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HP CP4525DN Laser CC494A#ABA manual Conventions used in this guide

Models: CP4525DN Laser CC494A#ABA

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Conventions used in this guide

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NOTE: Notes provide important information to explain a concept or to complete a task.

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HP CP4525DN Laser CC494A#ABA manual Conventions used in this guide

Contents

Color Laserjet Enterprise CP4020/CP4520 Page HP Color LaserJet Enterprise CP4020- CP4520 Series Printers Trademark Credits Copyright and LicenseConventions 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 C Regulatory information Appendix a Service and supportAppendix B Product specifications 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 1Relationship between the main product systems Basic operationPeriod Duration Description Sequence of operation1Sequence of operation 2Engine-control system Engine-control systemComponent abbreviation Component name DC controllerSolenoids Clutches SwitchesSensors SensorsAbbreviation Name Purpose Failure detection MotorsAbbreviation Name Cooling area Type Speed FansCircuit Description High-voltage power supply7High-voltage power supply circuits Biases for each color 8Converted DC voltages Low-voltage power supplySleep powersave mode SafetyLow-voltage power supply failure Overcurrent/overvoltage protectionType of component Abbreviation Name Function Fuser control9Fuser components Fuser sleeve temperature protection Fuser temperature controlFailure detection Fuser unit life detection Fuser unit identification8Laser/scanner system Laser/scanner systemLaser/scanner failure Protective-glass cleaners9Protective-glass cleaners PGCs Theory of operation ITB Image-formation system11Image-formation drive system Functional block Steps Description Image-formation processPrimary charging Pre-exposureDevelopment Laser-beam exposureSecondary transfer Primary transferSeparation FusingPrint cartridge ITB cleaningDrum cleaning 23Print-cartridge system Developing-roller engagement and disengagement 25 ITB unit Intermediate transfer belt ITB unit10Primary-transfer-roller engagement states Primary-transfer-roller engagement and disengagementSL1 Calibration 27ITB cleaning processImage-stabilization control Color-misregistration control11Image-stabilization controls 29 Paper path Pickup, feed, and delivery systemComponent Abbreviation Component 32Three main units of the pickup, feed, and delivery system Cassette pickup Pickup-and-feed unitPaper size Top switch Center switch Bottom switchCassette-presence detection Cassette multiple-feed prevention 35Cassette lift mechanism36Multiple-feed prevention Multipurpose tray pickup37Multipurpose tray pickup mechanism Paper feed38Paper-feed mechanism Paper detection Skew-feed prevention14Print mode and feed speed Fusing and delivery unitSimplex printing Duplex printing40Fuser and delivery unit Loop control41Loop-control mechanism 42Pressure-roller pressurization control Pressure-roller pressurization control43Duplexing unit Duplexing reverse and feed controlDuplex reverse and feed control Duplex print operationEnww 45Jam detection sensors Jam detectionJam Description 16Jams that the product detects461 x 500 optional paper feeder Optional paper feeder473 x 500-sheet optional paper feeder 17Electrical components for the paper feeder Motor controlComponent Abbreviation Component name Type Component Drives Failure detection18Pickup feed components 1 x 500-sheet paper feeder Paper-feeder pickup and feed operationSW2 SW3 SW4 OFF Paper-size detection and cassette-presence detectionSR2/SR8/SR9 Paper-feeder cassette lift operation51Jam detection 1 x 500-sheet paper feeder Paper feeder jam detection52Jam detection 3 x 500-sheet paper feeder Enww Removal and replacement Introduction Removal and replacement strategyRequired tools Electrostatic dischargeAfter performing service Before performing servicePrint-quality test Post-service testParts removal order 2Parts removal order 1 Removal and replacement3Parts removal order 2 Print cartridges Customer self repair CSR components5Remove the print cartridge 2 Toner-collection unit 7Remove the toner-collection unit 2 Removal and replacement8Remove the toner-collection unit 3 ESD sensitive component Formatter PCABefore proceeding, remove the following components Hard driveRemove the hard drive 13Remove the hard drive 3 Removal and replacement Remove the memory Dimm Memory DimmClick Settings Enable memoryClick the Device Settings tab Next to