bit 1 1 1 1 1 0 1 1 1 0 1 1 1 0 1 1 Test each switch individually.
O Tray 1 paper present sensor 1. Open Tray 1. 2. Toggle the Tray 1 paper-present sensor flag. Figure 3-19 Test the Tray 1 media-present sensor ENWW 3. Check the control-panel display for sensor response. 4. If there is no response, replace Tray 1.
P Tray 2 paper present sensor 1. Remove Tray 2. 2. Toggle the tray 2 paper-present sensor flag. Figure 3-20 Test the tray 2 paper-present sensor 3. Check the control-panel display for sensor response. 4. If there is no response, replace the cassette-pickup assembly. See Tray-pickup assembly on page 180.
Q Tray 2 paper surface 1 and 2 sensors 1. Remove the tray. 2. In the tray cavity, press the tray-closed tab to release the flag, and then toggle the flag. Figure 3-21 Tray 2 paper surface 1 and 2 ENWW 3. Check the control-panel display for sensor response. 4. If there is no response, replace the cassette-pickup assembly. See Tray-pickup assembly on page 180.
R Tray 2 paper size switches NOTE: These switches also detect cassette presence. If these switches fail, the message TRAY OPEN could appear on the control-panel display. 1. Remove the tray. From inside the tray cavity, push any of the three buttons. Figure 3-22 Test the Tray 2 paper size switches 2. Check the control-panel display for sensor response. 3. If there is no response, replace the lifter assembly. See Lifter base assembly on page 175.
S Tray 3 paper present sensor See P Tray 2 paper present sensor on page 262. T Tray 3 feed sensor 1. Remove the tray. 2. Insert a piece of paper between the rollers to activate the feed sensor. TIP: Use stiff paper when performing this test (for example a business card or index card). Figure 3-23 Test the Tray 3 feed sensor 3. Check the control-panel display for sensor response. 4. If no response, replace the cassette-pickup assembly. See Tray-pickup assembly on page 180.
Z Tray 4 paper size switches See R Tray 2 paper size switches on page 264. a Tray 5 paper present sensor See P Tray 2 paper present sensor on page 262. b Tray 5 feed sensor See T Tray 3 feed sensor on page 265. c Tray 5 paper surface 1 and 2 sensors See Q Tray 2 paper surface 1 and 2 sensors on page 263. d Tray 5 paper size switches See R Tray 2 paper size switches on page 264.
5V laser and 24V interlock and logic switches (and power switch) Location and testing 1. Press the power switch to turn the product off then on to test the switch function. 2. Remove the right-front cover. See Right-front cover on page 103. 3. Locate the link arms (callout 1) on the front and right doors (and access ports in the covers; callout 2) that actuate the front- and right-door interlock switch (behind the right-front cover).
4. Open and close the doors to make sure that the interlock switches are correctly functioning. The following figures show the interlock switch position with the front and right doors open and closed. ● Front-door safety switch Defeating ◦ Fold a stiff piece of paper, for example a business card or index card, into a 10 mm (.375 in) strip, and then wedge the strip into the opening at the front of the product.
● Front-door logic switch ◦ ● Right-door safety switch ◦ ENWW Fold a stiff piece of paper, for example a business card or index card, into a 10 mm (.375 in) strip with a bend at the end, and insert the strip into the opening at the front of the product. Fold a stiff piece of paper, for example a business card or index card, into a 10 mm (.375 in) strip, and then insert the strip into the opening at the right of the product.
● Right-door logic switch ◦ Use masking tape to keep the switch flag depressed. TIP: You might have to use two pieces of tape to overcome the tension return spring on the flag.
New ITB sensor NOTE: This sensor cannot be tested, but you can inspect the sensor, actuator, and the flag on the ITB for damage. 1. Remove the existing ITB. 2. Inspect the new ITB sensor. Press the actuator on the sensor toward the cyan print cartridge to verify that the actuator moves. Figure 3-24 Test the new ITB sensor 3. On the new ITB, locate and inspect the new ITB flag (callout 1). TIP: The new ITB flag is only present prior to installation.
Tray 3, 4, and 5 right door switch NOTE: There is no manual sensor test for this sensor. 1. Open the paper feeder right door. Check the control-panel display for the CLOSE LOWER RIGHT DOOR message. If the message does not display, open the door and inspect the flag for damage (callout 1). 2. Insert a piece of paper to activate the sensor. If there is no response, replace the switch. NOTE: Make sure that the door flag (callout 1) is not damaged or missing.
Paper-path sensors test This test displays the status of each paper-path sensor and allows viewing of sensor status while printing internal pages. 1. Press the Home 2. Press the down arrow to highlight the DIAGNOSTICS, menu and then press the OK button. 3. Press the down arrow OK button. to highlight the PAPER PATH SENSORS option, and then press the 4. Select the paper-path test options for the test you want to run. button. NOTE: Print an internal page to view sensor activity.
When the timer trips, the control panel display shows the message PRINTING STOPPED To continue press OK. Pressing Home will print the previously selected job. If you do not want the previous job to print, press Stop first, and then press Menu. NOTE: Do not try to perform a print/stop test while the product is calibrating, because you be required to power-cycle the product. If a jam message displays on the control panel during testing, activate the door switch.
Table 3-8 Component test details (continued) Component test Motor or solenoid number Comments YELLOW LASER SCANNER M9 Activates the yellow/magenta scanner motor for 10 seconds. FUSER MOTOR M2 Activate the fuser motor at a specified speed for 10 seconds. FUSER PRESSURE RELEASE MOTOR M2 reverse Reverses the fuser motor and pressurizes or depressurizes the fuser.
Table 3-8 Component test details (continued) Component test Motor or solenoid number Comments DUPLEX REFEED CLUTCH SOLENOID SL2: duplex reverse solenoid Activates the duplex flapper solenoid for 10 seconds causing the switch-back diverter to move. REPEAT 276 Chapter 3 Solve problems Allows you to specify the number of times the product sequences. The choices are ONCE (default) and CONTINUOUS.
Diagrams Block diagrams Figure 3-27 Product cross section 1 2 4 3 5 6 7 8 9 10 11 12 13 14 22 ENWW 21 20 19 18 17 16 15 Item Description Item Description 1 ITB 12 Media sensor 2 Primary transfer roller 13 Registration shutter 3 Duplex flapper (duplex model) 14 MP tray pickup roller 4 Duplex reverse roller (duplex model) 15 MP tray separation pad 5 Pressure roller 16 Registration roller 6 Fuser 17 Cassette separation roller 7 Fuser sleeve 18 Cassette feed roller 8
Figure 3-28 Optional paper feeder (1 x 500-sheet) 1 2 5 4 Item Description 1 Pickup roller 2 Feed roller 3 Separation roller 4 Storage space 5 Cassette 278 Chapter 3 Solve problems 3 ENWW
Figure 3-29 Optional paper feeder (3 x 500-sheet) 1 2 4 3 ENWW Item Description 1 Pickup roller 2 Feed roller 3 Separation roller 4 Cassette Tools for troubleshooting 279
Plug/jack locations 1 2 3 4 1 Hi-speed USB 2.
Location of connectors DC controller connector locations NOTE: The DC controller has 36 connectors: Five are for FFCs, 27 are for wire harnesses, and four are not used.
Table 3-10 DC controller connectors (continued) J106: not used J123: fuser motor (M2) J151: LVPS J107: Tray 3, 4, and 5 lifter motors (M7), and cassette paper size switch (SW4) J126: memory tag connector J152: 5V interlock switch (SW1) J108: environmental sensor J127: pre-exposure LEDs (rear), fuser delivery sensor (SR5), New ITB sensor (SR10) J153: power supply fan (FM1) J110: YM laser (FFC) J128: Delivery tray media full sensor (SR6), Fuser pressure release sensor (SR7), and pre-exposure LEDs (f
Controller PCA (1 x 500-sheet and 3 x 500-sheet optional paper feeders) Figure 3-32 Controller PCA connectors J410 J409 J408 J404 J407 J401 J406 J402 J405 J403 Table 3-11 Controller PCA connectors J401: not used J402: lifter motor 3 signal J403: cassette media presence 3 J404: right door open sensor J405: lifter motor 2 signal J406: cassette media presence 2 J407: lifter motor 1 signal J408: cassette media presence 1 J409: pickup motor J410: communication (command) ENWW Tools for troubleshooting 28
Locations of major components Figure 3-33 External component locations 1 12 2 11 3 10 4 9 5 8 6 7 Item Description Item Description 1 Rear-top cover 7 Power-supply cover 2 Right-door assembly 8 Rear cover 3 Right-rear cover 9 Tray 2 4 Right-front cover 10 Front-door assembly 5 Upper-left cover 11 Control-panel assembly 6 Left cover 12 Front-top cover 284 Chapter 3 Solve problems ENWW
Figure 3-34 Major component locations (1 of 3) 1 6 5 2 4 3 ENWW Item Description 1 Main drive assembly 2 Fuser 3 Registration assembly 4 Toner collection unit 5 Laser/scanner assembly (C/Bk) 6 Laser/scanner assembly (Y/M) Tools for troubleshooting 285
Figure 3-35 Major component locations (2 of 3) 1 9 8 7 2 6 3 4 5 Item Description Item Description 1 Duplex-drive assembly 6 Delivery fan 2 MP tray assembly 7 Cartridge fan 3 Delivery assembly 8 Residual toner full sensor 4 RD sensor assembly 9 Residual-toner-feed motor 5 Tray-pickup assembly 286 Chapter 3 Solve problems ENWW
Figure 3-36 Major component locations (3 of 3) 1 6 5 2 4 3 ENWW Item Description 1 Fuser-drive assembly 2 Tray-pickup drive assembly 3 Secondary transfer assembly 4 ITB 5 Lifter-drive assembly 6 Lifter base assembly Tools for troubleshooting 287
Figure 3-37 Motors, fans, and rollers component locations 1 16 2 15 3 4 5 6 14 7 13 8 12 11 9 10 Ite m Description Item Description 1 Fuser motor 9 Tray 2 feed roller 2 Pickup motor 10 Tray 2 separation roller 3 Tray 1 separation pad 11 Tray 2 pickup roller 4 Yellow drum motor 12 Secondary transfer roller 5 Magenta drum motor 13 Black drum motor 6 Cyan drum motor 14 Developing-disengagement motor 7 ITB motor 15 Tray 1 pickup roller 8 Power supply fan 16 Exhaust fa
Figure 3-38 PCA component locations 1 2 3 6 4 5 ENWW Item Description Item Description 1 Interconnect board (ICB) 4 High-voltage power supply upper (HVPS-T) 2 DC controller PCA 5 High-voltage power supply lower (HVPS-D) 3 Low-voltage power supply 6 Environment sensor PCA Tools for troubleshooting 289
Figure 3-39 Optional paper feeder (1 x 500-sheet) component locations (1 of 2) 1 8 2 7 3 6 4 5 Item Description Item Description 1 Rear-right cover 5 Rear cover 2 Right door 6 Right front cover 3 Right cover 7 Front door 4 Left cover 8 Tray 3 290 Chapter 3 Solve problems ENWW
Figure 3-40 Optional paper feeder (1 x 500-sheet) component locations (2 of 2) 5 1 2 4 3 ENWW Item Description Item Description 1 Lifter-drive assembly 4 Controller PCA 2 Pickup motor 5 Lifter base assembly 3 Pickup assembly Tools for troubleshooting 291
Figure 3-41 Optional paper feeder (3 x 500-sheet) component locations (1 of 2) 1 7 2 3 6 4 5 Item Description Item Description 1 Rear right cover 5 Rear cover 2 Right door 6 Right front cover 3 Right cover 7 Trays 3, 4, and 5 4 Left cover 292 Chapter 3 Solve problems ENWW
Figure 3-42 Optional paper feeder (3 x 500-sheet) component locations (2 of 2) 5 1 2 4 3 ENWW Item Description Item Description 1 Lifter-drive assembly (Trays 3, 4, and 5) 4 Controller PCA 2 Pickup motor 5 Lifter base assembly (Trays 3, 4, and 5) 3 Pickup assembly (Trays 3, 4, and 5) Tools for troubleshooting 293
294 Chapter 3 Solve problems 25 Secondary transfer bias 24 Primary transfer bias K 23 Primary transfer bias C 22 Primary transfer bias M 21 Primary transfer bias Y 20 Developing bias K 19 Developing bias C 18 Developing bias M 17 Developing bias Y 16 Primary charging bias K 15 Primary charging bias C 14 Primary charging bias M 13 Primary charging bias Y 12 Pickup motor 11 ITB motor 10 K drum motor 9 C drum motor 8 M drum motor 7 Y drum motor 6 TOP signal 5 Scanner motor 4 Fixing motor
Circuit diagrams Figure 3-44 General circuit diagram (1 of 2) 6 5 4 2 TA G (Bk) 1 1 2 TAG (M) TO IPTU & SS 1 2 3 4 5 6 7 8 J19 J85DH 11 10 9 9 10 11 12 13 14 15 16 17 18 19 20 J81DH 3 J47 SR9 J81L 2 SR6 TAG (Y) J82DH J82D 2 TA G (C) LED5 1 1 J82L LED6 1 LED7 J46 1 2 LED8 SR7 TH4 2 1 1 J85D 2 2 3 1 2 8 3 7 4 6 5 6 5 4 7 3 8 2 1 9 10 11 3 J60L J60D J60DH 1 A4 +5VB PREEXP4 +5VB PREEXP3 +5VB PREEXP2 +5VB 1 2 1 2 3 4 5 J107 6 J10 8
Figure 3-45 General circuit diagram (1 of 2) 3 2 1 5 6 7 1 2 +12V 1 2 3 1 2 3 J601 TB202 TB201 J607 4 HEA TER1 1 3 2 2 1 J50LB 1 2 3 1 2 3 1 2 3 4 J350 6 7 5 B7 J50LA J121 1 2 3 4 5 6 7 8 1 2 1 3 2 10 9 1 2 3 GND LED_O N PWRSWON PWRON AWAKE SGND JLPWRON CAN_L 1 2 3 4 5 1 2 3 1 2 HEA TERC J120 4 J140 1 2 3 4 5 6 7 8 16 15 14 13 12 11 10 9 1 2 3 4 6 7 8 M6 M M 1 2 3 1 2 M5 1 2 17 16 15 14 13 12 11 10 9 M4 M M M3 1 2 3 4 5 6 7 8 10 9 10 9 5 4 1 5 2 6
6 J17L 4 J15L 4 3 BOUT2 J13L 2 1 3 J13D J13LH 4 6 7 8 1 2 3 +3.3U J408 5 3 2 1 T3_PICK_SL +24V 2 1 1 2 J18D J18LH J18L J10LB 1x500 PD Controller PCA 9 10 2 J407 B5 A4 DCC I/F 8 7 6 5 4 J410 3 2 1 J10L J10LA 7 BOUT1 1 5 GND SL 1 6 AOUT2 +24V T3_LIFT_MTR T3_SIZE3 GND T3_SIZE2 2 4 2 5 AOUT1 J14 5 T3_SIZE1 J11D 3 +3.3U 2 GND 1 T3_PSNS J11L 1 T3_PATHS 3 2 SL1 3 GND SR4 4 +24V J12 T3_PLVL_P SR3 5 GND SR2 1 +3.
