HP Color LaserJet CP4025 manual

COL OR L A SERJET ENTERP RISE CP4020/CP4520 SERIES PRINTER CP40 2 5n CP40 2 5dn CP4 5 2 5n CP4 5 2 5dn CP4 5 2 5xh Service Manual[...]

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HP Color LaserJet Enterprise CP4020- CP4520 Series Printers Service Manua l[...]

Copyright and License © 2009 Copyright Hewlett-Packard Development C ompany, L.P. Reproduction, adaptation, or translation without prior written permission is prohibited, except as a llowed under the copyright laws. The information contained herein is subject to change without notice. The only warranties for HP product s and services are set forth[...]

Conventions u sed in this g uide TIP: Tips provi de helpful hi nts or shortcu ts. NOT E: Notes prov ide importa nt inform ation to exp lain a conc ept or to c omplete a task. CAUTION: Ca utions indi cate proced ures that y ou should follow to av oid losing data or damaging t he prod uct. WARNING! Warnings alert you to spec ific proc edures that you[...]

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Table of contents 1 Theor y of operat ion Basic opera tion ...................... .................. ......................... ................... .................. ......... ...................... 2 Sequence o f operation ....... ................ ........................ ................. .................. ................. ...... 3 Engine-cont [...]

Step 6: Secondary transfer ...... ...................... ............... ................ ............... ..... 26 Step 7: Separation ...... ........ ....... ........... ....... ........ .......... ........ ....... ........ ........... . 27 Step 8: Fusing ........ .............. ........... ........... ........... .............. ........... .......[...]

Before performi ng service ....... ........... .......... .............. .......... ........... .............. .......... ........... ... ............. 70 After perform ing service ............. .......... ........... .............. ........... .......... .............. ........... ........ ...... ......... 70 Post-service test ........... ........[...]

Cassette feed guide ....... .............. .............. .................. .............. ............. ................... ...... 1 18 Secondary t ransfer assembly ... ......... ......... ............ ......... ......... ........... ......... ......... .......... 11 9 Re inst all the secon dar y tr ans fer asse mbl y .... ..... ...... ..... ....[...]

Lifter-drive asse mbly .................. ...................... ................. .................. ...................... ....... 173 Remove the lifte r-drive assembly ..... .......... ....... ....... .......... ........ ....... ....... ....... 173 Lifter base assembly ..... ............. .......... ......... .......... ............. .......... [...]

Lifter-d rive assembly (optional pape r feeder) ..... ........ ....... ........ ....... ........ ....... ........ ....... . 230 Remove the li fter-drive ass embly (opti onal paper feeder ) .. ............................ 2 30 Pickup motor assemb ly (option al paper f eeder) ... ....... ....... ....... ....... ....... ........ ....... ....... . 231 [...]

S Tray 3 paper present sens or ....... .......... ....... ........ .......... ....... ...... 26 5 T Tray 3 fee d sensor ... ........ ....... ...... ...... ........ ....... ...... ........ ...... ..... 26 5 U Tr ay 3 pa per sur fac e 1 an d 2 se nsor s . ........ ..... ........ ..... ........ ..... 2 65 V Tray 3 paper size switches ....... .........[...]

Repetitive defe cts ruler ........ ....... ........ ......... ....... ........ ......... ....... ........ ......... ... 312 Calibrate the produ ct ................. ............ ................. ............ ............ ............ ..... 313 Control pane l menus ..... ................. ........................ ................ ..................[...]

Envelopes ja m or will not feed in the p roduct ....... ........... ............ ............ ............ ............ 405 Output is curled or wrinkled .......... ......... ......... ......... ............. ......... ......... ............ ......... .... 406 Product will not duplex or duplexes incorre ctly ................ ........... ............[...]

Internal compo nents (7 of 7) ................ .................. ............ .............. ................. .............. . 450 Cassettes 2-5 ........... ................. ........................ ................. ................. .................. ......... .. 452 Paper pickup assembly ............. ................. ................. ....[...]

Return and recycling i nstructions ................. ................. ................. ................. ................. 50 8 United S tates and Puert o Rico ......... ............. ........... ........... ................ ........... . 508 Multiple returns (more tha n one cartridge) ........ .......... ........ ....... .... 508 Single returns [...]

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List of tables Table 1-1 Sequence of op eration ........... ............. .................. ............ .............. ................. .......... ................ ........ 3 Table 1-2 Solenoid s .............. .......... .............. .......... ........... .............. .......... ........... .......... ... ........... .............. .......[...]

Table 3-17 Causes and solutions for fus er delivery del ay jams ...... .......... ........... .......... ........... .......... ....... .... 39 4 Table 3-18 Causes and solutions for wrapp ing jams .... ....... ......... ........ ........ ........ ........ ........ ........ ........ . ........ 39 4 Table 3-19 Causes and solutions for fuser deliver y[...]

Table B-2 Produ ct dimensions, with all doors an d trays fully opened ....... ......... .......... .......... .......... .......... ... . 502 Table B-3 Power requiremen ts ........................... .................... .................. .................... ............. .................... . 503 Table B- 4 Pow er consumptio n (averag e, in wat[...]

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List of figures Figure 1- 1 R elationship betw een the mai n product systems ....... ....... ...... ....... ...... ....... ...... ......... ....... ....... . ...... . 2 Figure 1- 2 Engi ne-control system ......... ............. .......... ......... ............. .......... ......... ............. ........ ..... ......... ......... . 4 Figure 1- 3 D[...]

Figure 1-3 5 Cas sette lift mec hanism ......... .................... ............... ................ .................... ........... .... ................ . 43 Figure 1-3 6 Mul tiple-feed p revention ........... .......................... ................... .................... .............. ............ .......... 44 Figure 1-37 Multipurp ose[...]

Figure 2- 27 Remove the tran sfer roller (2 of 3) .......... ................ ............ ........... ............ ................ .. .......... ....... 90 Figure 2- 28 Remove the tran sfer roller (3 of 3) .......... ................ ............ ........... ............ ................ .. .......... ....... 91 Figure 2- 29 Reinstall t he transf[...]

Figure 2-7 1 Remo ve the second ary transfer assembl y (1 of 3) .... ........ ......... ........... ......... ........ ........ .......... .. 119 Figure 2-7 2 Remo ve the second ary transfer assembl y (2 of 3) .... ........ ......... ........... ......... ........ ........ .......... .. 119 Figure 2-7 3 Remo ve the second ary transfer assembl y (3 [...]

Figure 2 -115 Remove t he delivery a ssembly (3 of 7) ....... ....... ....... ....... ....... ....... ...... ........ ....... ...... ....... ..... ... 146 Figure 2 -116 Remove t he delivery a ssembly (4 of 7) ....... ....... ....... ....... ....... ....... ...... ........ ....... ...... ....... ..... ... 147 Figure 2 -117 Remove t he delivery a sse[...]

Figure 2-1 59 Reinstall th e lifter base assembly (1 of 2) .. ............ .......... ................ .......... ............ ........ ... ........ 176 Figure 2-1 60 Reinstall th e lifter base assembly (2 of 2) .. ............ .......... ................ .......... ............ ........ ... ........ 177 Figure 2-1 61 Remove the t ray-pickup drive [...]

Figure 2- 203 Reinstall t he main-drive a ssembly (2 of 7) ............ ............... .............. ............. .............. ... ......... 207 Figure 2- 204 Reinstall t he main-drive a ssembly (3 of 7) ............ ............... .............. ............. .............. ... ......... 208 Figure 2- 205 Reinstall t he main-drive a ssembly [...]

Figure 3-6 Test t he loop se nsors .................. ........................... .................. .................... ................................. 248 Figure 3-7 Test t he fuser delivery sensor (1 of 2 ) ......... ......... ........... ........ ........ ........... ......... ........ ... ..... ........ . 249 Figure 3-8 Test t he fuser deli[...]

Figure 3- 50 Yellow compar ison page ..................... ................ ............... ............... ..................... .... ........... ...... 303 Figure 3-51 Black pr int-quality troubl eshooting page ....... ............ ............ .......... ............ ............ ......... ...... ..... 304 Figure 3- 52 Configuration page ... ...[...]

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1 Theory of operation ● Basi c operation ● Eng ine- cont rol sys tem ● Laser/scan ner system ● Image-for mation syst em ● Pickup, fee d, and deli very system ● Jam detecti on ● Optional paper fee der ENWW 1[...]

Basic operation The prod uct route s all high -level pr ocesses th rough the formatter, which s tores font informati on, process es the print image, and co mmunicat es with the host co mputer. The basi c product opera tion compris es the following s ystems: ● The engi ne-control s ystem, which i ncludes the power sup ply and the DC controller p r[...]

Sequence of operation The DC controller P CA control s the opera ting sequ ence, as de scribed i n the followi ng table . Table 1-1 Sequ ence of o peration Peri od Duration Description Waiting From the time the power is turned on, the door is closed, or when the product exits Sleep mode until t he product is ready for printing ● Heats the fuser s[...]

Engine-control system The en gine-con trol syst em rece ives comm ands fro m the for matter and i nteracts with th e other main system s to coor dinate all p roduct f unctions. T he engine- control s ystem consi sts of the followin g compon ents: ● DC controll er ● Low-volt age power suppl y ● High -vo lta ge pow er sup ply ● Fuse r contro [...]

DC controll er The DC controller c ontrols th e operati onal sequen ce of th e product. Figure 1-3 DC c ontro ller block diagr am Fuser High-volt age power supply T ITB unit AC input Low-voltage power supply Motor Solenoid Photointerrupter DC controller Laser scanner unit Formatter Switch Fan Sensor Print cartridge (Y/M/C/Bk) High-volt age power su[...]

Clutches Component abbreviation Component name CL1 Duplex re-pickup clutch (HP Color LaserJet CP4525dn, HP Color LaserJet CP4025dn, and HP Color LaserJe t CP4525xh only) Switches Table 1-3 Sw itches Component abbreviation Comp onent na me SW1 5V in terlo ck swi tc h SW2 24V i nter lock sw itch SW3 Power switch SW4 Cassette med ia size switch SW5 Fr[...]

Sensors Table 1-4 Se nsors Compo nent abbrev iati on C omponen t name NPLED Media sensor SR1 Yellow drum home position sensor SR2 Magenta drum home position sensor SR3 Cyan drum home pos ition sensor SR4 Black drum ho me position sensor SR5 Fuser delivery sensor SR6 Output bin full sensor SR7 Fuser pressur e release sensor SR8 MP-tray-media-presenc[...]

Motors The product has 13 motors. The motor s drive the compo nents in the paper- feed and image- formation system s. Table 1-5 M otors Abbreviation Name Purpos e Failure det ectio n M1 ITB mo tor Drives the ITB and residual toner feed screw Yes M2 Fuser mot or Drives the fu ser sleeve, pressure ro ller, fuser pressu re roller, and primary t ransfe[...]

The DC controller d etermine s if a motor has faile d and notifie s the for matter when it encounter s the foll owing conditi ons: ● Startup f ailure: the motor doe s not reac h a specifi ed speed wi thin a sp ecified tim e from when the motor s tarts. ● Rotational failure : the rotati onal sp eed of the motor is not in the s pecified ra nge fo[...]

High-voltage power supply The DC controller controls the high-v oltage pow er supply to genera te biases. The high- voltage pow er supply delivers the high-v oltage bias es to the following c omponents us ed to tran sfer ton er during th e image- formation pr ocess: ● Primar y-chargin g roller ( in the cart ridge) ● Developin g roller ( in the [...]

Circuit Description Primary-transfer-bias generation The primary transfer bias transfers th e toner from each photosensit ive drum onto the ITB. The primary transfer bias circuit in the high-v oltage power supply generates the biases f or each color. Secondary-transfer- bias generation The secondary transfer bias transfers the toner image from the [...]

Low-voltage power supply The low-v oltage power- supply circui t convert s the AC power from the wall receptacl e into the DC voltag e that the p roduct comp onents use. T he product h as two low -voltage powe r-supplies f or 110 Vo lt or 220 Volt in put. Figure 1-5 Low-v oltage p ower-suppl y circui t +3.3V 24RMT +24VA +12VA SW1 +5VC +24VB SW2 PWR[...]

Main DC vo ltage Sub-voltage Behavior +24 VB I nterrupted when the front door or right door open +5 V +5 VB Constantly supplied +5 VC Interrupted when the front door or right door open +3.3 V 3.3 V Constantly supplied 3.3 VS Stopped during Sleep (powersave) mode Overcurrent/ove rvoltage protection The low- voltage power su pply stops suppl ying the[...]

Fuser control The fus er heater-c ontrol circuit a nd the fus er heater saf ety circui t control t he fuser te mperatur e according to command s from the DC controll er. Figure 1-6 Fuser components H1 TH2 TH1 TP1 TH3 FUSER TEMPERATURE signal Pressure roller FUSER HEATER CONTROL signal Fuser sleeve Fuser heater control circuit Fuser heater safety ci[...]

Fuser temperature control The fuse r temperature co ntrol maintains the target surfa ce temperatur e of the fuser sleeve. Figure 1-7 Fus er tempera ture-contr ol circuit FSR TH3 FSR TH2 FSR TH1 FSRD1 TP1 /RLD TH3 TH2 TH1 CPU H1 FSRSAFE1 FSRSAFE2 FSR_CURRMS /ZEROX /FSRSNS /FSRNEW Fuser sleeve unit Fuser heater safety circuit DC controller Fuser Zero[...]

◦ Current de tection ci rcuit ◦ Therm oswitch ● DC controller : The DC contro ller monitor s the detected temper ature of the main thermi stor and sub ther mistors. The DC contr oller deactiv ates the FIXING HEAT ER CONTR OL signal and releases the relay to interrupt powe r supply to the fuser heater under the foll owing conditi ons: ◦ TH1:[...]

turned on, or if the det ected temperatu re of the thermistors doe s not rise to a specified tempe rature for a sp ecified tim e after th e fuser motor is t urned on. ● Thermistor open : The DC con trolle r determ ines a ther mistor ope n if: ◦ The dete cted temperat ure of TH1 is kept at 12° C (53° F) or lower for a specifi ed time a fter th[...]

Laser/sca nner syste m The lase r/scanner sy stem forms the lat ent electro static image on th e photo sensitive dr ums accord ing to the V IDEO signa ls sent fr om the forma tter. The p roduct has two laser/s canners: o ne for yel low and magenta and the ot her for cyan and bl ack. The ma in compo nents of th e laser/sc anner sys tem are the las e[...]

Laser/scanner failure The DC controller d etermine s that a las er/scanner h as failed wh en any of the follo wing con ditions occurs: ● Laser fa ilure : The detected las er intensity doe s not match a specifie d value when the product init ializes. ● Scanner mo tor startup f ailure : The scanner moto r does n ot reach a specified r otation w i[...]

Figure 1-9 Prote ctive-glas s cleaner s (PGC s) 20 Chapt er 1 Theo ry of oper ation ENWW[...]

Image-form ation system The i mage-format ion system c reates the p rinted imag e on the p aper. The system co nsists of the followi ng compon ents: ● Print ca rtri dges ● ITB ● Secon dary tran sfer rol ler ● Fuser ● Laser / scanner unit s The DC controller c ontrols th e laser sc anner unit and each of the high- voltage power supp lies t[...]

Figure 1-11 Image- formation dr ive system Fuser motor M2 ITB motor M1 M3 Developing rolle r Y drum motor M4 M drum motor M5 C drum motor M6 Bk drum motor Primary charging rolle r Developing rolle r Primary charging rolle r Developing rolle r Primary charging rolle r Developing rolle r Primary charging rolle r 22 Chapt er 1 Theo ry of oper ation EN[...]

Image-formation process The imag e-formation system consists of ten steps div ided into six fun ctional blo cks. Figure 1-12 Image-form ation process : Step : Block : Direction of drum rotation : Media path ITB cleaning 9. ITB cleaning Developing 4. Developing 5. Primary transfer 10. Drum cleaning Drum cleaning Latent image formation 1. Pre-exposur[...]

Step 1: P re-ex posur e Ligh t fro m the pre-expo sure LED stri kes the surf ace of the photose nsitive drum to remove any re sidual electr ical charges from the drum surface. Figure 1-13 Pre -exposu re Photosensitive drum LED Step 2: Primary cha rging The primar y-charging rol ler contacts the photo sensitive drum and charges the dr um with negati[...]

Step 3: Laser -beam e xposur e The l aser beam strikes th e surface of the phot osensitive drum in th e areas whe re the im age will fo rm. The negat ive charge neutr alizes in those ar eas, which are then read y to accept tone r. Figure 1-15 Laser-bea m exposure Laser beam Step 4: Develo pment Toner acqu ires a negative charg e as the developin g [...]

Step 5: Primary tra nsfer The posi tively charged prima ry-trans fer rollers contac t the ITB, giving the IT B a positive charge . The ITB attra cts the negatively cha rged toner from the su rface of each photos ensitive dru m, and the comple te toner ima ge transfers onto the ITB. Figure 1-17 Primary trans fer IT B Primary transfer bias Primary tr[...]

Step 7: Separa tion The s tiffness of the paper c auses it to separate from the ITB as the ITB bends. The s tatic-char ge elimin ator remov es excess charge from the paper t o make sur e that the toner fus es correctl y. Figure 1-19 Se paration IT B Secondary transfer rolle r Paper Secondary transfer opposed roller S t atic charge eliminator Step 8[...]

Step 9: ITB clean ing The c leaning bla de scrapes the resid ual toner o ff the surfac e of the ITB. The residu al toner f eed scre w deposit s residual toner in the toner collecti on box. Figure 1-21 ITB cle aning IT B Cleaning blade Residual toner feed screw Step 10: Drum cl eaning The c leaning blad e scrapes the residual toner off the surface o[...]

The DC controller r otates the d rum motor to drive the photose nsitive dr um, deve loping rol ler, and th e prim ary- charg ing roll er. Figure 1-23 Pri nt-cart ridge sys tem Primary charging roller SR1/SR2/SR3/SR4: Drum home position sensor SR11: Developing disengagement sensor DC controller Developing disengagement motor Memory tag M3/M4/M5/M6: [...]

The DC controller determine s a memory tag error a nd notifie s the forma tter when it fails to ei ther read from or write to the memory ta g. ● Cartridg e presence detection: T he DC co ntroller detec ts the pr esence of the cartri dges by monitori ng the mem ory tag. The DC controller notifies the formatter whe n a cartridge is missing or insta[...]

The deve loping-r oller engagem ent and diseng agement cont rol operat es as follows: Wh en the produc t is turn ed on and whe n each print job i s completed, al l four of the devel oping units are disengaged fro m the pho tosensitive dr ums. ● The drive of the de veloping di sengagem ent motor r otates the developin g disengag ement ca m. ● As[...]

Primary-tr ansfer-roller e ngage ment and disengagement The s equence of t he prim ary-transfer-rol ler engage ment and disengag ement contr ol is as follows: 1. The fuse r motor tur ns on the primary- transfer d isengagement solenoid and rotates the prim ary- transf er-roller di sengageme nt cam. 2. As the c am rotates , the Y/M/ C primary- transf[...]

Figure 1-26 Three states of pr imary-trans fer-roller eng agement and di sengageme nt M2 SL1 IT B DC controller Fuser motor Primary transfer disengagement solenoid SR9: Primary transfer disengagement sensor Primary transfer roller disengagement cam Bk primary transfer roller slide plate YMC primary transfer roller slide plate <Only black is enga[...]

ITB cleaning The c leaning blade in t he ITB clea ner scrape s the resi dual toner off the ITB surface . The re sidual toner feed sc rew deposi ts the resi dual tone r to the residual to ner feed unit. The ITB motor and the residu al toner feed m otor drive the screw. The DC contro l detects whe ther the toner collect ion box is full , using the re[...]

Color-misregistration control Interna l variation s in the lase r/scanne rs can cause the toner ima ges to become misaligne d. The col or- misregi stration control corrects the followi ng problems: ● Horizont al scanning sta rt position ● Horizont al scanning m agnificatio n ● Ver tic al s canni ng s tar t pos iti on The DC controller forms a[...]

Environm ental change s or deteriorat ion of the photosensi tive drums and toner can cause variati ons in the im age dens ity. The i mage-stabi lization c ontrol red uces these fluctuat ions. Table 1-11 Image-stabi lization controls Image density control (DMAX) This control corre cts variations in image d ensity related to det erioration of the pho[...]

Pickup, fee d, and delivery s ystem The pi ckup, feed, and deli very system uses a se ries of r ollers to m ove the pape r through the pro duct. Figure 1-29 Paper path Duplex model only Duplex media path Simplex media path Fuser sleeve Pressure roller Reverse roller Cassette pickup roller Cassette separation roller MP tray pickup roller MP tray sep[...]

Figure 1-30 Switc hes and sen sors for the pickup, feed , and del ivery sys tem Duplex model only Media sensor SW4 SR25 SR24 SR23 SR22 SR20 SR14 SR15 SR5 SR6 SR8 Table 1-12 Sw itches and sen sors for the p ickup, fee d, and delive ry system Abbreviation Componen t SR5 Fuser deliver y sensor SR6 Delivery tray m edia full sensor SR8 MP tray media p r[...]

Figure 1-31 Mot ors and so lenoids for the picku p, feed, an d delive ry system SL4 SL3 CL1 M2 M1 1 M1 M13 M7 Duplex model only SL2 Duplex flapper Lifter Pickup arm Table 1-13 M otors and sol enoids for the pickup, feed, and del ivery system Abbreviation Componen t M1 ITB motor M2 Fus er motor M7 Lifter motor M11 Duplex reverse motor (duplex m odel[...]

The pi ckup, feed, and deliver y system is divide d into th e following three bloc ks: ● Pickup- and-feed block: From each pi ckup sour ce to the fuser i nlet ● Fuser-and -delive ry block: F rom the fuser to th e deliver y destinati on ● Duplex block: F rom the duplex rever se unit to duplex re-pic kup unit (for dup lex models onl y) Figure 1[...]

Pickup-and-feed unit The pic kup-and-feed un it picks an in dividual she et of paper from the multipur pose tray or th e casse ttes, carries it through the seco ndary-tra nsfer unit, and feeds it into th e fuser. Figure 1-33 Pickup-a nd-feed uni t Pickup-and-feed block Duplex media path Simplex media path Casset te picku p The s equence of s teps f[...]

7. As the p ickup arm lo wers, the c assette pic kup roller touc hes the sur face of the paper stac k. 8. One sheet o f paper f eeds into the pr oduct. Figure 1-34 Cass ette-pickup m echanism M13 SL1 DC controller Cassette separation roller Cassette feed roller Cassette pickup cam Pickup arm Cassette pickup roller Pickup motor Cassette pickup solen[...]

Cassett e lift operation and cassette paper-presen ce detection The pr oduct ke eps the paper s tack surf ace at the correct pi ckup positi on. The cass ette lift-u p operation is perform ed under the followi ng conditions: ● The produ ct is turned on ● The cass ette is in serte d ● The paper sta ck surface in the cas sette lowers Figure 1-35[...]

The lo w friction force between t he sheets we akens the dri ving force from the cassette feed rolle r. There fore, the separation roller is driven by its ow n drivi ng force an d holds back any m ultiple- fed sheets from the cassette. Figure 1-36 Multiple-fe ed prevention Cassette separation roller follows the cassette feed roller Driving force fr[...]

The M P-tray me dia-presence sensor ( SR8) detects w hether pa per is pres ent in t he MP tray . Figure 1-37 Multipur pose tray pickup me chanism Lifting plate MP tray pickup roller MP tray separation pad SL2 SR8 M13 Pickup motor MP tray pickup solenoid MP tray media presence sensor DC controller Paper feed After the pickup operation , the paper f [...]

