HP Enterprise CC490A specs

HP Color LaserJet Enterprise CP4020- CP4520 Series Printers

Service Manual

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HP Enterprise CC490A manual HP Color LaserJet Enterprise CP4020- CP4520 Series Printers

Contents

Color Laserjet Enterprise CP4020/CP4520 Page HP Color LaserJet Enterprise CP4020- CP4520 Series Printers Trademark Credits Copyright and License Conventions 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 1Relationship between the main product systems Basic operation Sequence of operation 1Sequence of operationPeriod Duration Description 2Engine-control system Engine-control system DC controller SolenoidsComponent abbreviation Component name Clutches Switches Sensors Sensors Abbreviation Name Purpose Failure detection Motors Abbreviation Name Cooling area Type Speed Fans High-voltage power supply 7High-voltage power supply circuitsCircuit Description Biases for each color 8Converted DC voltages Low-voltage power supply Overcurrent/overvoltage protection SafetySleep powersave mode Low-voltage power supply failure Fuser control 9Fuser componentsType of component Abbreviation Name Function Fuser sleeve temperature protection Fuser temperature control Failure detection Fuser unit life detection Fuser unit identification 8Laser/scanner system Laser/scanner system Laser/scanner failure Protective-glass cleaners 9Protective-glass cleaners PGCs Theory of operation ITB Image-formation system 11Image-formation drive system Functional block Steps Description Image-formation process Primary charging Pre-exposure Development Laser-beam exposure Secondary transfer Primary transfer Separation Fusing ITB cleaning Drum cleaningPrint cartridge 23Print-cartridge system Developing-roller engagement and disengagement 25 ITB unit Intermediate transfer belt ITB unit 10Primary-transfer-roller engagement states Primary-transfer-roller engagement and disengagement SL1 Calibration 27ITB cleaning process Image-stabilization control Color-misregistration control 11Image-stabilization controls 29 Paper path Pickup, feed, and delivery system Component Abbreviation Component 32Three main units of the pickup, feed, and delivery system Cassette pickup Pickup-and-feed unit Top switch Center switch Bottom switch Cassette-presence detectionPaper size Cassette multiple-feed prevention 35Cassette lift mechanism 36Multiple-feed prevention Multipurpose tray pickup 37Multipurpose tray pickup mechanism Paper feed 38Paper-feed mechanism Paper detection Skew-feed prevention Duplex printing Fusing and delivery unit14Print mode and feed speed Simplex printing 40Fuser and delivery unit Loop control 41Loop-control mechanism 42Pressure-roller pressurization control Pressure-roller pressurization control 43Duplexing unit Duplexing reverse and feed control Duplex reverse and feed control Duplex print operation Enww 45Jam detection sensors Jam detection Jam Description 16Jams that the product detects 461 x 500 optional paper feeder Optional paper feeder 473 x 500-sheet optional paper feeder Component Drives Failure detection Motor control17Electrical components for the paper feeder Component Abbreviation Component name Type 18Pickup feed components 1 x 500-sheet paper feeder Paper-feeder pickup and feed operation SW2 SW3 SW4 OFF Paper-size detection and cassette-presence detection SR2/SR8/SR9 Paper-feeder cassette lift operation 51Jam detection 1 x 500-sheet paper feeder Paper feeder jam detection 52Jam detection 3 x 500-sheet paper feeder Enww Removal and replacement Introduction Removal and replacement strategy Required tools Electrostatic discharge After performing service Before performing service Print-quality test Post-service test Parts removal order 2Parts removal order 1 Removal and replacement 3Parts removal order 2 Print cartridges Customer self repair CSR components 5Remove the print cartridge 2 Toner-collection unit 7Remove the toner-collection unit 2 Removal and replacement 8Remove the toner-collection unit 3 ESD sensitive component Formatter PCA Hard drive Remove the hard driveBefore proceeding, remove the following components 13Remove the hard drive 3 Removal and replacement Remove the memory Dimm Memory Dimm Next to Automatic Configuration , select Update Now Enable memoryClick Settings Click