Automatic Configuration , select Update NowInstallable Options area Next to Automatic Configuration, select Update NowClick 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 29Reinstall the transfer roller Reinstall the transfer rollerIntermediate transfer belt ITB 32Remove the intermediate transfer belt 3 Enww Identification and location External panels, covers, and doors35Remove the upper-left cover 1 Remove one screw Upper-left cover37Remove the upper-left cover 3 38Remove the power-supply cover Removal and replacement Power-supply coverRemove the left cover Left coverRemove the front-top cover Front-top cover43Remove the front-top cover 3 Remove the rear-top cover Rear-top coverRemove the right-front cover Right-front coverReinstall the power button Remove the control-panel assembly Control-panel assemblyEnww Remove the front-door assembly Front-door assembly53Remove the front-door assembly 2 Remove two screws callout 55Remove the front-door assembly 4 Remove the right-rear cover Right-rear cover58Remove the right-rear cover 2 Remove the rear cover Rear cover61Remove the right-door assembly 2 Right-door assembly63Remove 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 Cassette feed guide Internal assemblies72Remove the secondary transfer assembly 2 Secondary transfer assemblyReinstall the secondary transfer assembly Remove the separation pad Tray Separation pad Tray78Remove the separation pad 4 Removal and replacement Enww Remove the RD sensor assembly Registration density 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 89Remove the registration assembly 2 Remove the registration assembly91Remove the registration assembly 4 Removal and replacement 93Remove the registration assembly 6 95Remove the registration assembly 8 Removal and replacement Remove the residual-toner-feed motor Residual-toner-feed motorRemove the residual-toner duct and feed assembly Residual-toner duct and feed assembly99Remove the residual-toner duct and feed assembly 3 Enww Remove the cartridge fan and environmental sensor Cartridge fan and environmental sensorEnww Enww Enww Toner-collection sensor and scanner-thermistor assembly Open the front-door assembly, and then remove one screw Remove the delivery fan Delivery fan112Remove the delivery fan 2 Removal and replacement Remove the delivery assembly Delivery assembly115Remove the delivery assembly 3 Removal and replacement Remove two screws 118Remove the delivery assembly 6 Remove the assembly 121Reinstall the delivery assembly 2 Reinstall the delivery assembly123Reinstall the delivery assembly 4 Removal and replacement Remove the duplex-drive assembly Duplex-drive assemblyRemove the power-supply fan Power-supply fanRemove the ICB Interconnect board ICB127Remove the ICB 2 Removal and replacement Remove the DC controller PCA only DC controller PCA onlyEnww Remove the low-voltage power supply Low-voltage power supply LvpsEnww 134Remove the low-voltage power supply 4 Enww Remove the DC controller PCA and tray DC controller PCA and trayRemove two screws Remove the high-voltage power supply lower High-voltage power supply lower HVPS-DRemove three screws 142Remove the high-voltage power supply lower 3 Release five tabs Reinstall the high-voltage power supply lower 146Remove the high-voltage power supply lower 7Remove the developing-disengagement motor Developing-disengagement motorRemove the exhaust fan and fan duct Exhaust fan and fan ductEnww 152Reinstall the exhaust fan and fan duct Reinstall the exhaust fan and fan ductRemove the pickup motor Pickup motorRemove the lifter-drive assembly Lifter-drive assemblyEnww Remove the lifter base assembly Lifter base assembly158Remove the lifter base assembly 2 Reinstall the lifter base assembly160Reinstall the lifter base assembly 2 Remove the tray-pickup drive assembly Tray-pickup drive assembly163Remove the tray-pickup drive assembly 3 Remove the tray-pickup assembly 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 176Remove the laser/scanner assembly Y/M 2 Remove the laser/scanner assembly Y/MEnww 179Remove the laser/scanner assembly Y/M 5 Laser/scanner assembly C/Bk 181Remove the laser/scanner assembly C/Bk 2 Remove the laser/scanner assembly C/BkEnww Reinstall the protective glass cleaner PGC actuators 184Remove the laser/scanner assembly C/Bk 5187Reinstall the PGC actuators 3 Removal and replacement 189Reinstall the PGC actuators 5 Remove the high-voltage power supply upper High-voltage power supply upper HVPS-T191Remove the high-voltage power supply upper 2 Reinstall the high-voltage power supply upper Remove the yellow, magenta, cyan, and black