The DC con troller noti fies the formatte r of a paper size mismatch error when the paper length detected by the TOP sensor do es not m atch the pape r size specified by the form atter. Figure 1-38 Paper-feed me chanism TO P sensor Registration shutter Pickup motor SR20 Media sensor M13 CL1 M1 ITB motor IT B Registration front feed roller Duplex re[...]

Skew-fee d preventio n The produc t can straighten the pap er without slowing the feed operation. 1. The lead ing edge of paper strik es the re gistration shutter, and the leadin g edge is al igned with t he shutter. 2. As the fe ed roll ers keep p ushin g the paper, the paper warps. 3. When the for ce is great enough, the registr ation shutter ope[...]

glossy film, o r overhead tr anspare ncy) and swi tches to the correc t print mode. The DC con troller determi nes a medi a mismatch error and notifies the formatte r under the follow ing cond ition: Simplex printing ● The spe cified print m ode is o verhead trans parency (O HT), but th e media sensor detec ts another paper type. ● The spe cifi[...]

The fac e-down tray me dia full sensor on th e output bin detect s whether the tray is full of printed pages. The DC controller n otifies t he formatter when the se nsor is o n for a s pecified ti me. Figure 1-40 Fuse r and de livery un it Duplex media path Simplex media path SR6 Fusing-and-delivery block Face-down tray media full sensor Loop contr[...]

sensor 2 is fo r heavy media. The DC c ontroller slows the fuser motor when the sensor is off and speeds up the s ensor when the sensor is on. Figure 1-41 Loop-contr ol mechani sm Pressure roller The pressure roller rotates faster than the secondary transfer roller Loop sensor: OFF SR14: Loop sensor 1 SR15: Loop sensor 2 Sensor flag IT B Loop senso[...]

Pressure-roller pressuriza tion control To prev ent excess ive wear o n the pr essure roll er and hel p with j am-clearing procedures, the pre ssure roller pre ssurizes only during printing and standby. The DC co ntroller rever ses the fuser mo tor. The fuser mo tor rotates the fuser pressure-release cam. Figure 1-42 Pressur e-roller pre ssurizati [...]

Duplexing unit (HP Color LaserJet CP 4525dn, HP Color LaserJet CP4025dn, and HP Color LaserJet CP4525xh only) For suppo rted model s, the duple xing unit rever ses the paper and fee ds it through the pap er path to print the second side. Figure 1-43 Duplex ing unit Duplex block Duplex media path Simplex media path Duplexing reve rse and feed contro[...]

5. The dupl ex reverse motor and th e duplex fee d clutch s top, and th e paper feed operat ion paus es. 6. After a spe cified period of time, the dup lex reverse motor rotates, and the duplex feed c lutch is turned on . The paper is then pi cked up ag ain. Figure 1-44 Dup lex reverse and fe ed control Duplex media path Simplex media path Dupl e x [...]

The form atter speci fies the duplex-medi a-feed mode for each tw o-sided pr int job. D uplex prin table media size (A4, Letter, B5, Legal and Exec utive) and designated p rint mode ( Auto, Norma l, Heavy m edia 1, Heavy med ia 2 (120 g/m2 or lighter ), Glossy media 1, Glossy media 2, Glossy media 3, Glossy film, Designa ted media 1, and De signate[...]

Jam dete ction The prod uct uses th e followi ng sensors to detect th e paper as it move s through the paper path and to repor t to the DC co ntroller i f the paper h as jamm ed. ● Fuser de livery s ensor (SR5) ● TOP (top of page) s ensor (SR20 ) ● Loop sens or 1 (SR 14) ● Loop sens or 2 (SR 15) ● Duplex r e-pickup s ensor (SR22 ) Figure [...]

Table 1-16 J ams that the p roduct detects Jam Description Pickup delay jam The TOP sens or does not detect t he leading edge of the paper within a specified time (inc luding two retries) af ter the pickup operat ion from the cassette, multipurpose tray, or optional paper feeder starts. Pickup stationary jam The TOP sens or does not detect t he tra[...]

Optional paper feed er The 1 x 5 00-sheet pape r feeder i s optionally ins talled at bo ttom of the produc t. The paper fee der picks up the pr int media an d feeds it to the product. There are two types of paper feeders: 1 x 50 0-sheet paper feede r and 3 x 500-sh eet paper fe eder. T he opera tional seque nce of th e paper fe eders is c ontrolle [...]

Figure 1-47 3 x 5 00-sheet opt ional pap er feeder PD feed roller PD pickup roller PD separation roller Figure 1-48 Signal s for the p aper feed er Paper deck controller Motor Solenoid Photointerrupter DC controller Switch +24V Paper deck +3.3V The inp ut trays cont ain several mot ors, solenoi ds, sensor s, and switche s, as described i n the foll[...]

Table 1-17 Electrical com ponents for the paper fee der Compone nt type Abbreviation Comp onent nam e Motors M1 PD l ifte r moto r 1 M2 PD pickup motor M3 PD lifter motor 2 (3 x 500-sheet paper feeder only) M4 PD lifter motor 3 (3 x 500-sheet paper feeder only) Solenoids SL1 PD pickup solenoid 1 SL2 PD pickup solenoid 2 (3 x 500-sheet paper feeder [...]

Compone nt Drive s Failure detection PD lifter motor 3 ( 3 x 500-sheet p aper feeder only) M4 Lifter of t he lower cass ette No PD pickup motor M2 PD pickup roller, PD feed roller, and PD separation roller No Paper-feeder pickup and feed operation The pa per feeder picks up o ne sheet from the pap er-feeder cassette an d feeds i t to the p roduct. [...]

Compone nt SR3 Tr ay 3 paper presence sensor SR4 Tr ay 3 paper present sensor SW2 Tray 3 paper size switches SL1 SL2 SL3 SR4 SW2 M2 M1 Pickup arm SR3 SR1 SR2 SR7 SW3 M3 SR6 SR5 SR8 SR10 SW4 M4 SR1 1 SR12 SR9 SW1 Components M1 PD li fter m otor 1 M2 PD pickup motor M3 PD lifter motor 2 (3 x 500-sheet paper feeder only) M4 PD lifter motor 3 (3 x 500-[...]

SR5 Tra y 4 paper surface senso r 1 (3 x 500-sheet paper feeder only) SR6 Tra y 4 paper surface senso r 2 (3 x 500-sheet paper feeder only) SR7 Tra y 4 feed sensor (3 x 500-sheet paper feeder only) SR8 Tra y 4 media-stack-s urface sensor (3 x 500-sheet paper feeder only) SR9 Tra y 5 paper surface senso r 1 (3 x 500-sheet paper feeder only) SR10 Tra[...]

Paper-feeder cassette lift operation The pape r feeder keeps the paper stack surface at the co rrect picku p position. The cass ette lift operati on occurs un der the following conditions: ● The produ ct is turned on. ● The cass ette is in serte d. ● The pape r stack s urface of th e cassette lowers. The s equence oc curs a s follows: 1. The [...]

Paper feeder jam detection The 1 x 500-sheet pap er feeder u ses the tray 3 paper presence sen sor (SR4) to detect the prese nce of paper and to ch eck whether paper has jammed. Figure 1-51 Jam detection (1 x 500 -sheet pape r feeder) SR4 The 1 x 500-s heet paper feeder det ects the follo wing jams: ● 1 x 500-s heet PD pickup delay jam: T ray 3 f[...]

Figure 1-52 Ja m detection (3 x 50 0-sheet pape r feeder) SR4 SR7 SR10 The 3 x 500-s heet paper feeder detects the follo wing jams: ● 3 x 500 -sheet P D pickup delay jam: One of the tr ay feed se nsors does not detect th e leading edge of paper wit hin a specifie d time (including two re tries) after the pickup operat ion starts. ● 3 x 500- she[...]

66 Chapt er 1 Theo ry of oper ation ENWW[...]

2 Removal and replacement ● Introductio n ● Removal an d replacement st rategy ● Electrostatic discharge ● Required tools ● Before p erformin g service ● After p erforming s ervice ● Post -servi ce tes t ● Parts removal order ● Customer self repa ir (CSR) c omponents ● External panels, cover s, and doors ● Internal a ssemblies[...]

Introd uction This ch apter descri bes the removal and replace ment of field-re placeabl e units (FRUs) only. Replaci ng FRUs i s generall y the rev erse of rem oval. O ccasionally, notes and tips are incl uded to pr ovide direc tions for diff icult or criti cal replaceme nt procedu res. HP does not suppor t repairing indivi dual subas semblie s or[...]

Electr ostatic di scharge CAUTION: S ome parts are sensiti ve to electr ostatic dis charge (E SD). Look fo r the ESD reminder when removing pr oduct par ts. Always p erform se rvice work at an ESD-prot ected worksta tion or mat, o r use a n ESD strap. If an ESD wo rkstatio n, mat, or strap i s not avai lable, g round your self by to uching t he she[...]

Before pe rforming service ● Remove all med ia from the product. ● Turn off the power using the power sw itch. ● Unplug the power cabl e and int erface cabl e or cables . ● Place the product on an ESD w orkstation or mat, or use an ESD strap (if one is ava ilable). If an ESD workst ation, mat , or strap is not availabl e, ground yours elf b[...]

Post-service tes t Perfor m the follo wing test to verify that the r epair or replacement was s uccessf ul. Print-quality test 1. Verify that you have compl eted the neces sary reass embly step s. 2. Make su re that th e tray con tains cl ean, unma rked paper . 3. Attach the power c ord and in terface cab le or interfac e cables, and then tu rn on [...]

Parts remo val order Figure 2-2 Parts removal or der (1 of 2) 72 Chapt er 2 Remov al and rep lacement ENWW[...]

Figure 2-3 Par ts remo val order (2 of 2) DCCA HVPS-upper DCCA HVPS-upper DCCA DCCA HVPS-upper 2T assembly DCCA HVPS-upper DCCA HVPS-upper ENWW Part s remova l order 73[...]

Customer self repair (CSR) components Print cartridges CAUTION: If t oner gets on your cloth ing, wipe it off with a dry cloth and wash clothing i n cold water . Hot w ater sets toner i nto fabric . 1. Open the front doo r. Make sure that the door is compl etely open. Figu re 2 -4 Re move the print c artridge (1 of 2) 74 Chapt er 2 Remov al and rep[...]

2. Grasp the print -cartridge handl e and pull out to re move. CAUTION: Do n ot touch th e green roller . Doing so can damage the cartridge. Do not expose t he cartri dge to stron g light. C over the c artridge wi th a sheet o f paper to protect it from light. Reinstallation tip Alig n the print c artridge wit h its slo t and insert th e print cart[...]

Toner-collection unit NOT E: The toner-c ollection unit is desi gned for a single use. Do not try to empty the toner- collection unit and reuse it. Doing so could cause toner to spill i nside the pr oduct and re sult in r educed pri nt quality. For rec ycling infor mation, s ee the pr oduct user g uide. 1. Open the front doo r. Make sure that the d[...]

3. To preven t toner spi lls, place the blue cap (callout 1) over the b lue opening at the top of the unit (callou t 2). Figure 2-8 Remove t he toner- collect ion unit (3 of 4) 1 2 Figure 2-9 Remove t he toner- collect ion unit (4 of 4) ENWW Custo mer self r epair (C SR) com ponents 77[...]

Formatter PC A CAUTION: ESD sens itive compone nt. 1. Turn the product of f and disco nnect the pow er and i nterface ca ble or in terface ca bles. 2. Unscrew the f ormatter thumb screws, and then firm ly pull the forma tter from the produ ct. Place the formatter on a clean , flat, grou nded surfac e. Figu re 2 -10 Re move the for mat ter NOT E: Wh[...]

Hard drive Before proceeding, remove t he following component s: ● Form atter PC A. See Formatter PC A on pag e 78 . Remove the hard drive CAUTION: E SD sensitive component. 1. Disconne ct two connector s. Figure 2-11 Remove the hard driv e (1 of 3) 2. Release one tab . Figure 2-12 Remove the hard driv e (2 of 3) ENWW Custo mer self r epair (C SR[...]

3. Rotate t he hard drive assembly away from the formatter until the s lots in the hinges are aligne d with the e longated hing e pins, and then slide the hard dr ive assembly off the h inge pins. Figu re 2 -13 R emove the hard dr ive (3 of 3) 1 2 80 Chapt er 2 Remov al and rep lacement ENWW[...]

Memory DIMM Before proceeding, remove t he following component s: ● Form atter PC A. See Formatter PC A on pag e 78 . Remove the memory DIMM CAUTION: E SD sensitive component. NOT E: See Ena ble memor y on page 82 after installin g a new memo ry DIMM . 1. Place the formatter on a clean, flat, gr ounded surfac e, and then spr ead the latches apart[...]

2. Lift the DIMM up at an a ngle, and pul l it out. Reinstallation tip Hold the DIMM by the edges . Align the notch on the DIMM with th e bar in the DIMM slot at an ang le and firmly pres s the DIMM in to the slot until it is fully seated. Wh en installed correc tly, the metal co ntacts are not vis ible. Push dow n on the DIMM unt il both latche s [...]

Windows 7 1. Click St art . 2. Click Devi ces and Printers . 3. Right-click the product driver icon, and then select Printer p roperties . 4. Click the Device Setting s tab. 5. Expand the area for Installable Options . 6. Next to Automatic Configuration , select Update Now . 7. Click OK . NOTE: If the memory is not updated co rrectly after using th[...]

Tray NOT E: Use this pr ocedure to remove Tray 2 and t he optiona l Trays 3, 4, and 5. 1. Pull the tray st raight out of the prod uct until i t stops. Figu re 2 -16 R emove the tray (1 of 2) 2. Carefully lift up on the tray to release it, and then re move the tray. Figu re 2 -17 R emove the tray (2 of 2) 84 Chapt er 2 Remov al and rep lacement ENWW[...]

Fuser CAUTION: The fus er might be hot. Allow eno ugh time after turni ng off the product powe r for the fuser to cool . NOT E: The produ ct detects a new fuse r using a fusible lin k that bl ows after 10 0 pages have been printe d. If a new fuser is inst alled for troub leshootin g purposes, be sure to remove it before pr inting 100 page s. 1. Ope[...]

Feed and separation rollers (Trays 2-5) CAUTION: Do not touch the spongy r oller surfac e unless y ou are re placing the r oller. Skin oi ls on the roller c an cause paper pic kup proble ms. 1. Locate the feed and separation rollers f or the tray. TIP: You do not have to separate the product from the feeder to remove the se roller s. Remove the cas[...]

Pickup roller (Tray 1) CAUTION: Do not touch the spongy r oller surf ace unless y ou are repl acing the rol ler. Skin oils on the rolle r can cause paper pic kup problems . 1. Open Tray 1. Figure 2-21 Remove t he pickup rol ler (Tray 1) (1 of 5) 2. Push the top edge o f the cover to releas e the tabs. Figure 2-22 Remove t he pickup rol ler (Tray 1)[...]

3. Open the right-do or assemb ly, and t hen remove the co ver. Figu re 2 -23 Remove the pic kup roller (Tray 1) (3 of 5) 4. Release the two blu e tabs. Figu re 2 -24 Remove the pic kup roller (Tray 1) (4 of 5) 88 Chapt er 2 Remov al and rep lacement ENWW[...]

5. Rotate the r oller body a way from the p roduct to remo ve it. Figure 2-25 Remove t he pickup rol ler (Tray 1) (5 of 5) ENWW Custo mer self r epair (C SR) com ponents 89[...]

Secondary transfer roller CAUTION: Do not touch the spongy r oller surfac e unless y ou are re placing the r oller. Skin oi ls on the roller c an cause image q uality proble ms. 1. Open the rig ht-door asse mbly. Figu re 2 -26 Remove th e transfer roller ( 1 of 3) 2. Use th e blue leve r to lowe r the s econdary transfer assembly . Figu re 2 -27 Re[...]

3. Grasp the roller sh aft colla rs, and lift the t ransfer r oller off o f the pr oduct. Figure 2-28 Remove the transfer roller (3 of 3 ) Reinstall the transf er roller When you reinstall the transfer roller, mak e sure tha t the pins on th e shaft col lars align with the holes in the mounti ng assembly. Afte r installing the new transfer roll er,[...]

Intermediate transfer belt (ITB) CAUTION: Do not touch the black-pl astic belt. Skin oils and fing erprints on th e belt c an cause print- quality problems. Always plac e the ITB o n a flat surf ace in a s afe and pr otected locatio n. 1. Open the rig ht-door asse mbly. Figu re 2 -30 Remove th e intermedi ate transfer belt (1 of 4) 2. Use th e blue[...]

3. Grasp the small ha ndles on the ITB and the n pull the IT B out of the product until two lar ge handles expand al ong the right- and left-side of the ITB . Figure 2-32 Remove t he intermedi ate transfer b elt (3 of 4) ENWW Custo mer self r epair (C SR) com ponents 93[...]

4. Grasp the l arge handles on the ITB and then pull the IT B straigh t out of th e product to remove it. CAUTION: The IT B is a se nsitive component. B e careful when handl ing the ITB s o that it is not damaged. Alw ays place the ITB in a saf e and pro tected locatio n. Figu re 2 -33 Remove th e intermedi ate transfer belt (4 of 4) Reinstal latio[...]

Exte rnal panels , covers , and doo rs Identification an d location Figure 2-34 Exter nal panels , covers, and doors; identifi cation and location 1 2 3 4 5 6 7 8 9 10 11 12 Item Description Item Description 1 Rear-to p cover (see Rear-top cover on page 102 ) 7 Power-supply c over (see Power-su pply cover on page 98 ) 2 Right-door assembly (see Rig[...]

Upper-left cover 1. Open the fron t-door assembly . Figu re 2 -35 Remove the u pper-left cover (1 of 3) 2. Remove on e screw. Figu re 2 -36 Remove the u pper-left cover (2 of 3) 96 Chapt er 2 Remov al and rep lacement ENWW[...]

3. Release two tabs, sl ightly p ush the cov er upward and toward t he rear of the produc t, pull out ward on the re ar corner , and then r emove the u pper-le ft cover. Figure 2-37 Remove t he upper-le ft cover (3 o f 3) ENWW Externa l panels, co vers, and door s 97[...]

Power-supply cover ▲ Remove one sc rew (callou t 1), release one tab ( callout 2), and then remove the powe r-supply cov er (callou t 3). Figu re 2 -38 Remove t he power-supp ly cover 2 1 3 98 Chapt er 2 Remov al and rep lacement ENWW[...]

Left cover Before proceeding, remove t he following component s: ● Upper-left cover. See Upper- left cove r on page 96 . ● Powe r-supp ly cove r. See Power -supply cov er on page 98 . Remove the left cover 1. Open the front- door assembly. 2. Remove four screw s. Figure 2-39 Remove the le ft cover (1 of 2) 3. Slide th e left cover toward the re[...]

Front-top cover Before proc eeding, remove the following c omponents: ● Upper-le ft cover. S ee Upper- left cover on page 96 . Remove the front-top cover 1. Open the fron t-door assembly . 2. Remo ve thre e scre ws. Figu re 2 -41 R emove the fron t-top cover (1 of 3) 3. Flex the b ack left corner of the cove r and lift t o release the pin. Figu r[...]

4. Remov e the co ver. Figure 2-43 Remove th e front-top cover (3 of 3) ENWW Externa l panels, co vers, and door s 10 1[...]

Rear-top cover Before proc eeding, remove the following c omponents: ● Upper-le ft cover. S ee Upper- left cover on page 96 . ● Front-t op cover. See Front- top cove r on page 10 0 . Remove the rear-top cove r 1. Remove two s crews. Figu re 2 -44 Remove th e rear-top cover (1 of 2) 2. Open the rig ht-door asse mbly. 3. Release thr ee tabs (call[...]

Right-front cover Before proceeding, remove t he following component s: ● Upper-left cover. See Upper- left cove r on page 96 . ● Front-top co ver. See Front-t op cover on page 100 . ● Rear-top cover. See Rear-top cover on pag e 102 . Remove th e right-fr ont cover NOT E: Be careful . When r emoving the cover, do not di slodge the p ower butt[...]

2. Release t wo tabs, a nd then remo ve the r ight-front cover. Figu re 2 -48 Remov e the right-front cove r (3 of 3) Reinstall the po wer button Snap th e power butto n into the holders on the cover . Make sure t hat the sp ring is c orrectly installed. Figure 2-49 Reinstall the power button 104 C hapter 2 Removal and replac ement ENWW[...]

Control-panel assembly Before proceeding, remove t he following component s: ● Upper-left cover. See Upper- left cove r on page 96 . ● Front-top co ver. See Front-t op cover on page 100 . ● Rear-top cover. See Rear-top cover on pag e 102 . ● Right-front cover. See Righ t-front cove r on page 10 3 . Remove the control-panel as sembly 1. Remo[...]

2. Disconne ct one connector, and then remov e the control-pane l assembly. Figu re 2 -51 Remove t he contr ol-panel as sembly (2 of 2) 106 C hapter 2 Removal and replac ement ENWW[...]

Front-door assembly Before proceeding, remove t he following component s: ● Upper-left cover. See Upper- left cove r on page 96 . ● Front-top co ver. See Front-t op cover on page 100 . ● Rear-top cover. See Rear-top cover on pag e 102 ● Right-front cover. See Righ t-front cove r on page 10 3 Remove the front-door assembly 1. Open the front-[...]

3. Squeeze th e tab on the left l ink arm usin g needle nose plier s to release it from t he front door assembl y. NOTE: Hold the link arm firmly whe n releasin g to preven t it from s napping agai nst the fr ont of the product . Figu re 2 -53 Remove the f ront-door a ssembly (2 of 5) 4. Remove tw o screw s (callout 1). Figu re 2 -54 Remove the f r[...]

5. Remo ve two sc rews. Figure 2-55 Remov e the front-door ass embly (4 of 5) 6. Remove the fr ont-door assemb ly. Figure 2-56 Remov e the front-door ass embly (5 of 5) ENWW Externa l panels, co vers, and door s 10 9[...]

Right-rear cover Before proc eeding, remove the following c omponents: ● Upper-le ft cover. S ee Upper- left cover on page 96 . ● Front-t op cover. See Front- top cove r on page 10 0 . ● Rear-top co ver. See Rear-top cov er on page 102 . Remove the rig ht-rear co ver 1. Open the rig ht-door asse mbly. 2. Release o ne tab. Figu re 2 -57 Remove[...]

3. Lift the c over to remove. Figure 2-58 Remove t he right-rear cover (2 o f 2) ENWW Externa l panels, co vers, and door s 11 1[...]

Rear cover Before proc eeding, remove the following c omponents: ● Upper-le ft cover. S ee Upper- left cover on page 96 . ● Powe r-sup ply cover. See Power-s upply co ver on page 98 , ● Front-t op cover. See Front- top cove r on page 10 0 . ● Rear-top co ver. See Rear-top cov er on page 102 . Remove the rear cover ▲ Remove tw o screws (ca[...]

Right-door assembly 1. Open the rig ht-door asse mbly. Figure 2-60 Remove the right-do or assemb ly (1 of 9) 2. Carefully remove the hinge c over (callo ut 1). Figure 2-61 Remove the right-do or assemb ly (2 of 9) 1 ENWW Externa l panels, co vers, and door s 11 3[...]