6 J23 SL 2 J20D J25LH 2 3 1 2 3 4 J25D 4 2 J24D J24DH 1 J24L J15L J22D J21D 1 J26 J25L J21L 4 3 2 BOUT1 BOUT2 +3.3V +24V T4_LIFT_MTR T4_SIZE3 GND T4_SIZE2 T4_SIZE1 +3.3U GND T4_PSNS T4_PLVL_P T4_PLVL_A +3.
HP Easy Printer Care Open the HP Easy Printer Care software Use one of the following methods to open the HP Easy Printer Care software: ● On the Start menu, select Programs, select Hewlett-Packard, select HP Easy Printer Care, and then click Start HP Easy Printer Care. ● In the Windows system tray (in the lower-right corner of the desktop), double-click the HP Easy Printer Care icon. ● Double-click the desktop icon.
Section Options Support tab ● Device Status section: This section shows product-identification information and the product status. It indicates product-alert conditions, such as a print cartridge that is at its estimated end of life. After you correct a problem with the in the upper-right corner of the window to product, click the refresh button update the status.
Section Options Alert Settings link Click Alert Settings to open the Alert Settings window, in which you can configure alerts for each product. NOTE: This item is available from the Overview and Support tabs. Color Access Control ● Alerting is on or off: Activates or deactivates the alerts feature. ● Printer Alerts: Select the option to receive alerts for critical errors only, or for any error. ● Job Alerts: For products that support it, you can receive alerts for specific print jobs.
Internal print-quality test pages Print-quality-troubleshooting pages Use the built-in print-quality-troubleshooting pages to help diagnose and solve print-quality problems. button. 1. Press the Home 2. Press the down arrow to highlight DIAGNOSTICS, and then press the OK button. 3. Press the down arrow print the pages. to highlight PQ TROUBLESHOOTING, and then press the OK button to The product returns to the Ready state after printing the print-quality-troubleshooting pages.
Figure 3-49 Yellow print-quality troubleshooting page Yellow Green Figure 3-50 Yellow comparison page Green Yellow Yellow cannot be easily seen unless combined with cyan, so half of each page is yellow and the other half is an amplified version of yellow problems (green half). Compare the yellow on page one with the corresponding green on page two for defects. You can also check the cyan page for defects.
Figure 3-51 Black print-quality troubleshooting page 1 2 3 1. Grids The grids are in inches and millimeters. They are label with letters and numbers so that defects can be described by position and by distance between repeats. 2. Color plane registration (CPR) bars After printing, the box with no extra color in each area on each page shows how far off the CPR of that color is. Each page has two process direction areas and three scan direction areas that are labeled x and y and 1–11.
Diagnostics page Use the diagnostics page to evaluate problems with color plane registration, EP parameters, and print quality. 1. Press the Home 2. Press the down arrow to highlight DIAGNOSTICS, and then press the OK button. 3. Press the down arrow to print the page. to highlight PRINT DIAGNOSTICS PAGE, and then press the OK button button.
Cleaning page Create and use the cleaning page . 1. Press the Home button 2. Press the up arrow or down arrow / to highlight the CONFIGURE DEVICE menu, and then press the OK button. 3. Press the up arrow or down arrow / to highlight the PRINT QUALITY menu, and then press the OK button. 4. If the product does not have automatic two-sided printing, press the up arrow or down arrow / to highlight the CREATE CLEANING PAGE option, and then press the OK button.
Configuration page Depending on the model, up to three pages print when you select PRINT CONFIGURATION. In addition to the main configuration page, an embedded Jetdirect configuration page prints. Configuration page Use the configuration page to view current product settings, to help troubleshoot product problems, or to verify installation of optional accessories, such as memory (DIMMs), paper trays, and printer languages. button. 1. Press the Home 2.
5 Memory 6 Event log 7 Security 8 Paper trays and options 308 Chapter 3 Solve problems ENWW
HP embedded Jetdirect page The second configuration page is the HP embedded Jetdirect page, which contains the following information: Figure 3-53 HP embedded Jetdirect page HP Color LaserJet CP 4520 Printers Embedded Jetdirect Page Page 1 1 4 2 5 3 6 1 HP Jetdirect Configuration indicates the product status, model number, hardware firmware version, port select, port configuration, auto negotiation, manufacturing identification, and manufactured date.
Embedded protocol page The embedded protocol page contains the following information: Figure 3-54 Embedded protocol page HP Color LaserJet CP 3525 Printers Embedded Protocol Page Page 1 3 1 4 2 1 IPX/SPX 2 Novell/NetWare 3 AppleTalk 4 DLC/LLC 310 Chapter 3 Solve problems ENWW
Finding important information on the configuration pages Certain information, such as the firmware date codes, the IP address, and the e-mail gateways, is especially helpful while servicing the product. This information is on the various configuration pages. Table 3-12 Important information on the configuration pages Type of information Specific information Configuration page Firmware date codes DC controller Look on the main configuration page, under “Device Information.
Print-quality troubleshooting tools Repetitive defects ruler If defects repeat at regular intervals on the page, use this ruler to identify the cause of the defect. Place the top of the ruler at the first defect. The marking that is beside the next occurrence of the defect indicates which component needs to be replaced.
Calibrate the product Calibration is a product function that optimizes print quality. If you experience any image-quality problems, calibrate the product. ENWW 1. Press the Home button 2. Press the down arrow button. to highlight the CONFIGURE DEVICE menu, and then press the OK 3. Press the down arrow to highlight the PRINT QUALITY menu, and then press the OK button. 4. Press the down arrow to highlight the FULL CALIBRATE NOW or QUICK CALIBRATE NOW setting, and then press the OK button. .
Control panel menus Control panel menus You can control the product by changing settings in the menus on the product control panel. Use the control panel to access features not supported by the printer driver or software application, and to configure trays for paper size and type. Show Me How menu The SHOW ME HOW menu prints pages that provide more information about the product. You can print the pages and keep them near the product for convenient reference.
Item Sub-item Sub-item Description ALL JOBS (WITH PIN) PRINT This message appears if a user has two or more stored jobs that require a PIN. If PRINT or PRINT AND DELETE is selected then the PIN will be requested. If the jobs have different PINs, only the jobs with the PIN entered will be printed. If the PIN does not match any of the jobs, an error message is displayed.
Item Sub-item Sub-item Description ALL JOBS (NO PIN) PRINT This message appears if a user has two or more stored jobs that do not require a PIN. PRINT AND DELETE ● COPIES ● JOB ● CUSTOM VALUE DELETE Either the PRINT option or the PRINT AND DELETE option displays, depending on the type of jobs listed. If the stored jobs are Personal or Proof and Hold jobs, PRINT AND DELETE is displayed. These jobs are deleted after they are printed.
Information menu Use the INFORMATION menu to access and print specific product information. To display: Press the Home button , and then select the INFORMATION menu. Item Description PRINT MENU MAP Prints the control-panel menu map, which shows the layout and current settings of the control-panel menu items. PRINT CONFIGURATION Prints the product configuration pages, which show the printer settings and installed accessories.
Menu item Value Description TRAY 1 SIZE A list of available sizes appears. Allows you to configure the paper size for Tray 1. The default is ANY SIZE. See the product user guide for a complete list of available sizes. TRAY 1 TYPE A list of available types appears. Allows you to configure the paper type for Tray 1. The default is ANY TYPE. See the product user guide for a complete list of available types. TRAY SIZE A list of available sizes appears.
Menu item Sub-menu item Values Description COLOR CARTRIDGES STOP Select what the product should do when the print cartridge is very near the end of its estimated life. PROMPT TO CONTINUE* CONTINUE STOP: The product stops until you replace the cartridge. PRINT IN BLACK PROMPT TO CONTINUE: The product stops until you clear the prompt message. CONTINUE: The product provides an alert message, but it continues printing.
Menu item Sub-menu item Values Description USER DEFINED LOW YELLOW CARTRIDGE Range from 0–100% Use the arrow buttons to enter the percentage of estimated cartridge life at which you want the product to alert you that the cartridge is low. Range from 0–100% Use the arrow buttons to enter the percentage of estimated cartridge life at which you want the product to alert you.
Menu item Sub-menu item RESTRICT COLOR USE Values Description ENABLE COLOR* This menu item controls the authorization of color printing. COLOR IF ALLOWED DISABLE COLOR DISABLE COLOR: All jobs sent to the product print only in monochrome. ENABLE COLOR: All color pages sent to the product print in color. COLOR IF ALLOWED: A permissions database is referenced to verify if color pages are printed in color or monochrome.
Menu item Values Description COPIES Range: 1 - 32000 Allows you to set the default number of copies for print jobs. The default number is 1. DEFAULT PAPER SIZE A list of available sizes appears. Allows you to set the default paper size. DEFAULT CUSTOM PAPER SIZE DUPLEX Sub-menu item ● UNIT OF MEASURE ● X DIMENSION ● Y DIMENSION Allows you to set the default size for any custom print job that does not specify the dimensions. The default unit of measure is MILLIMETERS.
PCL sub-menu This menu configures settings for the printer control language. To display: Press the Home button , select the CONFIGURE DEVICE menu, select the PRINTING menu, and then select the PCL menu. NOTE: Values that have an asterisk (*) are the factory-default values. Some menu items have no default. Item Values Description FORM LENGTH Range: 5-128 lines Sets vertical spacing for default paper size. The default is 60.
Print Quality menu To display: Press the Home button PRINT QUALITY menu. , select the CONFIGURE DEVICE menu, and then select the NOTE: Values that have an asterisk (*) are the factory-default values. Some menu items have no default.
Item Sub-item Sub-item Values Description X1 SHIFT Range: -5 mm to +5 mm The scan direction is referred to as X. X1 is the scan direction for a single-sided page or for the second side of a two-sided page. X2 is the scan direction for the first side of a two-sided page. Y1 SHIFT X2 SHIFT Y2 SHIFT AUTO SENSE MODE TRAY 1 SENSING The feed direction is referred to as Y. Y1 is the feed direction for a single-sided page or for the second side of a two-sided page.
Item Sub-item Sub-item Values Description ADJUST PAPER TYPES A list of paper types displays. PRINT MODE A list of print modes displays. Configure the print mode that is associated with each media type. RESISTANCE MODE HUMIDITY MODE PRE-ROTATION MODE FUSER TEMP MODE PAPER CURL MODE OPTIMIZE RESTORE MODES Use this feature to return all paper typemode settings to the factory-default settings. A list of available options displays.
Item EDGE CONTROL Sub-item Sub-item Values Description OFF The Edge Control setting determines how edges are rendered. Edge control has two components: adaptive halftoning and trapping. Adaptive halftoning increases edge sharpness. Trapping reduces the effect of color-plane misregistration by overlapping the edges of adjacent objects slightly. LIGHT NORMAL* MAXIMUM AUTO CLEANING OFF* ON CLEANING INTERVAL 500* 1000 2000 ● OFF turns off both trapping and adaptive halftoning.