the Device Settings tab Windows Next to Automatic Configuration, select Update NowInstallable Options area Click the Installable Options menu Tray 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 roller Intermediate transfer belt ITB 32Remove the intermediate transfer belt 3 Enww Identification and location External panels, covers, and doors 35Remove the upper-left cover 1 Remove one screw Upper-left cover 37Remove the upper-left cover 3 38Remove the power-supply cover Removal and replacement Power-supply cover Remove the left cover Left cover Remove the front-top cover Front-top cover 43Remove the front-top cover 3 Remove the rear-top cover Rear-top cover Remove the right-front cover Right-front cover Reinstall the power button Remove the control-panel assembly Control-panel assembly Enww Remove the front-door assembly Front-door assembly 53Remove the front-door assembly 2 Remove two screws callout 55Remove the front-door assembly 4 Remove the right-rear cover Right-rear cover 58Remove the right-rear cover 2 Remove the rear cover Rear cover 61Remove the right-door assembly 2 Right-door assembly 63Remove 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 assemblies 72Remove the secondary transfer assembly 2 Secondary transfer assembly Reinstall the secondary transfer assembly Remove the separation pad Tray Separation pad Tray 78Remove the separation pad 4 Removal and replacement Enww Remove the RD sensor assembly Registration density RD sensor assembly 84Remove 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 assembly 91Remove 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 motor Remove the residual-toner duct and feed assembly Residual-toner duct and feed assembly 99Remove the residual-toner duct and feed assembly 3 Enww Remove the cartridge fan and environmental sensor Cartridge fan and environmental sensor Enww Enww Enww Toner-collection sensor and scanner-thermistor assembly Open the front-door assembly, and then remove one screw Remove the delivery fan Delivery fan 112Remove the delivery fan 2 Removal and replacement Remove the delivery assembly Delivery assembly 115Remove 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 assembly 123Reinstall the delivery assembly 4 Removal and replacement Remove the duplex-drive assembly Duplex-drive assembly Remove the power-supply fan Power-supply fan Remove the ICB Interconnect board ICB 127Remove the ICB 2 Removal and replacement Remove the DC controller PCA only DC controller PCA only Enww Remove the low-voltage power supply Low-voltage power supply Lvps Enww 134Remove the low-voltage power supply 4 Enww Remove the DC controller PCA and tray DC controller PCA and tray Remove two screws Remove the high-voltage power supply lower High-voltage power supply lower HVPS-D Remove 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 7 Remove the developing-disengagement motor Developing-disengagement motor Remove the exhaust fan and fan duct Exhaust fan and fan duct Enww 152Reinstall the exhaust fan and fan duct Reinstall the exhaust fan and fan duct Remove the pickup motor Pickup motor Remove the lifter-drive assembly Lifter-drive assembly Enww Remove the lifter base assembly Lifter base assembly 158Remove the lifter base assembly 2 Reinstall the lifter base assembly 160Reinstall the lifter base assembly 2 Remove the tray-pickup drive assembly Tray-pickup drive assembly 163Remove the tray-pickup drive assembly 3 Remove the tray-pickup assembly Tray-pickup assembly Enww 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/M Enww 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/Bk Enww Reinstall the protective glass cleaner PGC actuators 184Remove the laser/scanner assembly C/Bk 5 187Reinstall 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-T 191Remove 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 motors Fuser motor 194Remove the fuser motor Remove the fuser motor Remove the ITB motor ITB motor Main-drive assembly 197Remove the main-drive assembly 2 Removal and replacement Remove the main-drive assembly 198Remove the main-drive assembly 3 Remove 10 screws Enww 203Reinstall the main-drive assembly 2 Reinstall the main-drive assembly Enww 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 7 Front door optional paper feeder Enww Rear