3. Remo ve thre e scre ws. Figu re 2 -62 Remove t he right-do or assembl y (3 of 9) 4. Remove th e hinge assembly. Reinstallat ion tip When th e hinge i s reinsta lled, make sure that the tab (ca llout 1) is correctly positione d on the door. Figu re 2 -63 Remove t he right-do or assembl y (4 of 9) 1 114 C hapter 2 Removal and replac ement ENWW[...]

5. Release one pin, and then rele ase the lin k arm (call out 1). CAUTION: The link arm is spring l oaded. Hol d the arm securely ( as shown) t o prevent the spring from abrup tly retr acting. Figure 2-64 Remove the right-do or assemb ly (5 of 9) 1 6. Release one tab , and then remo ve the cover (cal lout 1). TIP: Lift up on the seco ndary transfe [...]

7. Disconne ct two connector s. Figu re 2 -66 Remove t he right-do or assembl y (7 of 9) 8. Lift two link arms to r elease. Figu re 2 -67 Remove t he right-do or assembl y (8 of 9) 116 C hapter 2 Removal and replac ement ENWW[...]

9. Slide the rig ht-door assem bly toward the front of the produ ct and remove. Figure 2-68 Remove the right -door assemb ly (9 of 9) ENWW Externa l panels, co vers, and door s 11 7[...]

Interna l assemblie s TIP: For clar ity, so me photos i n this chap ter show co mponents removed that woul d not be re moved to service the product. If necessary, rem ove the compo nents listed at the begi nning of a procedu re before proc eeding to service the product. Cassette feed guide TIP: If a page i s jammed i n the pro duct, yo u might be a[...]

Secondary transfer assembly The second ary transfer assembly inc ludes the transfer roller. 1. Open the rig ht-door asse mbly. Figure 2-71 Remove the secondar y transfer a ssembly (1 of 3) 2. Release one tab and carefully remov e the stopper. NOTE: You might have to slig htly lift u p on the c orner of the assembly t o release th e stopper pi n fro[...]

3. Remove the se condary tran sfer as sembly. CAUTION: Do not dama ge the blue release lev er when removi ng the assembly. Figu re 2 -73 Remove t he secondar y transfer a ssembly ( 3 of 3) Reinst all the second ary tran sfer asse mbly Press a nd hold th e blue rele ase lever wh en you reinstall the assemb ly. Figure 2-74 Reinstall the sec ondary tr[...]

Separation pad (T ray 1) Before proceeding, remove t he following component s: ● Pickup ro ller. See Pickup roller (Tray 1) o n page 87 . ● Right door assembly. S ee Right-do or assembl y on page 113 . Remove the separation pad (Tray 1) 1. Remove two screw s (callou t 1) and the co ver (callo ut 2). Figure 2-75 Remove th e separatio n pad (1 of[...]

3. Release t wo tabs ( callout 1) an d slide the locking cap and s ub roller toward the edge of the tray. Figu re 2 -77 R emove the separa tion pad (3 of 6) 1 4. Release t wo tabs ( callout 1) an d slide the locking cap and s ub roller toward the edge of the tray. CAUTION: Do no t damage t he flag (call out 2). Figu re 2 -78 R emove the separa tion[...]

5. Release one tab (callout 1) and slide the pick up-roller hol der toward the edge of the tray. CAUTION: Do no t damage the flag (call out 2). Figure 2-79 Remove th e separatio n pad (5 of 6) 1 2 6. Release one tab (cal lout 1) and remove the separatio n pad. Figure 2-80 Remove th e separatio n pad (6 of 6) 1 2 ENWW Internal assemblies 123[...]

Registration den sity (RD) sensor assembly Before proc eeding, remove the following c omponents: ● Intermedi ate transfer belt (ITB ). See Intermed iate transfe r belt (ITB) on page 92 . ● Secondar y transfer assem bly. See Second ary transfe r assembly on page 119 . Remove the RD se nsor as sembly 1. Release one tab (c allout 1), and then rem [...]

2. Release one tab , and then remo ve the wire-har ness cove r. TIP: Open the f ront door to make i t easier to remov e the cover. Figure 2-83 Remove the RD sensor assembly (3 of 7) 3. Disconne ct three co nnectors. Figure 2-84 Remove the RD sensor assembly (4 of 7) ENWW Internal assemblies 125[...]

4. Remove two s crews. Figu re 2 -85 R emove the RD sens or asse mbly (5 of 7) 5. Slide the s hutter toward th e back side of th e product. Keep the shutter in t his position f or the following s tep. Figu re 2 -86 R emove the RD sens or asse mbly (6 of 7) 126 C hapter 2 Removal and replac ement ENWW[...]

6. Carefully remove t he assembly from the product. CAUTION: Do n ot damage the shutter as it pa sses throu gh the chas sis. Figure 2-87 Remove the RD sensor assembly (7 of 7) ENWW Internal assemblies 127[...]

Registration assembly Before proc eeding, remove the following c omponents: ● Intermedi ate transfer belt (ITB ). See Intermed iate transfe r belt (ITB) on page 92 . ● Secondar y transfer assem bly. See Second ary transfe r assembly on page 119 . 128 C hapter 2 Removal and replac ement ENWW[...]

Remove the regi strati on assem bly NOT E: If a replacement re gistration as sembly is install ed, you must use the con trol-pan el menus to reset the registrati on-roller c ount and input the media sens or value. See Servic e menu on page 420 and Servic e me nu on page 420 . 1. Release one tab (callout 1), and then re move the cove r (callou t 2).[...]

2. Release one tab, and then remove the wi re-har ness cover. TIP: To make the cover ea sier to remov e, open the front-do or assembly to clo se the RD-sensor shutter. Figu re 2 -90 Remov e the registr ation assembly (3 of 8) 3. Disconne ct two connector s. Figu re 2 -91 Remov e the registr ation assembly (4 of 8) 130 C hapter 2 Removal and replac [...]

4. Remove tw o screws (c allout 1), and then rem ove the casse tte feed guide (callout 2). Figure 2-92 Remov e the registrati on assembly (5 of 8) 1 2 5. Remove four screw s. Figure 2-93 Remov e the registrati on assembly (6 of 8) ENWW Internal assemblies 131[...]

6. Release tw o pins and the front of the assem bly. Figu re 2 -94 Remov e the registr ation assembly (7 of 8) 7. Remove th e assembly from the product. Reinstallat ion tip Whe n you reinstall the registration as sembly, ma ke sure that it is co rrectly positione d in the pr oduct. The tabs on th e assembly m ust fit into the slots i n the produc t[...]

Residual-toner-feed motor Before proceeding, remove t he following component s: ● Intermedi ate transfer belt (ITB ). See Intermediat e transfer belt (ITB) on page 92 . ● Upper-left cover. See Upper- left cove r on page 96 . Remove the residu al-toner- feed motor Remo ve one screw (callout 1 ), disconn ect one con nector (call out 2), and them [...]

Residual-toner duct and feed assembly Before proc eeding, remove the following c omponents: ● Toner-col lection unit. Se e Toner-col lection un it on page 76 . ● Intermedi ate transfer belt (ITB ). See Intermed iate transfe r belt (ITB) on page 92 . ● Upper-le ft cover. S ee Upper- left cover on page 96 . ● Residual- toner-f eed motor. Se e[...]

2. Release one tab, and then remove the waste tone r duct. Figure 2-98 Remove the residua l-toner duct and feed assembly (2 of 4) 3. Remove o ne screw. Figure 2-99 Remove the residua l-toner duct and feed assembly (3 of 4) ENWW Internal assemblies 135[...]

4. Push the resid ual-toner feed assembly int o the produc t and then remove th rough the print car tridge cavit y. CAUTION: The wa ste toner feed assem bly contain s toner. Pla ce a cloth be low the work area to catch any sp illed toner. Figu re 2 -10 0 Remo ve residua l-toner duct and fee d assembly (4 of 4 ) 136 C hapter 2 Removal and replac eme[...]

Cartridge fan and environmental sensor Before proceeding, remove t he following component s: ● Upper-left cover. See Upper- left cove r on page 96 . ● Powe r-supp ly cove r. See Power -supply cov er on page 98 . ● Left c over. Se e Left cover on p age 99 . Remove the cartridge fan and e nvironmental sensor 1. Remove fo ur screws (c allout 1),[...]

2. Release one spring. TIP: Close the fro nt-door asse mbly to reduce tens ion in the spring. Figu re 2 -10 2 Remo ve the cart ridge fan and envir onmental sensor (2 of 7) 3. Release on e tab and then slide the fan asse mbly towar d the back of th e product. Figu re 2 -10 3 Remo ve the cart ridge fan and envir onmental sensor (3 of 7) 138 C hapter [...]

4. Pull the fan asse mbly out of the prod uct, and t hen disconn ect two con nectors. TIP: One conn ector is b elow the sponge. Figure 2-10 4 Remove the cart ridge fan a nd environm ental se nsor (4 of 7) 5. Release two tabs (c allout 1), a nd then remo ve the cov er (callo ut 2). Figure 2-10 5 Remove the cart ridge fan a nd environm ental se nsor [...]

6. Disconne ct one connector (c allout 1), and then rem ove the fan (call out 2). Figu re 2 -10 6 Remo ve the cart ridge fan and envir onmental sensor (6 of 7) 1 2 7. Carefully release one tab, and then remo ve the environm ental sensor . CAUTION: ESD-sen sitive part. Figu re 2 -10 7 Remo ve the cart ridge fan and envir onmental sensor (7 of 7) 140[...]

Toner-collection senso r and scanner-thermistor assembly Before proceeding, remove t he following component s: ● Toner-co llection unit. S ee Toner-co llection unit on pa ge 76 . ● Upper-left cover. See Upper- left cove r on page 96 . ● Powe r-supp ly cove r. See Power -supply cov er on page 98 . ● Left c over. Se e Left cover on p age 99 .[...]

2. Open the front-do or assembly, and then remove one screw . Figu re 2 -10 9 Remo ve the toner -collection s ensor and scanner-ther mistor as sembly (2 of 3) 3. Disconne ct two conn ectors (cal lout 1), and then remov e the tone r-collect ion sensor and scanne r- thermist or assemb ly (callout 2). Figu re 2 -11 0 Remo ve the toner -collection s en[...]

Delivery fan Before proceeding, remove t he following component s: ● Upper-left cover. See Upper- left cove r on page 96 . ● Front-top co ver. See Front-t op cover on page 100 . ● Rear-top cover. See Rear-top cover on pag e 102 . Remove the de livery fan 1. Remove on e screw (call out 1), disc onnect one connector (ca llout 2), and r elease o[...]

2. Release one tab (c allout 1), and then rem ove the delivery fan ( callout 2). Figu re 2 -11 2 Remove th e delive ry fan (2 of 2) 2 1 144 C hapter 2 Removal and replac ement ENWW[...]

Delivery assembly Before proceeding, remove t he following component s: ● Fuser. S ee Fuser on page 85 . ● Intermedi ate transfer belt (ITB ). See Intermediat e transfer belt (ITB) on page 92 . ● Upper-left cover. See Upper- left cove r on page 96 . ● Powe r-supp ly cove r. See Power -supply cov er on page 98 . ● Front-top co ver. See Fro[...]

2. Remove tw o screws (callout 1) , and the n remove th e paper gui de (callou t 2). NOTE: Duplex models only: pre ss the du plex solen oid (call out 3) to create enoug h clearanc e to remove the pap er guide (callout 2) . TIP: The fu ser delive ry sensor is insta lled on t he rear of the pap er guide. Leave th e sensor attached to the guide , and [...]

4. Remo ve two sc rews. Figure 2-11 6 Remove the del ivery assem bly (4 of 7) 5. Pull one tab out, and then pus h the tab down to release the bushin g. Figure 2-11 7 Remove the del ivery assem bly (5 of 7) ENWW Internal assemblies 147[...]

6. Remove two s crews. Figu re 2 -11 8 Remove the deliver y assembly (6 of 7) 7. Remove th e assem bly. Figu re 2 -11 9 Remove the deliver y assembly (7 of 7) 148 C hapter 2 Removal and replac ement ENWW[...]

Reinsta ll the delive ry assembly NOT E: For duple x models, the solenoid pl unger must b e removed fr om the discar ded assembl y, and then installed on the replacem ent assembly . For all mode ls, the output- bin full sens or must be rem oved from t he discard ed assembl y, and then i nstalled on the re placemen t assembly. 1. Duplex models only [...]

b. Hold the del ivery ass embly with the diverter ( callout 1) in the dep ressed po sition to move the sensor flag (call out 2) away from the s ensor. Rele ase one tab (callout 3). Figure 2-122 Reinstall th e delivery as sembly (3 of 4) 2 3 1 c. Slid e the sen sor up toward the top of the deliver y assembl y to relea se two ho oks (callout 1), and [...]

Duplex-drive assembly Before proceeding, remove t he following component s: ● Fuser. S ee Fuser on page 85 . ● Intermedi ate transfer belt (ITB ). See Intermediat e transfer belt (ITB) on page 92 . ● Upper-left cover. See Upper- left cove r on page 96 . ● Powe r-supp ly cove r. See Power -supply cov er on page 98 . ● Front-top co ver. See[...]

Power-supply fan Before proc eeding, remove the following c omponents: ● Upper-le ft cover. S ee Upper- left cover on page 96 . ● Powe r-sup ply cover. See Power-s upply co ver on page 98 . ● Front-t op cover. See Front- top cove r on page 10 0 . ● Rear-top co ver. See Rear-top cov er on page 102 . ● Right-re ar cove r. See Right-r ear co[...]

Interc onnect board (ICB) Before proceeding, remove t he following component s: ● Form atter. See Form atter P CA on page 78 . ● Upper-left cover. See Upper- left cove r on page 96 . ● Powe r-supp ly cove r. See Power -supply cov er on page 98 . ● Front-top co ver. See Front-t op cover on page 100 . ● Rear-top cover. See Rear-top cover on[...]

2. Carefully rotate and slide the ICB up and away from the chassi s, disconnect one connector, and then remove the ICB . Figu re 2 -12 7 Remove the ICB (2 of 2) 154 C hapter 2 Removal and replac ement ENWW[...]

DC con troller PC A only NOT E: Use the following pr ocedure to repla ce only the DC controlle r PCA. To ac cess com ponents behind the DC co ntroller, rem ove the PCA and the sheet-metal backing tr ay. See DC controller PCA and tray on page 161 . Before proceeding, remove t he following component s: ● Upper-left cover. See Upper- left cove r on [...]

2. Remove fo ur screws (callout 1) , and then remove the DC control ler PCA. Figu re 2 -12 9 Remove th e DC controller PCA only (2 of 2) 156 C hapter 2 Removal and replac ement ENWW[...]

Low-voltage power supply (LVPS) Before proceeding, remove t he following component s: ● Form atter. See Form atter P CA on page 78 . ● Upper-left cover. See Upper- left cove r on page 96 . ● Powe r-supp ly cove r. See Power -supply cov er on page 98 . ● Left c over. Se e Left cover on p age 99 . ● Front-top co ver. See Front-t op cover on[...]

2. Disconne ct five con nectors, an d then re lease th e wire har nesses fr om the g uides as necessary . NOTE: To locate DC control ler connector l ocations, see DC con troller connect or locati ons on page 28 1 . Figu re 2 -13 1 Remove the low-vol tage power s upply (1 o f 6) 3. Disconne ct one c onnector, and then release the wire ha rness from [...]

4. Remo ve thre e scre ws. Figure 2-13 3 Remove the low-vol tage power s upply (3 of 6) 5. Remo ve thre e scre ws. Reinstallation tip When t he low-volt age power supply is reinstall ed, make s ure the tab o n the mounting bracket beh ind the bott om screw (c allout 1) , is insert ed in the sl ot in the prod uct chass is. When co rrectly i nstalled[...]

6. Slide the bottom of t he assembly away from the product, tip the top of the assembly aw ay from the product, and then remove the assembl y. Figu re 2 -13 5 Remove the low-vol tage power s upply (5 o f 6) 1 2 7. Place th e assembly on a fla t surface. Remove two s crews (call out 1), and then sepa rate the formatter cage (callout 2) from the low-[...]

DC controller PCA an d tray Before proceeding, remove t he following component s: ● Upper-left cover. See Upper- left cove r on page 96 . ● Powe r-supp ly cove r. See Power -supply cov er on page 98 . ● Front-top co ver. See Front-t op cover on page 100 . ● Rear-top cover. See Rear-top cover on pag e 102 . ● Rear co ver. S ee Rear cove r [...]

2. Remove two s crews. Figu re 2 -13 8 Remove th e DC control ler PCA and tray (2 of 3) 3. Disengage three tabs ( two along the left edge of the PC A and one at the top- right co rner of the PCA). Figu re 2 -13 9 Remove th e DC control ler PCA and tray (3 of 3) 162 C hapter 2 Removal and replac ement ENWW[...]

High-voltage power supply lower (HVPS-D) Before proceeding, remove t he following component s: ● Form atter. See Form atter P CA on page 78 . ● Upper-left cover. See Upper- left cove r on page 96 . ● Powe r-supp ly cove r. See Power -supply cov er on page 98 . ● Left c over. Se e Left cover on p age 99 . ● Front-top co ver. See Front-t op[...]

2. Remo ve thre e scre ws. Figu re 2 -14 1 R emove the hi gh-vol tage po wer s upp ly lo wer (2 o f 7) 164 C hapter 2 Removal and replac ement ENWW[...]

3. Release fou r locking cli ps. NOTE: Sque eze each lockin g clip to remo ve. Figure 2-14 2 Remove the high-volta ge power supply low er (3 of 7) Figure 2-14 3 Remove the high-volta ge power supply low er (4 of 7) ENWW Internal assemblies 165[...]

4. Release f ive tabs. Figu re 2 -14 4 R emove the hi gh-vol tage po wer s upp ly lo wer (5 o f 7) 5. Rotate the t op of the power suppl y away from the chassi s, and then dis connect two conne ctors on the back of the power supply. NOTE: Remove the FFC (callout 1) with th e high-vol tage power s upply PCA. Do not d isconnect this FFC. Figu re 2 -1[...]

6. Disconne ct one FFC (callout 1). Rel ease onl y the wire harnesse s from the guide (cal lout 2) and then rem ove the p ower suppl y. NOTE: Remo ve the FFC (call out 1) and guide (callout 2) wi th the PCA. Replac ement high-vo ltage power s upply PC As have the FFC and guide in stalled. Figure 2-14 6 Remove the high-volta ge power supply low er ([...]

Developing-disengagement motor Before proc eeding, remove the following c omponents: ● Form atter. Se e Form atter PC A on page 78 . ● Upper-le ft cover. S ee Upper- left cover on page 96 . ● Powe r-sup ply cover. See Power-s upply co ver on page 98 . ● Left cove r. See Lef t cover o n page 99 . ● Front-t op cover. See Front- top cove r o[...]

Exhaust fan and fan duct Before proceeding, remove t he following component s: ● Form atter. See Form atter P CA on page 78 . ● Upper-left cover. See Upper- left cove r on page 96 . ● Powe r-supp ly cove r. See Power -supply cov er on page 98 . ● Left c over. Se e Left cover on p age 99 . ● Front-top co ver. See Front-t op cover on page 1[...]

2. Release f ive tabs ( callout 1) and remove the cover ( callout 2) . Figu re 2 -15 0 Remove th e exhaust fan and fan duc t (2 of 3) 1 2 3. Disconne ct one connector, and then remove the fan from the duct. Figu re 2 -15 1 Remove th e exhaust fan and fan duc t (3 of 3) 170 C hapter 2 Removal and replac ement ENWW[...]

Reinstall the exhaust fan and fan duct Be sure that the toroid (c allout 1) is corr ectly aligned in the FFC cab le guide before attempt ing to reinstal l the exh aust fan and duct. Figure 2-152 Reinst all the e xhaust fan a nd fan duct 1 ENWW Internal assemblies 171[...]

Pickup motor Before proc eeding, remove the following c omponents: ● Form atter. Se e Form atter PC A on page 78 . ● Upper-le ft cover. S ee Upper- left cover on page 96 . ● Powe r-sup ply cover. See Power-s upply co ver on page 98 . ● Left cove r. See Lef t cover o n page 99 . ● Front-t op cover. See Front- top cove r on page 10 0 . ● [...]

Lifter-drive assembly Before proceeding, remove t he following component s: ● Form atter. See Form atter P CA on page 78 . ● Intermedi ate transfer belt (ITB ). See Intermediat e transfer belt (ITB) on page 92 . ● Upper-left cover. See Upper- left cove r on page 96 . ● Powe r-supp ly cove r. See Power -supply cov er on page 98 . ● Left c [...]

2. Disconne ct one connector (c allout 1), and then rem ove two screws (c allout 2). Figu re 2 -15 5 Remove the lifter-drive assemb ly (2 of 3) 2 1 3. Remove the lifte r-drive assem bly from the produc t. CAUTION: The spring on the as sembly is not c aptive. Do no t lose the spring wh en the assem bly is rem oved. Figu re 2 -15 6 Remove the lifter-[...]

Lifter base assembly Before proceeding, remove t he following component s: ● Form atter. See Form atter P CA on page 78 ● Upper-left cover. See Upper- left cove r on page 96 . ● Powe r-supp ly cove r. See Power -supply cov er on page 98 . ● Left c over. Se e Left cover on p age 99 . ● Front-top co ver. See Front-t op cover on page 100 ●[...]

2. From inside the Tray 2 cavity , remove four screw s, and then rem ove the lifter b ase assembly. NOTE: Pull th e assembly s traight fro m the produc t without tipping to prev ent the spr ing from falling f rom the assembl y. Reinstal lation tip If the tray doe s not com pletely cl ose when r einstall ed, push on the lev er in the opening (ca llo[...]

2. Place th e spring i n the lif ter before ins talling t he assembly on the p roduct. Figure 2-16 0 Reinstall the lifter b ase assembly (2 o f 2) ENWW Internal assemblies 177[...]

Tray-pickup drive assembly Before proc eeding, remove the following c omponents: ● Form atter. Se e Form atter PC A on page 78 . ● Upper-le ft cover. S ee Upper- left cover on page 96 . ● Powe r-sup ply cover. See Power-s upply co ver on page 98 . ● Left cove r. See Lef t cover o n page 99 . ● Front-t op cover. See Front- top cove r on pa[...]

2. Remove t wo scre ws (callo ut 1), dis connect one connecto r (callou t 2), and t hen remov e the pick up motor ( callout 35 ). Figure 2-16 2 Remove the tray -pickup d rive asse mbly (2 of 3) 1 2 3 3. Remove th ree screw s, and then remove the tray-pic kup drive assembly. NOTE: The c ams on the m ain-driv e assembly c an prevent the tray- pickup [...]

Tray-pickup assembly Before proc eeding, remove the following c omponents: ● Form atter. Se e Form atter PC A on page 78 . ● Secondar y transfer assem bly. See Second ary transfe r assembly on page 119 . ● Intermedi ate transfer belt (ITB ). See Intermed iate transfe r belt (ITB) on page 92 . ● Upper-le ft cover. S ee Upper- left cover on p[...]

2. From the f ront of th e product, rem ove one screw (call out 1), a nd then remo ve one tray rail (callou t 2). Figure 2-16 5 Remove the tray-pickup a ssembly (2 of 1 1) 1 2 3. From the r ight side of the pr oduct, remov e two scre ws (callo ut 1) and on e cover (c allout 2). Figure 2-16 6 Remove the tray-pickup a ssembly (3 of 1 1) 1 2 ENWW Inte[...]

4. Close the right-door a ssembly. Pus h in and the n push up on the stop per to releas e. Figu re 2 -16 7 Remo ve the tray-pickup assembly (4 o f 11) 5. Open the right-do or assembly . Lift the two link arms (callout 1) to release from th e product, and then remo ve the pa per guide (callout 2). Figu re 2 -16 8 Remo ve the tray-pickup assembly (5 [...]

