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HP CP4525DN Laser CC494A#ABA manual Cassettes

Models: CP4525DN Laser CC494A#ABA

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452 Chapter 4 Parts and diagrams

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HP CP4525DN Laser CC494A#ABA manual Cassettes

Contents

Color Laserjet Enterprise CP4020/CP4520 Page HP Color LaserJet Enterprise CP4020- CP4520 Series Printers Copyright and License Trademark CreditsConventions used in this guide Iv Conventions used in this guide Table of contents Removal and replacement Print-quality test 119 Enww Solve problems 265 383 Parts and diagrams Appendix B Product specifications Appendix a Service and supportAppendix C Regulatory information 515 Xvi List of tables 17 Causes and solutions for fuser delivery delay jams 394 Table B-4 Enww List of figures 49Paper-feeder pickup and feed operation 41 Remove the front-top cover 1 100 71 Remove the secondary transfer assembly 1 119 115 Remove the delivery assembly 3 146 161 Remove the tray-pickup drive assembly 1 178 209 Remove the fuser-drive assembly 1 212 19 Test the Tray 1 media-present sensor 261 20 Paper feeder external covers, panels, and doors 470 Xxx Theory of operation Basic operation 1Relationship between the main product systems1Sequence of operation Sequence of operationPeriod Duration Description Engine-control system 2Engine-control systemSolenoids DC controllerComponent abbreviation Component name Switches ClutchesSensors SensorsMotors Abbreviation Name Purpose Failure detectionFans Abbreviation Name Cooling area Type Speed7High-voltage power supply circuits High-voltage power supplyCircuit Description Biases for each color Low-voltage power supply 8Converted DC voltagesSafety Sleep powersave modeLow-voltage power supply failure Overcurrent/overvoltage protection9Fuser components Fuser controlType of component Abbreviation Name Function Fuser temperature control Fuser sleeve temperature protectionFailure detection Fuser unit identification Fuser unit life detectionLaser/scanner system 8Laser/scanner systemProtective-glass cleaners Laser/scanner failure9Protective-glass cleaners PGCs Theory of operation Image-formation system ITB11Image-formation drive system Image-formation process Functional block Steps DescriptionPre-exposure Primary chargingLaser-beam exposure DevelopmentPrimary transfer Secondary transferFusing SeparationDrum cleaning ITB cleaningPrint cartridge 23Print-cartridge system Developing-roller engagement and disengagement Intermediate transfer belt ITB unit 25 ITB unitPrimary-transfer-roller engagement and disengagement 10Primary-transfer-roller engagement statesSL1 27ITB cleaning process CalibrationColor-misregistration control Image-stabilization control11Image-stabilization controls Pickup, feed, and delivery system 29 Paper pathComponent Abbreviation Component 32Three main units of the pickup, feed, and delivery system Pickup-and-feed unit Cassette pickupCassette-presence detection Top switch Center switch Bottom switchPaper size 35Cassette lift mechanism Cassette multiple-feed preventionMultipurpose tray pickup 36Multiple-feed preventionPaper feed 37Multipurpose tray pickup mechanism38Paper-feed mechanism Skew-feed prevention Paper detectionFusing and delivery unit 14Print mode and feed speedSimplex printing Duplex printingLoop control 40Fuser and delivery unit41Loop-control mechanism Pressure-roller pressurization control 42Pressure-roller pressurization controlDuplexing reverse and feed control 43Duplexing unitDuplex print operation Duplex reverse and feed controlEnww Jam detection 45Jam detection sensors16Jams that the product detects Jam DescriptionOptional paper feeder 461 x 500 optional paper feeder473 x 500-sheet optional paper feeder Motor control 17Electrical components for the paper feederComponent Abbreviation Component name Type Component Drives Failure detectionPaper-feeder pickup and feed operation 18Pickup feed components 1 x 500-sheet paper feederSW2 SW3 SW4 Paper-size detection and cassette-presence detection OFFPaper-feeder cassette lift operation SR2/SR8/SR9Paper feeder jam detection 51Jam detection 1 x 500-sheet paper feeder52Jam detection 3 x 500-sheet paper feeder Enww Removal and replacement