cover optional paper feeder 220Remove the right-front cover optional paper feeder Right-front cover optional paper feeder Right door optional paper feeder Enww Remove the left cover optional paper feeder Left cover optional paper feeder Enww Remove the right cover optional paper feeder Right cover optional paper feeder Remove the rear-right cover optional paper feeder Rear-right cover optional paper feeder Remove the pickup assembly optional paper feeder Pickup assembly optional paper feeder 231Remove the pickup assembly optional paper feeder 3 Enww Remove the lifter assembly optional paper feeder Lifter assembly optional paper feeder Remove the lifter-drive assembly optional paper feeder Lifter-drive assembly optional paper feeder Remove the pickup motor optional paper feeder assembly Pickup motor assembly optional paper feeder Remove the controller PCA optional paper feeder Controller PCA optional paper feeder Solve problems Solve problems checklist Solve problems checklist Print a menu map Menu map 1Pre-troubleshooting checklist Troubleshooting processDetermine the problem source Pre-troubleshooting checklist Calibrate the product on Event log Information pages Image quality Interface Troubleshooting flowchart2Troubleshooting flowchart Power on Power-on timing approximate Power subsystemPower-on checks Power-on troubleshooting overview Enww Understand lights on the formatter Tools for troubleshootingIndividual component diagnostics LED diagnostics Engine diagnostics Heartbeat LEDDefeating interlocks Engine-test button Disable cartridge check 3Engine-test button Paper-path test Manual sensor test special-mode test 3Manual sensor diagnostic testsDefault state of bits Sensor or switch name Sensor or switch number TOP 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 sensor Front-door switch Right-door switch Manual sensor test 2 special-mode test 5Manual sensor test 2 diagnostic tests Test 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 surface 1 and 2 sensors Tray 3 paper size switchesTray 3 paper present sensor Tray 3 feed sensor Tray 5 feed sensor Tray 4 paper size switchesTray 5 paper size switches Tray 5 paper present sensor Enww Defeating Enww Enww 25Test the new ITB sensor New ITB sensor 26Test the right door switch Solve problems Tray 3, 4, and 5 right door switch Sensor name Sensor number 7Paper-path sensors diagnostic testsPaper-path sensors test Print/stop test Component tests Component test special-mode test8Component test details Alienation Motor Yellow Laser ScannerFuser Motor Fuser Pressure Release Motor Repeat Duplex Refeed Clutch Solenoid Block diagrams Diagrams 28Optional paper feeder 1 x 500-sheet 29Optional paper feeder 3 x 500-sheet 9Formatter PCA Plug/jack locations DC controller connector locations Location of connectors 10DC controller connectors 11Controller PCA connectors 32Controller PCA connectors 33External component locations Locations of major components 34Major component locations 1 35Major component locations 2 36Major component locations 3 Ite Description 11 9 38PCA 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 chart General circuit diagram 1 Circuit diagrams Control 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 Overview and Support tabs Settings tabSection Options Support tab HP Proactive Support Color Access Control Section Options Alert Settings link Internal print-quality test pages Print-quality-troubleshooting pages Yellow Green 51Black print-quality troubleshooting Diagnostics Diagnostics Create and use the cleaning Cleaning Configuration Configuration Memory Event log Security Paper trays and options HP embedded Jetdirect Security Settings information 54 Embedded protocol Embedded protocol Finding important information on the configuration pages 12Important information on the configuration pagesColor-band test Repetitive defects ruler Print-quality troubleshooting tools Calibrate the product Retrieve job menu Control panel menusControl panel menus Show Me How menu Enww Delete When Print or Print and Delete isALL Jobs no PIN Print Hold jobs, Print and Delete is Paper handling menu Information menu Manage supplies menu Transfer KIT Stop Color Cartridges StopContinue Print in Black Black Cartridge Transfer KIT User Defined LOW Yellow CartridgeMagenta