Item Sub-item CREATE CLEANING PAGE Sub-item Values Description Prints a page of instructions for cleaning excess toner off the pressure roller in the fuser. NOTE: This option is available only for the HP Color LaserJet CP4025n printer and the HP Color LaserJet CP4525n printer. PROCESS CLEANING PAGE Allows you to create and process a cleaning page for cleaning the pressure roller in the fuser. When the cleaning process runs, a cleaning page is printed. This page can be discarded.
System setup menu Use the SYSTEM SETUP menu to change product-configuration defaults such as sleep mode, product personality (language), and jam recovery. To display: Press the Home button SYSTEM SETUP menu. , select the CONFIGURE DEVICE menu, and then select the NOTE: Values that have an asterisk (*) are the factory-default values. Some menu items have no default. Item Sub-item Values Description DATE/TIME DATE - - - - /[MMM]/[DD] YEAR = Allows you to set the correct date.
Item Sub-item Values Description USE REQUESTED TRAY EXCLUSIVELY* USE REQUESTED TRAY handles jobs that have specified a specific input tray. Two options are available: FIRST MANUALLY FEED PROMPT ALWAYS* UNLESS LOADED PS DEFER MEDIA ENABLED* DISABLED SIZE/TYPE PROMPT DISPLAY* DO NOT DISPLAY 330 Chapter 3 Solve problems ● EXCLUSIVELY: The product never selects a different tray when the user has indicated that a specific tray should be used, even if that tray is empty.
Item Sub-item Values Description USE ANOTHER TRAY ENABLED* This option turns on or off the control-panel prompt to select another tray when the specified tray is empty. DISABLED ALTERNATIVE LETTERHEAD MODE ON OFF* When this option is ON you can load letterhead or preprinted paper the same way for every job, whether printing on one or both sides of the page. NOTE: This option is available only for models that have automatic duplexing.
Item Sub-item Values Description WAKE TIME OFF* Select the CUSTOM option to configure the daily wake time for the product to avoid warm-up or calibration time. Select a day of the week, set the wake time for that day, and then choose whether the wake time should be applied to all days of the week. CUSTOM OPTIMUM SPEED/ENERGY USAGE FASTER FIRST PAGE* Controls the fuser cool down behavior.
Item AUTO CONTINUE Sub-item Values Description OFF Determines product behavior when the system generates an Auto Continuable error. ON* JAM RECOVERY AUTO* OFF ON RAM DISK AUTO* OFF ● ON: Allows the product to continue printing. ● OFF: Stops the product from printing until the error is cleared by the user. Sets whether the product will attempt to reprint pages after a jam. If you select AUTO, the product reprints pages if enough memory is available for full-speed two-sided printing.
I/O menu Items on the I/O (input/output) menu affect the communication between the product and the computer. If the product contains an HP Jetdirect print server, you can configure basic networking parameters by using this submenu. You can also configure these and other parameters through HP Web Jetadmin or the embedded Web server. For more information on these options, see the product user guide. To display: Press the Home button O menu.
Table 3-13 Embedded Jetdirect menu (continued) Item Sub-item Sub-item Sub-item Description IPV4 SETTINGS CONFIG METHOD BOOTP Specifies the method that TCP/IPv4 parameters will be configured on the HP Jetdirect print server. DHCP* AUTO IP Use BOOTP (Bootstrap Protocol) for automatic configuration from a BootP server. MANUAL Use DHCP (Dynamic Host Configuration Protocol) for automatic configuration from a DHCPv4 server.
Table 3-13 Embedded Jetdirect menu (continued) Item Sub-item Sub-item Sub-item Description DHCP RENEW NO* This menu appears if CONFIG METHOD is set to DHCP and a DHCP lease for the print server exists. YES NO: The print server does not request to renew the DHCP lease. YES: The print server requests to renew the current DHCP lease. IPV6 SETTINGS PRIMARY DNS Specify the IP address (n.n.n.n) of a Primary DNS Server. SECONDARY DNS Specify the IP address (n.n.n.
Table 3-13 Embedded Jetdirect menu (continued) Item Sub-item Sub-item Sub-item PROXY SERVER Description Specifies the proxy server to be used by embedded applications in the product. A proxy server is typically used by network clients for Internet access. It caches Web pages, and provides a degree of Internet security, for those clients. To specify a proxy server, enter its IPv4 address or fully-qualified domain name. The name can be up to 255 octets.
Table 3-13 Embedded Jetdirect menu (continued) Item Sub-item Sub-item IPSEC Sub-item Description KEEP Specify the IPSec status on the print server. DISABLE* KEEP: IPSec status remains the same as currently configured. DISABLE: IPSec operation on the print server is disabled. 802.1X RESET Specify whether the 802.1X settings on the print server are reset to the factory defaults. KEEP* RESET: The 802.1X settings are reset to the factory defaults. KEEP: The current 802.1X settings are maintained.
Table 3-13 Embedded Jetdirect menu (continued) Item Sub-item Sub-item Sub-item Description SNMP TEST YES This test checks operation of SNMP communications by accessing predefined SNMP objects on the product. NO* Select YES to choose this test, or NO to not choose it. DATA PATH TEST YES NO* This test helps to identify data path and corruption problems on an HP postscript level 3 emulation product.
Table 3-13 Embedded Jetdirect menu (continued) Item Sub-item Sub-item Sub-item Description PRINT RESULTS YES If the ping test was not set for continuous operation, you can choose to print the test results. Select YES to print results. If you select NO, results are not printed. NO* EXECUTE YES NO* PING RESULTS Use this item to view the ping test status and results using the control panel display.
Table 3-13 Embedded Jetdirect menu (continued) Item Sub-item Sub-item Sub-item Description REFRESH YES When viewing the ping test results, this item updates the ping test data with current results. Select YES to update the data, or NO to maintain the existing data. However, a refresh automatically occurs when the menu times out or you manually return to the main menu.
Resets menu The RESETS menu allows you to reset factory settings, and disable or enable sleep mode. To display: Press the Home button RESETS menu. , select the CONFIGURE DEVICE menu, and then select the NOTE: Values that have an asterisk (*) are the factory-default values. Some menu items have no default.
Item Sub-item Values Description PAPER PATH SENSORS Performs a test on each of the product’s sensors to determine if they are working correctly and displays the status of each sensor. PAPER PATH TEST Tests the paper-handling features of the product, such as the configuration of the trays. PRINT TEST PAGE SOURCE Generates a page for testing the paper-handling features. You must define the path for the test in order to test specific paper paths.
Item Sub-item COLOR BAND TEST PRINT TEST PAGE COPIES Values Description Prints a color band test page that is used to identify arcing in the highvoltage power supply. Range is 1 to 30. The default value is 1. Specify how many copies of the internal page are printed. Service menu The SERVICE menu is locked and requires a PIN for access. This menu is intended for use by authorized service personnel. See Service mode functions on page 420.
Interpret control-panel messages Control-panel message types Four types of control-panel messages can indicate the status of or problems with the product. Message type Description Status messages Status messages reflect the current state of the product. They inform you of normal product operation and require no interaction to clear them. They change as the state of the product changes.
Table 3-14 Control-panel messages (continued) Description Recommended action 11.XX Internal clock error The product real-time clock has experienced an error. To continue press OK 13.XX.YY FUSER AREA JAM ● XX = 01; clock battery failed ● XX = 02; real time clock failed A jam has occurred in the fuser area. Whenever the product is turned off and then turned on again, set the time and date at the control panel. See System setup menu on page 329.
Table 3-14 Control-panel messages (continued) Description Recommended action 22 EMBEDDED I/O BUFFER OVERFLOW Too much data was sent to the embedded HP Jetdirect print server. Press the OK button to print the transferred data. (Some data might be lost.) To continue press OK Check the host configuration. 22 PARALLEL I/O BUFFER OVERFLOW The product's parallel buffer has overflowed. Press the OK button to print the transferred data. (Some data might be lost.
Table 3-14 Control-panel messages (continued) Description Recommended action 49.XXXX ERROR A firmware error has occurred. To continue turn off then on This error can be caused by corrupted print jobs, software applications issues, nonproduct specific printer drivers, poor-quality USB or network cables, bad network connections or incorrect configurations, invalid firmware operations, or unsupported accessories. 1. Turn the product off and then on. 2.
Table 3-14 Control-panel messages (continued) Description Recommended action 50.3 FUSER ERROR High fuser temperature Reinstall the fuser. Check connector J50 between the fuser and the product. If either is damaged, replace the connector or fuser. See Fuser on page 85. If the error persists, replace the low-voltage power supply. See Low-voltage power supply (LVPS) on page 157. 50.4 FUSER ERROR 50.5 FUSER ERROR 50.7 FUSER ERROR 50.
Table 3-14 Control-panel messages (continued) Description Recommended action 50.9 FUSER ERROR High fuser temperature. Reinstall the fuser. Check the connector J50 between the fuser and the product. If either is damaged, replace the connector or fuser. See Fuser on page 85. If the error persists, replace the low-voltage power supply. See Low-voltage power supply (LVPS) on page 157. 50.X FUSER ERROR A fuser error has occurred. Make sure you have the correct fuser. Reseat the fuser.
Table 3-14 Control-panel messages (continued) Description Recommended action 56.X ERROR A temporary printing error has occurred (XX = 01; illegal input). Turn the product off, and then turn the product on. Cartridge fan (FM2) is defective. 1. Reconnect the cartridge fan connector J65, connector J263 on the high-voltage power supply lower, and connector J114 on the DC controller PCA. 2. Turn the product off, and then on.
Table 3-14 Control-panel messages (continued) Description Recommended action 59.20 ERROR Motor rotation error. Perform the motor component tests in the DIAGNOSTICS menu. 59.30 ERROR Fuser motor startup error Reconnect the connector J13 of the fuser motor and the connector J123 on the DC controller PCA. Perform the fuser motor component test in the DIAGNOSTICS menu. If the message persists, replace the fuser motor. See Fuser motor on page 200. 59.
Table 3-14 Control-panel messages (continued) Description Recommended action 59.63 ERROR Yellow image drum motor rotation error Perform the drum-motors component test in the DIAGNOSTICS menu. If the message persists, replace the yellow drum motor. See Yellow, magenta, cyan, and black drum motors on page 199. 59.90 ERROR ITB motor startup error Reconnect the connector J14 of the ITB motor and the connector J140 on the DC controller PCA.
Table 3-14 Control-panel messages (continued) Description Recommended action 59.F0 ERROR Transfer alienation failure 60.02 ERROR 60.03 ERROR 354 Chapter 3 Solve problems Tray 2 is not lifting correctly. Tray 3 is not lifting correctly. 1. Verify that the ITB is installed. 2. Reconnect the primary-transfer disengagement sensor J19, and connector J128 on the DC controller PCA . 3.
Table 3-14 Control-panel messages (continued) Description Recommended action 60.04 ERROR Tray 4 is not lifting correctly. 60.05 ERROR 62 NO SYSTEM Tray 5 is not lifting correctly. 1. Reconnect connector J406 on the paper deck controller PCA and the intermediate connector J21. 2. Run the sensor test in sensor monitor mode to verify that the cassette media stack surface sensor is functioning properly. If it is not, replace the pickup assembly. See Pickup assembly (optional paper feeder) on page 226.
Table 3-14 Control-panel messages (continued) Description Recommended action 68.X PERMANENT STORAGE WRITE FAIL The product NVRAM is failing to write. Printing can continue, but some unexpected To continue press OK functions might occur if an error occurred in permanent storage. Press the OK button to clear the message. If the message is not cleared, turn the product off, and then turn the product on. X values 68.X STORAGE ERROR SETTINGS CHANGED To continue press OK 69.
Table 3-14 Control-panel messages (continued) Description Recommended action Bad Signature The firmware upgrade code does not match the product signature. Download the correct firmware upgrade file for this product, and then reinstall the upgrade. See the product user guide for more information. BLACK CARTRIDGE LOW The product indicates when a supply level is low. Actual print cartridge life might vary.
Table 3-14 Control-panel messages (continued) Description Recommended action CARD SLOT DEVICE FAILURE The specified device has failed. Press the OK button to clear. A PJL file system command attempted to perform an illogical operation. Press the OK button to clear. A PJL file system command could not store something on the file system because the file system was full. Press the OK button to clear. The file system device is protected and no new files can be written to it.
Table 3-14 Control-panel messages (continued) Description Recommended action CLOSE LOWER RIGHT DOOR 3 x 500 optional paper feeder only Close the door. The right door on the optional paper feeder is open. If the message appears when the door is closed: CLOSE RIGHT DOOR A door on the right side of the product is open. 1. Reconnect connector J19 of the PD right door switch and connector J147 on the controller PCA. 2. Check the right door sensor flag.
Table 3-14 Control-panel messages (continued) Description Recommended action CYAN CARTRIDGE VERY LOW The product indicates when a supply level is very low. Actual print cartridge life might vary. Consider having a replacement print cartridge available to install when print quality is no longer acceptable. You do not need to replace the print cartridge at this time unless print quality is no longer acceptable.