Removal and replacement strategy IntroductionElectrostatic discharge Required toolsBefore performing service After performing servicePost-service test Print-quality test2Parts removal order 1 Removal and replacement Parts removal order3Parts removal order 2 Customer self repair CSR components Print cartridges5Remove the print cartridge 2 7Remove the toner-collection unit 2 Removal and replacement Toner-collection unit8Remove the toner-collection unit 3 Formatter PCA ESD sensitive componentRemove the hard drive Hard driveBefore proceeding, remove the following components 13Remove the hard drive 3 Removal and replacement Memory Dimm Remove the memory DimmEnable memory Click SettingsClick the Device Settings tab Next to Automatic Configuration , select Update NowNext to Automatic Configuration, select Update Now Installable Options areaClick the Installable Options menu WindowsTray Fuser Feed and separation rollers Trays Pickup roller Tray 24Remove the pickup roller Tray 1 4 Removal and replacement Enww Secondary transfer roller Reinstall the transfer roller 29Reinstall the transfer rollerIntermediate transfer belt ITB 32Remove the intermediate transfer belt 3 Enww External panels, covers, and doors Identification and locationUpper-left cover 35Remove the upper-left cover 1 Remove one screw37Remove the upper-left cover 3 Power-supply cover 38Remove the power-supply cover Removal and replacementLeft cover Remove the left coverFront-top cover Remove the front-top cover43Remove the front-top cover 3 Rear-top cover Remove the rear-top coverRight-front cover Remove the right-front coverReinstall the power button Control-panel assembly Remove the control-panel assemblyEnww Front-door assembly Remove the front-door assembly53Remove the front-door assembly 2 Remove two screws callout 55Remove the front-door assembly 4 Right-rear cover Remove the right-rear cover58Remove the right-rear cover 2 Rear cover Remove the rear coverRight-door assembly 61Remove the right-door assembly 263Remove the right-door assembly 4 Removal and replacement 65Remove the right-door assembly 6 67Remove the right-door assembly 8 Removal and replacement 68Remove the right-door assembly 9 Internal assemblies Cassette feed guideSecondary transfer assembly 72Remove the secondary transfer assembly 2Reinstall the secondary transfer assembly Separation pad Tray Remove the separation pad Tray78Remove the separation pad 4 Removal and replacement Enww Registration density RD sensor assembly Remove the RD sensor assembly84Remove the RD sensor assembly 4 86Remove the RD sensor assembly 6 Removal and replacement Carefully remove the assembly from the product Registration assembly Remove the registration assembly 89Remove the registration assembly 291Remove the registration assembly 4 Removal and replacement 93Remove the registration assembly 6 95Remove the registration assembly 8 Removal and replacement Residual-toner-feed motor Remove the residual-toner-feed motorResidual-toner duct and feed assembly Remove the residual-toner duct and feed assembly99Remove the residual-toner duct and feed assembly 3 Enww Cartridge fan and environmental sensor Remove the cartridge fan and environmental sensorEnww Enww Enww Toner-collection sensor and scanner-thermistor assembly Open the front-door assembly, and then remove one screw Delivery fan Remove the delivery fan112Remove the delivery fan 2 Removal and replacement Delivery assembly Remove the delivery assembly115Remove the delivery assembly 3 Removal and replacement Remove two screws 118Remove the delivery assembly 6 Remove the assembly Reinstall the delivery assembly 121Reinstall the delivery assembly 2123Reinstall the delivery assembly 4 Removal and replacement Duplex-drive assembly Remove the duplex-drive assemblyPower-supply fan Remove the power-supply fanInterconnect board ICB Remove the ICB127Remove the ICB 2 Removal and replacement DC controller PCA only Remove the DC controller PCA onlyEnww Low-voltage power supply Lvps Remove the low-voltage power supplyEnww 134Remove the low-voltage power supply 4 Enww DC controller PCA and tray Remove the DC controller PCA and trayRemove two screws High-voltage power supply lower HVPS-D Remove the high-voltage power supply lowerRemove three screws 142Remove the