drum motors Yellow, magenta, cyan, and black drum motorsFuser motor 194Remove the fuser motor Remove the fuser motorRemove the ITB motor ITB motorMain-drive assembly 197Remove the main-drive assembly 2 Removal and replacement Remove the main-drive assembly198Remove the main-drive assembly 3 Remove 10 screws Enww 203Reinstall the main-drive assembly 2 Reinstall the main-drive assemblyEnww 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 Reinstall the fuser-drive assembly 215Remove the fuser-drive assembly 7Front door optional paper feeder Enww Rear cover optional paper feeder 220Remove the right-front cover optional paper feeder Right-front cover optional paper feederRight door optional paper feeder Enww Remove the left cover optional paper feeder Left cover optional paper feederEnww Remove the right cover optional paper feeder Right cover optional paper feederRemove the rear-right cover optional paper feeder Rear-right cover optional paper feederRemove the pickup assembly optional paper feeder Pickup assembly optional paper feeder231Remove the pickup assembly optional paper feeder 3 Enww Remove the lifter assembly optional paper feeder Lifter assembly optional paper feederRemove the lifter-drive assembly optional paper feeder Lifter-drive assembly optional paper feederRemove the pickup motor optional paper feeder assembly Pickup motor assembly optional paper feederRemove the controller PCA optional paper feeder Controller PCA optional paper feederSolve problems Solve problems checklist Solve problems checklist Print a menu map Menu mapDetermine the problem source Troubleshooting processPre-troubleshooting checklist 1Pre-troubleshooting checklistCalibrate the product on 2Troubleshooting flowchart Troubleshooting flowchartPower on Event log Information pages Image quality InterfacePower-on checks Power subsystemPower-on troubleshooting overview Power-on timing approximateEnww Individual component diagnostics Tools for troubleshootingLED diagnostics Understand lights on the formatterDefeating interlocks Engine diagnosticsHeartbeat LED Engine-test button Disable cartridge check3Engine-test button Paper-path testDefault state of bits 3Manual sensor diagnostic testsSensor 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 16 Media sensor Media sensorFront-door switch Right-door switch Manual sensor test 2 special-mode test 5Manual sensor test 2 diagnostic testsTest 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 present sensor Tray 3 paper size switchesTray 3 feed sensor Tray 3 paper surface 1 and 2 sensorsTray 5 paper size switches Tray 4 paper size switchesTray 5 paper present sensor Tray 5 feed sensorEnww Defeating Enww Enww 25Test the new ITB sensor New ITB sensor26Test the right door switch Solve problems Tray 3, 4, and 5 right door switchPaper-path sensors test 7Paper-path sensors diagnostic testsPrint/stop test Sensor name Sensor number8Component test details Component testsComponent test special-mode test Fuser Motor Yellow Laser ScannerFuser Pressure Release Motor Alienation MotorRepeat Duplex Refeed Clutch SolenoidBlock diagrams Diagrams28Optional paper feeder 1 x 500-sheet 29Optional paper feeder 3 x 500-sheet 9Formatter PCA Plug/jack locationsDC controller connector locations Location of connectors10DC controller connectors 11Controller PCA connectors 32Controller PCA connectors33External component locations Locations of major components34Major component locations 1 35Major component locations 2 36Major component locations 3 Ite Description 11 938PCA 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 Timing chart General timing chartGeneral circuit diagram 1 Circuit diagramsControl Paper feeder circuit diagram 1 X 500-sheet Paper feeder circuit diagram 3 X 500-sheet HP Easy Printer Care software sections HP Easy Printer CareOpen the HP Easy Printer Care software Section Options Support tab Settings tabHP Proactive Support Overview and Support tabsColor Access Control Section Options Alert Settings linkInternal print-quality test pages Print-quality-troubleshooting pagesYellow Green 51Black print-quality troubleshooting Diagnostics DiagnosticsCreate and use the cleaning CleaningConfiguration ConfigurationMemory Event log Security Paper trays and options HP embedded Jetdirect Security Settings information54 Embedded protocol Embedded protocolColor-band test Finding important information on the configuration pages12Important information on the configuration pages Repetitive defects ruler Print-quality troubleshooting toolsCalibrate the product Control panel menus Control panel menusShow Me How menu Retrieve job