Table 3-14 Control-panel messages (continued) Description Recommended action EIO IS WRITE PROTECTED The file system device is protected and no new files can be written to it. Press the OK button to clear. EIO NOT INITIALIZED This file-storage component must be initialized before use. Use the embedded Web server or HP Web Jetadmin to initialize the component. Event log empty No product events are in the log. No action is necessary.
Table 3-14 Control-panel messages (continued) Description Recommended action Incorrect The PIN is incorrect. Use the up arrow and down arrow buttons to enter the correct PIN. Initializing The product is starting. No action is necessary. Please wait until the Ready message appears on the display. Initializing permanent storage Displayed when the product is turned on to show that permanent storage is being initialized. No action is necessary.
Table 3-14 Control-panel messages (continued) Description Recommended action LOAD TRAY 1 [TYPE] [SIZE] The indicated tray is loaded and configured for a type and size other than the one specified in the job. To continue press OK LOAD TRAY 1 [TYPE] [SIZE] Tray 1 is empty and the other trays are available. 1. If the correct paper is loaded, press the OK button. 2. Otherwise, remove the incorrect paper and load the tray with the specified paper. 3.
Table 3-14 Control-panel messages (continued) Description Recommended action LOADING PROGRAM Programs and fonts can be stored on the product’s file system and are loaded into RAM when the product is turned on. The number XX specifies a sequence number indicating the current program being loaded. No action necessary. Do not turn the product off. MAGENTA CARTRIDGE LOW The product indicates when a supply level is low. Actual print cartridge life might vary.
Table 3-14 Control-panel messages (continued) Description Recommended action MANUALLY FEED OUTPUT STACK The product has printed the first side of a manual duplex job and is waiting for the user to insert the output stack to print the second side. Then press OK to print second side MOVING SOLENOID 1. Maintaining the same orientation, remove document from the output bin. 2. Flip document printed side up. 3. Load document in Tray 1. 4. Press the OK button to print.
Table 3-14 Control-panel messages (continued) Description Recommended action Processing... The product is currently processing a job but No action is necessary. is not yet picking pages. When paper motion begins, this message will be replaced by a message that indicates which tray the job is being printed from. Processing... The product is processing a cleaning page. No action is necessary. Processing... copy of The product is currently processing or printing collated copies.
Table 3-14 Control-panel messages (continued) Description Recommended action REMOVE SHIPPING SHEET The transfer unit shipping sheet was not removed before you turned the product on. REPLACE CARTRIDGE REPLACE FUSER KIT REPLACE SUPPLIES REPLACE SUPPLIES - Using black only ENWW The product indicates when a supply level is at its estimated end of life. The actual life remaining might be different than the estimation.
Table 3-14 Control-panel messages (continued) Description Recommended action REPLACE SUPPLY At least one print cartridge has reached the very low condition and you have set the COLOR CARTRIDGES items to the PRINT IN BLACK option. Printing black only The supply life remaining is used to determine if a supply is very low. The supply life remaining is an approximation only and varies depending on the types of documents printed and other factors. No action is required for printing to continue in black.
Table 3-14 Control-panel messages (continued) Description Recommended action ROM DISK FILE OPERATION FAILED A PJL file system command attempted to perform an illogical operation. Press the OK button to clear. To clear press OK ROM DISK FILE SYSTEM IS FULL To clear press OK ROM DISK IS WRITE PROTECTED A PJL file system command could not store Press the OK button to clear. something on the file system because the file system was full.
Table 3-14 Control-panel messages (continued) Description Recommended action SUPPLIES LOW This message appears when at least two supplies have reached the low threshold. The actual supply life remaining might vary. You do not need to replace the supplies at this time unless print quality is no longer acceptable. After an HP supply has reached the very low threshold, the HP premium protection warranty for that supply has ended.
Table 3-14 Control-panel messages (continued) Description Recommended action TONER COLLECTION UNIT LOW The toner collection unit is almost full. The actual supply life remaining might vary. You do not need to replace the toner collection unit at this time unless print quality is no longer acceptable. To continue printing, either press the OK button or replace the toner collection unit. See Toner-collection unit on page 76. TONER COLLECTION UNIT VERY LOW The toner collection unit is almost full.
Table 3-14 Control-panel messages (continued) Description Recommended action TRAY [TYPE] [SIZE] This message states the current type and size configuration of the tray. To change size or type press the OK button. To accept settings press the back arrow . TRAY EMPTY [TYPE] [SIZE] The specified tray is empty and the current job does not need this tray to print. Refill the tray at a convenient time. TRAY OPEN The specified tray is open or not closed completely. Close the tray.
Table 3-14 Control-panel messages (continued) Description Recommended action UNSUPPORTED DRIVE INSTALLED A non-supported hard drive has been installed. Turn off the product, remove the hard drive, and then turn on the product. UNSUPPORTED SUPPLY IN USE A non-supported supply has been installed. Turn off the product, remove the supply, and then turn on the product. The print cartridge is for a different HP product. If print quality is no longer acceptable, replace the print cartridge.
Table 3-14 Control-panel messages (continued) Description Recommended action WAIT FOR PRINTER TO REINITIALIZE This message can appear for a variety of reasons: ● The RAM DISK settings changed before the product has restarted. ● The product is restarting after changing external device modes. ● Diagnostics has been exited. ● A new formatter has been installed with an old engine or a new engine has been installed with an old formatter. No action is necessary.
Table 3-14 Control-panel messages (continued) Description Recommended action YELLOW CARTRIDGE VERY LOW The product indicates when a supply level is If print quality is no longer acceptable, replace very low. Actual print cartridge life might vary. the print cartridge. See Print cartridges Consider having a replacement print on page 74. cartridge available to install when print quality is no longer acceptable.
Event log messages This section describes messages that only appear in the event log. For additional numeric messages, see the control-panel message section in this manual. See Control-panel messages on page 345. Print an event log Use the event log to help diagnose and solve product problems. button. 1. Press the Home 2. Press the down arrow to highlight DIAGNOSTICS, and then press the OK button. 3. Press the down arrow the pages.
Sample event log Figure 3-56 Sample event log hp color LaserJet CP 4520 Series Event Log Page 1 1 2 3 4 5 6 1 Product information 2 Event number 3 Date and time 4 Engine cycles 5 Event log code 6 Firmware version number 7 Description of personality 7 Clear the event log Use the SERVICE menu to clear the event log. ENWW button. 1. Press the Home 2. Press the down arrow to highlight SERVICE, and then press the OK button. 3. Press the down arrow the pages.
Event log message table Event log message Description 10.XX.00 Black toner cartridge 10.XX.01 Cyan toner cartridge 10.XX.02 Magenta toner cartridge 10.XX.03 Yellow toner cartridge 10.XX.04 Drum cartridge 10.XX.05 Black drum cartridge 10.XX.06 Cyan drum cartridge 10.XX.07 Magenta drum cartridge 10.XX.08 Yellow drum cartridge 10.XX.22 Transfer belt 10.XX.23 Fuser 10.XX.24 Transport kit 10.XX.26 Maintenance kit 10.XX.31 Cleaning bottle 10.XX.33 Transfer roller 10.XX.
ENWW Event log message Description 13.13.00 DUPLEX PATH, PAPER STOPPED JAM 13.1C.00 FUSER ACCORDION JAM 13.20.00 PRINTER COULD NOT AUTOMATICALLY EJECT PAPER 13.21.00 DOOR OPEN JAM 13.30.00 PAPER FEED 1, PAPER LATE JAM 41.XX.00 ● X=11 Yellow laser scanner ● X=12 Magenta laser scanner ● X=13 Cyan laser scanner ● X=14. Black laser scanner ● X=15. Main drive ● X=16. Main drive ● X=17. Main drive scanner Comments 54.01 The humidity-environment sensor is abnormal.
Event log message Description 54.0B.XX The density sensor is out of range. 54.0C.XX 54.0D.XX 54.0F.XX ● XX = 00 Black ● XX = 01 Cyan ● XX = 02 Magenta ● XX = 03 Yellow Comments Halftone calibration error.
Event log message Description 54.1E.XX Halftone calibration error ● XX = 00 Bad internal data ● XX = 01 Bad external data ● XX = 02 Memory allocation ● XX = 03 No default tables ● XX = 04 Bad parameters ● XX = 05 Cyan data is out of range. ● XX = 06 Magenta data is out of range. ● XX = 07 Yellow data is out of range. ● XX = 08 Black data is out of range. ● XX = 09 Cyan data is noisy. ● XX = 0A Magenta data is noisy. ● XX = 0B Yellow data is noisy. ● XX = 0C Black data is noisy.
Event log message Description 68 8X05 The permanent storage date does match the engine. Comments Disk error: either the number does not match or the write failed 74.00 New registration roller 8x7345 The disk was successfully cleaned and sanitized. x = slot number 8x7346 The hard disk or compact flash disk cleaning or sanitizing failed. This is usually caused by a failure of the disk hardware. x = slot number 8x7347 Some of the sanitized disk did not verify correctly. 88.00.
Clear paper jams Common causes of jams The product is jammed. Cause Solution The paper does not meet specifications. Use only paper that meets HP specifications. See the product user guide. A component is installed incorrectly. Verify that the transfer belt and transfer roller are correctly installed. You are using paper that has already passed through a product or copier. Do not use paper that has been previously printed on or copied. An input tray is loaded incorrectly.
The product is jammed. Cause Solution Not all product packing material was removed. Verify that the packing tape, cardboard, and plastic shipping locks have been removed from the product. The HP postcard media insert is installed in Tray 2, and you are not printing on 10 x 15 cm (4 x 6 in) paper. Always use the HP postcard media insert when printing on 10 x 15 cm (4 x 6 in) paper, but remove it when printing on other sizes.
Item Description Item Description X SR7 (PDU) Tray 4 feed sensor F SR6 Delivery tray media full sensor b SR10 (PDU) Tray 5 feed sensor X-1 Registration stop position A SR20 Top-of-Page sensor (TOP) X-2 Duplex media waiting position 1 (duplex models only) B, C SR14/15 Loop sensors 1/2 X-3 Duplex media waiting position 2 (duplex models only) D SR5 Fuser delivery sensor Table 3-15 Common causes of jams (by area) Jam code Jammed media position 13.01.
Jam locations Use this illustration to identify locations of jams. In addition, instructions appear on the control panel to direct you to the location of jammed paper and how to clear it. NOTE: Internal areas of the product that might need to be opened to clear jams have green handles or green labels.
Type of jam Procedure 13.XX.YY JAM IN TRAY 1 See Clear jams in Tray 1 on page 390. 13.XX.YY JAM IN TRAY 2 See Clear jams in Tray 2 or optional Trays 3, 4, or 5 on page 392. 13.XX.YY JAM IN OPTIONAL TRAYS See Clear jams in Tray 2 or optional Trays 3, 4, or 5 on page 392. 13.XX.YY JAM IN LOWER RIGHT DOOR See Clear jams in the lower right door (Tray 3, 4, or 5) on page 393. Clear jams in the right door CAUTION: The fuser can be hot while the product is in use.
3. If paper is visible entering the bottom of the fuser, gently pull downward to remove it. CAUTION: Do not touch the rollers on the transfer roller. Contaminants can affect print quality. 4. If paper is jammed as it enters the output bin, remove the fuser and gently pull the paper downward to remove it. 5. Paper could be jammed inside the fuser where it would not be visible. Remove the fuser to check for jammed paper inside. CAUTION: The fuser can be hot while the product is in use.
7. Open the jam-access door. If paper is jammed inside the fuser, gently pull it straight up to remove it. If the paper tears, remove all paper fragments. CAUTION: Even if the body of the fuser has cooled, the rollers that are inside could still be hot. Do not touch the fuser rollers until they have cooled. 8. Close the jam-access door, and push the fuser completely into the product. 9. Close the right door.
Clear jams in the output bin area 1. If paper is visible from the output bin, grasp the leading edge and remove it. Clear jams in Tray 1 1. If jammed paper is visible in Tray 1, clear the jam by gently pulling the paper straight out. Press the OK button to clear the message. 2. If you cannot remove the paper, or if no jammed paper is visible in Tray 1, close Tray 1 and open the right door.
3. Gently pull the paper out of the pick up area. 4. Close the right door.
Clear jams in Tray 2 or optional Trays 3, 4, or 5 CAUTION: Opening a tray when paper is jammed can cause the paper to tear and leave pieces of paper in the tray, which might cause another jam. Be sure to clear jams before opening the tray. 1. Open Tray 2 and make sure that the paper is stacked correctly. Remove any jammed or damaged sheets of paper. To access jammed paper from the tray cavity, remove Tray 2 from the product. 2. Close the tray.
Clear jams in the lower right door (Tray 3, 4, or 5) 1. Open the lower right door. 2. If paper is visible, gently pull the jammed paper up or down to remove it. 3. Close the lower right door.