6. Close the right-do or assembl y. Push the two tabs towa rd each other , and then push u p to release the feed guide. Figure 2-16 9 Remove the tray-pickup a ssembly (6 of 1 1) 7. Open the right-door assembly, a nd then r emove the fe ed guide . Figure 2-17 0 Remove the tray-pickup a ssembly (7 of 1 1) ENWW Internal assemblies 183[...]

8. Remove tw o screws (callout 1) , and the n remove tw o brackets ( callout 2). Figu re 2 -17 1 Remo ve the tray-pickup assembly (8 o f 11) 1 2 9. Release o ne tab (cal lout 1), and then sli de the feed g uide (call out 2) towar d the fro nt of the p roduct to remove. Figu re 2 -17 2 Remo ve the tray-pickup assembly (9 o f 11) 1 2 184 C hapter 2 R[...]

10. Remove o ne screw. Figure 2-17 3 Remove the tray-p ickup a ssembly (10 of 11) 11. Remo ve th e tra y-pic kup assem bly. Figure 2-17 4 Remove the tray-p ickup a ssembly (11 of 11) ENWW Internal assemblies 185[...]

Laser/scanner assembly (Y/M) Before proc eeding, remove the following c omponents: ● Toner collectio n unit. See Tone r-co llec tion unit on page 76 . ● Intermedi ate transfer belt (ITB ). See Intermed iate transfe r belt (ITB) on page 92 . ● Upper-le ft cover. S ee Upper- left cover on page 96 . ● Powe r-sup ply cover. See Power-s upply co[...]

Remove the l aser/sca nner assembly (Y/M ) NOT E: After inst alling a new l aser/sc anner assem bly, be sure to ca librate the produc t. See Calib rate the produ ct on page 313 . 1. Release one spring. CAUTION: The s pring is no t captive. D o not los e the sprin g when it is remov ed. Use a pai r of needle -nose pli ers to saf ely reta in the s pr[...]

3. Release o ne spring (callou t 1), and the n disconnec t one FFC (callou t 2). Reinstal lation tip Wh en reinst alled, the t oroid (call out 3) mus t be correct ly positioned on the wire guide (in the provide d slots) so tha t the fan duc t will fully s eat in the produ ct when it is reinstalle d. Figu re 2 -17 7 Remove the lase r/scanner as semb[...]

4. Rotate the front of t he laser/scanner assem bly down (callou t 1), and then slide it toward the right (callout 2 ). Lower the left corner, and then rotate the left corner out of th e product (call out 3). Reinstallation tip When th e scanner i s reinsta lled, make sure that the tab on th e front o f the laser/s canner is inse rted in the alignm[...]

Laser/scanner assembly (C/Bk) Before proc eeding, remove the following c omponents: ● Toner collectio n unit. See Tone r-co llec tion unit on page 76 . ● Intermedi ate transfer belt (ITB ). See Intermed iate transfe r belt (ITB) on page 92 . ● Upper-le ft cover. S ee Upper- left cover on page 96 . ● Powe r-sup ply cover. See Power-s upply c[...]

Remove the l aser/sca nner assembly (C/ Bk) NOT E: After inst alling a new l aser/sc anner assem bly, be sure to ca librate the produc t. See Calib rate the produ ct on page 313 . 1. Release one sp ring (callou t 1), and then disconne ct one FFC (cal lout 2). CAUTION: The s pring is no t captive. D o not los e the sprin g when it is remov ed. Use a[...]

3. Remove fi ve screws ( callout 1) , and then r emove the cover (c allout 2). CAUTION: Be c areful. The PGC ac tuators are easily dislo dged when the c over is remove d. See Figure 2- 185 Reinstall the PGC actuators (1 of 5) on pag e 193 . To reinst all the actuato rs, see Reinst all the pro tective gla ss cleaner (PGC) a ctuators on page 193 . Fi[...]

5. Rotate the c orner of the assembly away from the produ ct until yo u can se e the PCA, and then remove the as sembly fro m the product. Reinstallation tip When the laser/s canner is c orrectly positioned i n the chas sis, the p lastic part s which pr otrude at the front and re ar of the p roduct will be firmly sea ted agains t the locator tabs o[...]

2. Remove the actu ator and spring fro m the product. Instal l the spring on the actua tor. Figu re 2 -18 6 Reinstall the PGC act uators (2 of 5) 3. Before proceedin g, take no te of the fo llowing: ● Callout 1 : The pin on the actuato r will be installed into the slot in the chas sis. ● Callout 2 : The pin on the pivot a rm will be installed i[...]

4. Place the end of the actuator in to the PGC rod, and then use a s mall flat b lade screw driver to fasten the end of the spri ng on the tab on the chassis. Figure 2-18 8 Reinstal l the PGC actuators (4 of 5) 5. Push down o n the actuato r to seat it into plac e. Verify that the actuators is corr ectly instal led. The PGC actu ator must free ly m[...]

High-voltage power supply upper (HVPS-T) Before proc eeding, remove the following c omponents: ● Form atter. Se e Form atter PC A on page 78 . ● Upper-le ft cover. S ee Upper- left cover on page 96 . ● Powe r-sup ply cover. See Power-s upply co ver on page 98 . ● Left cove r. See Lef t cover o n page 99 . ● Front-t op cover. See Front- to[...]

2. Remove th ree screws ( callout 1), r elease four tabs (callo ut 2), and then r emove the pow er supply. Figure 2-19 1 Remove the high-v oltage pow er supply upper (2 o f 2) 2 1 ENWW Internal assemblies 197[...]

Reinstall the high -voltage pow er supply upper When y ou reinstal l the pow er supply, look throu gh the holes in the PC A and mak e sure that the high- voltage contact springs a re correctl y seate d against t he PCA. NOT E: For a repla cement power s upply, remov e one wire harness (callout 1) and then ins tall it on the replac ement power su pp[...]

Yellow, magenta, cyan, and black drum motors Before proceeding, remove t he following component s: ● Upper-left cover. See Upper- left cove r on page 96 . ● Powe r-supp ly cove r. See Power -supply cov er on page 98 . ● Left c over. Se e Left cover on p age 99 . ● Front-top co ver. See Front-t op cover on page 100 . ● Rear-top cover. See [...]

Fuser motor Before proc eeding, remove the following c omponents: ● Form atter. Se e Form atter PC A on page 78 . ● Upper-le ft cover. S ee Upper- left cover on page 96 . ● Powe r-sup ply cover. See Power-s upply co ver on page 98 . ● Left cove r. See Lef t cover o n page 99 . ● Front-t op cover. See Front- top cove r on page 10 0 . ● R[...]

Remove the fuser motor Remo ve three screws (call out 1), disconnect one co nnector (callou t 2), and then remov e the motor (call out 3). Figure 2-194 Remove th e fuser mot or 1 2 3 ENWW Internal assemblies 201[...]

ITB motor Before proc eeding, remove the following c omponents: ● Upper-le ft cover. S ee Upper- left cover on page 96 . ● Powe r-sup ply cover. See Power-s upply co ver on page 98 . ● Front-t op cover. See Front- top cove r on page 10 0 . ● Rear-top co ver. See Rear-top cov er on page 102 . ● Left cove r. See Lef t cover o n page 99 . ?[...]

Main-drive assembly NOT E: Removing th e main-d rive ass embly typic ally requ ires more than 2 hours to complete . Before proceeding, remove t he following component s: ● Form atter. See Form atter P CA on page 78 . ● Intermedi ate transfer belt (ITB ). See Intermediat e transfer belt (ITB) on page 92 . ● Upper-left cover. See Upper- left co[...]

Remove the main -drive assemb ly 1. Remove ei ght conne ctors (call out 1), a nd then rele ase the w ire harness es from th e guides (callou t 2). NOTE: Leave th e wire har nesses wit h the pr oduct. Figu re 2 -19 6 R emove t he m ain-dri ve as sembl y (1 of 6) 1 2 2. Remove tw o screws (callout 1) , disconne ct one conne ctor (cal lout 2), and the[...]

3. Remove o ne scre w (callout 1) , and then remove the wire gu ide from the main-d rive ass embly (callou t 2). NOTE: Leav e the wire harnesses connected to the wir e guide and attached to the produc t for easier re installat ion. Figure 2-19 8 Remove the ma in-drive assem bly (3 of 6) 1 2 4. Remo ve 10 scr ews. Figure 2-19 9 Remove the ma in-driv[...]

5. Separate the main-drive asse mbly from the pro duct. Figu re 2 -20 0 R emove t he m ain-dri ve as sembl y (5 of 6) 6. Release the wir e harness (callout 1) fr om the guides, and then rem ove the main-dr ive assemb ly from the produ ct. Reinstallat ion tip It mig ht be easier to pass this ha rness over the edge of t he assembly chassis after the [...]

Reinsta ll the main-drive asse mbly 1. Locate the cams (call out 1) o n the back side of the assembly. Figure 2-20 2 Rein stall the main -drive as sembly (1 of 7) 1 2. Slowly ro tate the shaft near the black cam. WARNING! D o not touch the plastic gears or cams . You must not wipe away any of the gr ease that is appli ed to these compo nents. Alway[...]

3. Continu e to rotate t he shaft unti l the hol es in the bl ack-cam gear align as shown below. When cor rectly aligned, th e bottom-mo st hole in the gear is aligned with a ho le in the sheet-meta l chas sis. NOTE: The hol es in the o ther cam ge ars have a different al ignment. You must make sur e that the holes in the blac k-cam ge ar are cor r[...]

4. Ver ify th at th e cams ( callo ut 1) align co rrec tly. TIP: The seco nd cam in from the r ight (the wh ite cam to t he left of the blac k cam), s hould have the se cond hole aligne d with the hole in the sheet -metal cha ssis. The third cam in from the right, should have the third hole aligned with the hole in the shee t-metal chas sis. The fo[...]

6. When placi ng the assembly on the ch assis, align the holes in the assembly with the holes in the chas sis. Reinstallat ion tip If the upper-left corner of the assemb ly is difficult to seat, you might need to rotate the ITB motor to align the gear shaft with the hole in the chassis. Figu re 2 -20 7 Reinstall the main-drive assem bly (6 of 7) 7.[...]

Fuser-drive assembly NOT E: Removin g the fuser-driv e assembl y typ ically requi res more tha n 2 hours to comp lete. Before proceeding, remove t he following component s: ● Form atter. See Form atter P CA on page 78 . ● Fuser. S ee Fuser on page 85 . ● Upper-left cover. See Upper- left cove r on page 96 . ● Powe r-supp ly cove r. See Powe[...]

Remove the f user-drive a ssembly 1. Remove on e screw ( callout 1) , and then remove the cover (callout 2). Figu re 2 -20 9 Remove the fuser-drive ass embly (1 of 7) 1 2 2. Release the wir e harness (callout 1) fr om the guides. Figu re 2 -21 0 Remove the fuser-drive ass embly (2 of 7) 1 212 C hapter 2 Removal and replac ement ENWW[...]

3. Remove tw o screws (callout 1) , one static wire (c allout 2), a nd one switc h (callo ut 3). Figure 2-21 1 Remove the fuser-drive assembly (3 o f 7) 2 1 3 4. Release one tab , and then slide the wir e harness holde r (callout 1) to re lease it from the fuser- drive assembl y. NOTE: Rele asing the wire harne ss provi des cleara nce when the asse[...]

5. Disconne ct two connector s. Figu re 2 -21 3 Remove the fuser-drive ass embly (5 of 7) 6. Remo ve thre e scre ws. Figu re 2 -21 4 Remove the fuser-drive ass embly (6 of 7) 214 C hapter 2 Removal and replac ement ENWW[...]

7. Carefully remove the assembly. Figure 2-21 5 Remove the fuser-drive assembly (7 o f 7) Reinsta ll the fuser-driv e assembly Rotat e the motor until the gears align, and the assembl y is flat against the ch assis. Figure 2-216 Reinstall the fuser-driv e assembl y ENWW Internal assemblies 215[...]

Optional pape r feeder assemblies (1 x 500-sh eet and 3 x 500-sheet) NOT E: For infor mation ab out removi ng the Tray 3, 4, or 5 feed a nd separati on rolle rs, see F eed and separ ation rol lers (T rays 2-5) on page 86 . For inform ation about remov ing the Tray 3, 4, or 5 cassettes, see Tray on page 84 . For info rmation about remov ing the righ[...]

2. Release the link ar m (callou t 1), and then remov e the front d oor (callout 2). Figure 2-21 8 Remove the fr ont door (optio nal paper feeder) (2 of 2) 1 2 ENWW Optiona l paper feeder assemblies (1 x 500 -sheet and 3 x 500-sh eet) 21 7[...]

Rear cover (optional p aper feeder) ▲ Remove tw o screws (callout 1) , and the n remove th e rear cover (callou t 2). Figu re 2 -21 9 Remo ve the rear cover (opti onal paper feeder) 1 2 218 C hapter 2 Removal and replac ement ENWW[...]

Right-front cover (opt ional paper feeder) ▲ Open the front and right door s, remove one screw ( callout 1), and then lif t the right-fron t cover (ca llo ut 2) to remo ve. Figure 2-22 0 Remove the right- front cover (optional paper feed er) 1 2 ENWW Optiona l paper feeder assemblies (1 x 500 -sheet and 3 x 500-sh eet) 21 9[...]

Right door (optional paper feeder) 1. Open the right do or, releas e one tab (callout 1) , and then r emove the s topper (c allout 2 ) Figu re 2 -22 1 Remove the right door (optiona l paper feeder) (1 of 3) 2 1 2. Close the righ t door sli ghtly, and then release the upp er link arm. Figu re 2 -22 2 Remove the right door (optiona l paper feeder) (2[...]

3. Slide th e door to release the l ower lin k arm, and then rem ove the right door. Figure 2-22 3 Remove the right do or (optiona l paper feeder) (3 of 3) ENWW Optiona l paper feeder assemblies (1 x 500 -sheet and 3 x 500-sh eet) 22 1[...]

Left cover (optional pap er feeder) Before proc eeding, remove the following c omponents: ● Front door (optional paper fe eder). See Front doo r (optional pap er feeder) on page 216 . ● Right-fro nt cover (option al paper feeder ). See Right-fr ont cover (opti onal paper feede r) on page 21 9 . Remove the left cover ( optional paper f eeder) 1.[...]

2. 1 x 500 p aper fee der only: Rem ove three s crews (cal lout 1), and then rem ove the storag e box (callou t 2). Figure 2-22 5 Remove the left cov er (optional paper fee der) (2 of 3) 1 2 3. Release five tabs ( callout 1) , and then remove the left cover (callout 2) . Figure 2-22 6 Remove the left cov er (optional paper fee der) (3 of 3) 1 2 ENW[...]

Right cover (optional paper feeder) Before proc eeding, remove the following c omponents: ● Right door (optional paper feeder ). See Right door (opt ional paper feeder) on page 220 . Remove the right cove r (optional paper feede r) ▲ Remove t wo scr ews (callout 1), releas e one tab ( callout 2) , and the n remove t he right cover ( callout 3).[...]

Rear-right cover (optio nal paper feeder) Before proceeding, remove t he following component s: ● Right door (optional paper fe eder). See Right do or (option al paper feeder) on pa ge 220 . Remove the rear-right cover (opti onal paper feeder) ▲ Remove o ne screw ( callout 1) , and then li ft the re ar-right cov er (callo ut 2) to remove. Figur[...]

Pickup assembly (optional paper feeder) Before proc eeding, remove the following c omponents: ● Paper feeder right fro nt cover. See Right-fr ont cover (optional paper fee der) on page 219 . ● Pape r feed er re ar cov er. Se e Rear c over (opt ional paper feeder) on p age 218 . NOT E: The following pr ocedure shows steps for removi ng the picku[...]

2. 1 x 500-sheet o ptional paper feeder only: Remo ve three screws (call out 1), dis connect on e connecto r (callout 2), and then rem ove the motor asse mbly (callout 3) . Figure 2-23 0 Remove the pick up asse mbly (opti onal pape r feeder) (2 of 5) 2 1 3 3. 3 x 500-sheet o ptional paper feeder only: Remo ve four screws ( callout 1), disconnec t t[...]

4. Remove on e screw ( callout 1), an d then di sconnect three conne ctors (c allout 2). Figu re 2 -23 2 Remove the pickup as sembly (optio nal paper feede r) (4 of 5) 1 2 5. Remove on e screw ( callout 1) , and then remove the pickup assembly (callout 2). Figu re 2 -23 3 Remove the pickup as sembly (optio nal paper feede r) (5 of 5) 1 2 228 C hapt[...]

Lifter assembly (optional paper feeder) Before proceeding, remove t he following component s: ● Rear cover (op tional paper feeder ). See Rear c over (opt ional paper feeder) on pa ge 218 . Remove the lifter as sembly (optional paper feed er) 1. Disconne ct one connector (callout 1). Figure 2-23 4 Remove the lifte r assembly (optional paper feede[...]

Lifter-drive assembly (optional paper feeder) Before proc eeding, remove the following c omponents: ● Rear cover (optional paper fee der). See Rear c over (option al paper feeder) o n page 218 . Remove the lifter-drive a ssembly ( optional paper f eeder) 1. Disconne ct one connector (c allout 1), and then rel ease the wire ha rnesses (cal lout 3)[...]

Pickup motor assembly (optional p aper feeder) Before proceeding, remove t he following component s: ● Rear cover (op tional paper feeder ). See Rear c over (opt ional paper feeder) on pa ge 218 . Remove the pickup motor (optional paper feeder) assembly 1. 1 x 500-sheet o ptional paper feeder only: Remo ve three screws (call out 1), dis connect o[...]

Controller PCA (optiona l paper feeder) Before proc eeding, remove the following c omponents: ● Rear cover (optional paper fee der). See Rear c over (option al paper feeder) o n page 218 . Remove the controller PCA (option al paper feeder) 1. 1 x 500-s heet optio nal paper fe eder only: D isconnect fo ur connector (callout 2), a nd then remov e t[...]

3 Solve problems To use the info rmation in this ch apter, you need to have a basi c understa nding of the HP LaserJ et printi ng process. Ex planation s of each mechanical as sembly, the printer syst ems, and the basic theor y of o peration are c ontained i n Theory of operati on on page 1 . Do not perform an y of these troublesho oting proce sses[...]

Solve p roblems checklis t If the product is not responding co rrectly, comple te the steps in the foll owing checkli st, in order. If the produc t does not pass a step, follow the correspond ing troubles hooting sugges tions. If a step res olves the pro blem, yo u can stop without per forming the other steps on the c hecklist. 1. Make sure tha t t[...]

8. Verify that you have instal led the HP Color La serJet Enter prise CP4020 -CP4520 Se ries printer driver. Ch eck the program to make sure that you are using the HP Color LaserJe t Enterp rise CP4020 -CP4520 Se ries printe r driver. 9. Print a sho rt document fro m a different program that has w orked in the past. If this soluti on works, the pro[...]

Menu map Prin t a menu map 1. Press the OK butto n to open t he menus. 2. Use the arrow but tons to naviga te to the INFORMATION su bmenu, and t hen press the OK button. 3. Us e the a rrow but tons to na vig ate to the PRIN T MENU MAP subm enu, and th en pr ess t he OK button to print the men u structure. 4. Press the bac k arrow to exi t the menus[...]

Troubles hooting proc ess Determine the problem source When t he produ ct malfuncti ons or encounters an unexpec ted situation , the prod uct contr ol panel ale rts you to the situatio n. This se ction co ntains a pre- troublesho oting ch ecklist to fi lter ou t many pos sible causes o f the pro blem. A troubleshoot ing flowchar t helps you diagnos[...]

Input trays ● Is the amount of media in the tray within specifications? ● Is the media correctly placed in the tray? ● Are the paper guides aligned with the stack? ● Is the paper tray correctly installed in the product? Print ca rtridges ● Is each print cartridge installed correctly? ● Are original HP print c artridges installed? ● Ar[...]

Troubleshooting f lowchart This flowc hart highligh ts the genera l processes that y ou can follow to quic kly isolate and s olve product hardw are p robl ems. Each row depicts a major trou bleshooti ng step. A “ yes” ans wer to a que stion allow s you to proceed t o the ne xt major ste p. A “no” answer in dicates tha t more testing is need[...]

Power subsystem Power-on chec ks The bas ic product functions should start up whe n the product is plu gged into an el ectrical ou tlet and the power s witch is pushed t o the on po sition. If the product do es not st art, use the i nformati on in this s ection to isol ate and sol ve the problem . Power-on trouble shooting overview Turn on the prod[...]

● 00:36 sec onds; HP lo go appear s on the control-pa nel displa y ● 00:60 sec onds; en gine noises stop (you can run en gine tes t at this p oint) ● 00:83 se conds; Init ializing co ntinues ● 00:85 fans rotate at slow s peed ● 00:90 sec onds; produ ct enter s the Rea dy state ENWW Troublesh ooting proces s 24 1[...]

Tools f or troubl eshooti ng The sect ion describes the tools that can hel p you so lve problems with your device. Individual component diagnostics LED diagnostics LED, engine , and individ ual diagnostics c an identify and tro ubleshoot pro duct problems . Understand light s on the form atter Three LEDs on the formatte r indicate that the pro duct[...]

4. Press the dow n arrow to hi ghlight the EMBEDDED JET DIREC T MENU option, and then pr ess the OK button. 5. Press the dow n arrow to highl ight the L INK SP EED menu, and then press the OK butt on. 6. Select t he approp riate link speed, and then press the OK bu tton. Heartbeat LED The heartbea t LED indic ates that the formatter is fun ctioning[...]

3. Insert a f olded piece of paper into each slot at the same time until the produ ct is in a Read y sta te. Figu re 3 -2 Di agnostic te st (2 of 2) Disable car tridge check Use this diagnostic test to print interna l pages or send an ex ternal job to the pr oduct when one or more print c artridges a re removed o r exchanged. Consumable s upply err[...]

horiz ontal lines. The test page can use only Tray 2 as the paper source , so make sure that paper is loaded in T ray 2. Figure 3-3 Engine -test button Paper-path test This di agnostic test genera tes one or more test p ages that you can us e to isolate the cause of jams. To isolat e a problem , specify whic h input tray to us e, specify w hether t[...]

Manual sensor test (spe cial-mode test) Use t his diagnost ic test to manu ally test the p roduct sens ors and swit ches. Each s ensor is repr esented by a letter and num ber on the contr ol panel disp lay. 1. Press the Hom e button . 2. Press the dow n arrow to highl ight the DIAGNOSTICS menu, and th en press t he OK button. 3. Press the dow n arr[...]

A TOP (top of page ) sens or 1. Open the right door . 2. Insert a piece of pa per to acti vate the TOP sensor. Figure 3-4 Test the TOP sensor (1 o f 2) NOTE: Open the reg istration shut ter to verify the p aper activate s the sensor. Figure 3-5 Test the TOP sensor (2 o f 2) 3. Check the co ntrol-panel display for sensor resp onse. 4. If there i s n[...]

B and C loop sensors 1. Open the right door. 2. Lower the second ary transfer ass embly. 3. Slowly i nsert a piec e of paper at the ent rance of the fuser to activate th e B and C l oop sensor s underneath the fus er. Figu re 3 -6 Test the loop se nsors 4. Check the control-p anel displ ay for a sensor response. 5. If there is no resp onse, replace[...]