Cartridge Cyan Cartridge Printing menu Configure device menu Print PS Errors OFF Default Paper SizeDefault Custom Paper Unit of Measure Size Dimension PCL sub-menu Print Quality menu X2 Shift Mode ExpandedX1 Shift Y1 Shift NOW Delay Adjust PaperPrint Mode Restore Optimize Edge Control OFF Auto Cleaning OFFCleaning Auto Cleaning Letter Select the Create Cleaning CreateProcess System setup menu First PS Defer Media EnabledDisabled USE Requested Tray Exclusively Alternative USE Another Tray EnabledLetterhead Mode OFF Sleep Delay Minute Usage Save Energy Wake TimeCustom Optimum SPEED/ENERGY Faster First Language JAM Recovery AutoAuto Continue OFF RAM Disk Auto 13Embedded Jetdirect menu Menu Default IP Auto IP IPV4 Settings Config Method BootpSettings Subnet Mask Default Primary DNS IPV6 Settings EnableSettings Dhcp Renew OFF DLC/LLC Enable Idle TimeoutIPX/SPX Enable Appletalk Enable Diagnostics Embedded Tests DisableReset Reset Security YES Tests Snmp Test YESData Path Test YES Select ALL YES Packets Print Results YESPing Results Packets Sent Link Speed Auto 10T Half 10T Full 100TX Half 100TX Full Refresh YES Diagnostics menu Resets menu Tray Paper Path SensorsPaper Path Test Source ALL Trays Color Band Test Print Test Service menuProduct PINs Voltage power supply XX values Interpret control-panel messagesControl-panel message types Control-panel messages 13.XX.YY JAM in Lower Right Door 13.XX.YY Fuser Area JAM13.XX.YY Fuser Wrap JAM 13.XX.YY JAM Above TOP Output BIN Parallel Serial Buffer Transfer Unit ErrorEmbedded I/O Buffer Overflow Parallel I/O Buffer Overflow Xxxx Error Fuser ErrorTo continue turn off then on See Fuser on XY Error XX Error55.XX.YY DC Controller Error See DC controller PCA and tray Error Description Recommended action Error Replace Toner Collection Unit 59.A0 ErrorBO Cleaning Motor Error 59.C0 Error 59.F0 Error Values No SystemPermanent Storage Full Changed Storage Error Settings8X.YYYY EIO Error 8X.YYYY Embedded Jetdirect Error Black Cartridge Very LOW Calibration Reset PendingBlack Cartridge LOW Black Cartridge LOW Less than Xxxx Pages Card Slot File System is Full Cleaning Disk X% CompleteCard Slot Device Failure Card Slot File Operation Failed Collection Unit Almost Full Cleaning Cyan Cartridge LOWClose Lower Right Door Close Right Door EIO X Disk Initializing Cyan Cartridge Very LOWData Received DATE/TIME = YYYY/MMMM/DD Hhmm Expected Drive Missing HP Secure Drive DisabledEIO is Write Protected EIO not Initialized Install Transfer Unit Install Color CartridgeInstall Fuser Install Supplies Media insert required in tray Magenta Cartridge Very LOW Loading ProgramMagenta Cartridge LOW Magenta Cartridge LOW Less than Xxxx Pages Printing Stopped NON HP Supply InstalledMoving Solenoid Moving Solenoid and Motor RAM Disk is Write Protected RAM Disk Device FailureRAM Disk File Operation Failed RAM Disk File System is Full Replace Fuser KIT Replace Supplies Using black onlyRemove Shipping Sheet Replace Color Cartridge ROM Disk Device Failure Replace Transfer KIT Sanitizing Disk X% Complete ROM Disk File Operation FailedROM Disk File System is Full ROM Disk is Write Protected Supplies Very LOW Supplies LOWManage Supplies menu on Printing Black only Transfer KIT LOW Less than Xxxx Pages Toner Collection Unit LOWToner Collection Unit Very LOW Transfer KIT LOW Tray X Overfilled Tray X Type SizeTray X Empty Type Size Tray X Open USB Accessory not Functional Unsupported Drive InstalledUnsupported Supply Installed USB Accessory Error Yellow Cartridge LOW Wait for Printer to ReinitializeWaiting for Tray X to Lift Warming UP Yellow Cartridge Very LOW To continue press OK Yellow Cartridge Very LOW Event log messages Print an event logShow an event log Clear the event log Sample event log Event log message Description Comments Event log message table Quick Calibrate NOW, Configure DEVICE, and then 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 Jam code 15Common causes of jams by area Jam locations Type of jam Procedure 13.XX.YY JAM in Optional Trays Clear jams in the right door Enww Enww Clear jams in Tray Clear jams in the output bin area Enww 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 21Causes and solutions for pickup delay jams 20Causes and solutions for residual media jams 22Causes and solutions