menuEnww ALL Jobs no PIN Print When Print or Print and Delete isHold jobs, Print and Delete is DeletePaper handling menu Information menuManage supplies menu Continue Color Cartridges StopPrint in Black Transfer KIT StopMagenta Cartridge User Defined LOW Yellow CartridgeCyan Cartridge Black Cartridge Transfer KITPrinting menu Configure device menuDefault Custom Paper Unit of Measure Default Paper SizeSize Dimension Print PS Errors OFFPCL sub-menu Print Quality menu X1 Shift Mode ExpandedY1 Shift X2 ShiftPrint Mode Adjust PaperRestore Optimize NOW DelayCleaning Auto Cleaning OFFAuto Cleaning Letter Edge Control OFFProcess Select the Create CleaningCreate System setup menu Disabled PS Defer Media EnabledUSE Requested Tray Exclusively FirstLetterhead Mode OFF USE Another Tray EnabledSleep Delay Minute AlternativeCustom Wake TimeOptimum SPEED/ENERGY Faster First Usage Save EnergyAuto Continue OFF JAM Recovery AutoRAM Disk Auto Language13Embedded Jetdirect menu MenuSettings Subnet Mask IPV4 Settings Config Method BootpDefault Default IP Auto IPSettings IPV6 Settings EnableDhcp Renew Primary DNSIPX/SPX Enable Idle TimeoutAppletalk Enable OFF DLC/LLC EnableReset DisableReset Security YES Diagnostics Embedded TestsData Path Test YES Snmp Test YESSelect ALL YES TestsPing Results Print Results YESPackets Sent PacketsLink Speed Auto 10T Half 10T Full 100TX Half 100TX Full Refresh YESDiagnostics menu Resets menuPaper Path Test Paper Path SensorsSource ALL Trays TrayProduct PINs Service menuVoltage power supply Color Band Test Print TestControl-panel message types Interpret control-panel messagesControl-panel messages XX values13.XX.YY Fuser Wrap JAM 13.XX.YY Fuser Area JAM13.XX.YY JAM Above TOP Output BIN 13.XX.YY JAM in Lower Right DoorEmbedded I/O Buffer Overflow Transfer Unit ErrorParallel I/O Buffer Overflow Parallel Serial BufferTo continue turn off then on Xxxx ErrorFuser Error See Fuser on 55.XX.YY DC Controller Error XY ErrorXX Error See DC controller PCA and tray ErrorDescription Recommended action Error BO Cleaning Motor Error 59.A0 Error59.C0 Error Replace Toner Collection Unit59.F0 Error Permanent Storage Full ValuesNo System 8X.YYYY EIO Error Storage Error Settings8X.YYYY Embedded Jetdirect Error ChangedBlack Cartridge LOW Calibration Reset PendingBlack Cartridge LOW Less than Xxxx Pages Black Cartridge Very LOWCard Slot Device Failure Cleaning Disk X% CompleteCard Slot File Operation Failed Card Slot File System is FullClose Lower Right Door Cleaning Cyan Cartridge LOWClose Right Door Collection Unit Almost FullData Received Cyan Cartridge Very LOWDATE/TIME = YYYY/MMMM/DD Hhmm EIO X Disk InitializingEIO is Write Protected HP Secure Drive DisabledEIO not Initialized Expected Drive MissingInstall Fuser Install Color CartridgeInstall Supplies Install Transfer UnitMedia insert required in tray Magenta Cartridge LOW Loading ProgramMagenta Cartridge LOW Less than Xxxx Pages Magenta Cartridge Very LOWMoving Solenoid NON HP Supply InstalledMoving Solenoid and Motor Printing StoppedRAM Disk File Operation Failed RAM Disk Device FailureRAM Disk File System is Full RAM Disk is Write ProtectedRemove Shipping Sheet Replace Supplies Using black onlyReplace Color Cartridge Replace Fuser KITROM Disk Device Failure Replace Transfer KITROM Disk File System is Full ROM Disk File Operation FailedROM Disk is Write Protected Sanitizing Disk X% CompleteManage Supplies menu on Supplies LOWPrinting Black only Supplies Very LOWToner Collection Unit Very LOW Toner Collection Unit LOWTransfer KIT LOW Transfer KIT LOW Less than Xxxx PagesTray X Empty Type Size Tray X Type SizeTray X Open Tray X OverfilledUnsupported Supply Installed Unsupported Drive InstalledUSB Accessory Error USB Accessory not FunctionalWaiting for Tray X to Lift Wait for Printer to ReinitializeWarming UP Yellow Cartridge LOWYellow Cartridge Very LOW To continue press OK Yellow Cartridge Very LOWShow an event log Event log messagesPrint an event log Clear the event log Sample event logEvent log message Description Comments Event log message tableQuick Calibrate NOW, Configure DEVICE, and thenThen press theOK button DC controller Nvrm is not Reading the header number and size 99.00.08 Product is jammed Clear paper jamsCommon causes of jams ITB Jam code 15Common causes of jams by areaJam locations Type of jam Procedure13.XX.YY JAM in Optional Trays Clear jams in the right doorEnww Enww Clear jams in Tray Clear jams in the output bin areaEnww 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 fuser and transfer area Jam causes and solutionsJams in the output bin 19Causes and solutions for fuser