high-voltage power supply lower 3 Release five tabs 146Remove the high-voltage power supply lower 7 Reinstall the high-voltage power supply lowerDeveloping-disengagement motor Remove the developing-disengagement motorExhaust fan and fan duct Remove the exhaust fan and fan ductEnww Reinstall the exhaust fan and fan duct 152Reinstall the exhaust fan and fan ductPickup motor Remove the pickup motorLifter-drive assembly Remove the lifter-drive assemblyEnww Lifter base assembly Remove the lifter base assemblyReinstall the lifter base assembly 158Remove the lifter base assembly 2160Reinstall the lifter base assembly 2 Tray-pickup drive assembly Remove the tray-pickup drive assembly163Remove the tray-pickup drive assembly 3 Tray-pickup assembly Remove the tray-pickup assemblyEnww 168Remove the tray-pickup assembly 5 Removal and replacement Enww 172Remove the tray-pickup assembly 9 Removal and replacement 173Remove the tray-pickup assembly 10 Laser/scanner assembly Y/M Remove the laser/scanner assembly Y/M 176Remove the laser/scanner assembly Y/M 2Enww 179Remove the laser/scanner assembly Y/M 5 Laser/scanner assembly C/Bk Remove the laser/scanner assembly C/Bk 181Remove the laser/scanner assembly C/Bk 2Enww 184Remove the laser/scanner assembly C/Bk 5 Reinstall the protective glass cleaner PGC actuators187Reinstall the PGC actuators 3 Removal and replacement 189Reinstall the PGC actuators 5 High-voltage power supply upper HVPS-T Remove the high-voltage power supply upper191Remove the high-voltage power supply upper 2 Reinstall the high-voltage power supply upper Yellow, magenta, cyan, and black drum motors Remove the yellow, magenta, cyan, and black drum motorsFuser motor Remove the fuser motor 194Remove the fuser motorITB motor Remove the ITB motorMain-drive assembly Remove the main-drive assembly 197Remove the main-drive assembly 2 Removal and replacement198Remove the main-drive assembly 3 Remove 10 screws Enww Reinstall the main-drive assembly 203Reinstall the main-drive assembly 2Enww Enww Enww Fuser-drive assembly Remove the fuser-drive assembly 212Remove the fuser-drive assembly 4 213Remove the fuser-drive assembly 5 Remove three screws 215Remove the fuser-drive assembly 7 Reinstall the fuser-drive assemblyFront door optional paper feeder Enww Rear cover optional paper feeder Right-front cover optional paper feeder 220Remove the right-front cover optional paper feederRight door optional paper feeder Enww Left cover optional paper feeder Remove the left cover optional paper feederEnww Right cover optional paper feeder Remove the right cover optional paper feederRear-right cover optional paper feeder Remove the rear-right cover optional paper feederPickup assembly optional paper feeder Remove the pickup assembly optional paper feeder231Remove the pickup assembly optional paper feeder 3 Enww Lifter assembly optional paper feeder Remove the lifter assembly optional paper feederLifter-drive assembly optional paper feeder Remove the lifter-drive assembly optional paper feederPickup motor assembly optional paper feeder Remove the pickup motor optional paper feeder assemblyController PCA optional paper feeder Remove the controller PCA optional paper feederSolve problems Solve problems checklist Solve problems checklist Menu map Print a menu mapTroubleshooting process Determine the problem sourcePre-troubleshooting checklist 1Pre-troubleshooting checklistCalibrate the product on Troubleshooting flowchart 2Troubleshooting flowchartPower on Event log Information pages Image quality InterfacePower subsystem Power-on checksPower-on troubleshooting overview Power-on timing approximateEnww Tools for troubleshooting Individual component diagnosticsLED diagnostics Understand lights on the formatterHeartbeat LED Engine diagnosticsDefeating interlocks Disable cartridge check Engine-test buttonPaper-path test 3Engine-test button3Manual sensor diagnostic tests Default state of bitsSensor or switch name Sensor or switch number Manual sensor test special-mode testTOP top of page sensor C loop sensors Fuser delivery sensor Duplex re-pickup sensor Output bin full sensor Developer alienation Fuser pressure-release sensor Primary transfer-roller-disengagement sensor Enww Media sensor 16 Media sensorFront-door switch Right-door