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HP CP4525DN Laser CC494A#ABA manual CC489-90936* *CC489-90936

Models: CP4525DN Laser CC494A#ABA

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CC489-90936 CC489-90936

CC489-90936

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HP CP4525DN Laser CC494A#ABA manual CC489-90936* *CC489-90936

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 a Service and support Appendix B Product specificationsAppendix 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 systemsSequence of operation 1Sequence of operationPeriod Duration Description Engine-control system 2Engine-control systemDC controller SolenoidsComponent abbreviation Component name Switches ClutchesSensors SensorsMotors Abbreviation Name Purpose Failure detectionFans Abbreviation Name Cooling area Type SpeedHigh-voltage power supply 7High-voltage power supply circuitsCircuit Description Biases for each color Low-voltage power supply 8Converted DC voltagesLow-voltage power supply failure SafetySleep powersave mode Overcurrent/overvoltage protectionFuser control 9Fuser componentsType 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 SeparationITB cleaning Drum 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 pickupTop switch Center switch Bottom switch Cassette-presence detectionPaper size 35Cassette lift mechanism Cassette multiple-feed preventionMultipurpose tray pickup 36Multiple-feed preventionPaper feed 37Multipurpose tray pickup mechanism38Paper-feed mechanism Skew-feed prevention Paper detectionSimplex printing Fusing and delivery unit14Print mode and feed speed 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 Component Abbreviation Component name Type Motor control17Electrical components for the paper feeder 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 componentHard drive Remove the hard driveBefore proceeding, remove the following components 13Remove the hard drive 3 Removal and replacement Memory Dimm Remove the memory DimmClick the Device Settings tab Enable memoryClick Settings Next to Automatic Configuration , select Update NowClick the Installable Options menu Next to Automatic Configuration, select Update NowInstallable Options area 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 mapPre-troubleshooting checklist Troubleshooting processDetermine the problem source 1Pre-troubleshooting checklistCalibrate the product on Power on Troubleshooting flowchart2Troubleshooting flowchart Event log Information pages Image quality InterfacePower-on troubleshooting overview Power subsystemPower-on checks Power-on timing approximateEnww LED diagnostics Tools for troubleshootingIndividual component diagnostics Understand lights on the formatterEngine diagnostics Heartbeat LEDDefeating interlocks Disable cartridge check Engine-test buttonPaper-path test 3Engine-test buttonSensor or switch name Sensor or switch number 3Manual sensor diagnostic testsDefault state of bits 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 feed sensor Tray 3 paper size switchesTray 3 paper present sensor Tray 3 paper surface 1 and 2 sensorsTray 5 paper present sensor Tray 4 paper size switchesTray 5 paper size switches 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 problemsPrint/stop test 7Paper-path sensors diagnostic testsPaper-path sensors test Sensor name Sensor numberComponent tests Component test special-mode test8Component test details Fuser Pressure Release Motor Yellow Laser ScannerFuser 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 HP Easy Printer Care Open the HP Easy Printer Care softwareHP Easy Printer Care software sections HP Proactive Support Settings tabSection Options Support tab 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 protocolFinding important information on the configuration pages 12Important information on the configuration pagesColor-band test Print-quality troubleshooting tools Repetitive defects rulerCalibrate the product Show Me How menu Control panel menusControl panel menus Retrieve job menuEnww Hold jobs, Print and Delete is When Print or Print and Delete isALL Jobs no PIN Print DeleteInformation menu Paper handling menuManage supplies menu Print in Black Color Cartridges StopContinue Transfer KIT StopCyan Cartridge User Defined LOW Yellow CartridgeMagenta Cartridge Black Cartridge Transfer KITConfigure device menu Printing menuSize Dimension Default Paper SizeDefault Custom Paper Unit of Measure Print PS Errors OFFPCL sub-menu Print Quality menu Y1 Shift Mode ExpandedX1 Shift X2 ShiftRestore Optimize Adjust PaperPrint Mode NOW DelayAuto Cleaning Letter Auto Cleaning OFFCleaning Edge Control OFFSelect the Create Cleaning CreateProcess System setup menu USE Requested Tray Exclusively PS Defer Media EnabledDisabled FirstSleep Delay Minute USE Another Tray EnabledLetterhead Mode OFF AlternativeOptimum SPEED/ENERGY Faster First Wake TimeCustom Usage Save EnergyRAM Disk Auto JAM Recovery AutoAuto Continue OFF LanguageMenu 13Embedded Jetdirect menuDefault IPV4 Settings Config Method BootpSettings Subnet Mask Default IP Auto IPDhcp Renew IPV6 Settings EnableSettings Primary DNSAppletalk Enable Idle TimeoutIPX/SPX Enable OFF DLC/LLC EnableReset Security YES DisableReset Diagnostics Embedded TestsSelect ALL YES Snmp Test YESData Path Test YES TestsPackets Sent Print Results YESPing Results PacketsRefresh YES Link Speed Auto 10T Half 10T Full 100TX Half 100TX FullResets menu Diagnostics menuSource ALL