Jam causes and solutions For locations of jam sensors, see Jam detection on page 55. Jams in the output bin Table 3-16 Causes and solutions for delivery delay jam Cause Solution The output-bin full sensor flag is damaged. Replace the paper delivery assembly. See Delivery assembly on page 145. See Manual sensor test (special-mode test) on page 246 for troubleshooting information. Poor contact of the output-bin full sensor connector.
Table 3-18 Causes and solutions for wrapping jams (continued) Cause Solution The output bin full sensor on the face-down tray has a poor connection. Reconnect connector (J47) on the output bin full sensor and (J128) on the DC controller PCA. The output bin full sensor is defective. Run the manual sensor test to verify the output bin full sensor is functioning properly. See F output bin full sensor on page 251. If not, replace the sensor.
Table 3-20 Causes and solutions for residual media jams Cause Solution The sensor detecting a residual media jam is not working. One of the four sensors is reporting a residual jam. Test each sensor using the manual sensor test. See Manual sensor test (special-mode test) on page 246 for information. If the sensor does not respond, replace the component indicated: If service was recently performed on the product, a sensor connector might be disconnected.
Table 3-21 Causes and solutions for pickup delay jams 2 (continued) Cause Solution The pickup solenoid is defective. Run the solenoid drive test in the actuator drive mode to verify that the pickup solenoid is functioning properly. If it is not, replace the tray-pickup drive assembly. See Tray-pickup drive assembly on page 178. The pickup motor is defective. Run the pickup motor drive test in the actuator drive mode to verify that the pickup motor is functioning properly.
Table 3-24 Causes and solutions for duplex repick jams (continued) Cause Solution Poor contact of the duplex re-pickup sensor connector Reconnect the intermediate connector (J74) and connector (J145) on the DC controller PCA. The duplex re-pickup sensor (SR22) is defective. Run the manual sensor test to verify that the duplex re-pickup sensor (SR22) is functioning properly. See Manual sensor test (special-mode test) on page 246 for information. If it is not, replace the right-door assembly.
Table 3-25 Causes and solutions for residual media jams (continued) Cause Solution The spring of the duplex repickup sensor lever is unhooked. Check the spring and place it in the correct position. The sensor is located in the right door behind the cover close to the engine side. The duplex pickup sensor lever is damaged. Replace the right door assembly. See Right-door assembly on page 113.
Table 3-27 Causes and solutions for pickup stationary jams Cause Solution Multiple feed of media Replace any worn or deformed parts (tray separation pad, tray feed roller, MP tray pickup roller or MP tray separation pad). If replacing the MP tray separation pad, you must replace the right door assembly. See Right-door assembly on page 113. Check the separation pad and MP tray separation pad to see if they are firmly seated and coupled with the torque limiter.
Table 3-28 Causes and solutions for pickup delay and pickup stationary jams (continued) Cause Solution The paper-feeder pickup solenoid is defective. Run the solenoid drive test in the actuator drive mode to verify that the paperfeeder pickup solenoid is functioning properly. If it is not, replace the pickup assembly of the specific tray. See Pickup assembly (optional paper feeder) on page 226. Poor contact of paper-feeder pickup motor drive connector.
Change jam recovery This product provides a jam recovery feature that reprints jammed pages. The following options are available: ● AUTO — The product attempts to reprint jammed pages when enough memory is available. This is the default setting. ● OFF — The product does not try to reprint jammed pages. Because no memory is used to store the most recent pages, performance is optimal.
Solve paper-handling problems Product feeds multiple sheets Product feeds multiple sheets Cause Solution The input tray is overfilled. Open the tray and verify that the paper stack is below the maximum stack height mark. Remove excess paper from the input tray. Print paper is sticking together. Remove paper, flex it, rotate it 180 degrees or flip it over, and then reload it into the tray. NOTE: Do not fan paper. Fanning can cause static electricity, which can cause paper to stick together.
Product pulls from incorrect tray Cause Solution The paper size is not configured correctly for the input tray. Print a configuration page or use the control panel to determine the paper size for which the tray is configured. The guides in the tray are not against the paper. Verify that the guides are touching the paper. Paper does not feed automatically Paper does not feed automatically Cause Solution Manual feed is selected in the software program.
Paper does not feed from Tray 2, 3, 4, or 5 Cause Solution None of the optional trays appear as input tray options. The optional trays only display as available if they are installed. Verify that any optional trays are correctly installed. Verify that the printer driver has been configured to recognize the optional trays. An optional tray is incorrectly installed. Print a configuration page to confirm that the optional tray is installed.
Envelopes jam or will not feed in the product Cause Solution Envelopes are sealing because the moisture content is too high. Try using different envelopes. Store envelopes in a controlled environment. Envelope orientation is incorrect. Verify that the envelope is loaded correctly. This product does not support the envelopes being used. Refer to the HP LaserJet Printer Family Print Media Guide. Tray 1 is configured for a size other than envelopes. Configure Tray 1 size for envelopes.
Product will not duplex (print 2-sided jobs) or duplexes incorrectly ENWW Cause Solution The product model does not support automatic 2-sided printing. The HP Color LaserJet CP4525 and HP Color LaserJet CP4525n models do not support automatic 2-sided printing. The product configuration is not set for duplexing. In Windows, run the automatic configuration feature: 1. Click the Start button, point to Settings, and then click Printers (for Windows 2000) or Printers and Faxes (for Windows XP). 2.
Use manual print modes Try the following multi-purpose (MP) modes to see if they solve the image-quality problems. These options can be found in the ADJUST PAPER TYPES and OPTIMIZE submenus under the PRINT QUALITY menu on the control panel.
Table 3-30 MP modes under the ADJUST PAPER TYPES sub menu (continued) FUSER TEMP MODE If you are seeing a faint image of the page repeated at the bottom of the page or on the following page, first make sure the Paper Type and Print Mode settings are correct for the type of paper you are using. If you continue to see ghost images on your print jobs, set the Fuser Temp feature to one of the Alternate settings . Try the ALTERNATE 1 setting first and see if it solves the problem.
Solve image-quality problems This section helps you define print-quality problems and what to do to correct them. Often print-quality problems can be handled easily by making sure that the product is maintained, using paper that meets HP specifications, or running a cleaning page. Image defects table The following examples depict letter-size paper that has passed through the product short-edge first.
Problem Cause Solution The page is all black or a solid color. Poor contact exists in the primary charging bias or developing bias contacts between the print cartridge and the product. Clean each contact of the color that produces the all black or solid color. If the problem remains after cleaning, check the contacts for damage. Replace any deformed or damaged parts. Replace the affected print cartridge. White spots appear in an image The primary transfer roller is deformed or has deteriorated.
Problem Sample Vertical white lines appear in a particular color. Cause Solution The laser beam window is dirty. Clean the window and remove any foreign substances. Scratches are present on the circumference of the developing cylinder or photosensitive drum. Remove the affected print cartridge and re-install. The PGCs will clean the glass. White scratch down the page could mean the scanner glass needs to be cleaned. Vertical white lines appear in all colors.
Problem Image in a particular color does not print in the correct color. Dropouts appear. The toner is not fully fused to the paper. Sample Cause Solution Poor contact exists in the primary charging bias or developing bias contacts between the print cartridge and the product. Clean each contact of the color that produces the missing color. If the problem remains after cleaning, check the contacts for damage. Replace any deformed or damaged parts.
Problem Sample Some color is misregistered. Cause Solution The product is incorrectly calibrated. Calibrate the product. The ITB unit is defective. If the ITB does not rotate smoothly or a cleaning malfunction occurs (ITB is dirty), replace the ITB. See Intermediate transfer belt (ITB) on page 92. The drive gear of the ITB motor is worn or chipped. Check each drive gear between the ITB drive roller and the ITB motor. If the gear is worn or chipped, replace the drive unit.
Problem The printed page contains wrinkles or creases. The front of the page is dirty. Sample Cause Solution The roller or media feed guide is dirty. Clean any dirty components. A feed roller is deformed or has deteriorated. Replace any deformed or deteriorated rollers. The paper feed guide is damaged. Replace the paper-feed-guide unit. The photosensitive drum is dirty. Replace the print cartridge. The fuser roller or pressure roller is dirty. Execute a Pressure roller clean mode.
Clean the product Over time, particles of toner and paper accumulate inside the product. This can cause print-quality problems during printing. Cleaning the product eliminates or reduces these problems. Clean the paper path and print-cartridge areas every time that you change the print cartridge or whenever print-quality problems occur. As much as possible, keep the product free from dust and debris. Clean the product 1. Turn the product off and then unplug the power cord and all interface cables. 2.
Solve performance problems Problem Cause Solution Pages print but are totally blank. The document might contain blank pages. Check the document that you are printing to see if content appears on all of the pages. The product might be malfunctioning. To check the product, print a Configuration page. Heavier paper types can slow the print job. Print on a different type of paper. Complex pages can print slowly. Proper fusing may require a slower print speed to ensure the best print quality.
Solve connectivity problems Solve direct-connect problems If you have connected the product directly to a computer, check the cable. ● Verify that the cable is connected to the computer and to the product. ● Verify that the cable is not longer than 2 meters (6 feet). Replace the cable if necessary. ● Verify that the cable is working correctly by connecting it to another product. Replace the cable if necessary.
Check your system for proper network operating system setup. 8. Is your protocol enabled? Check the status of your protocol on the Configuration page. You can also use the embedded Web server to check the status of other protocols. See the product user guide. 9. ENWW Does the product appear in HP Web Jetadmin or other management application? ● Verify network settings on the Network configuration page.
Service mode functions Service menu The SERVICE menu is PIN-protected for added security. Only authorized service people have access to the SERVICE menu. When you select SERVICE from the list of menus, the product prompts you to enter an eight-digit PIN number. The PINs for the HP Color LaserJet Enterprise CP4020-CP4520 Series are 11402509 and 11452509. 1. Press the Home 2. Press the down arrow 3. Enter the eight-digit PIN using the alphanumeric keypad. 4.
ENWW REFURBISH PAGE COUNT The number of pages a product is set to print when it is refurbished. The count is kept for legal purposes. If it becomes necessary to refurbish a product, you must be able to set the page count so that it represents the age of the print engine when it was refurbished. This menu item allows SERVICE ID to be reset after being refurbished, if total page count minus refurbish page count is less than 500.
SERVICE ID Use this item to show the date that the product was first used on the control panel. This eliminates the need for users to keep paper receipts for proof of warranty. Restore the service ID If you replace the formatter, the date is lost. Use this menu item to reset the date to the original date that the product was first used. The date format is YYDDD. Use the following formula to calculate the dates. The date 17-October-2002 is used as an example. 1.
Product resets Restore factory-set defaults The RESETS menu allows you to reset factory settings, and disable or enable sleep mode. To display: Press the Home button RESETS menu. , select the CONFIGURE DEVICE menu, and then select the Select RESTORE FACTORY SETTINGS from the submenu, and then press the OK button. Hard disk initialization (optional) A hard disk initialization will erase and reformat the product's hard disk.
Product cold reset Before beginning, print a configuration page and supplies status page. Use these pages to verify resets have occurred. 1. Press the Home 2. Press the down arrow button. to highlight the CONFIGURE DEVICE menu, and then press the OK 3. Press the down arrow to highlight the RESET menu, and then press the OK button. 4. Press the down arrow the OK button. to highlight the RESTORE FACTORY SETTINGS menu, and then press button.
4 ENWW Parts and diagrams ● Order parts, accessories, and supplies ● Part numbers ● Screws ● How to use the parts lists and diagrams ● External covers, panels, and doors ● Right door assembly ● Front door assembly ● Internal components ● Assessories ● Alphabetical parts list ● Numerical parts list 425
Order parts, accessories, and supplies You can obtain the following items directly from HP: ● Replacement parts: To order replacement parts in the U.S., go to www.hp.com/go/hpparts/. Outside the United States, order parts by contacting your local authorized HP service center. ● Supplies and accessories: To order supplies in the U.S., go to www.hp.com/go/ljsupplies. To order supplies worldwide, go to www.hp.com/ghp/buyonline.html. To order accessories, go to www.hp.com/support/cljcp4025 or www.hp.
Part numbers The following list of accessories was current at the time of printing. Ordering information and availability of the accessories might change during the life of the product.
Customer self repair (CSR) parts Product name Product number Part number Self-repair level Formatter assembly kit CC493-69001 1A HP postcard media insert replacement CC497-67902 1A Feed and separation roller kit (Trays 2–5) CC493-67907 1A Secondary transfer (T2) roller kit CC493-67908 1A Tray 1 roller kit CC493-67906 1A Toner collection unit kit CC493-67913 1A CC493-67910 1A CC493-67909 1A Includes 1 each, feed and separation rollers Maintenance transfer kit CE249A Includes ITB,
Unique components Use the following tables as a quick reference to identify component part numbers by product voltage, or function (simplex or duplex).
Screws NOTE: The screw illustrations in the following table are for reference only. Screws might vary in size and appearance from those shown in this table.
How to use the parts lists and diagrams The figures in this chapter show the major subassemblies in the product and their component parts. A parts list table follows each exploded view assembly diagram. Each table lists the item number, the associated part number, and the description of each part. If a part is not listed in the table, then it is not a field replacement unit (FRU). CAUTION: Be sure to order the correct part.