for pickup stationary jams 23Causes and solutions for duplexing reverse jams24Causes and solutions for duplex repick jams Right-door assembly on 25Causes and solutions for residual media jams Jams in Tray 1, Tray 2 and internal paper path 26Causes and solutions for pickup delay jam 1 tray pickup Jams in Tray 3, 4, 27Causes and solutions for pickup stationary jams 29Causes and solutions for residual media jams Set the jam recovery feature Change jam recovery Product pulls from incorrect tray Solve paper-handling problemsProduct feeds multiple sheets Product feeds incorrect page size Paper does not feed from Tray 2, 3, 4, or Paper does not feed automaticallyPaper does not feed from Tray 2, 3, 4, or Paper does not feed automatically Envelopes jam or will not feed in the product Transparencies or glossy paper will not feedEnvelopes jam or will not feed in the product Transparencies or glossy paper will not feed Output 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 Problem Cause Solution Solve performance problems Solve connectivity problems Solve direct-connect problemsSolve network problems Solve connectivity problems Service menu Service mode functions Refurbish page Count Refurbish Cycle CountSerial Number Media Sensor Value Service IDCold Reset Paper NEW Registration Roller Nvram initialization Product resetsRestore factory-set defaults Hard disk initialization optional Product cold reset Product updates Parts and diagrams Order parts, accessories, and supplies Memory AccessoriesPart numbers Print cartridges and toner collection unit Service maintenance kits 1Maintenance kitsCustomer self repair CSR parts Unique components 2110V and 220V unique components3Simplex and duplex unique components 4Common fasteners Screws How to use the parts lists and diagrams 1External covers, panels, and doors External covers, panels, and doors Description Part number Qty 5External covers, panels, and doors 2Right door assembly Right door assembly 6Right door assembly Front door assembly 7Front door assembly Internal components 1 Internal components 8Internal components 1 Internal components 2 9Internal components 2 6Internal components 3 Internal components 3 10Internal components 3 Internal components 4 11Internal components 4 8Internal components 5 Internal components 5 12Internal components 5 Simplex Model Duplex Model Internal components 6 13Internal components 6 10Internal components 7 Internal components 7 14Internal components 7 Cassettes Cassettes 15 Cassette Paper pickup assembly 16Paper pickup assembly 13Tray 1 paper pickup assembly Tray 1 paper pickup assembly 17Tray 1 paper pickup assembly Simplex Model Duplex Model 18Registration assembly 15Secondary transfer assembly 19Secondary Transfer assembly 16Delivery assembly 20Delivery assembly Fuser assembly Fuser assembly 21Fuser assembly 18 PCAs PCAs 22 PCAs Assessories Paper feedersPaper feeders 23Paper feeders 1x500 3x500 Paper feeder external covers, panels, and doors 24Paper feeder external covers, panels, and doors 500 paper feeder main body 500 paper feeder main body 251 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 list Alphabetical 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 list RC2-4218-000CN 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 Agreement Enww Customer self-repair warranty service Customer support Product specifications Table B-1Product dimensions Physical specificationsPerformance specifications Electrical specifications Table B-4Power consumption average, in watts1246 Acoustic specificationsEnvironmental specifications Table B-3Power requirements Table B-6Media registration and image placement accuracy Skew specifications Regulatory information FCC regulations Environmental product stewardship program Non-U.S. returns Return and recycling instructionsPaper United States and Puerto Rico Material restrictions Chemical substancesHP Color LaserJet Enterprise CP4020-CP4520 Series Material Safety Data Sheet Msds For more information Declaration of Conformity Power cord statement Japan Safety statementsLaser safety Vcci statement Japan Power cord instructions Varoitus GS statement Germany Cabinet/stand Symbols/Numerics Dhcp See also jams Nvram See also counts Enww Recycling Enww See also cassette Enww Page CC489-90936* *CC489-90936