Trays Paper Path SensorsPaper Path Test TrayVoltage power supply Service menuProduct PINs Color Band Test Print TestControl-panel messages Interpret control-panel messagesControl-panel message types XX values13.XX.YY JAM Above TOP Output BIN 13.XX.YY Fuser Area JAM13.XX.YY Fuser Wrap JAM 13.XX.YY JAM in Lower Right DoorParallel I/O Buffer Overflow Transfer Unit ErrorEmbedded I/O Buffer Overflow Parallel Serial BufferXxxx Error Fuser ErrorTo continue turn off then on See Fuser on XY Error XX Error55.XX.YY DC Controller Error Error See DC controller PCA and trayDescription Recommended action Error 59.C0 Error 59.A0 ErrorBO Cleaning Motor Error Replace Toner Collection Unit59.F0 Error Values No SystemPermanent Storage Full 8X.YYYY Embedded Jetdirect Error Storage Error Settings8X.YYYY EIO Error ChangedBlack Cartridge LOW Less than Xxxx Pages Calibration Reset PendingBlack Cartridge LOW Black Cartridge Very LOWCard Slot File Operation Failed Cleaning Disk X% CompleteCard Slot Device Failure Card Slot File System is FullClose Right Door Cleaning Cyan Cartridge LOWClose Lower Right Door Collection Unit Almost FullDATE/TIME = YYYY/MMMM/DD Hhmm Cyan Cartridge Very LOWData Received EIO X Disk InitializingEIO not Initialized HP Secure Drive DisabledEIO is Write Protected Expected Drive MissingInstall Supplies Install Color CartridgeInstall Fuser Install Transfer UnitMedia insert required in tray Magenta Cartridge LOW Less than Xxxx Pages Loading ProgramMagenta Cartridge LOW Magenta Cartridge Very LOWMoving Solenoid and Motor NON HP Supply InstalledMoving Solenoid Printing StoppedRAM Disk File System is Full RAM Disk Device FailureRAM Disk File Operation Failed RAM Disk is Write ProtectedReplace Color Cartridge Replace Supplies Using black onlyRemove Shipping Sheet Replace Fuser KITReplace Transfer KIT ROM Disk Device FailureROM Disk is Write Protected ROM Disk File Operation FailedROM Disk File System is Full Sanitizing Disk X% CompletePrinting Black only Supplies LOWManage Supplies menu on Supplies Very LOWTransfer KIT LOW Toner Collection Unit LOWToner Collection Unit Very LOW Transfer KIT LOW Less than Xxxx PagesTray X Open Tray X Type SizeTray X Empty Type Size Tray X OverfilledUSB Accessory Error Unsupported Drive InstalledUnsupported Supply Installed USB Accessory not FunctionalWarming UP Wait for Printer to ReinitializeWaiting for Tray X to Lift Yellow Cartridge LOWYellow Cartridge Very LOW Yellow Cartridge Very LOW To continue press OKEvent log messages Print an event logShow 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 Clear paper jams Common causes of 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 Jam causes and solutions Jams in the output binJams 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 jams22Causes and solutions for pickup stationary jams 23Causes and solutions for duplexing reverse 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 featureProduct feeds incorrect page size Solve paper-handling problemsProduct feeds multiple sheets Product pulls from incorrect trayPaper does not feed automatically Paper does not feed automaticallyPaper does not feed from Tray 2, 3, 4, or Paper does not feed from Tray 2, 3, 4, orTransparencies or glossy paper will not feed Transparencies or glossy paper will not feedEnvelopes jam or will not feed in the product Envelopes jam or will not feed in the productOutput is curled or wrinkled Product will not duplex or duplexes incorrectlyOutput is curled or wrinkled Under Installable Options, click Update Now Automatic Configuration listProperties or Printing Preferences 30MP modes under the Adjust Paper Types sub menu PRE-ROTATION ModeUse manual print modes 31MP modes under the Optimize submenu Solve image-quality problems Problem Sample Cause SolutionImage 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 product Clean the paper pathClean the product Solve performance problems Problem Cause SolutionSolve connectivity problems Solve direct-connect problemsSolve network problems Solve connectivity problems Service mode functions Service menuRefurbish page Count Refurbish Cycle CountSerial Number NEW Registration Roller Service IDCold Reset Paper Media Sensor ValueHard disk initialization optional Product resetsRestore factory-set defaults Nvram initializationProduct updates Product cold resetParts and diagrams Order parts, accessories, and supplies Print cartridges and toner collection unit AccessoriesPart numbers MemoryService maintenance kits 1Maintenance kitsCustomer self repair CSR parts Unique components 2110V and 220V 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 Assessories Paper feedersPaper 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 Electrical specifications Physical specificationsPerformance specifications Table B-1Product dimensionsTable B-3Power requirements Acoustic specificationsEnvironmental specifications Table B-4Power consumption average, in watts1246Skew specifications Table B-6Media registration and image placement accuracyRegulatory information FCC regulations Environmental product stewardship program United States and Puerto Rico Return and recycling instructionsPaper Non-U.S. returnsMaterial restrictions Chemical substancesHP Color LaserJet Enterprise CP4020-CP4520 Series Material Safety Data Sheet Msds For more information Declaration of Conformity Vcci statement Japan Power cord instructions Safety statementsLaser safety 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