switch 5Manual sensor test 2 diagnostic tests Manual sensor test 2 special-mode testTest each switch individually Solve problems Tray 1 paper present sensor Tray 2 paper present sensor Tray 2 paper surface 1 and 2 sensors Tray 2 paper size switches Tray 3 paper size switches Tray 3 paper present sensorTray 3 feed sensor Tray 3 paper surface 1 and 2 sensorsTray 4 paper size switches Tray 5 paper size switchesTray 5 paper present sensor Tray 5 feed sensorEnww Defeating Enww Enww New ITB sensor 25Test the new ITB sensorTray 3, 4, and 5 right door switch 26Test the right door switch Solve problems7Paper-path sensors diagnostic tests Paper-path sensors testPrint/stop test Sensor name Sensor numberComponent test special-mode test Component tests8Component test details Yellow Laser Scanner Fuser MotorFuser Pressure Release Motor Alienation MotorDuplex Refeed Clutch Solenoid RepeatDiagrams Block diagrams28Optional paper feeder 1 x 500-sheet 29Optional paper feeder 3 x 500-sheet Plug/jack locations 9Formatter PCALocation of connectors DC controller connector locations10DC controller connectors 32Controller PCA connectors 11Controller PCA connectorsLocations of major components 33External component locations34Major component locations 1 35Major component locations 2 36Major component locations 3 11 9 Ite Description38PCA component locations 39Optional paper feeder 1 x 500-sheet component locations 1 40Optional paper feeder 1 x 500-sheet component locations 2 41Optional paper feeder 3 x 500-sheet component locations 1 42Optional paper feeder 3 x 500-sheet component locations 2 General timing chart Timing chartCircuit diagrams General circuit diagram 1Control Paper feeder circuit diagram 1 X 500-sheet Paper feeder circuit diagram 3 X 500-sheet Open the HP Easy Printer Care software HP Easy Printer CareHP Easy Printer Care software sections Settings tab Section Options Support tabHP Proactive Support Overview and Support tabsSection Options Alert Settings link Color Access ControlPrint-quality-troubleshooting pages Internal print-quality test pagesYellow Green 51Black print-quality troubleshooting Diagnostics DiagnosticsCleaning Create and use the cleaningConfiguration ConfigurationMemory Event log Security Paper trays and options Security Settings information HP embedded JetdirectEmbedded protocol 54 Embedded protocol12Important information on the configuration pages Finding important information on the configuration pagesColor-band test Print-quality troubleshooting tools Repetitive defects rulerCalibrate the product Control panel menus Control panel menusShow Me How menu Retrieve job menuEnww When Print or Print and Delete is ALL Jobs no PIN PrintHold jobs, Print and Delete is DeleteInformation menu Paper handling menuManage supplies menu Color Cartridges Stop ContinuePrint in Black Transfer KIT StopUser Defined LOW Yellow Cartridge Magenta CartridgeCyan Cartridge Black Cartridge Transfer KITConfigure device menu Printing menuDefault Paper Size Default Custom Paper Unit of MeasureSize Dimension Print PS Errors OFFPCL sub-menu Print Quality menu Mode Expanded X1 ShiftY1 Shift X2 ShiftAdjust Paper Print ModeRestore Optimize NOW DelayAuto Cleaning OFF CleaningAuto Cleaning Letter Edge Control OFFCreate Select the Create CleaningProcess System setup menu PS Defer Media Enabled DisabledUSE Requested Tray Exclusively FirstUSE Another Tray Enabled Letterhead Mode OFFSleep Delay Minute AlternativeWake Time CustomOptimum SPEED/ENERGY Faster First Usage Save EnergyJAM Recovery Auto Auto Continue OFFRAM Disk Auto LanguageMenu 13Embedded Jetdirect menuIPV4 Settings Config Method Bootp Settings Subnet MaskDefault Default IP Auto IPIPV6 Settings Enable SettingsDhcp Renew Primary DNSIdle Timeout IPX/SPX EnableAppletalk Enable OFF DLC/LLC EnableDisable ResetReset Security YES Diagnostics Embedded TestsSnmp Test YES Data Path Test YESSelect ALL YES TestsPrint Results YES Ping ResultsPackets Sent PacketsRefresh YES Link Speed Auto 10T Half 10T Full 100TX Half 100TX FullResets menu Diagnostics menuPaper Path Sensors Paper Path TestSource ALL Trays TrayService menu Product PINsVoltage power supply Color Band Test Print TestInterpret control-panel messages Control-panel message typesControl-panel messages XX values13.XX.YY