D fuser delive ry sensor 1. Open the rig ht-door asse mbly. 2. Lower th e secon dary transfer as sembly. 3. Remove th e fuser, and then verify that the sens or flag on th e fuser m oves freely . If the sensor fl ag does not move fr eely, replace the fuser. See Fuser on page 85 . Figure 3-7 Test the fuser del ivery sensor (1 of 2) 4. Insert a piece [...]

E duplex r e-pickup sensor 1. Open the right door. 2. Lift th e seconda ry-tran sfer a ssembly. 3. Press the flag to acti vate the senso r. Figu re 3 -9 Tes t th e d upl ex r e-pi ckup se nsor 4. Check th e contr ol-panel di splay for sensor respons e. 5. If there is no resp onse, replace the regi stration asse mbly. See Registr ation assemb ly on [...]

F output bin full sensor NOT E: The front-top , rear-top, and right- front cover s have been removed for clarity. 1. Lift th e flapper on the delive ry assemb ly to move the output- bin full s ensor fla g. Figure 3-10 Test the output-bin-f ull sensor 2. Check the co ntrol-panel display for sensor resp onse. 3. If there i s no resp onse, remov e the[...]

I developer alie nation This sens or is located inside the main- drive asse mbly and cannot be accessed for direct manual tes ting. To test th is sensor, do t he follow ing. 1. Access the manual-sensor test menu and select sen sor test I. 2. Locate conne ctor J112 on the DC cont roller PCA. CAUTION: ESD s ensitive c omponent. 3. Disconne ct conne c[...]

J fuser pres sure-relea se sensor 1. Open the rig ht-door asse mbly. 2. Lower th e secon dary transfer as sembly. 3. Remove th e fuser. 4. Insert a piece of pa per to acti vate the fuser pr essure-rele ase sensor. Figure 3-11 Test the fuser pre ssure-relea se sensor 5. Check the co ntrol-panel display for sensor resp onse. 6. If there is no re spon[...]

K primary transfer-rolle r-disengageme nt sensor NOT E: The front-top , rear-top, and right- front covers hav e been removed for clarity. 1. Open the rig ht-door asse mbly. 2. Lower the seconda ry transfe r assembly, and then rem ove the fuser and ITB. 3. Rotate the ge ar (callo ut 1) to mov e the flag ( callout 2) . If the fl ag does not move, rep[...]

4. From ins ide the ITB cavity, pres s up on the primary- transfer-rolle r-dise ngagement fla g to activa te the sensor. Figure 3-14 Test the p rimary tran sfer-roll er-disengage ment sens or (3 of 4) 5. Check the co ntrol-panel display for sensor resp onse. 6. If there is no resp onse, remove the rear-top cov er (see Rear-top cover on pa ge 102 ) [...]

L media sensor 1. You canno t test this sen sor with a manua l sensor test. T est using the pa per-path sen sors test. See Paper-p ath sensors te st on page 273 . Figu re 3 -16 Media s ensor 2. Access the paper-pa th sensors tes t. 3. Print a confi guration page. 4. The media sens or (on the regis tration assembl y) detects the type of media as it [...]

M front- door switch 1. Open the front-do or assembly to dise ngage the front -door switch . Figure 3-17 Test the f ront-door swi tch 2. Close the front-d oor assembly , and then check the control pan el on the product f or sensor resp onse. TIP: You ca n leave the fr ont door open a nd use a slend er blade scr ew driver or pe ncil to activa te the[...]

N right-door s witch 1. Open the right-do or assembly to diseng age the rig ht-door switch. Figu re 3 -18 Test the righ t door switch 2. Close the r ight-door a ssembly, or us e your finger to depress the s witch flag , and check the control panel on the produ ct for senso r response. 3. If there is no resp onse, replace the rig ht-door switc h. 25[...]

Manual sensor test 2 (spec ial-mode test) Use this test to test pap er-path sen sors and the p aper-size swi tches manuall y. The followi ng illustrat ions and tabl e show t he locations of these sensors. 1. Press the Hom e button . 2. Press the dow n arrow to highl ight the DIAGNOSTICS menu, an d then pres s the OK button. 3. Press the dow n arrow[...]

Table 3-6 Default state of bits Label O P Q R S T U V W X Y Z a b c d B i t 1 111 101 11 011 101 1 ● Test ea ch swit ch individua lly. 260 C hapter 3 Solve problems ENWW[...]

O Tray 1 paper present sensor 1. Open Tray 1. 2. Toggle the Tray 1 pape r-present sensor flag. Figure 3-19 Test the T ray 1 media -present sen sor 3. Check the co ntrol-panel display for sensor resp onse. 4. If there is no resp onse, repla ce Tray 1. ENWW Tools fo r troublesho oting 261[...]

P Tray 2 paper pre sent sensor 1. Remove Tray 2. 2. Toggle the tra y 2 paper-present sensor flag. Figu re 3 -20 Test th e tray 2 pa per-pre sent se nsor 3. Check th e contr ol-panel di splay for sensor respons e. 4. If there is no resp onse, replace the cas sette-pickup as sembly. See Tray-pi ckup assembl y on page 18 0 . 262 C hapter 3 Solve probl[...]

Q Tray 2 paper surface 1 and 2 sensors 1. Remove th e tray. 2. In the tra y cavi ty, press the tray-clos ed tab to r elease th e flag, and th en toggle the flag. Figure 3-21 Tray 2 pa per surface 1 and 2 3. Check the co ntrol-panel display for sensor resp onse. 4. If there i s no re sponse, re place the cassette-pi ckup asse mbly. S ee Tray-pi ckup[...]

R Tray 2 paper size switches NOT E: These switc hes also detec t cassette pre sence. If these swi tches fail , the mes sage TRAY <X> OPEN could a ppear on the con trol-panel display . 1. Remove th e tray. From inside the tray cavi ty, push any of the t hree butto ns. Figu re 3 -22 Test th e Tray 2 pap er size switche s 2. Check th e contr ol-[...]

S Tray 3 paper present sens or See P Tr ay 2 pap er pr esen t se nsor on page 262 . T Tray 3 feed senso r 1. Remove th e tray. 2. Insert a piece of pa per between the rolle rs to acti vate the f eed sensor . TIP: Use s tiff paper wh en performi ng this tes t (for exam ple a busi ness card or ind ex card). Figure 3-23 Test the Tray 3 feed sensor 3. [...]

Z Tray 4 paper size switches See R Tray 2 paper si ze switches on p age 264 . a Tray 5 paper p resent sens or See P Tray 2 paper pre sent senso r on page 262 . b Tray 5 feed senso r See T Tray 3 feed sens or on page 26 5 . c Tray 5 paper surfa ce 1 and 2 sensors See Q Tray 2 paper surfac e 1 and 2 sensors on page 263 . d Tray 5 paper size switches [...]

5V l aser a nd 24 V int erl ock a nd log ic sw itch es ( and powe r swit ch) Location a nd testing 1. Press the p ower switch to turn the product off then on to test the sw itch functio n. 2. Remove the rig ht-front cover. See Right-front cover on page 10 3 . 3. Locate the link arms (callout 1) on the fr ont and righ t doors (and access por ts in t[...]

4. Open and close the doors to ma ke sure that the interlock switches are corr ectly func tioning. Th e following fi gures show the interlock switc h position with the front and right do ors open and close d. Defeating ● Front-d oor safety swi tch ◦ Fold a s tiff piec e of paper, for example a business card or ind ex card, in to a 10 mm ( .375 [...]

● Front-door logic sw itch ◦ Fold a st iff piece of paper, for exam ple a bus iness card or index card , into a 10 m m (.375 in) strip w ith a bend a t the end, and insert the stri p into the op ening at the front of t he produc t. ● Right-door safety swi tch ◦ Fold a st iff piece of paper, for exam ple a bus iness card or index card , into[...]

● Right-doo r logic sw itch ◦ Use mas king tape to keep the s witch flag d epressed. TIP: You might ha ve to use two pi eces of tape to overcome the tens ion return spring on the flag. 270 C hapter 3 Solve problems ENWW[...]

New ITB sensor NOT E: This sen sor cannot be tested, bu t you can i nspect the sensor, ac tuator, an d the flag on the ITB fo r damage . 1. Remove the e xisting ITB. 2. Inspect t he new ITB sensor. Pr ess the ac tuator on th e sensor to ward the cy an print c artridge to verify tha t the actuator moves. Figure 3-24 Test the ne w ITB sensor 3. On th[...]

Tray 3, 4, and 5 right door switch NOT E: There is no manual s ensor test for thi s sensor. 1. Open the paper fee der right door . Check the control-pan el displ ay for the CLOSE LOWER RIGHT DOOR message . If the m essage does not displ ay, open the door and inspect the f lag for da mage (callou t 1). 2. Insert a piece of pa per to activ ate the se[...]

Paper-path sensors tes t This test dis plays the statu s of each paper-path se nsor and allows viewing of sensor stat us while printi ng inte rnal pages. 1. Press the Hom e button. 2. Press the dow n arrow to highl ight the DIAGNOSTICS , menu and then press the OK button . 3. Press the dow n arrow to highl ight the PAPER PA TH SENS ORS option, and [...]

When t he timer trips, the control pane l display show s the message PRINTING ST OPPED To cont inu e press OK . Pressing Hom e will print the previously selected job. If you do not want t he previ ous job to print, p ress Stop first, and then press Me nu . NOT E: Do not try to perform a p rint/stop test wh ile the product is calibrating, bec ause y[...]

Comp onent test Mo tor or sole noid nu mber Comme nts YELLO W LASER SCANNER M9 Activates the yellow/magenta scanner mo tor for 10 se conds. FUSER MOTOR M2 Acti vate the fus er motor at a specified speed for 10 seconds. FUSER PRESSURE RELEASE MOTOR M2 reverse R everses the fuse r motor and pressuri zes or depressurizes the fuser. ALIEN ATION MOTOR M[...]

Compone nt test Mot or or sol enoid nu mber Comments DUPLEX REFEE D CLUTCH SOLENOID SL2: duplex rever se solenoid A ctivates the duplex flapper solenoid for 10 seconds causing the switch-back diverter t o move. REPEAT Allows you t o specify the number of times the product sequences. The choices are ONCE (default) and CONTINUOUS . To termin ate the [...]

Diagrams Block diagrams Figure 3-27 Product c ross secti on 11 12 13 14 15 16 17 18 19 22 1 2 3 4 5 6 7 8 9 10 20 21 Item Description Item Descrip tion 1 ITB 12 Med ia sensor 2 Primary transfer r oller 13 Regist ration shutter 3 Duplex flapper (d uplex model) 14 MP tray pickup roller 4 Duplex reverse roller (duplex model) 15 MP tray separation pad [...]

Figure 3-28 Optional paper feede r (1 x 500-sheet) 1 2 3 4 5 Item Description 1 Pickup roller 2 Feed roller 3 Separation roller 4 Storage s pace 5 Cassette 278 C hapter 3 Solve problems ENWW[...]

Figure 3-29 Optio nal paper fe eder (3 x 500-sh eet) 1 2 3 4 Item Description 1 Pickup roller 2 Feed roller 3 Separation roller 4 Cassette ENWW Tools fo r troublesho oting 279[...]

Plug/jack loc ations 1 2 3 4 1 Hi-speed USB 2. 0 printing port 2 Local area net work (LAN) ethernet ( RJ-45) networ k port 3 EIO interface expansion slot 4 Slot for a cable-type security lock Figure 3-30 Formatter PCA 2 1 3 4 Table 3-9 For matter PCA Item Description 1 DIMM slot 2 Internal hard dr ive 3 USB por ts 4 EIO sl ot 280 C hapter 3 Solve p[...]

Location of connectors DC controller connector locations NOT E: The DC controll er has 36 connectors : Five are for FFCs, 27 are for wire har nesses, and fou r are n ot use d. Figure 3-31 DC controller c onnector l ocations J130 J160 J123 J127 J162 J145 J131 J147 J1 15 J103 J1 14 J152 J1 10 J1 1 1 J1 12 J150 J126 J161 J105 J101 J120 J1 16 J1 13 J10[...]

J106 : not used J123 : fuser motor (M2) J151 : LVPS J107 : Tray 3, 4, and 5 lifter mo tors (M7), and cassette paper size switch (SW4) J126 : memory tag co nnector J152 : 5V interlock switch (S W1) J108 : environmental sensor J127 : pre-expos ure LEDs (rear), fuser delivery sensor (SR5), New ITB sensor (SR10) J153 : power sup ply fan (FM1) J110 : YM[...]

Controller PCA (1 x 500-sheet and 3 x 500-shee t optional paper feeders) Figure 3-32 Controll er PCA conne ctors J404 J409 J407 J403 J402 J401 J410 J408 J406 J405 Table 3-11 C ontroller PCA co nnectors J401 : not u sed J402 : lifter motor 3 signal J403 : cassette media presence 3 J404 : right door open sensor J405 : lifter motor 2 signal J406 : cas[...]

Locations of major components Figure 3-33 Exter nal compon ent locatio ns 1 2 3 4 5 6 7 8 9 10 11 12 Item Description Item Description 1 Rear-top cover 7 Power-supply cov er 2 Right-door assembly 8 Rear cover 3 Right-rear cover 9 Tra y 2 4 Right-front cover 10 Front-door a ssembly 5 Upper-left cover 11 Control-panel assembly 6 Left cover 12 Front-t[...]

Figure 3-34 Major component loc ations (1 of 3) 1 5 6 2 3 4 Item Description 1 Main drive assembly 2 Fuse r 3 Registration assembly 4 Toner collection unit 5 Laser/scanner assembly (C/Bk) 6 Laser/scanner assembly (Y/M) ENWW Tools fo r troublesho oting 285[...]

Figure 3-35 Major c omponent loc ations (2 of 3 ) 1 2 3 4 5 6 7 8 9 Item Description Ite m Description 1 Duplex-drive assembly 6 Deli ver y f an 2 MP tray as sembly 7 Cartridge fa n 3 Delivery assembly 8 Residual toner full sensor 4 RD s ensor assembly 9 R esidual-toner-feed motor 5 Tray-picku p assembly 286 C hapter 3 Solve problems ENWW[...]

Figure 3-36 Major component loc ations (3 of 3) 1 2 3 4 5 6 Item Description 1 Fuser-drive as sembly 2 Tray-pickup drive as sembly 3 Secondary tra nsfer assembly 4 ITB 5 Lifter-drive assembly 6 Lifter base assembly ENWW Tools fo r troublesho oting 287[...]

Figure 3-37 Motors, fans, and ro llers co mponent loca tions 1 2 3 4 5 6 7 8 9 10 11 12 16 13 14 15 Ite m Description Item Description 1 Fuser mot or 9 Tray 2 feed roller 2 Pickup motor 10 Tray 2 s eparation roller 3 Tray 1 separat ion pad 11 Tray 2 pickup roller 4 Yel low drum mo tor 12 Secondar y transfer roller 5 Magenta drum motor 13 Bl ack dru[...]

Figure 3-38 PCA c omponent locations 1 2 3 4 5 6 Item Description Item Descripti on 1 Inte rconnect board (ICB) 4 H igh-voltage power supply upper (HVPS-T) 2 DC c ontroller PCA 5 High-voltage pow er supply lower (HVPS-D) 3 Low-volt age power supply 6 Environ ment sensor PCA ENWW Tools fo r troublesho oting 289[...]

Figure 3-39 Optio nal paper fe eder (1 x 500-she et) compone nt locations (1 of 2) 1 2 3 5 6 8 4 7 Item Description Ite m Description 1 Rear-ri ght cover 5 Rear cover 2 Rig ht door 6 Rig ht front cover 3 R ight cover 7 Front d oor 4 Le ft cover 8 Tray 3 290 C hapter 3 Solve problems ENWW[...]

Figure 3-40 Optio nal paper fe eder (1 x 500-she et) compone nt locations (2 of 2) 1 2 3 5 4 Item Description Item Descripti on 1 Lifter-drive ass embly 4 Controller PCA 2 Pi ckup motor 5 Lifter base assembly 3 Picku p assembly ENWW Tools fo r troublesho oting 291[...]

Figure 3-41 Optio nal paper fe eder (3 x 500-she et) compone nt locations (1 of 2) 1 2 3 5 6 4 7 Item Description Ite m Description 1 R ear right cove r 5 R ear cover 2 Rig ht door 6 Rig ht front cover 3 R ight cover 7 Tray s 3, 4, and 5 4 Le ft cover 292 C hapter 3 Solve problems ENWW[...]

Figure 3-42 Optio nal paper fe eder (3 x 500-she et) compone nt locations (2 of 2) 1 2 3 5 4 Item Description Item Descripti on 1 Lifter -drive assembly (Trays 3, 4, and 5) 4 Controller PCA 2 Pi ckup motor 5 Lifter base assembly (Trays 3, 4, and 5) 3 Picku p assembly (Trays 3, 4, and 5) ENWW Tools fo r troublesho oting 293[...]

General timing c hart Figure 3-43 General timing chart STBY STBY Operation PRINT INTR LSTR 1 Cassette pickup solenoid 2 TOP sensor 3 Fixing delivery sensor Print command 9 C drum motor 10 K drum motor Y drum motor 7 5 Scanner motor 8 M drum motor 6 TOP signal 4 Fixing motor 11 ITB motor 13 Primary charging bias Y 16 Primary charging bias K 14 Prima[...]

Circuit diagrams Figure 3-44 General circuit dia gram (1 of 2) 6 4 5 TAG (Bk) TAG (C) T AG (M) TAG (Y) SL SL 23 M M MM 29 29 21 21 M 23 23 23 M A4 B5 +5VB +5VB SGND +3.3V DUP_SL +5V +5V +5V +5V RD-SNS 1TR1S 1TR2S HVTCL K 2TRS 2TRCNT DUPSL DEVHP SGND 3.3V S PGND 24VA PGND 24VA /VDO12O LD1CTRL2 LD1CTRL1 LD1CTRL0 LD2CTRL2 LD2CTRL1 LD2CTRL0 LD3CTRL2 LD[...]

Figure 3-45 General circuit d iagram (1 of 2) A 3 32 B C D MM TP M 35 CL B7 A5 B7 A5 SL M M M M SL MEDIA-SNS HEA TER1 N L +5VB +5VB +5VB +5VB +24VB FP 0 FPCLK /FPCS SGND PGND +24V A LED_O N PREEXP1 MEDIA-SNS PREEXP4 PREEXP3 PREEXP2 PGND PGND +24VA +24VA +24VA +24VA PGND PGND +24VA +24VA PGND PGND +24VB +24VB PGND PGND 3.3V S SGND 3.3V S SGND DRMHP3[...]

Figure 3-46 Pa per feeder circuit diagram ( 1 X 500 -sheet) A 65 4 3 2 1 B C D SL M M B5 A4 DCC I/F GND T3_PSNS T3_PL VL_P T3_PL VL_A GND T3_P ATHS +24V T3_PICK_SL HRD_TMG +3.3V GND +24V GND CLK STS CMD GND T3_SIZE2 T3_SIZE1 T3_SIZE3 T3_LIFT_MTR +24V AOUT1 AOUT2 BOUT2 BOUT1 +3.3U +3.3U J1 1LH 12345 J1 1L J18LH 1234 J17D J17LH J10LA J10L J10LB 1 2 3[...]

Figure 3-47 Paper feeder circ uit diagram (3 X 500 -sheet) A 65 4 3 21 B C D SL M M M SL A4 B5 M SL J24DH DCC I/F +24V GND GND GND T3_PSNS T3_PLVL_P T3_PLVL_A GND T3_PA THS +24V T3_PICK_SL J150DH T3_SIZE1 T3_SIZE2 GND T3_SIZE3 +24V T3_LIFT_MTR AOUT2 BOUT1 BOUT2 AOUT1 J19 T4_PICK_SL +24V T4_PA THS GND T4_PLVL_A T4_PLVL_P T4_PSNS GND T4_SIZE1 T4_SIZE[...]

HP Easy Printer Care Open the HP Easy Printer Ca re softwa re Use one of the fol lowing method s to open the HP E asy Printer Care softwa re: ● On the Start menu, select Progra ms , select Hewlet t-Pac kard , select HP Easy Pri nter Care , and then cl ick Start HP Easy Printer Care . ● In the Windows sy stem tray (in the lo wer-right corne r of[...]

Section Options Support tab Provides links to s upport information ● Device Status section: This section shows product -identification information and the product s tatus. It indicates product -alert conditions, such as a print cartridge that is at its esti mated end of life. After you correct a p roblem with the product, click the refresh button[...]

Section Option s Alert Settings link NOTE: This item is available from the Overview and Support tabs. Click Al ert Settings to open the Alert Settings window, in which you can configure alerts for each product. ● Alerting is on or off: Activates or deactivates the alerts feature. ● Printer Alerts : Select the option to receive alerts for critic[...]

Internal pri nt-quality test pages Print-quality-troubleshooting p ages Use the buil t-in print-q uality-tro ubleshooting pages to help dia gnose and solve print-quali ty problems. 1. Press the Hom e button. 2. Press the dow n arrow to highl ight DIAGNOSTICS , a nd then pres s the OK button. 3. Press the dow n arrow to highl ight PQ TROU BLES HOOTI[...]

Figure 3-49 Yellow print -quality trou bleshooting pa ge Ye l l o w Gr een Figure 3-50 Ye llow compar ison page Gr een Y ello w Yellow cannot be e asily seen unless c ombined w ith cyan, s o half of each page i s yellow a nd the othe r half is an ampl ified vers ion of y ellow probl ems (gree n half). Compare the yellow o n page one wi th the corre[...]

Figure 3-51 Black prin t-quality tro ubleshooting pa ge 1 3 2 1. Grids The grids are in inches and m illimeters. They are label with letters and numbers so that defects can be described by position and b y distance between rep eats. 2. Color plane regis tration (CPR) bars After printing, the box with no extra color in each area on eac h page shows [...]

Diagnostics page Use the diagnostic s page to ev aluate prob lems wit h color plane registra tion, EP parameter s, and pr int qual ity. 1. Press the Hom e button. 2. Press the dow n arrow to highl ight DIAGNOSTICS , a nd then pres s the OK button. 3. Press th e down arrow to hi ghlight PRINT DIAGNOSTICS PAGE , and the n press the OK butt on to prin[...]

Cleaning page Create and use th e cleaning page 1. Press the Hom e button . 2. Press the up arrow or down arrow / to hig hlight the CONFIGU RE DEVICE menu, and then press the OK button. 3. Press the up arrow or down arrow / to highli ght the PRINT QUALITY menu, and then press the OK button. 4. If the produc t does not h ave automatic two-sided prin[...]

Configuration page Depe nding on the m odel, up to three pages print when y ou select PR INT CONFIGURATION . In additi on to th e main conf iguration pa ge, an em bedded Jetd irect conf iguration page pri nts. Configuration page Use the configurati on page to v iew current product set tings, to hel p troubles hoot produc t problems , or to ver ify [...]

5 Memor y 6 Event log 7 Secur ity 8 Paper trays an d options 308 C hapter 3 Solve problems ENWW[...]

HP embedded Jetdirect page The second configuration pag e is the HP embedded Jetdire ct page, which cont ains the followin g infor matio n: Figure 3-53 HP embedded Jet direct page HP Color LaserJet CP 4520 Printers Embedded Jetdirect P age Pag e 1 2 3 1 4 5 6 1 HP Jetdirect Configuration indicates the product status, model number, hardwar e firmwar[...]

Embedded pr otocol page The em bedded proto col page c ontains the followin g inform ation: Figure 3-54 Embedded protocol page HP Color LaserJet CP 3525 Printers Embedded Protocol P age Pag e 1 2 1 4 3 1 IPX/ SPX 2 Novell/NetWare 3 AppleTalk 4 DLC/LLC 310 C hapter 3 Solve problems ENWW[...]