External covers, panels, and doors Figure 4-1 External covers, panels, and doors 9 15 15 6 3 14 16 12 *A01 10 15 16 15 11 7 15 2 15 8 1 15 5 Right door assembly See Figure 4-2 Front door assembly See Figure 4-3 4 432 Chapter 4 Parts and diagrams 13 15 ENWW
Table 4-5 External covers, panels, and doors; ENWW Ref Description Part number Qty 1 Grip, left front RC2-4268-000CN 1 2 Grip, left rear RC2-4269-000CN 1 3 Cover, left upper RC2-4270-000CN 1 4 Cover, right front RC2-4272-000CN 1 5 Cover, right rear RC2-4273-000CN 1 6 Cover, upper RC2-4276-000CN 1 7 Cover, left lower RC2-4300-000CN 1 8 Cover, inner RM1-5520-000CN 1 9 Tray, face-down swing RC2-4547-000CN 1 10 Cover, left rear RC2-8213-000CN 1 11 Control-panel ass
Right door assembly Figure 4-2 Right door assembly *A08 *A06 *A04 *A06 *A03 *A07 *A06 *A06 *A05 *A02 *A01 *A09 *A09 *A06 3 1 2 434 Chapter 4 Parts and diagrams ENWW
Table 4-6 Right door assembly ENWW Ref Description Part number Qty 1 Right door assembly RM1-5509-000CN 1 3 Cover, M.P.
Front door assembly Figure 4-3 Front door assembly 1 *A16 *A08 *A09 *A18 *A01 *A10 *A18 *A11 *A13 *A05 *A03 *A17 *A18 *A15 *A01 *A07 *A07 *A19 *A12 *A02 *A17 *A06 436 Chapter 4 Parts and diagrams *A14 ENWW
Table 4-7 Front door assembly ENWW Ref Description Part number Qty 1 Front door assembly RM1-5506-000CN 1 Front door assembly 437
Internal components Internal components (1 of 7) Figure 4-4 Internal components 1 of 7 5 9 1 (FM3) (J62) 6 3 4 9 DUPLEX MODEL 2 SIMPLEX MODEL 2 (SR5) (J48) 8 7 438 Chapter 4 Parts and diagrams ENWW
Table 4-8 Internal components (1 of 7) ENWW Ref Description Part number Qty 1 Paper delivery fan assembly RM1-5501-000CN 1 2 Guide, paper feed, simplex RC2-4566-000CN 1 2 Duplexing guide assembly, duplex RM1-5531-000CN 1 3 Paper delivery fan duct assembly RM1-5583-000CN 1 4 Holder, cable RC2-3997-000CN 1 5 Rod, paper delivery fan RC2-4070-000CN 1 6 Spring, compression RU6-2310-000CN 1 7 Holder, right door handle RC2-4573-000CN 1 8 Photo interrupter, TLP1243 WG8-5696-0
Internal components (2 of 7) Figure 4-5 Internal components 2 of 7 26 20 19 26 5 3 23 22 PCA See Figure 4-18 PCA See Figure 4-18 23 22 9 21 17 26 24 26 A 27 (J68) (J1) 25 26 (J2) 14 (J3) 24 26 26 19 (J4) 1 13 5 A 16 3 15 26 16 2 *A01 4 6 18 11 7 8 12 26 10 26 440 Chapter 4 Parts and diagrams ENWW
Table 4-9 Internal components (2 of 7) ENWW Ref Description Part number Qty 1 Bushing RC2-9719-000CN 4 3 Lever, CRG. lock RC2-3986-000CN 4 4 Tray, waste toner catch RC2-4218-000CN 1 5 Spring, torsion RU6-2247-000CN 4 7 Spring, grounding RC2-4469-000CN 1 8 Bushing RC2-4470-000CN 1 12 Lifter base assembly RM1-5913-000CN 1 17 Cover RC2-4403-000CN 3 18 Cover RC2-5962-000CN 1 19 Crg.
Internal components (3 of 7) Figure 4-6 Internal components 3 of 7 *A04 (J60) 21 25 *A05 22 25 7 10 (J82) (J66) 24 4 20 *A04 1 *A04 9 25 (SR7) (J46) 2 *A01 17 15 (SW5) (J45) 18 5 23 6 25 (SW3) (J84) 16 12 25 (SW2) (FT1) 8 (SW1) (FT2) 25 Tray See Figure 4-11 19 11 14 *A03 19 25 13 *A02 3 25 3 25 442 Chapter 4 Parts and diagrams ENWW
Table 4-10 Internal components (3 of 7) ENWW Ref Description Part number Qty 1 Hinge, front door RC2-4291-000CN 1 2 Hinge, front door RC2-4292-000CN 1 3 Cover RC2-4308-000CN 1 5 Lever, shutter RC2-4415-000CN 4 6 Spring, compression RU6-2316-000CN 4 7 Front inner cover upper assembly RM1-5495-000CN 1 8 Interlock assembly RM1-5496-000CN 1 9 Waste toner collection kit (includes instructions and wipe) CC493-67913 1 10 Waste toner duct assembly RM1-5519-000CN 1 11 Power
Internal components (4 of 7) Figure 4-7 Internal components 4 of 7 10 18 1 (SR9) (J19) 20 19 11 (J78) *A02 Paper delivery assembly See Figure 4-16 20 3 20 13 8 *A04 *A01 14 (J47) 18 20 4 (J63) 9 (SR6) 20 2 17 20 *A05 4 16 5 *A03 *A05 6 (FM2) (J65) Fuser assembly See Figure 4-17 7 15 12 444 Chapter 4 Parts and diagrams ENWW
Table 4-11 Internal components (4 of 7) ENWW Ref Description Part number Qty 4 Spring, tension RU6-2235-000CN 4 5 Spring, tension RU6-2376-000CN 1 6 Cartridge fan assembly RM1-5499-000CN 1 8 Waste toner motor assembly RM1-5605-000CN 1 9 Laser scanner kit (includes instructions and one scanner assy.
Internal components (5 of 7) Figure 4-8 Internal components 5 of 7 16 16 *A01 *A01 Right door assembly See Figure 4-2 12 *A04 15 17 22 19 16 *A03 2 1 *A02 16 16 6 9 10 16 Secondary transfer assembly See Figure 4-15 21 22 7 18 *A03 (J83) Paper pickup assembly See Figure 4-12 13 20 16 14 4 3 5 16 11 8 446 Chapter 4 Parts and diagrams Registration assembly See Figure 4-14 16 ENWW
Table 4-12 Internal components (5 of 7) ENWW Ref Description Part number Qty 2 Cover, inner RC2-3981-000CN 1 3 Shaft support (included in secondary transfer kit; see Figure 4– 15) RC2-4162-000CN 1 4 Spacer RC2-4514-000CN 1 6 Guide RC2-4527-000CN 1 7 Link, right door RC2-4726-000CN 1 8 Guide, cassette option RC2-4741-000CN 1 9 Holder, duct cable RC2-8239-000CN 1 11 Cassette guide assembly RM1-5504-000CN 1 12 Paper feed roller assembly RM1-5525-000CN 1 13 Density det
Internal components (6 of 7) Figure 4-9 Internal components 6 of 7 15 (M2) (J13) (M2) (J13) 15 15 14 14 12 12 DUPLEX MODEL 15 10 SIMPLEX MODEL 15 8 (M3),(J18) (M4),(J17) (M5),(J16) (M6),(J15) *A03 10B 10A 15 15 DUPLEX MODEL (M10) (J38) 2 (M11) (J39) 15 (SL2) (J69) (M1) (J14) *A02 3 1 4 15 11 15 15 15 (M13)15 (J37) *A01 9A 9 7 13 15 5 16 6 (FM4) (J79) 6A 448 Chapter 4 Parts and diagrams ENWW
Table 4-13 Internal components 6 of 7 ENWW Ref Description Part number Qty 3 Duplexing drive assembly RM1-5546-000CN 1 5 Spring, tension RU6-2468-000CN 1 6A Cartridge fan RK2-2418-000CN 1 7 Flexible flat cable assembly (includes two FFC; DCC to laser/ scanner) RM1-5498-000CN 1 8 Main DC motor assembly RM1-5521-000CN 4 9 Paper pickup drive assembly RM1-5549-000CN 1 10 Main drive assembly kit (includes instructions) CC493-67915 1 10A ITB motor assembly RM1-5777-000CN 1 10
Internal components (7 of 7) Figure 4-10 Internal components 7 of 7 22 15 9 (J60) (J47) (J45) (J19) (J128) (J129) (J106) (J85) (J74) (J83) (J77) (J64) (J75) (J52) (J201) (J113) *A05 PCA See Figure 4-18 (J43) *A01 (J38) (J84) (J112) PCA See Figure 4-18 *A05 8 (J79) (FT1) (FT2) 16 (J303) 21 5 (J202) (J39) (J69) (J99) (J200) (J116) 2 PCA See Figure 4-18 24 (J264) (J66) (J68) (J82) (J36) 6 (J263) (J81) 24 25 (J65) (J67) 24 14 10 (J58) (J59) (J61) (J108) (J71) (J67) (J107) (J72
Table 4-14 Internal components 7 of 7 ENWW Ref Description Part number Qty 4 Fan RK2-2577-000CN 1 5 Cable, flexible flat, H.V.T. RK2-2603-000CN 1 7 Contact assembly RM1-5502-000CN 1 8 Fan cable assembly RM1-5821-000CN 1 9 H.V.