Fuser Area JAM 13.XX.YY Fuser Wrap JAM13.XX.YY JAM Above TOP Output BIN 13.XX.YY JAM in Lower Right DoorTransfer Unit Error Embedded I/O Buffer OverflowParallel I/O Buffer Overflow Parallel Serial BufferFuser Error Xxxx ErrorTo continue turn off then on See Fuser on XX Error XY Error55.XX.YY DC Controller Error Error See DC controller PCA and trayDescription Recommended action Error 59.A0 Error BO Cleaning Motor Error59.C0 Error Replace Toner Collection Unit59.F0 Error No System ValuesPermanent Storage Full Storage Error Settings 8X.YYYY EIO Error8X.YYYY Embedded Jetdirect Error ChangedCalibration Reset Pending Black Cartridge LOWBlack Cartridge LOW Less than Xxxx Pages Black Cartridge Very LOWCleaning Disk X% Complete Card Slot Device FailureCard Slot File Operation Failed Card Slot File System is FullCleaning Cyan Cartridge LOW Close Lower Right DoorClose Right Door Collection Unit Almost FullCyan Cartridge Very LOW Data ReceivedDATE/TIME = YYYY/MMMM/DD Hhmm EIO X Disk InitializingHP Secure Drive Disabled EIO is Write ProtectedEIO not Initialized Expected Drive MissingInstall Color Cartridge Install FuserInstall Supplies Install Transfer UnitMedia insert required in tray Loading Program Magenta Cartridge LOWMagenta Cartridge LOW Less than Xxxx Pages Magenta Cartridge Very LOWNON HP Supply Installed Moving SolenoidMoving Solenoid and Motor Printing StoppedRAM Disk Device Failure RAM Disk File Operation FailedRAM Disk File System is Full RAM Disk is Write ProtectedReplace Supplies Using black only Remove Shipping SheetReplace Color Cartridge Replace Fuser KITReplace Transfer KIT ROM Disk Device FailureROM Disk File Operation Failed ROM Disk File System is FullROM Disk is Write Protected Sanitizing Disk X% CompleteSupplies LOW Manage Supplies menu onPrinting Black only Supplies Very LOWToner Collection Unit LOW Toner Collection Unit Very LOWTransfer KIT LOW Transfer KIT LOW Less than Xxxx PagesTray X Type Size Tray X Empty Type SizeTray X Open Tray X OverfilledUnsupported Drive Installed Unsupported Supply InstalledUSB Accessory Error USB Accessory not FunctionalWait for Printer to Reinitialize Waiting for Tray X to LiftWarming UP Yellow Cartridge LOWYellow Cartridge Very LOW Yellow Cartridge Very LOW To continue press OKPrint an event log Event log messagesShow an event log Sample event log Clear the event logEvent log message table Event log message Description CommentsConfigure DEVICE, and then Quick Calibrate NOW,Then press theOK button DC controller Nvrm is not Reading the header number and size 99.00.08 Common causes of jams Clear paper jamsProduct is jammed ITB 15Common causes of jams by area Jam codeType of jam Procedure Jam locationsClear jams in the right door 13.XX.YY JAM in Optional TraysEnww Enww Clear jams in the output bin area Clear jams in TrayEnww Clear jams in Tray 2 or optional Trays 3, 4, or Clear jams in the lower right door Tray 3, 4, or Jams in the output bin Jam causes and solutionsJams in the fuser and transfer area 19Causes and solutions for fuser delivery stationary jams 20Causes and solutions for residual media jams 21Causes and solutions for pickup delay jams23Causes and solutions for duplexing reverse jams 22Causes and solutions for pickup stationary jams24Causes and solutions for duplex repick jams 25Causes and solutions for residual media jams Right-door assembly on26Causes and solutions for pickup delay jam 1 tray pickup Jams in Tray 1, Tray 2 and internal paper path27Causes and solutions for pickup stationary jams Jams in Tray 3, 4,29Causes and solutions for residual media jams Change jam recovery Set the jam recovery featureSolve paper-handling problems Product feeds multiple sheetsProduct feeds incorrect page size Product pulls from incorrect trayPaper does not feed automatically Paper does not feed from Tray 2, 3, 4, orPaper does not feed automatically Paper does not feed from Tray 2, 3, 4, orTransparencies or glossy paper will not feed Envelopes jam or will not feed in the productTransparencies or glossy paper will not feed Envelopes jam or will not feed in the productProduct will not duplex or duplexes incorrectly Output is curled or wrinkledOutput is curled or wrinkled Automatic Configuration list Under Installable Options, click Update NowProperties