Finding important information on the configur ation pages Certain informatio n, such as the firmware date codes , the IP address, and the e- mail gateways, i s especi ally helpful whi le servicing the product. This informati on is on the variou s configurati on pages. Table 3-12 Im portant information on the configuration pages Type of informa tion[...]

Print-quality troubleshooting tools Repetitive defects ruler If defe cts repeat at reg ular interv als on the page, use this ruler to iden tify the cause of the de fect. Place the top o f the rul er at the fi rst defect. The marking that is b eside the ne xt occurr ence of the defect indica tes which compone nt needs to be replaced. Figure 3-55 Rep[...]

Calibrate the product Calibr ation is a product functi on that optimize s print quality. If you experience an y image-qu ality proble ms, calibrate the pr oduct. 1. Press the Hom e button . 2. Press the dow n arrow to highl ight the CONFIGURE DEVICE m enu, and the n press the OK button. 3. Press the dow n arrow to highl ight the PRINT QUALITY menu [...]

Control panel menus Control panel menus You can con trol the produc t by changing setti ngs in the menus on the produ ct control panel. Use the contro l panel t o access f eatures not supporte d by the pr inter driver or softwa re applica tion, and to configu re trays for paper size and type. Show Me How menu The SHOW ME HOW menu prints pages that [...]

Item Sub-it em Sub-ite m D escription ALL JOBS (WITH P IN) PRINT PRINT AND DELETE ● COPI ES ● JOB ● CUST OM VALUE DELETE This message appears if a user has two or more stored jobs that require a PIN. If PRINT or PRINT A ND DELETE is selected then the P IN will be request ed. If the jobs have different PINs, only the jobs with the P IN entered[...]

Item Sub- item Sub-item Description ALL JOBS (NO PIN) PRINT PRINT AND DELETE ● COPIES ● JOB ● CUSTO M VALUE DELETE This message appears if a user has two or more s tored jobs that do not require a PIN. Either the PRINT option or the PRINT AND DELETE option displays, depending on the type of jobs listed. If t he stored jobs are Personal or Pro[...]

Information menu Use the INFORMATION menu to access and print specific p roduct inf ormation. To display: Press t he Home button , and then select the INFORMATION menu. Item Description PRINT ME NU MAP Prints the contro l-panel menu map, which s hows the layout and current settings of the control-panel menu items. PRINT CONFIGU RATION Prints the pr[...]

Menu item Val ue Description TRA Y 1 SIZE A list of available sizes appears. Allows you to configure the paper size for Tray 1. The defa ult is ANY SIZE . See the product user guide for a complete list of available sizes. TRA Y 1 TYPE A list of available t ypes appears. Allows you to configure the paper type for Tray 1. The defa ult is ANY TYPE . S[...]

Menu it em Sub-menu it em Value s Description COLOR CARTRIDGES STO P PROMPT T O CONTINU E * CONTINUE PRINT IN B LACK Select what the product should do when the print cartridge is very near the end of its estimated life. STOP : T he product stops until you replace the cartridge. PROMPT TO C ONTINUE : The product stops unt il you clear the prompt mes[...]

Menu i tem Sub-menu item Val ues Description USER DEFINED LOW YELLOW CARTRID GE MAGENTA CARTRIDG E CYAN CARTRIDGE BLACK CARTRIDGE Range from 0–100% Use the arrow buttons to enter the percentage of estimated cartridge life at which you want the product to alert you that the cartridge is low. TRANSFER KIT Range from 0–100% Defa ult is 2% Use the [...]

Menu it em Sub-menu it em Value s Description RESTRI CT COLOR USE EN ABLE CO LOR * COLOR IF ALLOWED DISABLE COLOR This menu item controls the authorization of color printing. DISABLE COLOR : All jobs sent to the product print only in monochrome. ENABLE COLOR : All color pages sent to the product print in color. COLOR IF ALLOWED : A permissions data[...]

Menu item Sub -menu item Values Description COPIES Range: 1 - 32000 Allows you to set the default number of copies for print jobs. The default number is 1 . DEFAULT PAPE R SIZE A list of available sizes appears. Allows you to s et the default paper size. DEFAULT CUSTOM PAP ER SIZE ● UNIT OF MEASURE ● X DIMEN SION ● Y DIMEN SION Allows you to [...]

PCL sub-menu This me nu configur es settings for the printer co ntrol language . To display: Press t he Home button , select the CONF IGUR E D EVI CE menu, se lect the PR INTING menu, an d then se lect the PCL menu . NOT E: Values that have an asterisk (*) are t he factor y-default v alues. Som e menu item s have no default. Item Value s D escripti[...]

Print Quality menu To display: Press the Home button , select the CONFIGURE DEVI CE menu, and then selec t the PRINT QUALITY menu. NOT E: Values that have an asterisk (*) ar e the factory-def ault values . Some menu items hav e no defa ult . Item Sub-it em Sub-it em Value s Description ADJUST COLO R HIGHLIGHTS ● CYAN DENSITY ● MAGENTA DENSI TY [...]

Item Sub-it em Sub-item Value s Description X1 SHIFT Y1 S HIFT X2 S HIFT Y2 S HIFT Range: -5 m m to +5 mm The scan direction is referred to as X. X1 is the scan direc tion for a single-s ided page or for the second side of a two-sided page. X2 is the scan direction for the first side of a two-sided page. The feed direction is referred to as Y. Y1 i[...]

Item Sub-it em Sub-it em Value s Description ADJUST PAP ER TYPES A list of pa per types displa ys. PRINT M ODE RESISTANCE MODE HUMIDITY MODE PRE-ROT ATION MODE FUSER T EMP MODE PAPER CURL MODE A list of p rint modes displays. Configure the print mode that is associated w ith each media type. RESTOR E MODES Us e this feature to return all paper type[...]

Item Sub-it em Sub-item Value s Description EDGE CONTROL OFF LIGHT NORMAL * MAXIM UM The Edge Control setting determines how edges are rendered. Edge control has two components: adaptive halftoning and trapping. Adaptive half toning increases edge sharpness . Trapping reduces t he effect of color-plane misregistration by overlapping the edges of ad[...]

Item Sub-it em Sub-it em Value s Description CREATE CLEANING PAGE Prints a page of instructions for cleaning excess toner off the pressure roller in the fuse r. NOTE: This option is available only for the HP Co lor LaserJet CP4025n printer and the HP Color LaserJet C P4525n printer. PROCE SS CLEANING PAGE A llows you to create and process a cleanin[...]

System setup menu Use t he SYST EM SE TUP menu to change pr oduct-confi guration defau lts such as sleep mod e, product perso nality (langu age), and jam recovery . To display: Press t he Home button , select the CONF IGUR E D EVI CE menu, an d then selec t the SYSTEM S ETUP menu. NOT E: Values that have an asterisk (*) are t he factor y-default v [...]

Item Sub-it em Valu es D escription USE REQUE STED TRAY EXCLU SIVELY * FIRST USE REQUES TED TRAY handles jobs that have specified a specific input tray. Two options are available: ● EXCLUSIV ELY : The produ ct never selects a differ ent tray when the us er has indicated that a specific t ray should be used, even if that tray is empty. ● FIRST :[...]

Item Sub-i tem Values Description USE ANOT HER TRAY ENABLED * DISABLED This option turns on or off the control-panel prompt to select another tray when the specified tray is empty. ALT ERNATIVE LETTERHEAD MODE ON OFF * When this option is ON you can load letterhead o r preprinted paper the same way f or every job, whether printing on one or both si[...]

Item Sub-it em Valu es D escription WAKE TIME <DAY O F THE WEEK> OFF * CUSTOM Select the CUSTOM option to configure the daily wake time for the product to avoid warm-up or calibration time. S elect a day of the week, set the wak e time for that day, and t hen choose whether the wake time should be applied to all days of the week. OPTI MUM SPE[...]

Item Sub-i tem Values Description AUTO CONTINUE OFF ON * Determines product behavior when the sys tem generates an Auto Continuable error. ● ON : Allows the product to continue printing. ● OFF : Stops the product from printing until the error is cleared by the user. JAM RECOVERY AUT O * OFF ON Sets whether the product will attempt to reprint pa[...]

I/O menu Items on the I/O (input/output) me nu affect the communi cation betwe en the product and the compu ter. If the pr oduct contai ns an HP Jetdir ect print se rver, you ca n configure ba sic networkin g parameters by using th is submenu. Y ou can also co nfigure these and other param eters through HP Web Jetadmin or the embe dded Web s erver.[...]

Item Sub- item Sub- item Sub-it em Description IPV4 SETTI NGS CONFIG METHOD BOOTP DHCP * AUTO IP MANUAL Specifies the method that TCP/IPv4 parameters will be configured on the HP J etdire ct print server . Use BOOTP (Bootstrap Proto col) for automatic c onfiguration from a BootP server. Use DHCP (Dynamic Host Configuration Protocol) for automatic c[...]

Item Sub- item Sub- item Sub- item D escription DH CP RENEW NO * YES This menu appears if CONFIG METHOD is set to DHCP and a DHCP lease for the print server ex ists. NO : The print server does not request t o renew the DHCP lease. YES : The print server req uests to renew the current DH CP lease. P RIMARY DNS Specify t he IP address (n.n.n .n) of a[...]

Item Sub- item Sub- item Sub-it em Description PR OXY SERVER Specifies the proxy serv er to be used by embedded applications in the product. A proxy server is typically used by network clients for Internet access. It caches Web pages, and provides a degree o f Internet secur ity, for thos e clients . To specify a proxy server, ent er its IPv4 addre[...]

Item Sub- item Sub- item Sub- item D escription IP SEC KEE P DISABLE * Specify the IPSec status on the print serv er. KEEP : IPSec status remains the same as currently config ured. DIS ABLE : IPSec operation on the print server is disabled. 802.1X RESET KEEP * Specify whether the 802.1X settings on the print serve r are reset t o the factory def au[...]

Item Sub- item Sub- item Sub-it em Description SNMP TES T YE S NO * This test checks operation of SNMP communications by access ing predefined SNMP obje cts on the product . Selec t YES to choose this test, or NO to not choose it. DA TA PA TH TES T YES NO * This test helps to identify data path and corruption problems on an HP post script level 3 e[...]

Item Sub- item Sub- item Sub- item D escription PRINT RESU LTS YE S NO * If the ping test was not set for continuous operation, you c an choose to print t he test results. S elect YES to pri nt results. If you selec t NO , results are not printed. E XECUTE YES NO * Specify whether to initiate the ping test. Selec t YES to initi ate the test, or NO [...]

Item Sub- item Sub- item Sub-it em Description RE FRESH YES NO * When viewing the ping test results, this item updates the ping test data with current results. S elect YES to update the data, or NO to maintain the existing data. H owever, a refresh automatically occurs when the menu times out or you manually return to the main menu. LINK SPEED AUT [...]

Resets menu The RESETS menu all ows you to reset factor y settings, and disab le or enable sleep mode. To display: Press the Home button , select the CONFIGURE DEVI CE menu, and then selec t the RESE TS menu. NOT E: Values that have an asterisk (*) ar e the factory-def ault values . Some menu items hav e no defa ult . Item Sub-item Values Descripti[...]

Item Su b-item Values Descrip tion PAPER PAT H SENSORS Performs a test on each of the product’s sensors to determine if they are working correctly and displays the status of each sensor. PAPER PAT H TEST Tests t he paper-handling features of the product, such as the configuration of t he trays. PRINT TEST PAGE Generates a page for testing the pap[...]

Item S ub-item Valu es Description COLOR BAND TEST PRINT TEST PA GE Prints a color band test page that is used to identify arcing in the high- voltage power s upply. COPIES Range is 1 to 30. The default value is 1. Specify how many copies of the internal page are printed. Servi ce menu The SERVIC E menu is locked an d requires a P IN for acces s. T[...]

Interpret control-panel messages Contr ol-pan el mess age ty pes Four ty pes of contr ol-panel m essages can indicate the status o f or probl ems with t he produ ct. Message type Description Status messages S tatus messages reflect the current state of the product. They inform yo u of normal product operation and require no int eraction to clear th[...]

Description Rec ommended action 11.XX Internal clock error To continue press OK The product real-t ime clock has experienced an error. ● XX = 01; clock battery failed ● XX = 02; real time clock failed Whenever the product is turned off and then turned on again, set the time and date at the control panel. See System setup menu on page 329 . If t[...]

Description Recommended action 22 EMBEDDED I /O BUFFER OVERFLOW To continue press OK Too much dat a was sent to th e embedded HP Jetd irect pri nt server. Press the OK button to print the transferred data. (Some data might be lost.) Check the host configuration. 22 PARALLEL I/O BUFFER OVERFLO W To continue press OK The product's parallel buffe[...]

Description Rec ommended action 49.XX XX ERROR To continue turn off then on A firm wa re er ror ha s oc curr ed. This error can be caused by corrupted print jobs, software applications issues, non- product sp ecific printer drivers, poor-quality USB or network cables, bad network connections or incorrec t configurations, invalid firmware oper ation[...]

Description Recommended action 50.3 FUSER ERROR High fuser temperat ure Reinsta ll the f user. Check connec tor J50 between the fuse r and the product. If either is damaged, replace the connector or fuser. See Fuse r on page 85 . If the error persists, replace the low-voltage power supply. See Low-voltage power supply (LVP S) on page 157 . 50.4 FUS[...]

Description Rec ommended action 50.9 FUSER ERR OR High fuser temperature. Reinstall the fuser. Check the connector J5 0 between the fuser and the product. If either is damaged, replace the connector or fuser. See Fuse r on page 85 . If the error persists, replace the low-voltage power supply. S ee Low-voltage power supply (LVP S) on page 15 7 . 50.[...]

Description Recommended action 56.X ERROR To continue t urn off then on A temporary printing error has occurred (XX = 01; illegal input ). Turn the product off, and then turn the product o n. 57.03 ERROR To continue t urn off then on Cartridge fan (FM2) is defective. 1. R econnect the cartridge fan connector J65, connector J263 on the high-volt age[...]

Description Rec ommended action 59.20 ERROR Motor rotation err or. Perform the motor component tests in the DIAGNOSTICS menu. 59.30 ERROR Fuser motor start up error Reconnect the connector J1 3 of the fuser motor and the connector J123 o n the DC controller PCA. Perform the fuser mot or component test in the D IAGNOSTICS menu. If the message persis[...]

Description Recommended action 59.63 ERROR Yellow image drum motor rotation error Perform the drum-motor s component test in the DIAG NOS TIC S menu. If the m essage persists, replace the yellow dru m motor. See Yellow, magenta, cyan, and black drum motors on page 199 . 59.90 ERROR ITB motor startup error Reconnect the connector J14 of the ITB moto[...]

Description Rec ommended action 59.F0 ERROR Transfer alienation failure 1. Verify that the ITB is installed. 2. Reconnect the primary-trans fer disengagement sensor J19, and connector J128 on the DC c ontroller PCA . 3. Run the sensor test in the sensor monitor mode to v erify that the pr imary transfer disengagement sensor is functioning properly.[...]

Description Recommended action 60.04 ERROR Tray 4 is not lifting correctly. 1. Reconnect connector J406 on the paper deck controller PCA and the intermediate connector J21. 2. Run the s ensor test in sensor monitor mode to verify that the cassette media stack surfac e sensor is functioning properly. If it is not, replace t he pickup assemb ly. See [...]

Description Rec ommended action 68.X PER MANE NT ST ORAG E W RITE F AIL To continue press OK The product NV RAM is failing to wr ite. Printing can continue, but some unexpected functions might occur if an error occurred in permanent storage. X value s ● 0 = Internal memor y ● 1 = Removable disk Press the OK button t o clear the message. If the [...]

Description Recommended action Ba d Signa ture Upgrade cancelled The firmware upgrade code does not match the product signature. Download the correct firmware upgrade f ile for this product, and then reinstall the upgrade. See the produ ct user guide for more information. BLACK CA RTRIDGE LOW The product indicates when a supply level is low. Actual[...]

Description Rec ommended action CARD SLOT DEVIC E FAILURE To clear press OK The specified devic e has failed. Press the OK button to clear. CARD SLOT FILE OPER ATION FAILED To clear press OK A PJL file s ystem command at tempted to perform an illogical oper ation. Press the OK button to clear. CARD SLO T FILE SYSTEM I S FULL To clear press OK A PJL[...]

Description Recommended action CLOSE LOWER RI GHT DOOR 3 x 500 optional paper feeder only The right door on the optional paper feeder is open. Close the door. If the message appears when the door is closed: 1. Reconnect connec tor J19 of the PD right door switch and connec tor J147 on the controller PCA. 2. Check the right door sensor flag. If it i[...]

Description Rec ommended action CYAN CARTRIDG E VERY LOW The pr oduct indicates when a sup ply level is very low. Actual pr int cartridge life might vary. Consider having a replacement print cartridge available to install when print quality is no longer acceptable. You do not need to replace the pr int cartridge at this time unless print quality is[...]

Description Recommended action EIO I S WRIT E PRO TECTED To clear press OK The file system device is protected and no new files can be written to it. Press the OK button to clear. EIO NOT INITIA LIZED This file-storage component must be initialized before use. Use the embedded Web server or HP Web Jetadmin to initialize t he component. Event log em[...]

Description Rec ommended action Incorrect The PIN is incorrect. Use the u p arrow an d down arrow buttons to enter the correct PIN. Initia lizin g The product is starting. N o action is necessary. Please wait until the Ready message appears on the display. Initializing permanent sto rage Displayed when t he product is turned on to show that permane[...]

Description Recommended action LOAD TRAY 1 [TYPE ] [SIZE] To continue press OK The indicated tray is loaded and configured for a type and size other th an the one specified in the job. 1. If the correct paper is loaded, press the OK button. 2. Otherwise, remove the incorrect paper and load the tray with the specified paper. 3. If prompted , confirm[...]

Description Rec ommended action LOADING PROGRAM <XX> Do no t powe r off Programs and fonts can be stored on the product’s file system and are loaded into RAM when the product is turned on. The number XX specifies a sequence number indicating the current program being loaded. No action necessar y. Do not turn the product off. MAGENTA CARTRI [...]

Description Recommended action MANUALLY F EED OUTPUT STACK Then press OK to print second side The product has printed the first side of a manual duplex job and is waiting for t he user to insert the output stack to print the second side . 1. Maintaining th e same orientation, remove document from the output bin. 2. Flip document p rinted side up. 3[...]

Description Rec ommended action Processing... The product is currently processing a job but is not yet pick ing pages. When paper motion begins, this message will be replaced by a message that indicates which tray the job is being printed from. No action is necessary. Processing... CLEANING PAGE The product is processing a cl eaning page. No ac tio[...]

Description Recommended action REM OVE S HIPPI NG SH EET The transfer unit shipping sheet was not removed bef ore you turned t he product on. 1. Open the right door. 2. Remove the s hipping sheet. 3. Close the r ight door. REPLACE <COL OR> CARTRIDGE The product indicates when a supply level is at its estimated end of life. The actual lif e re[...]

Description Rec ommended action REPLACE SUPPLY Printing bl ack only At least one print cartridge has reached the very low con dition and you have s et the COLOR CARTRIDGES items to the PRINT IN BLACK opt ion. The supply lif e remaining is used to determine if a s upply is very low. The supply life remaining is an approximation only and varies depen[...]

Description Recommended action ROM DISK FILE OPERATIO N FAILED To clear press OK A PJL file syst em command atte mpted to perform an illogical ope ration. Press the OK button to clear. RO M DISK FI LE SYSTE M IS FULL To clear press OK A PJL file s ystem command c ould not store something on the file system because the file system was f ull. Press t[...]

Description Rec ommended action SUPP LIES LO W This message appears when at least two supplies ha ve reached the low thre shold. The actual supply life r emaining might vary. You do not need to replace the supplies at this time unless print quality is no longer acceptable. After a n HP supply has reached the very low threshold, the HP premium prote[...]

Description Recommended action TONER COLLECTION UNIT LOW The toner collection unit is almost full. The actual supply life remaining might vary. You do not need to replace the toner collection unit at this time unless print quality is no longer accepta ble. To continue printing, either press the OK button or replace the toner collect ion unit. See T[...]

Description Rec ommended action TRAY <X> [TYPE] [ SIZE] To change size or type press OK To accept settings press This message states the c urrent type and size configuration of the tray. To change size or type press the OK button. To accept settings press the back arro w . TRAY <X> EMPTY [T YPE ] [SIZE] The s pecified tray is empty an d[...]

Description Recommended action UNSU PPO RTED D RIV E INST ALLE D A non-supported hard drive has been installed. Turn off the product, remove the hard drive, and then turn on the product. UNSU PPO RTED SU PPL Y IN US E For help press A non-supported supply has been installed. Turn off the pr oduct, remove the su pply, and then turn on the product. U[...]

Description Rec ommended action WAIT FOR PRINTER TO REINITIALIZE This message can appear for a variety of reasons: ● The RAM DI SK settings changed before the product has restarted. ● The product is restarting after c hanging external device modes. ● Diagnostics has been exited. ● A new formatter has been ins talled with an old engine or a [...]

Description Recommended action YELLOW CARTRIDGE VE RY LOW The product indicates when a supply level is very low. Actual print c artridge life might vary. Consider having a replacement print cartridge available to install wh en print quality is no longer acceptable. You do not need to replace the p rint cartridge at this time unless print quality is[...]

Event log messages This secti on describes mess ages that only appea r in the event log . For additiona l numeric mes sages, see the control -panel messa ge section in this manual . See Control- panel mess ages on p age 345 . Print an event log Use the event lo g to help di agnose an d solve prod uct proble ms. 1. Press the Hom e button. 2. Press t[...]

Sample event log Figure 3-56 Sam ple event l og hp color LaserJet CP 4520 Series Event Log P age 1 1 2 3 4 5 6 7 1 Product information 2 Event number 3 Date and tim e 4 Engine cycles 5 Event log code 6 Firm wa re ve rsi on nu mbe r 7 Description of personality Clear th e event log Use the SERVICE menu to cle ar the ev ent log. 1. Press the Hom e bu[...]

Event log me ssage table Event log message Description Comm ents 10.XX.00 Black toner cartridge 10.XX.01 Cyan toner cartridge 10.XX.02 Magenta toner cart ridge 10.XX.03 Yellow toner cartridge 10.XX.04 Drum cartridge 10.XX.05 Black drum cartridge 10.XX.06 Cyan drum cartridge 10.XX.07 Magenta drum cart ridge 10.XX.08 Yellow drum cartridge 10.XX.22 Tr[...]

Event log message Description Comm ents 13.13.00 DUPLEX PA TH, PAPER STOPPED JAM 13.1C.00 FUSER ACCORDION JAM 13.20.00 PRINTER COULD NOT AUTOMA TICALLY EJ ECT PAPER 13.21.00 DOOR OPEN JAM 13.30.00 PAPER FEE D 1, PAPER LA TE JAM 41.XX.00 ● X=11 Yellow laser scanner ● X=12 Magenta laser scanner ● X=13 Cyan laser scanner ● X=14. Black lase r s[...]

Event log message Description Comm ents 54.0B.XX The density sensor is out of range. ● XX = 00 Blac k ● XX = 01 Cyan ● XX = 02 Magenta ● XX = 03 Yellow 54.0C.XX Halftone calibration error. ● XX = 00: Black Dhalf warning ● XX = 01: Cy an Dhalf warning ● XX = 02: M agenta Dhalf warning ● XX = 03: Yellow Dhalf warning 54.0D.XX ● XX =[...]