Cassettes 2-5 Figure 4-11 Cassettes 2-5 1 *A21 *A13 *A26 *A06 *A24 *A22 *A27 *A18 *A25 *A07 *A14 *A08 *A09 *A16 *A09 *A20 *A17 *A11 *A04 *A23 * A19 *A05 *A09 *A17 *A10 *A12 *A09 *A25 *A02 452 Chapter 4 Parts and diagrams *A05 *A03 *A15 *A01 ENWW
Table 4-15 Cassette ENWW Ref Description Part number Qty 1 Cassette RM1-5928-000CN 1 Internal components 453
Paper pickup assembly Figure 4-12 Paper pickup assembly 3 *A02 *A09 *A07 *A11 *A03 *A28 *A08 *A04 *A10 *A15 *A13 *A12 3 *A33 (J58) *A29 (SL4) (J59) *A15 *A06 *A14 *A05 1 *A30 *A32 *A36 *A26 *A19 *A22 *A31 *A23 *A35 *A16 *A37 *A21 *A25 *A38 *A34 *A20 2 *A18 *A27 *A01 *A24 *A17 2 454 Chapter 4 Parts and diagrams ENWW
Table 4-16 Paper pickup assembly ENWW Ref Description Part number Qty 1 Roller, paper pickup RL1-2099-000CN 1 2 Paper feed roller RM1-0037-020CN 2 3 Paper pickup assembly RM1-5919-000CN 1 Internal components 455
Tray 1 paper pickup assembly Figure 4-13 Tray 1 paper pickup assembly *A08 *A14 *A18 *A04 *A13 *A01 *A23 *A21 *A10 *A15 1 *A26 *A19 *A09 *A26 2 *A17 *A11 *A33 *A22 *A01 *A13 *A03 *A16 *A20 *A25 (SL3) (J52) *A12 *A29 *A26 *A27 *A02 *A31 *A32 *A06 *A05 *A30 *A34 *A32 *A07 (J22) *A26 (J75) *A28 (SR8) (J22) *A24 456 Chapter 4 Parts and diagrams ENWW
Table 4-17 Tray 1 paper pickup assembly ENWW Ref Description Part number Qty 1 Pickup roller (Tray 1) kit (includes instructions) CC493–67906 1 2 Separation pad (Tray 1) RL1-1937-000CN 1 Internal components 457
Registration assembly Figure 4-14 Registration assembly 1 *A46 *A38 *A09 *A08 *A09 *A08 *A09 *A06 *A19 *A10 *A35 *A17 *A42 *A14 *A20 *A02 *A31 *A03 *A42 *A44 *A11 *A21 *A18 *A42 *A05 *A43 *A24 *A35 *A23 *A04 *A15 *A15 *A44 *A42 *A05 *A27 *A42 *A28 *A12 *A29 *A07 *A45 *A25 *A39 *A36 *A33 *A26 *A38 *A30 *A13 *A05 *A42 *A03 *A32 *A02 *A01 *A40 *A05 *A42 (J74) (J27) (J23) (J77) (J53) *A37 *A16 *A34 SIMPLEX MODEL 458 Chapter 4 Parts and diagrams (CL1) (J53) (J20) (J21) *A22 *
Table 4-18 Registration assembly ENWW Ref Description Part number Qty 1 Registration assembly kit, simplex (includes instructions) CC493-67916 1 1 Registration assembly kit, duplex (includes instructions) CC493-67917 1 Internal components 459
Secondary transfer assembly Figure 4-15 Secondary transfer assembly 2 *A02 1 *A10 *A11 *A19 *A03 *A09 *A19 *A16 *A01 *A18 *A14 *A21 *A17 *A15 *A08 *A13 DUPLEX MODEL *A25 *A12 *A07 *A20 *A04 *A05 *A24 *A06 *A22 DUPLEX MODEL *A23 *A26 DUPLEX MODEL 460 Chapter 4 Parts and diagrams ENWW
Table 4-19 Secondary Transfer assembly ENWW Ref Description Part number Qty 1 Secondary transfer roller assembly kit (includes instructions) CC493-67908 1 2 Secondary transfer assembly, duplex kit (includes shaft-support clip; # 3 Figure 4–8) CC493-67901 1 2 Secondary transfer assembly, simplex kit (includes shaft-support clip; # 3 Figure 4–8) CC493-67902 1 Internal components 461
Delivery assembly Figure 4-16 Delivery assembly 1 *A28 *A10 *A16 *A07 *A23 *A03 *A16 *A11 *A07 *A19 *A27 *A17 *A23 *A29 *A02 *A20 *A26 DUPLEX MODEL *A15 *A12 *A05 *A09 *A27 *A21 *A08 *A24 *A30 *A04 *A22 DUPLEX MODEL SR6 J47 *A18 *A01 *A26 *A13 *A27 *A25 *A14 *A06 462 Chapter 4 Parts and diagrams ENWW
Table 4-20 Delivery assembly ENWW Ref Description Part number Qty 1 Simplex delivery assembly kit CC493-67918 1 1 Duplex delivery assembly kit CC493-67919 1 Internal components 463
Fuser assembly Figure 4-17 Fuser assembly 1 464 Chapter 4 Parts and diagrams ENWW
Table 4-21 Fuser assembly ENWW Ref Description Part number Qty 1 Fuser 110 V assembly kit (includes instructions) CC493-67911 1 1 Fuser 220 V assembly kit (includes instructions) CC493-67912 1 Internal components 465
PCAs Figure 4-18 PCAs 3 8 4 1 7 7 2 7 7 9 6 466 Chapter 4 Parts and diagrams ENWW
Table 4-22 PCAs ENWW Ref Description Part number Qty 1 DC controller PCA assembly RM1-5758-000CN 1 2 Low voltage power supply PCA assembly, 110V RM1-5763-000CN 1 2 Low voltage power supply PCA assembly, 220V RM1-5764-000CN 1 3 High voltage power supply PCA, lower (includes FFC; DCC to HVPS lower) RM1-5779-000CN 1 4 High voltage power supply, upper RM1-5781-000CN 1 6 Inner connecting PCA assembly RM1-5636-020CN 1 7 Toner remain PCA assembly RM1-5771-020CN 4 8 Formatter kit
Assessories Paper feeders Figure 4-19 Paper feeders 1x500 Cassette 3 3x500 Cassette 3 Cassette 4 Cassette 5 468 Chapter 4 Parts and diagrams ENWW
Table 4-23 Paper feeders ENWW Ref Description Part number Qty NA Cassette RM1-5928-000CN NA Assessories 469
Paper feeder external covers, panels, and doors Figure 4-20 Paper feeder external covers, panels, and doors 5 7 *A04 *A02 *A01 6 4 *A01 9 13 3 *A01 17 1x500 13 14 1x500 12 15 16 *A05 *A01 15 *A03 8 *A02 2 *A01 470 Chapter 4 Parts and diagrams 1 11 *A01 3x500 8 10 *A01 ENWW
Table 4-24 Paper feeder external covers, panels, and doors ENWW Ref Description Part number Qty 4 Cover, rear lower RC2-5378-000CN 1 5 Cover, rear RC2-5379-000CN 1 7 Cover, left RC2-5393-000CN 1 8 Cover, right front, 1x500 RC2-5356-000CN 1 8 Cover, right front, 3x500 RC2-5357-000CN 1 9 Cover, right rear RC2-5380-000CN 1 11 Cover, right center RC2-5394-000CN 1 14 Right door assembly 3x500 RM1-5937-000CN 1 14 Right door assembly 1x500 RM1-5936-000CN 1 16 Door, stock,
1 X 500 paper feeder main body Figure 4-21 1 X 500 paper feeder main body 2 *A16 8 *A04 (J10) (J17) (J410) (J409) (J408) *A11 3 (J11) (J15) (J407) (J14) (J18) *A14 *A28 *A13 *A32 *A26 *A17 *A15 *A16 *A12 *A05 *A20 *A16 *A28 *A28 *A24 *A09 1 *A33 (J15) *A29 (J13) *A16 4 *A16 *A16 11 7 (M2) (J14) *A08 *A07 6 *A16 *A16 *A02 *A16 *A25 5 *A29 *A16 *A03 *A22 *A16 *A01 *A29 *A21 *A06 *A19 *A27 *A23 *A19 *A19 *A27 *A01 Cassette See Figure 4-11 *A01 *A27 9 *A16 *A10 *A18
Table 4-25 1 X 500 paper feeder main body ENWW Ref Description Part number Qty 3 Lifter base assembly RM1-5913-000CN 1 4 Lifter assembly RM1-5914-000CN 1 7 Paper pickup drive assembly, 1x500 RM1-5934-000CN 1 8 Feeder PCA assembly, 1x500 RM1-5854-000CN 1 9 Paper pickup assembly RM1-5929-000CN 1 Assessories 473
3 X 500 paper feeder main body Figure 4-22 3 X 500 paper feeder main body 1 (J10) (J410) (J408) (J409) *A15 *A02 *A09 10 2 *A12 *A15 *A11 *A26 *A19 *A17 *A08 *A08 *A15 *A10 *A07 (J15) (J24) (J34) *A08 *A23 (J13) (J11) (J15) (J404) (J14) (J407) (J18) (J19) (J22) 8 (J406) (J25) (J21) (J405) (J24) (J20) (J402) (J32) (J31) (J403) (J30) (J35) *A16 (J34) *A14 *A03 7 (J17) *A27 9 *A15 3 *A17 *A15 6 *A15 13 (M2) (J14) *A06 5 *A05 *A15 *A15 4 *A13 *A17 *A15 *A21 *A01 *A18 *A25 *A04
Table 4-26 3 X 500 paper feeder main body ENWW Ref Description Part number Qty 2 Lifter base assembly RM1-5913-000CN 1 3 Lifter assembly RM1-5914-000CN 1 6 Paper pickup drive assembly 3x500 RM1-5935-000CN 1 10 Feeder PCA assembly 3x500 RM1-5958-000CN 1 11 Paper pickup assembly RM1-5929-000CN 3 Assessories 475
Alphabetical parts list Table 4-27 Alphabetical parts list Description Part number Table and page Arm, door link supporting, right RC2-4055-000CN Internal components (5 of 7) on page 447 Bushing RC2-9719-000CN Internal components (2 of 7) on page 441 Bushing RC2-4470-000CN Internal components (2 of 7) on page 441 Cable cover assembly RM1-6695-000CN Internal components (5 of 7) on page 447 Cable, flexible flat, H.V.T.
Table 4-27 Alphabetical parts list (continued) ENWW Description Part number Table and page Cover, inner RM1-5520-000CN External covers, panels, and doors; on page 433 Cover, inner RC2-3981-000CN Internal components (5 of 7) on page 447 Cover, left RC2-5393-000CN Paper feeder external covers, panels, and doors on page 471 Cover, left lower RC2-4300-000CN External covers, panels, and doors; on page 433 Cover, left rear RC2-8213-000CN External covers, panels, and doors; on page 433 Cover, l
Table 4-27 Alphabetical parts list (continued) Description Part number Table and page Density detect assembly RM1-5641-000CN Internal components (5 of 7) on page 447 Developing disengaging motor RK2-2415-000CN Internal components 6 of 7 on page 449 Door, stock, 1x500 RC2-5377-000CN Paper feeder external covers, panels, and doors on page 471 Duplex delivery assembly kit CC493-67919 Delivery assembly on page 463 Duplexing cable assembly, duplex RM1-5803-000CN Internal components 7 of 7 on pag
Table 4-27 Alphabetical parts list (continued) ENWW Description Part number Table and page Fuser drive assembly, simplex RM1-6702-000CN Internal components 6 of 7 on page 449 Grip, left front RC2-4268-000CN External covers, panels, and doors; on page 433 Grip, left rear RC2-4269-000CN External covers, panels, and doors; on page 433 Guide RC2-4527-000CN Internal components (5 of 7) on page 447 Guide, cassette option RC2-4741-000CN Internal components (5 of 7) on page 447 Guide, paper feed
Table 4-27 Alphabetical parts list (continued) Description Part number Table and page Lever, shutter RC2-4415-000CN Internal components (3 of 7) on page 443 Lifter assembly RM1-5914-000CN Internal components 6 of 7 on page 449 Lifter assembly RM1-5914-000CN 1 X 500 paper feeder main body on page 473 Lifter assembly RM1-5914-000CN 3 X 500 paper feeder main body on page 475 Lifter base assembly RM1-5913-000CN Internal components (2 of 7) on page 441 Lifter base assembly RM1-5913-000CN 1 X
Table 4-27 Alphabetical parts list (continued) ENWW Description Part number Table and page Photo interrupter WG8-5696-000CN Internal components (3 of 7) on page 443 Photo interrupter WG8-5696-000CN Internal components (4 of 7) on page 445 Photo interrupter, TLP1243 WG8-5696-000CN Internal components (1 of 7) on page 439 Pickup roller (Tray 1) kit (includes instructions) CC493–67906 Tray 1 paper pickup assembly on page 457 Position detect assembly RM1-5500-000CN Internal components (4 of 7
Table 4-27 Alphabetical parts list (continued) Description Part number Table and page Shutter arm assembly RM1-5585-000CN Internal components (2 of 7) on page 441 Shutter arm assembly RM1-5586-000CN Internal components (2 of 7) on page 441 Shutter assembly RM1-5488-000CN Internal components (2 of 7) on page 441 Shutter assembly RM1-5489-000CN Internal components (2 of 7) on page 441 Simplex delivery assembly kit CC493-67918 Delivery assembly on page 463 Spacer RC2-4514-000CN Internal com
Table 4-27 Alphabetical parts list (continued) ENWW Description Part number Table and page Upper main cable assembly RM1-5800-000CN Internal components 7 of 7 on page 451 Waste toner collection kit (includes instructions and wipe) CC493-67913 Internal components (3 of 7) on page 443 Waste toner detect assembly RM1-5545-000CN Internal components (3 of 7) on page 443 Waste toner duct assembly RM1-5519-000CN Internal components (3 of 7) on page 443 Waste toner motor assembly RM1-5605-000CN I
Numerical parts list Table 4-28 Numerical parts list Part number Description Table and page CC493-67901 Secondary transfer assembly, duplex kit (includes shaft-support clip; # 3 Figure 4–8) Secondary Transfer assembly on page 461 CC493-67902 Secondary transfer assembly, simplex kit (includes shaft-support clip; # 3 Figure 4–8) Secondary Transfer assembly on page 461 CC493-67908 Secondary transfer roller assembly kit (includes instructions) Secondary Transfer assembly on page 461 CC493-67909 Int
Table 4-28 Numerical parts list (continued) ENWW Part number Description Table and page RC2-4218-000CN Tray, waste toner catch Internal components (2 of 7) on page 441 RC2-4268-000CN Grip, left front External covers, panels, and doors; on page 433 RC2-4269-000CN Grip, left rear External covers, panels, and doors; on page 433 RC2-4270-000CN Cover, left upper External covers, panels, and doors; on page 433 RC2-4272-000CN Cover, right front External covers, panels, and doors; on page 433 RC
Table 4-28 Numerical parts list (continued) Part number Description Table and page RC2-4741-000CN Guide, cassette option Internal components (5 of 7) on page 447 RC2-4747-000CN Cover, M.P.
Table 4-28 Numerical parts list (continued) ENWW Part number Description Table and page RK2-2604-000CN Flat flexible cable (DCC to HVPS lower) Internal components 6 of 7 on page 449 RL1-1937-000CN Separation pad (Tray 1) Tray 1 paper pickup assembly on page 457 RL1-2099-000CN Roller, paper pickup Paper pickup assembly on page 455 RM1-0037-020CN Paper feed roller Paper pickup assembly on page 455 RM1-5486-000CN Crg.