or Printing Preferences PRE-ROTATION Mode 30MP modes under the Adjust Paper Types sub menuUse manual print modes 31MP modes under the Optimize submenu Problem Sample Cause Solution Solve image-quality problemsImage defects table Transfer belt ITB on Assembly Y/M on page 186 or Power supply lower HVPS-D Assembly. See Secondary transfer Execute a Pressure roller clean Clean the paper path Clean the productClean the product Solve performance problems Problem Cause SolutionSolve direct-connect problems Solve connectivity problemsSolve network problems Solve connectivity problems Service mode functions Service menuRefurbish Cycle Count Refurbish page CountSerial Number Service ID Cold Reset PaperNEW Registration Roller Media Sensor ValueProduct resets Restore factory-set defaultsHard disk initialization optional Nvram initializationProduct updates Product cold resetParts and diagrams Order parts, accessories, and supplies Accessories Part numbersPrint cartridges and toner collection unit Memory1Maintenance kits Service maintenance kitsCustomer self repair CSR parts 2110V and 220V unique components Unique components3Simplex and duplex unique components Screws 4Common fastenersHow to use the parts lists and diagrams External covers, panels, and doors 1External covers, panels, and doors5External covers, panels, and doors Description Part number QtyRight door assembly 2Right door assembly6Right door assembly Front door assembly 7Front door assembly Internal components Internal components 18Internal components 1 Internal components 2 9Internal components 2 Internal components 3 6Internal components 310Internal components 3 Internal components 4 11Internal components 4 Internal components 5 8Internal components 512Internal components 5 Internal components 6 Simplex Model Duplex Model13Internal components 6 Internal components 7 10Internal components 714Internal components 7 Cassettes Cassettes15 Cassette Paper pickup assembly 16Paper pickup assembly Tray 1 paper pickup assembly 13Tray 1 paper pickup assembly17Tray 1 paper pickup assembly Simplex Model Duplex Model 18Registration assembly 15Secondary transfer assembly 19Secondary Transfer assembly 16Delivery assembly 20Delivery assembly Fuser assembly Fuser assembly21Fuser assembly PCAs 18 PCAs22 PCAs Paper feeders AssessoriesPaper feeders 23Paper feeders Paper feeder external covers, panels, and doors 1x500 3x50024Paper feeder external covers, panels, and doors 500 paper feeder main body 500 paper feeder main body251 X 500 paper feeder main body 223 X 500 paper feeder main body 263 X 500 paper feeder main body Alphabetical parts list 27Alphabetical parts listAlphabetical parts list Delivery assembly Fuser drive assembly, simplex RM1-6702-000CN Paper pickup assembly Tray 1 paper pickup assembly Shutter arm assembly RM1-5585-000CN Upper main cable assembly RM1-5800-000CN Numerical parts list 28Numerical parts listRC2-4218-000CN Tray, waste toner catch Enww RK2-2604-000CN Flat flexible cable DCC to Hvps lower RM1-5520-000CN Cover, inner RM1-5781-000CN High voltage power supply, upper Enww WC2-5637-000CN Switch, push Enww Service and support Hewlett-Packard limited warranty statement Page HP Color LaserJet Fuser Kit Limited Warranty Statement End User License Agreement TransferEnww Customer self-repair warranty service Customer support Product specifications Physical specifications Performance specificationsElectrical specifications Table B-1Product dimensionsAcoustic specifications Environmental specificationsTable B-3Power requirements Table B-4Power consumption average, in watts1246Skew specifications Table B-6Media registration and image placement accuracyRegulatory information FCC regulations Environmental product stewardship program Return and recycling instructions PaperUnited States and Puerto Rico Non-U.S. returnsChemical substances Material restrictionsHP Color LaserJet Enterprise CP4020-CP4520 Series Material Safety Data Sheet Msds For more information Declaration of Conformity Safety statements Laser safetyVcci statement Japan Power cord instructions Power cord statement JapanVaroitus GS statement Germany Symbols/Numerics Cabinet/standDhcp See also jams Nvram See also counts Enww Recycling Enww See also cassette Enww Page CC489-90936* *CC489-90936