Event log message Description Comm ents 54.1E.XX Halftone calibration error ● XX = 00 B ad internal data ● XX = 01 B ad external data ● XX = 02 M emory allocation ● XX = 03 No def ault tables ● XX = 04 B ad parameters ● XX = 05 Cyan data is out of range. ● XX = 06 M agenta data is out of range. ● XX = 07 Yellow data is out of range.[...]

Event log message Description Comm ents 68 8X05 The permanent storage date does match the engine. Disk error: either the numbe r does not match or the wr ite failed 74.00 New registration roller 8x7345 The disk was successfully cleaned and sanitized. x = slot number 8x7346 The hard disk or compact flash disk cleaning or sa nitizing failed. This is [...]

Clear paper jams Common causes o f jams The product is jammed. Cause Soluti on The paper does not meet specifications. Use only paper that meets HP s pecifications. See the product user guide. A component is installed incorrectly. Verify that the transfer belt and transfer roller are correctly installed. You are using paper that has already passed [...]

The pr oduct i s jam med. Cause Soluti on Not all product packing material was removed. Verify that the packing tape, car dboard, and plastic shipping locks have been removed fr om the product. The HP postcard media insert is installed in Tray 2, and you are not printing on 10 x 15 cm (4 x 6 in) paper. Or The HP postcard media insert is not install[...]

Item Description Item Descri ption X SR7 (PDU) Tray 4 feed sensor F SR6 Delivery tray media full sensor b SR10 (PDU) Tray 5 feed sensor X-1 Registration stop position A SR20 Top-of-Page sensor (TOP) X-2 Duplex media waiting position 1 (duplex models only) B, C SR14/15 Loop sensor s 1/2 X-3 Duplex media waiting position 2 (duplex models only) D SR5 [...]

Jam locations Use this illustrat ion to iden tify locatio ns of jams. In addition, instructions appear on the c ontrol panel to direc t you to the l ocation o f jammed paper and h ow to clear it. NOT E: Internal areas of th e product th at might need to be op ened to c lear jams have green handles or green labe ls. Figure 3-58 Jam loc ations 2 3 5 [...]

Type of jam Procedure 13.XX.YY JAM IN TRAY 1 See Clear jams in Tray 1 on page 390 . 13.XX.YY JAM IN TRAY 2 See Clear jams in Tray 2 or optional Trays 3, 4, or 5 on page 392 . 13.XX.YY JAM IN OPTIONAL TRAYS See Clear jams in Tray 2 or optional Trays 3, 4, or 5 on page 392 . 13.XX.YY JAM IN LOWER RIGHT DOOR See Clear jams in the low er right door ( T[...]

3. If paper is visible entering the bottom of the fuser, gently pull downward to remove it . CAUTION: Do not touc h the rollers on the transfe r roller. Contaminants can affect print quality . 4. If paper is jammed as it enters the outp ut bin, remove the fuse r and gently pull th e paper downward to remove it. 5. P aper could be jammed inside the [...]

7. Ope n the jam-acce ss door. If paper is jam med inside the fuser, gently pu ll it st raight up t o remov e it. If the p aper tears, remove all paper fragme nts. CAUTION: Ev en if the body of the fuser has cooled , the roller s that are inside could st ill be hot. Do not touch the fus er rollers until the y have c ool ed. 8. C lose the jam-a cces[...]

Clear jams in the output b in area 1. If paper is vis ible from the output bin, grasp the leading edge and remove it . Clear jams in Tray 1 1. If jammed paper is vis ible in Tray 1, clear the jam by gently pul ling the p aper strai ght out. Pres s the OK button to c lear the mess age. 2. If you canno t remove the paper, o r if no jam med paper is v[...]

3. Gen tly pull the paper ou t of the p ick up are a. 4. C lose the right door . ENWW Clear pap er jams 39 1[...]

Clear jams in Tray 2 or optional Trays 3, 4, or 5 CAUTION: Open ing a tra y when paper is jamme d can caus e the pape r to tear a nd leave pieces of paper in the tr ay, which m ight cause another jam . Be sure t o clear ja ms before o pening th e tray. 1. Ope n Tray 2 and make sure that the paper is stacke d correctly . Remove any jam med or damage[...]

Clear jam s in the lower ri ght door (Tray 3, 4, or 5) 1. Ope n the lowe r right door. 2. If paper is visible, gently pull the jammed paper up or down to remove it. 3. C lose the lower right door . ENWW Clear pap er jams 39 3[...]

Jam causes and solutions For loca tions o f jam sens ors, see Jam d etecti on on page 55 . Jams in the output bin Table 3-16 C auses and so lutions for d elivery delay j am Cause So luti on The output-bin full sensor flag is damaged. Rep lace the paper delivery assembly. See Delivery assembly on page 145 . See Manual sensor test (special-mode test)[...]

Cause So luti on The output bin full sensor on the face-down tray has a poor connection. Reconnect c onnector (J47) on the output bin full sensor and (J128) on the D C controller PCA. The output bin full s ensor is defective . Run the manual sensor test to verify the output bin full sensor is functioning properly. See F output bin full sensor on pa[...]

Table 3-20 C auses and sol utions for resid ual medi a jams Cause So luti on The sensor detecting a residual media jam is not working. One of the four sensors is reporting a residual jam. T est each sensor using the manual sensor test. See Manual sensor test (special-mode test) on p age 246 for information. If t he sensor does n ot respond, replace[...]

Cause So lution The pickup so lenoid is defective. Run the solenoid drive test in the actuator drive mode to verify that the pickup solenoid is functio ning properly. If it is not, replace t he tray-pickup drive assembly. See Tray-pickup driv e assembly on page 178 . The pickup motor is defective. Run the pickup motor drive test in the actuator dri[...]

Cause So luti on Poor contact of the duplex re-pickup sensor connector Reconnect the intermediate connector (J74) and connector (J145) on the DC controll er PCA. The duplex re-pickup sensor (SR22) is defective. Run the ma nual sensor test t o verify that the dup lex re-pickup s ensor (SR22) is functioning properly. See Manual sensor test (special-m[...]

Cause So luti on The spring of the duplex repickup s ensor lever is unhooked. Check the spring and place it in the correct position. The sensor is located in the right d oor behind the cover close to the eng ine side. The duplex pickup sensor lever is damaged. Re place the right door assembly. See Right-door assembly on page 113 . Poor contact of t[...]

Table 3-27 Caus es and solutio ns for picku p stationary jams Cause So luti on Multiple feed of media Replace an y worn or deform ed parts (tray separation pad, tray feed roller, MP tray pickup roller or MP tray s eparation pad). If replacing the MP tray separation pad, you must replace the right door assembly. See Right-door assembly on page 113 .[...]

Cause So luti on The paper-feeder p ickup solenoid is defect ive. Run the solenoid dr ive test in the actuator drive mode to verify that the paper- feeder pickup solenoid is functioning proper ly. If it is not, replace the pickup assembly of t he specific tray. See Pickup assembly ( optional paper feeder) on page 226 . Poor contact of paper-feeder [...]

Change jam recovery This produ ct provides a jam re covery featur e that reprint s jammed pages. The followin g options are avail able: ● AUTO — The product attem pts to repr int jammed pages wh en enough mem ory is av ailable. T his is the de fault settin g. ● OFF — The produc t does not try to reprin t jammed pa ges. Becaus e no memory is[...]

Solve pa per-handl ing proble ms Product feeds multiple sheets Product feeds multiple sheets Cause Soluti on The input tray is overfilled. Open the tray and verif y that the paper stack is below the maximum stack height mark. Remove exces s paper from the input tray. Print paper is s ticking together. Remove paper, flex it, rotate it 180 degrees or[...]

Product pulls from incorrect tray Cause Soluti on The paper size is not configured correctly for the input tray. Print a config uration page or use the control panel to determine the paper size for which the tray is configured. The guides in the tray are not against the paper . Verify that the guides are touching the paper. Paper does not feed auto[...]

Paper does not feed from Tray 2, 3, 4, or 5 Cause Soluti on None of the optional trays appear as input tray options. The optional trays only display as available if they are installed. Verify that any opt ional trays are corre ctly installed. Verify that the printer driver h as been configured to recognize the optional trays. An optional tray is in[...]

Envel opes ja m or wi ll not feed i n the prod uct Cause Soluti on Envelopes are se aling because the moisture content is to o high. Try using different env elopes. Store envelopes in a controlled environment. Envelope orientation is incorrect. Verify that the envelope is loaded c orrectly. This product does not support the envelopes being used. Re[...]

Product will not duplex (print 2-sided jobs) or duplexes incorrectly Cause Soluti on The product model does not support automatic 2-sided printing. The HP Color LaserJet CP4525 and HP Color LaserJ et CP4525n models do not support automatic 2-sided printing. The product configuration is not set for duplexing. In Windows, run the automatic configurat[...]

Use ma nual prin t modes Try the fol lowing multi-p urpose (MP) modes to see if they so lve the image-q uality pro blems. Thes e options can be found in the ADJUST P APER TY PES and OPTIMIZE submenu s under the PRINT QUALITY menu on the contr ol panel. Table 3-30 M P modes under the ADJUST PAPER TYPES sub menu PRINT MO DE ● AUTOSEN SE MODE ● NO[...]

FUSER TEMP MODE If you are seeing a faint image of the page repeated at the bottom of the page or on the following page, first make sure the Paper Type and Print Mode settings ar e correct for the type of paper you are using. If y ou continue t o see ghost images on your print jobs, set the Fuser Temp feature to one of the Alternate settings . T ry[...]

Solve i mage-quality problems This se ction hel ps you defi ne print-q uality problem s and wh at to do t o correct t hem. Ofte n print-qu ality proble ms can be hand led easil y by making sur e that the produ ct is main tained, using paper that meets HP speci fications, or runni ng a cleaning page . Image defects table The fo llowing e xamples dep[...]

Probl em Sampl e Cause Solu tion The page is all blac k or a solid color . Poor contact exists in the primary char ging bias or developing bias contac ts between the print cartridge and the p roduct. Clean each contact of the color that produces the all black or solid color. If the problem remains after cleaning, check the contacts for damage. Repl[...]

Probl em Sampl e Cause Soluti on Vertical white lines appear in a particular col or. The laser beam window is dirty. Clean the window and remove any foreign substances . Scratches are present on the circumference o f the developing cylinder or photosensitive drum. White scratch do wn the page could mean the scanner glass needs to be cleaned. Remove[...]

Probl em Sampl e Cause Solu tion Image in a particular color does not print in t he correct color. Poor contact exists in the primary char ging bias or developing bias contac ts between the print cartridge and the p roduct. Clean each contact of the color that produces the missing color. If the problem remains af ter cleaning, check the contacts fo[...]

Probl em Sampl e Cause Soluti on Some color is misregistered. The product is inc orrectly calibrated. Calibrate the product . The ITB unit is defective. If the ITB does not rotate s moothly or a cleaning malfunction occur s (ITB is dirty), replace the ITB. See Intermediate transfer belt (ITB) on page 92 . The drive gear of the ITB motor is worn or [...]

Probl em Sampl e Cause Solu tion The printed page contains wrinkles or creases. The roller or media feed guide is dirty. Clean any dirty components. A feed ro ller is deformed or has deteriora ted. Replace any deforme d or deteriorated ro llers. The paper feed guide is damaged. Replace the pape r-feed-guide unit. The front of the page is dirty. T h[...]

Clean the prod uct Over time, par ticles of toner and paper accumulat e inside the produ ct. This can cause print-quali ty proble ms during printi ng. Cleaning the pr oduct eliminat es or reduces these problems. Clean th e paper path and p rint-cartrid ge areas e very time tha t you cha nge the print cartri dge or whene ver print- quality problems [...]

Solve pe rformance problems Proble m Cause Soluti on Pages print but a re totally blank. The document might contain blank pages. Check the document that you are printing to see if cont ent appears on all of the pages. The product might be malfunctioning. To c heck the product, print a Configuration page. Pages print very slowly. Heavie r paper type[...]

Solve c onnecti vity p roblems Solve direct-connect problems If you have con nected the product directly to a computer, ch eck the cable. ● Verify that the cable is connected to the comp uter and to the product. ● Verify that the cable is not longer than 2 meters (6 feet). Replace the ca ble if necess ary. ● Verify that the cable is working c[...]

Check your sys tem for proper net work oper ating system se tup. 8. Is your pro tocol enabled? Check the st atus of your p rotocol on the C onfiguration p age. You can also use the emb edded Web server to check the status o f other pr otocols. S ee the prod uct user guide. 9. Does the product app ear in HP W eb Jetadmi n or other managemen t applic[...]

Servic e mode functi ons Service menu The SERVI CE menu is PIN-prote cted for added secur ity. Only author ized service peo ple have acces s to the SE RVICE menu. When yo u sel ect SERVICE from the lis t of menu s, the prod uct prom pts you to enter an ei ght-digit PIN num ber. The PINs for the HP Col or LaserJet Ent erprise CP40 20-CP4520 Series a[...]

REFURBISH PA GE COUNT The num ber of pages a produ ct is set to print when it is refurbished. The count is ke pt for legal purposes. If it become s necessary to refurbish a product, you must be able to set the page count so that it represents the age of the print engine when it was refurbished. This menu item allows SER VICE ID to be reset after be[...]

SERVIC E ID Use this item to show the date t hat the product was first used on the control panel. This eliminates the need for users to keep paper receipts for proof of warranty. Restore the servi ce ID If you replace the f ormatter, the date is lost. Use this menu item to reset the date to the original date that the product was first used. The dat[...]

Product resets Restore factory-set defaults The RESETS me nu allows y ou to re set factory settings, a nd disable or enable s leep mode. To display: Press t he Home button , select the CONF IGUR E D EVI CE menu, an d then selec t the RESE TS menu. Select RESTOR E FACTORY SE TTINGS from the su bmenu, and th en press t he OK button. Hard disk init ia[...]

Prod uct cold r eset Before beginning , print a confi guration page and supplies status page. Use these pages to veri fy resets have occurred. 1. Press the Hom e button. 2. Press the dow n arrow to highl ight the CONF IGUR E D EVIC E menu, and then press th e OK button. 3. Press the dow n arrow to highl ight the RESET menu , and then pr ess the OK [...]

4 Parts and diagrams ● Order pa rts, access ories, and sup plies ● Part nu mbers ● Screws ● How to use the parts li sts and diagrams ● External covers , panels, and doo rs ● Right doo r assembly ● Front door as sembly ● Internal c omponents ● Asse ssori es ● Alphabeti cal parts list ● Numeric al parts list ENWW 425[...]

Order par ts, accessories , and supp lies You ca n obtain the following items dir ectly from HP: ● Replacement parts: To ord er replacement parts in the U.S., go to www.hp.c om/ go/hpparts / . Outside the United States, ord er parts b y contactin g your l ocal aut horized HP service cen ter. ● Supplies a nd accessories : To order supplies in th[...]

Part numbers The fol lowing list of acc essories wa s current at the tim e of printin g. Ordering info rmation and ava ilability of the a ccessories might chang e during the life of the product. Accessories Produc t name Product number Part n umbe r HP Color LaserJet 1 x 500 Paper Feeder and stand CC422A CC493-67902 HP Color LaserJet 3 x 500 Paper [...]

Customer self repair (CSR) parts Produc t name Produc t number Part number Self-repair level Formatter assembly kit CC493-6 9001 1A HP postcard media insert replacement CC497-67902 1A Feed and separation r oller kit (Trays 2–5) Includes 1 each, feed and separatio n rollers CC493-67907 1A Secondary transfer (T2) roller kit CC493-67908 1A Tray 1 ro[...]

Uni que com pon ent s Use the followin g tables as a quick r eference to identify component p art numbers by prod uct voltage , or functi on (simplex or dup lex). Table 4-2 110V and 220V unique components Item Part num ber Fuser kit, 110 V CC493-67911 Fuser kit, 220 V CC493-67912 Low-voltage power supply, 110 V RM1-5763-000CN Low-voltage power supp[...]

Screws NOT E: The scre w illust rations in the fol lowing ta ble are for reference only. Sc rews mi ght vary in size and appear ance from those sho wn in this table. Table 4-4 C ommon fastene rs Example Descripti on Size Part Numb er Screw, with washer M3X8 X A9-1420-000CN Screw, tapping, t russ head M4X 10 XB4-7401-005CN Scre w, t ap M3X6 XA9-1503[...]

How to u se the p arts list s and di agra ms The fi gures in t his chapter s how the m ajor subas semblies i n the produc t and their component parts. A parts list tabl e follows e ach explode d view assem bly diagra m. Each table lists the item n umber, the associat ed part num ber, and the des cription of e ach part. If a pa rt is not listed in t[...]

External cov ers, pane ls, and doors Figure 4-1 External covers, p anels, a nd doors Front door assembly See Figure 4-3 Right door assembly See Figure 4-2 1 2 3 4 5 6 7 8 9 10 11 12 14 13 15 15 16 16 15 15 15 15 15 15 *A01 432 C hapter 4 Parts and diagr ams ENWW[...]

Table 4-5 Ex ternal covers, panels, a nd doors; Ref Description Part number Qty 1 Grip, left front RC2-4268-000CN 1 2 Grip, left rear RC2-4269-000CN 1 3 Cover, left upper RC2-427 0-000CN 1 4 Cover, right front RC2-4272-000CN 1 5 Cover, r ight rear RC2-4273-000CN 1 6 Cover, up per RC2-427 6-000CN 1 7 Cover, left lower RC2-4300-000CN 1 8 Cover, inner[...]

Right door a ssembly Figure 4-2 Right do or assembly 2 1 3 *A01 *A02 *A03 *A04 *A05 *A06 *A06 *A06 *A06 *A06 *A07 *A08 *A09 *A09 434 C hapter 4 Parts and diagr ams ENWW[...]

Table 4-6 Right door assemb ly Ref Description Part number Qty 1 Right door assembly RM1-5509-000CN 1 3 Cover, M.P. crossm ember R RC2-4747-000CN 1 ENWW Right d oor assem bly 435[...]

Front door a ssembly Figure 4-3 Front do or assemb ly 1 *A01 *A01 *A02 *A19 *A03 *A05 *A06 *A07 *A07 *A08 *A09 *A10 *A1 1 *A12 *A13 *A14 *A15 *A16 *A17 *A17 *A18 *A18 *A18 436 C hapter 4 Parts and diagr ams ENWW[...]

Table 4-7 Fr ont door assemb ly Ref Description Part number Qty 1 Front door assembly RM1-5506-000C N 1 ENWW Front door assem bly 437[...]

Intern al co mponents Internal components (1 of 7) Figure 4-4 Internal co mponents 1 o f 7 DUPLEX MODEL (FM3) (J62) (SR5) (J48) SIMPLEX MODEL 1 22 3 4 5 6 7 9 9 8 438 C hapter 4 Parts and diagr ams ENWW[...]

Table 4-8 Inter nal componen ts (1 of 7) Ref Description Part number Qty 1 Paper delivery f an assembly RM1-5501-000C N 1 2 Guide, paper feed, simplex RC2-456 6-000CN 1 2 Duplexing guide assembly, duplex RM1-5531-000C N 1 3 Paper delivery f an duct assembly RM1-5583-000CN 1 4 Holder, cab le RC2-3997-000CN 1 5 Rod, paper delivery fan RC2-4070-000CN [...]

Internal components (2 of 7) Figure 4-5 Internal co mponents 2 o f 7 A A PCA See Figure 4-18 PCA See Figure 4-18 (J1) (J68) (J2) (J3) (J4) 1 2 3 5 6 7 8 10 11 12 13 14 15 16 16 17 18 19 20 21 22 23 24 25 9 26 26 26 26 26 24 27 26 26 26 26 26 23 22 5 3 4 19 *A01 440 C hapter 4 Parts and diagr ams ENWW[...]

Table 4-9 Inter nal componen ts (2 of 7) Ref Description Part number Qty 1 Bushing RC2-9719-000CN 4 3 Lever, CR G. lock RC2-3986-000CN 4 4 Tray, waste toner catch RC2-4218-000CN 1 5 Spring, torsion RU6-2247-000CN 4 7 Spring, grounding RC2-4469-000CN 1 8 Bushing RC2-4470-000CN 1 12 Lift er bas e assembly RM1- 5913-000CN 1 17 Cover RC2-4403-000CN 3 1[...]

Internal components (3 of 7) Figure 4-6 Internal co mponents 3 o f 7 Tr a y See Figure 4-1 1 (SW2) (FT1) (SW5) (J45) (SW3) (J84) (SW1) (FT2) (SR7) (J46) (J60) (J66) (J82) 1 2 3 4 5 6 8 10 11 12 13 14 3 16 21 22 15 17 18 20 19 23 19 25 25 25 25 25 25 25 25 25 9 7 24 *A01 *A02 *A04 *A04 *A04 *A03 *A05 442 C hapter 4 Parts and diagr ams ENWW[...]

Table 4-10 In ternal compone nts (3 of 7) Ref Description Part number Qty 1 Hinge, front door RC2-4291-000CN 1 2 Hinge, front door RC2-4292-000CN 1 3 Cover RC2-430 8-000CN 1 5 Lever, shutter RC2-4415-000CN 4 6 Spring, compression RU6-231 6-000CN 4 7 Front inner cover upper assemb ly RM1- 5495-000CN 1 8 Interlock assemb ly RM1-5496-000CN 1 9 Waste t[...]

Internal components (4 of 7) Figure 4-7 Internal co mponents 4 o f 7 Paper delivery assembly See Figure 4-16 Fuser assembly See Figure 4-17 (FM2) (J65) (SR9) (J19) (SR6) (J47) (J78) (J63) 1 2 3 4 5 6 8 9 10 12 4 11 19 13 14 17 16 15 7 18 20 20 20 20 20 20 18 *A01 *A02 *A03 *A04 *A05 *A05 444 C hapter 4 Parts and diagr ams ENWW[...]

Table 4-11 In ternal compone nts (4 of 7) Ref Description Part number Qty 4 Spring, tension RU6-2235-000CN 4 5 Spring, tension RU6-2376-000CN 1 6 Cartridge fan assembly RM1-5499-000CN 1 8 Waste toner motor assembly RM1-5605-000C N 1 9 Laser scanner kit (includes inst ructions and one scanner assy.) CC493-6 7914 2 10 Position detect assembly RM1-550[...]

Internal components (5 of 7) Figure 4-8 Internal co mponents 5 o f 7 Right door assembly See Figure 4-2 Registration assembly See Figure 4-14 Secondary transfer assembly See Figure 4-15 Paper pickup assembly See Figure 4-12 (J83) 2 3 4 5 6 7 8 9 19 10 11 12 13 14 15 17 20 21 22 1 18 22 16 16 16 16 16 16 16 16 16 *A01 *A01 *A02 *A04 *A03 *A03 446 C [...]

Table 4-12 In ternal compone nts (5 of 7) Ref Description Part number Qty 2 Cover, inner RC2-3981-000CN 1 3 Shaft support (included in secondary transfer kit; se e Figure 4– 15) RC2-4162-000CN 1 4 Spacer RC2-4514-000CN 1 6 Guide RC2-452 7-000CN 1 7 Link, right door RC2-4726-000CN 1 8 Guide, cassette option RC2-4741-000CN 1 9 Holder, duct cable RC[...]