Table 4-28 Numerical parts list (continued) Part number Description Table and page RM1-5520-000CN Cover, inner External covers, panels, and doors; on page 433 RM1-5521-000CN Main DC motor assembly Internal components 6 of 7 on page 449 RM1-5525-000CN Paper feed roller assembly Internal components (5 of 7) on page 447 RM1-5531-000CN Duplexing guide assembly, duplex Internal components (1 of 7) on page 439 RM1-5545-000CN Waste toner detect assembly Internal components (3 of 7) on page 443 RM
Table 4-28 Numerical parts list (continued) ENWW Part number Description Table and page RM1-5781-000CN High voltage power supply, upper PCAs on page 467 RM1-5786-000CN Control-panel assembly External covers, panels, and doors; on page 433 RM1-5799-000CN Connecting cable assembly Internal components 7 of 7 on page 451 RM1-5800-000CN Upper main cable assembly Internal components 7 of 7 on page 451 RM1-5801-000CN Lower main cable assembly Internal components 7 of 7 on page 451 RM1-5803-000C
Table 4-28 Numerical parts list (continued) Part number Description Table and page RM1-5928-000CN Cassette Paper feeders on page 469 RM1-5929-000CN Paper pickup assembly 1 X 500 paper feeder main body on page 473 RM1-5929-000CN Paper pickup assembly 3 X 500 paper feeder main body on page 475 RM1-5934-000CN Paper pickup drive assembly, 1x500 1 X 500 paper feeder main body on page 473 RM1-5935-000CN Paper pickup drive assembly 3x500 3 X 500 paper feeder main body on page 475 RM1-5936-000CN
Table 4-28 Numerical parts list (continued) ENWW Part number Description Table and page WC2-5637-000CN Switch, push Internal components 7 of 7 on page 451 WC4-5303-000CN Switch Internal components (3 of 7) on page 443 WG8-5696-000CN Photo interrupter, TLP1243 Internal components (1 of 7) on page 439 WG8-5696-000CN Photo interrupter Internal components (3 of 7) on page 443 WG8-5696-000CN Photo interrupter Internal components (4 of 7) on page 445 Numerical parts list 491
492 Chapter 4 Parts and diagrams ENWW
A ENWW Service and support ● Hewlett-Packard limited warranty statement ● HP's Premium Protection Warranty: LaserJet print cartridge limited warranty statement ● HP Color LaserJet Fuser Kit Limited Warranty Statement ● End User License Agreement ● Customer self-repair warranty service ● Customer support 493
Hewlett-Packard limited warranty statement HP PRODUCT DURATION OF LIMITED WARRANTY HP Color LaserJet CP4025n, CP4025dn, CP4525n, CP4525dn, CP4525xh One-year on-site warranty HP warrants to you, the end-user customer, that HP hardware and accessories will be free from defects in materials and workmanship after the date of purchase, for the period specified above.
HP's Premium Protection Warranty: LaserJet print cartridge limited warranty statement This HP product is warranted to be free from defects in materials and workmanship. This warranty does not apply to products that (a) have been refilled, refurbished, remanufactured or tampered with in any way, (b) experience problems resulting from misuse, improper storage, or operation outside of the published environmental specifications for the printer product or (c) exhibit wear from ordinary use.
HP Color LaserJet Fuser Kit Limited Warranty Statement This HP product is warranted to be free from defects in materials and workmanship until the printer provides a low-life indicator on the control panel.
End User License Agreement PLEASE READ CAREFULLY BEFORE USING THIS SOFTWARE PRODUCT: This End-User License Agreement (“EULA”) is a contract between (a) you (either an individual or the entity you represent) and (b) Hewlett-Packard Company (“HP”) that governs your use of the software product (“Software”). This EULA does not apply if there is a separate license agreement between you and HP or its suppliers for the Software, including a license agreement in online documentation.
Software will agree to this EULA. Upon transfer of the HP Software, your license is automatically terminated. b. Restrictions. You may not rent, lease or lend the HP Software or Use the HP Software for commercial timesharing or bureau use. You may not sublicense, assign or otherwise transfer the HP Software except as expressly provided in this EULA. 5. PROPRIETARY RIGHTS.
Customer self-repair warranty service HP products are designed with many Customer Self Repair (CSR) parts to minimize repair time and allow for greater flexibility in performing defective parts replacement. If during the diagnosis period, HP identifies that the repair can be accomplished by the use of a CSR part, HP will ship that part directly to you for replacement. There are two categories of CSR parts: 1) Parts for which customer self repair is mandatory.
Customer support Get telephone support, free during your warranty period, for your country/region Country/region phone numbers are on the flyer that was in the box with your product or at www.hp.com/support/. Have the product name, serial number, date of purchase, and problem description ready. Get 24-hour Internet support www.hp.com/support/cljcp4025 or www.hp.com/support/ cljcp4525 Get support for products used with a Macintosh computer www.hp.
B ENWW Product specifications ● Physical specifications ● Performance specifications ● Electrical specifications ● Acoustic specifications ● Environmental specifications ● Skew specifications 501
Physical specifications Table B-1 Product dimensions Product Height Depth Width Weight HP Color LaserJet CP4025n 420 mm (16.5 in) 522 mm (20.6 in) 540 mm (21.3 in) 38.5 kg (84.6 lb) HP Color LaserJet CP4025dn 420 mm (16.5 in) 522 mm (20.6 in) 540 mm (21.3 in) 38.5 kg (84.6 lb) HP Color LaserJet CP4525n 420 mm (16.5 in) 522 mm (20.6 in) 540 mm (21.3 in) 38.5 kg (84.6 lb) HP Color LaserJet CP4525dn 420 mm (16.5 in) 522 mm (20.6 in) 540 mm (21.3 in) 38.5 kg (84.
Table B-3 Power requirements Specification 110-volt models 220-volt models Power requirements 100 to 127 volts (± 10%) 220 to 240 volts (± 10%) 50/60 Hz (± 2 Hz) 50/60 Hz (± 2 Hz) 8.5 Amps 4.5 Amps Rated current Table B-4 Power consumption (average, in watts)1246 Product model Printing Ready Sleep Off HP Color LaserJet CP4525 model 740 W 72 W 19 W 0.3 W HP Color LaserJet CP4025 model 1 Values subject to change. See www.hp.com/go/cljcp4025_regulatory or www.hp.
Skew specifications Table B-6 Media registration and image placement accuracy Cut sheet simplex and automatic duplex1 Envelopes and postcards Skew - vertical ≤ 1.5 mm / 260 mm2 ≤ 3.3 mm / 220 mm First line / leading edge position 5.0 mm ± 2.0 mm 10.0 mm ± 3.0 mm Left margin accuracy 5.0 mm ± 2.0 mm 10 mm ± 2.5 mm Parallelism ≤ 0.75% N/A Image or text stretching - vertical ≤ 1.0 % N/A Image or text stretching - horizontal ≤ 1.0 % N/A Duplex registration - vertical, horizontal ≤ 2.
C ENWW Regulatory information ● FCC regulations ● Environmental product stewardship program ● Declaration of Conformity ● Safety statements 505
FCC regulations This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy, and if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.
Environmental product stewardship program Protecting the environment Hewlett-Packard Company is committed to providing quality products in an environmentally sound manner. This product has been designed with several attributes to minimize impacts on our environment. Ozone production This product generates no appreciable ozone gas (O3).
Return and recycling instructions United States and Puerto Rico The enclosed label in the HP LaserJet toner cartridge box is for the return and recycling of one or more HP LaserJet print cartridges after use. Please follow the applicable instructions below. Multiple returns (more than one cartridge) 1. Package each HP LaserJet print cartridge in its original box and bag. 2. Tape the boxes together using strapping or packaging tape. The package can weigh up to 31 kg (70 lb). 3.
Material restrictions This HP product does not contain added mercury. This HP product contains a battery that might require special handling at end-of-life. The batteries contained in or supplied by Hewlett-Packard for this product include the following: HP Color LaserJet Enterprise CP4020-CP4520 Series Type Carbon monofluoride lithium Weight 0.8 g Location On formatter board User-removable No For recycling information, you can go to www.hp.
Material Safety Data Sheet (MSDS) Material Safety Data Sheets (MSDS) for supplies containing chemical substances (for example, toner) can be obtained by accessing the HP Web site at www.hp.com/go/msds or www.hp.com/hpinfo/ community/environment/productinfo/safety.
Declaration of Conformity Declaration of Conformity according to ISO/IEC 17050–1 and EN 17050–1, DoC#: BOISB-0806-00-rel.1.
Safety statements Laser safety The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration has implemented regulations for laser products manufactured since August 1, 1976. Compliance is mandatory for products marketed in the United States. The device is certified as a “Class 1” laser product under the U.S. Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968.
EMC statement (China) EMC statement (Korea) EMI statement (Taiwan) Laser statement for Finland Luokan 1 laserlaite Klass 1 Laser Apparat HP Color LaserJet CP4025n, CP4025dn, CP4525n, CP4525dn, CP4525xh, laserkirjoitin on käyttäjän kannalta turvallinen luokan 1 laserlaite. Normaalissa käytössä kirjoittimen suojakotelointi estää lasersäteen pääsyn laitteen ulkopuolelle. Laitteen turvallisuusluokka on määritetty standardin EN 60825-1 (1994) mukaisesti.
Mikäli kirjoittimen suojakotelo avataan, olet alttiina näkymättömällelasersäteilylle laitteen ollessa toiminnassa. Älä katso säteeseen. VARNING ! Om laserprinterns skyddshölje öppnas då apparaten är i funktion, utsättas användaren för osynlig laserstrålning. Betrakta ej strålen. Tiedot laitteessa käytettävän laserdiodin säteilyominaisuuksista: Aallonpituus 775-795 nm Teho 5 m W Luokan 3B laser.
Index Symbols/Numerics 500-sheet paper and heavy media tray specifications, physical 501 A AC to DC conversion accessories ordering 426 part numbers 427 screws 430 accessories installed, information 311 acoustic specifications after-service checklist AppleTalk information 12 503 70 310 B bands, troubleshooting 411 batteries included 509 beam-detect (BD) failure 19 bias generation high-voltage power supply xvii black-only printing mode developing roller state 30 primary transfer roller state 32 blank pag
PCA locations xxviii pickup, feed, and delivery 37 print cartridge 28 protection for 13, 15 configuration page 242 configuration pages information 311 printing 307 configure device menu 321 connectors controller PCA (optional paper feeder) 283 DC controller PCA 281, xxviii control panel cleaning page, printing 416 I/O menu 334 menus 314 messages, alphabetical list xvii messages, numerical list 345 messages, types of 345 Show Me How menu 314 control-panel assembly removing 95 control-panel menus manage suppl
drive circuit power-supply frequency range 17 drum cleaning 28 duplex printing (double-sided) Show Me How menu 314 duplexer specifications, physical 501 duplexing unit components 52 duplex-drive assembly, removing 151 jam causes 397 motors 8 print operation 53 See also pickup, feed, and delivery E EIO cards part number 427 reset by NVRAM initialization 423 electrical specifications 502 electrostatic discharge (ESD) 69 embedded protocol page 310 end-of-life disposal 509 energy specifications 502 engine diagn
I I/O (input/output) menu 334 I/O menu 334 image placement accuracy xix image quality issues examples and solutions 239 image stabilization controls 35 image-formation process development process 25 drum cleaning 28 fusing process 27 ITB cleaning 28 laser-beam exposure 25 pre-exposure 24 primary charging 24 primary transfer process 26 secondary transfer process 26 separation process 27 steps 23 imaging drums color drums disengagement 30 diagnostic test 244 information menu 317 initial rotation period 3 init
main-drive assembly removing 203 manage supplies menu 318 manual print modes 408 material restrictions 509 Material Safety Data Sheet (MSDS) 510 media Show Me How menu 314 media registration accuracy xix media sensor value Service menu reset 422 memory information 307 insufficient 346, 362 NVRAM initialization 423 part numbers 427 permanent storage error messages 355 supply errors 345 memory DIMM, removing 81 menu map description 317 print 236 menus configure device 321 diagnostics 342 I/O (input/output) 33
lifter-drive assembly, removing 230 motor control 59 multifeed prevention 43 optional 1 x 500-sheet 57 optional 3 x 500-sheet 57 paper detection 47 pickup and feed operation 60 pickup assembly, removing 226 pickup motor assembly, removing 231 rear cover, removing 218 rear-right cover, removing 225 right cover, removing 224 right door, removing 216 right-front cover, removing 219 skew feed prevention 47 See also pickup, feed, and delivery paper feeders parts lists and diagrams 468, 470 paper handling menu 31
Q quality.
security settings 334 security settings information 309 security slot locating 280 sensor tests manual 5V laser and 24V interlock and logic switches 267 developer alienation sensor (I) 252 duplex re-pickup sensor (E) 250 front-door switch (M) 257 fuser delivery sensor (D) 249 fuser pressure-release sensor (J) 253 loop sensors (B and C) 248 media sensor (L) 256 new ITB sensor 271 output bin full sensor (F) 251 primary transfer-rollerdisengagement sensor (K) 254 right-door switch (N) 258 TOP sensor (A) 247 tr
TCP/IP settings 334 technical support online 500 temperature control for fuser 15 thresholds for fuser components 15, 16 values, printed 305 temperature requirements 503 tests color band 311 component tests list and descriptions xvii disable cartridge check 244 engine 240 manual sensor 246 networks 338 paper path 245 paper-path sensors 256 post-service 71 print-quality 71 print/stop 273 special-mode test 259 text, troubleshooting 414 thermistors fuser 14, 15 open detection 17 thermopiles fuser 15 thermoswit
Material Safety Data Sheet (MSDS) 510 ordering supplies 426 white spots, troubleshooting 411 wrinkles, troubleshooting 415 524 Index ENWW
© 2010 Hewlett-Packard Development Company, L.P. www.hp.