delivery stationary jams 21Causes and solutions for pickup delay jams 20Causes and solutions for residual media jams24Causes and solutions for duplex repick jams 22Causes and solutions for pickup stationary jams23Causes and solutions for duplexing reverse jams Right-door assembly on 25Causes and solutions for residual media jamsJams in Tray 1, Tray 2 and internal paper path 26Causes and solutions for pickup delay jam 1 tray pickupJams in Tray 3, 4, 27Causes and solutions for pickup stationary jams29Causes and solutions for residual media jams Set the jam recovery feature Change jam recoveryProduct feeds multiple sheets Solve paper-handling problemsProduct feeds incorrect page size Product pulls from incorrect trayPaper does not feed from Tray 2, 3, 4, or Paper does not feed automaticallyPaper does not feed automatically Paper does not feed from Tray 2, 3, 4, orEnvelopes jam or will not feed in the product Transparencies or glossy paper will not feedTransparencies or glossy paper will not feed Envelopes jam or will not feed in the productOutput is curled or wrinkled Output is curled or wrinkledProduct will not duplex or duplexes incorrectly Properties or Printing Preferences Under Installable Options, click Update NowAutomatic Configuration list Use manual print modes 30MP modes under the Adjust Paper Types sub menuPRE-ROTATION Mode 31MP modes under the Optimize submenu Image defects table Solve image-quality problemsProblem Sample Cause Solution 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 product Clean the productClean the paper path Problem Cause Solution Solve performance problemsSolve network problems Solve connectivity problemsSolve direct-connect problems Solve connectivity problems Service menu Service mode functionsSerial Number Refurbish page CountRefurbish Cycle Count Cold Reset Paper Service IDNEW Registration Roller Media Sensor ValueRestore factory-set defaults Product resetsHard disk initialization optional Nvram initializationProduct cold reset Product updatesParts and diagrams Order parts, accessories, and supplies Part numbers AccessoriesPrint cartridges and toner collection unit MemoryCustomer self repair CSR parts Service maintenance kits1Maintenance kits 3Simplex and duplex unique components Unique components2110V and 220V unique components 4Common fasteners ScrewsHow to use the parts lists and diagrams 1External covers, panels, and doors External covers, panels, and doorsDescription Part number Qty 5External covers, panels, and doors2Right door assembly Right door assembly6Right door assembly Front door assembly 7Front door assembly Internal components 1 Internal components8Internal components 1 Internal components 2 9Internal components 2 6Internal components 3 Internal components 310Internal components 3 Internal components 4 11Internal components 4 8Internal components 5 Internal components 512Internal components 5 Simplex Model Duplex Model Internal components 613Internal components 6 10Internal components 7 Internal components 714Internal components 7 Cassettes Cassettes15 Cassette Paper pickup assembly 16Paper pickup assembly 13Tray 1 paper pickup assembly Tray 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 18 PCAs PCAs22 PCAs Paper feeders AssessoriesPaper feeders 23Paper feeders 1x500 3x500 Paper feeder external covers, panels, and doors24Paper 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 27Alphabetical parts list Alphabetical 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 28Numerical parts list Numerical 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 Transfer End User License AgreementEnww Customer self-repair warranty service Customer support Product specifications Performance specifications Physical specificationsElectrical specifications Table B-1Product dimensionsEnvironmental specifications Acoustic specificationsTable B-3Power requirements Table B-4Power consumption average, in watts1246Table B-6Media registration and image placement accuracy Skew specificationsRegulatory information FCC regulations Environmental product stewardship program Paper Return and recycling instructionsUnited States and Puerto Rico Non-U.S. returnsHP Color LaserJet Enterprise CP4020-CP4520 Series Material restrictionsChemical substances Material Safety Data Sheet Msds For more information Declaration of Conformity Laser safety Safety statementsVcci statement Japan Power cord instructions Power cord statement JapanVaroitus GS statement Germany Cabinet/stand Symbols/NumericsDhcp See also jams Nvram See also counts Enww Recycling Enww See also cassette Enww Page CC489-90936* *CC489-90936