Internal components (6 of 7) Figure 4-9 Internal co mponents 6 o f 7 DUPLEX MODEL SIMPLEX MODEL DUPLEX MODEL (J79) (FM4) (J39) (M1 1) (J37) (M13) (J14) (M1) (J38) (M10) (J13) (M2) (J13) (M2) (J69) (SL2) (M3),(J18) (M4),(J17) (M5),(J16) (M6),(J15) 1 2 4 5 6 7 8 9 10 10A 11 12 13 12 9A 3 15 15 15 15 15 15 15 15 15 15 15 15 15 15 14 14 10B 6A 16 *A01 [...]

Table 4-13 In ternal compone nts 6 of 7 Ref Description Part number Qty 3 Duplexing drive assembly RM1-5546-000CN 1 5 Spring, tension RU6-2468-000CN 1 6A Cartridge fan RK2-2418-000CN 1 7 Flexible flat ca ble assembly (includes two FFC; DCC to laser/ scanner) RM1-5498-000CN 1 8 Main DC moto r assembly RM1-5521-000C N 4 9 Paper pickup driv e assembly[...]

Internal components (7 of 7) Figure 4-10 Internal c omponents 7 of 7 A A PCA See Figure 4-18 PCA See Figure 4-18 PCA See Figure 4-18 PCA See Figure 4-18 (J130) (J145) (J131) (J148) (J74) (J83) (J77) (J64) (J75) (J52) (J84) (J108) (J103) (J1 12) (J261) (J1 13) (J129) (J128) (J60) (J45) (J19) (J47) (J201) (J81) (J71) (J67) (J38) (J87) (J72) (J1 15) ([...]

Table 4-14 In ternal compone nts 7 of 7 Ref Description Part number Qty 4 Fan RK2-2577-000CN 1 5 Cable, flexible f lat, H.V.T. RK2-2603-000CN 1 7 Contact assembly RM1-5502-000CN 1 8 Fan cable assembly RM1-5821-000CN 1 9 H.V. power supply cable assemb ly RM1-5724-000CN 1 10 Lower main cable assembly RM1-5801-000CN 1 11 Switch, push WC2-5637-000CN 1 [...]

Cassettes 2-5 Figure 4-11 Cassettes 2-5 *A02 *A05 *A05 *A03 *A15 *A25 *A17 *A09 *A12 *A09 * A19 *A23 *A1 1 *A20 *A16 *A08 *A07 *A18 *A22 *A24 *A06 *A13 *A21 *A26 *A27 *A04 *A25 *A09 *A17 *A09 *A10 *A01 *A14 1 452 C hapter 4 Parts and diagr ams ENWW[...]

Table 4-15 Cassette Ref Description Part number Qty 1 Cassette RM1-5928-000CN 1 ENWW Intern al component s 453[...]

Paper pickup assembly Figure 4-12 Paper pickup as sembly (SL4) (J59) (J58) 1 2 2 3 3 *A01 *A02 *A03 *A04 *A05 *A06 *A07 *A08 *A09 *A10 *A1 1 *A12 *A13 *A14 *A15 *A15 *A17 *A28 *A18 *A19 *A20 *A22 *A21 *A23 *A24 *A25 *A38 *A26 *A27 *A29 *A30 *A31 *A32 *A33 *A34 *A35 *A37 *A36 *A16 454 C hapter 4 Parts and diagr ams ENWW[...]

Table 4-16 Pap er pickup assembly Ref Description Part number Qty 1 Roller, paper pickup RL1-2099-000CN 1 2 Paper feed roller RM1-0037-020C N 2 3 Paper pickup as sembly RM1-5919-000CN 1 ENWW Intern al component s 455[...]

Tray 1 paper pickup assembly Figure 4-13 Tray 1 paper pic kup assembly (SL3) (J52) (J75) (J22) (J22) (SR8) 1 2 *A01 *A01 *A02 *A03 *A04 *A05 *A06 *A07 *A28 *A08 *A10 *A1 1 *A12 *A13 *A14 *A15 *A20 *A23 *A13 *A16 *A17 *A18 *A19 *A09 *A21 *A22 *A24 *A25 *A26 *A26 *A26 *A26 *A27 *A29 *A30 *A31 *A32 *A32 *A33 *A34 456 C hapter 4 Parts and diagr ams ENW[...]

Table 4-17 Tr ay 1 paper pickup asse mbly Ref Description Part number Qty 1 Pickup roller (Tray 1) kit (includes instructions) CC493–679 06 1 2 Separation pad (Tray 1) RL1-1937-000CN 1 ENWW Intern al component s 457[...]

Registration assembly Figure 4-14 Regist ration a ssembly (J53) (J23) (J27) (J74) (J77) (J21) (J20) DUPLEX MODEL SIMPLEX MODEL (J53) (CL1) 1 *A13 *A01 *A02 *A03 *A04 *A05 *A05 *A05 *A05 *A06 *A07 *A08 *A08 *A09 *A09 *A09 *A10 *A1 1 *A23 *A12 *A14 *A15 *A15 *A16 *A17 *A18 *A19 *A20 *A21 *A22 *A24 *A25 *A26 *A27 *A28 *A33 *A29 *A30 *A31 *A32 *A34 *A3[...]

Table 4-18 Registration ass embly Ref Description Part number Qty 1 Registration assembly kit, simplex (inc ludes instructions) CC493-67916 1 1 Registration assembly kit, duple x (includes instructions) CC493-67917 1 ENWW Intern al component s 459[...]

Secondary transfer assembly Figure 4-15 Seco ndary tran sfer asse mbly DUPLEX MODEL DUPLEX MODEL DUPLEX MODEL 1 2 *A23 *A08 *A03 *A15 *A16 *A17 *A18 *A21 *A14 *A04 *A20 *A05 *A12 *A13 *A07 *A06 *A01 *A19 *A09 *A02 *A19 *A1 1 *A10 *A24 *A26 *A22 *A25 460 C hapter 4 Parts and diagr ams ENWW[...]

Table 4-19 Secondary Tr ansfer as sembly Ref Description Part number Qty 1 Secondary transfer roller assembly kit (includes instructions) CC493-67908 1 2 Secondary transfer assembly, duplex kit (includes shaft-support clip; # 3 F igure 4–8) CC493-67901 1 2 Secondary transf er assembly, simplex kit (includes shaft-support clip; # 3 F igure 4–8) [...]

Delivery assembly Figure 4-16 De livery ass embly DUPLEX MODEL DUPLEX MODEL 1 *A10 *A1 1 *A23 *A07 *A06 *A27 *A26 *A13 *A16 *A24 *A22 *A09 *A05 *A02 *A03 *A07 *A16 *A08 *A21 *A27 *A19 *A27 *A17 *A20 *A23 *A04 *A18 *A01 *A26 *A15 *A14 *A12 *A30 *A29 *A25 *A28 SR6 J47 462 C hapter 4 Parts and diagr ams ENWW[...]

Table 4-20 D elivery assembly Ref Description Part number Qty 1 Simplex delivery assembly kit CC493-67918 1 1 Duplex delivery assembly kit CC493-67919 1 ENWW Intern al component s 463[...]

Fuser assembly Figure 4-17 Fuser as sembly 1 464 C hapter 4 Parts and diagr ams ENWW[...]

Table 4-21 F user assemb ly Ref Description Part number Qty 1 Fuser 110 V assembly kit (i ncludes instructions) CC493-6 7911 1 1 Fuser 220 V assembly kit (i ncludes instructions) CC493-6 7912 1 ENWW Intern al component s 465[...]

PCAs Figure 4-18 PCAs 1 2 3 4 7 7 7 7 9 6 8 466 C hapter 4 Parts and diagr ams ENWW[...]

Table 4-22 PCAs Ref Description Part number Qty 1 DC controller P CA assembly RM1-5758-000CN 1 2 Low voltage power supply PCA assembly, 110V RM1-5763-000CN 1 2 Low voltage power supply PCA assembly, 220V RM1-5764-000CN 1 3 High voltage power supply PCA, lower (includes FFC; DCC to HVPS lower) RM1-5779-000CN 1 4 High voltage power supply, upper RM1-[...]

Assesso ries Paper feeders Figure 4-19 Paper feeders 1x500 3x500 Cassette 3 Cassette 3 Cassette 4 Cassette 5 468 C hapter 4 Parts and diagr ams ENWW[...]

Table 4-23 Paper feeders Ref Description Part number Qty NA Cassette RM1-5928-000CN NA ENWW Ass essor ies 469[...]

Paper feeder external covers, panels, and do ors Figure 4-20 Paper feeder e xternal co vers, p anels, a nd doors 3x500 1x500 1x500 1 2 3 4 5 6 7 8 8 9 10 11 12 13 13 17 16 15 15 14 *A01 *A01 *A03 *A01 *A02 *A02 *A05 *A01 *A01 *A01 *A04 *A01 470 C hapter 4 Parts and diagr ams ENWW[...]

Table 4-24 Paper feeder exte rnal covers, panels, a nd doors Ref Description Part number Qty 4 Cover, rear low er RC2-5378-000CN 1 5 Cover, rear RC2-5379-000CN 1 7 Cover, left RC2-5393-000CN 1 8 Cover, right front, 1x500 RC2-5356-000CN 1 8 Cover, right front, 3x500 RC2-5357-000CN 1 9 Cover, r ight rear RC2-5380-000CN 1 11 Cover, right center RC2-53[...]

1 X 500 paper feeder main bod y Figure 4-21 1 X 500 paper feeder main b ody (J410) (J10) (J15) (J14) (M2) Cassette See Figure 4-1 1 (J408) (J409) (J407) (J18) (J14) (J15) (J13) (J17) (J1 1) 1 2 5 6 7 8 11 9 4 3 *A04 *A05 *A06 *A07 *A08 *A09 *A1 1 *A12 *A13 *A14 *A32 *A15 *A33 *A17 *A16 *A16 *A16 *A16 *A16 *A16 *A16 *A16 *A16 *A16 *A16 *A16 *A19 *A1[...]

Table 4-25 1 X 500 paper feeder main body Ref Description Part number Qty 3 Lifter base a ssembly RM1-5913-000C N 1 4 Lifter assem bly RM1- 5914-000CN 1 7 Paper pickup driv e assembly, 1x5 00 RM1-5934-000CN 1 8 Feeder PCA assembly, 1x500 RM1-5854-000C N 1 9 Paper pickup as sembly RM1-5929-000CN 1 ENWW Ass essor ies 473[...]

3 X 500 paper feeder main bod y Figure 4-22 3 X 500 paper feeder main b ody (J410) (J10) (J402) (J403) (J35) (J34) (J32) (J30) (J31) (J21) (J406) (J405) (J25) (J15) (J24) (J34) (J24) (J22) (J20) Cassette See Figure 4-1 1 (J14) (M2) (J409) (J408) (J404) (J18) (J19) (J14) (J15) (J13) (J17) (J1 1) (J407) 7 8 9 1 2 3 4 5 6 10 11 13 *A02 *A03 *A04 *A05 [...]

Table 4-26 3 X 500 paper feeder main body Ref Description Part number Qty 2 Lifter base a ssembly RM1-5913-000C N 1 3 Lifter assem bly RM1- 5914-000CN 1 6 Paper pickup driv e assembly 3x500 RM1-5935-000C N 1 10 Feeder PCA assembly 3x500 RM 1-5958-000CN 1 11 Paper pickup assembly RM1-5929-000C N 3 ENWW Ass essor ies 475[...]

Alphab etic al par ts list Table 4-27 A lphabetical p arts list Description Part number Ta ble a nd page Arm, door link support ing, right RC2 -4055-000CN Internal components ( 5 of 7) on page 447 Bushing RC2-9719-000 CN Internal components (2 of 7 ) on page 441 Bushing RC2-4470-000 CN Internal components (2 of 7 ) on page 441 Cable cover asse mbly[...]

Description Part n umbe r Table and page Cover, inner RM1-5520-000CN External covers, panels, and doors; on page 433 Cover, inner RC2-3981-000CN Internal components (5 of 7) on page 447 Cover, left RC2-5393-000CN Paper feeder external covers, panels, and doo rs on page 471 Cover, left lower RC2-4300-000CN External cov ers, panels, and doors; on pag[...]

Description Part number Ta ble a nd page Density detect assembly RM1-5641-000CN Internal components ( 5 of 7) on page 447 Developing disengaging motor RK 2-2415-000CN Internal components 6 of 7 on page 449 Door, stock, 1x500 RC2-5377-000CN Paper feeder external covers, panels, and door s on page 471 Duplex delivery ass embly kit CC493-67919 Deliver[...]

Description Part n umbe r Table and page Fuser drive assembly, simplex RM1-6702 -000CN Internal components 6 of 7 on page 449 Grip , left fron t RC2-4268-000CN Externa l covers, panels, and doors; on page 433 Grip, l eft rear RC2-4269-000CN External covers, panels, and doors; on page 433 Guide RC2-4527-000CN Internal components ( 5 of 7) on page 44[...]

Description Part number Ta ble a nd page Lever, shutter RC2-4415-000 CN Internal components (3 of 7 ) on page 443 Lifter assembly RM1-5914-000CN Internal components 6 of 7 on page 449 Lifter assembly RM1-5914-000CN 1 X 500 paper feeder main body on page 473 Lifter assembly RM1-5914-000CN 3 X 500 paper feeder main body on page 475 Lifter base assemb[...]

Description Part n umbe r Table and page Photo interrupter WG8-569 6-000CN Internal com ponents (3 of 7) on page 443 Photo interrupter WG8-569 6-000CN Internal com ponents (4 of 7) on page 445 Photo interrupter, T LP1243 WG8-5696-000CN Internal components (1 of 7) on page 439 Pickup roller (Tray 1) kit (includes instructions) CC493–67906 Tray 1 p[...]

Description Part number Ta ble a nd page Shutter arm assembly RM1-5585-000CN Internal components (2 of 7) on page 441 Shutter arm assembly RM1-5586-000CN Internal components (2 of 7) on page 441 Shutter assembly RM1-5488-000CN Internal comp onents (2 of 7) on page 441 Shutter assembly RM1-5489-000CN Internal comp onents (2 of 7) on page 441 Simplex[...]

Description Part n umbe r Table and page Upper main cable assembly RM 1-5800-000CN Internal components 7 of 7 on page 451 Waste toner collection kit (includes instructions and wipe) CC493-67913 Internal com ponents (3 of 7) on page 443 Waste toner detect assembly RM1-5545-000CN Internal com ponents (3 of 7) on page 443 Waste toner duct assembly RM [...]

Numerical par ts list Table 4-28 N umerical parts list Part number Description Ta ble an d pa ge CC493-67901 Secondary trans fer assembly, duplex kit (includes shaft-support clip; # 3 F igure 4–8) Secondary Transf er assembly on page 461 CC493-67902 Secondary t ransfer assembly, simplex kit (includes sh aft-support clip; # 3 F igure 4–8) Second[...]

Part num ber Descripti on Table and page RC2-4218-000CN Tray, waste toner catch Internal components (2 of 7) on page 441 RC2-4268-000CN Gr ip, left front Externa l covers, panels, and doors; on page 433 RC2-4269-000CN Grip, left rear Ex ternal covers, panels, and doors; on page 433 RC2-4270-000CN Cover, lef t upper External covers, panels, and door[...]

Part number Description Ta ble an d pa ge RC2-4741-000CN Guide, cassette option I nternal comp onents (5 of 7) on page 447 RC2-4747-000CN Cover, M.P . crossmember R Right door assembly on page 435 RC2-5356-000CN Cover, righ t front, 1x500 Paper feeder external covers, panels, and door s on page 471 RC2-5357-000CN Cover, righ t front, 3x500 Paper fe[...]

Part num ber Descripti on Table and page RK2-2604-000CN Flat flexible cable (DCC to HVPS lowe r) Internal components 6 of 7 on page 449 RL1-1937-000CN S eparation pad (Tray 1) Tray 1 paper pickup assembly on page 457 RL1-2099-000CN R oller, paper pickup Paper pickup assembly on page 455 RM1-0037-020CN P aper feed roller Paper pickup assembly on pag[...]

Part number Description Ta ble an d pa ge RM1-5520-000CN C over, inner External covers, panels, and doors; on page 433 RM1-5521-000CN Main DC motor asse mbly Internal components 6 of 7 on page 449 RM1-5525-000CN P aper feed roller assembly Internal comp onents (5 of 7) on page 447 RM1-5531-000CN D uplexing guide assembly, duplex Int ernal component[...]

Part num ber Descripti on Table and page RM1-5781-000CN H igh voltage power supply, upper PC As on page 467 RM1-5786-000CN C ontrol-panel assembly Externa l covers, panels, and doors; on page 433 RM1-5799-000CN C onnecting cable assembly Internal components 7 of 7 on page 451 RM1-5800-000CN U pper main cable assembly Internal components 7 of 7 on p[...]

Part number Description Ta ble an d pa ge RM1-5928-000CN C assette Paper feeders on page 469 RM1-5929-000CN P aper pickup assembly 1 X 500 paper feeder main body on page 473 RM1-5929-000CN P aper pickup assembly 3 X 500 paper feeder main body on page 475 RM1-5934-000CN P aper pickup drive assembly, 1x500 1 X 500 paper feeder main body on page 473 R[...]

Part num ber Descripti on Table and page WC2-5637-000CN Switch, push Internal com ponents 7 of 7 on page 451 WC4-5303-000CN Switch Internal components ( 3 of 7) on page 443 WG8-5696-000CN P hoto interrupter, TLP1243 Internal components ( 1 of 7) on page 439 WG8-5696-000CN P hoto interrupter Internal com ponents (3 of 7) on page 443 WG8-5696-000CN P[...]

492 C hapter 4 Parts and diagr ams ENWW[...]

A Service and support ● Hewlett -Packard limited wa rranty st atement ● HP's Premi um Protect ion Warranty: Laser Jet print cartr idge limited wa rranty st atement ● HP Color Lase rJet Fuser Ki t Limited Warr anty Stateme nt ● End User Lic ense Agreeme nt ● Custom er self-re pair warrant y service ● Customer support ENWW 493[...]

Hewlett-Packard limited warranty statement HP PRODUCT DURATION OF LIMITED WARRANTY HP Color LaserJet CP4025n, CP4025dn, CP4525n, CP4525dn, CP4525xh One-year on-site warranty HP war rants to y ou, the en d-user custo mer, that HP hardwar e and acces sories wi ll be free from defects in materi als and workman ship after the date of purch ase, for the[...]

HP's Premi um Pr otec tion W arran ty: La ser Jet prin t cartridge limited wa rranty statement This HP product is warranted to be fr ee from defec ts in mater ials and workmansh ip. This war ranty does not apply to products that (a) have been r efilled, refurbis hed, remanuf actured or tamp ered with in any way, (b) experi ence probl ems resul[...]

HP Color La serJet Fuser Kit L imited Warr anty Statement This HP product is warranted to be fre e from defec ts in m aterials and w orkmanship until t he printer provi des a low-life indicat or on the contr ol panel. This war ranty does not apply to products that (a) h ave been r efurbished , remanufac tured or tampered with i n any way, (b) expe [...]

End User Li cens e Agreem ent PLEASE REA D CAREFULLY BEFORE USING THIS SOFT WARE PR ODUCT: This E nd-User License Agreem ent (“EULA” ) is a c ontract betw een (a) y ou (eithe r an indiv idual or the entity y ou repres ent) and (b) Hewl ett-Packard C ompany (“HP”) that governs you r use of the software pro duct (“Softwa re”). This EULA d[...]

Software wi ll agree t o this EULA. Up on transfer of the HP Softw are, your licen se is auto matically termin ated. b. Re stricti ons . You may no t rent, leas e or lend the HP Soft ware or U se th e HP S oftw are fo r co mmerci al timesha ring or bureau use. You may not subl icense, assign or othe rwise transfe r the HP Software exce pt as exp re[...]

Cust omer self -repa ir war ranty se rvice HP produc ts are designed with many Customer Self Repa ir (CSR) parts to minimize repai r time and allow fo r greater fle xibility in performing d efective part s replacement. If during the di agnosis peri od, HP identifi es that th e repair can b e accomplis hed by the use of a CSR part, HP will ship tha [...]

Customer supp ort Get telephone support, free during your warranty period, for your country/region Have the pr oduct name, serial num ber, date of purchase , and problem description read y. Country/region phone num bers are on the flyer t hat was in the box with your product or at www.hp.com/ suppo rt/ . Get 24-hour Internet support www.hp.co m/ su[...]

B Product specifications ● Physic al specifica tions ● Perfo rmance spec ifications ● Electri cal specifi cations ● Acousti c specific ations ● Env iro nment al sp ecif icat ions ● Skew spe cifications ENWW 501[...]

Physical sp ecifications Table B-1 Product d imensions Produc t Height Depth Width Weight HP Color LaserJet CP4025n 420 mm (16.5 in) 522 mm (20.6 in) 540 mm ( 21.3 in) 38.5 kg (84. 6 lb) HP Color LaserJet CP4025dn 420 mm (16.5 in) 522 mm (20.6 in) 540 mm ( 21.3 in) 38.5 kg (84. 6 lb) HP Color LaserJet CP4525n 420 mm (16.5 in) 522 mm (20.6 in) 540 m[...]

Table B-3 Power requirements Specification 110-volt model s 220-volt mod els Power requirements 100 to 127 volts (± 10%) 50/60 Hz (± 2 Hz) 220 to 240 volts (± 10%) 50/60 Hz ( ± 2 Hz) Rated current 8.5 Amps 4.5 Amps Table B-4 Power consumption (average, in watts) 1246 Produc t model Printing Ready Sleep Off HP Color LaserJet CP4525 model HP Colo[...]

Skew spec ifications Table B-6 Media registration and image placement accuracy Cut sheet simplex and automatic duplex 1 Envelopes and postcards Skew - vert ical ≤ 1. 5 mm / 260 mm 2 ≤ 3.3 mm / 220 mm First line / leading edge pos ition 5.0 mm ± 2.0 mm 10.0 mm ± 3.0 mm Left margin acc uracy 5.0 mm ± 2.0 mm 10 mm ± 2.5 mm Parallelism ≤ 0.75[...]

C R egulatory information ● FCC regul ations ● Environ mental pro duct stewards hip program ● Decl ara tion of Conf ormi ty ● Safety stateme nts ENWW 505[...]

FCC regulations This equ ipment has been tested and found to comply wi th the limits for a Class A digital d evice, pursua nt to Part 15 of the FCC rules. These li mits are designed to pr ovide reason able protectio n against harmfu l interfe rence in a residen tial instal lation. Thi s equipmen t genera tes, uses, and can r adiate radi o frequen c[...]

Environm ental product stewar dship program Protecting the enviro nment Hewlett- Packard C ompany is committed to providing quality products in an env ironmental ly sound manner . This produc t has been designed with several attributes to m inimize im pacts on our environme nt. Ozone productio n This produ ct generates no appreciabl e ozone gas (O [...]

Return and recycling instru ctions Unit ed States an d Puerto Rico The en closed l abel in th e HP Lase rJet toner cartrid ge box is fo r the re turn and rec ycling of o ne or more HP Laser Jet print cartridge s after use. Pleas e follow the app licable instruc tions belo w. Multiple returns (more than one cartridge) 1. Package each HP Las erJet pr[...]

Material restrictions This HP prod uct does not conta in added mercury . This HP product contains a ba ttery that might requ ire special handling at end-of- life. The batteries contain ed in or supplied by Hew lett-Packard for t his product inclu de the following: HP Color LaserJet E nterprise CP4020-CP4520 Series Type Carbon monofluoride lithium W[...]

Material Safety Data Sheet (MSDS) Materi al Safety Data S heets (MSDS) for supplie s containing chem ical substan ces (for exampl e, toner) can be o btained by a ccessing the HP Web site at www.hp.co m/ go/ msds or www.hp.com/ hpi nfo/ commu nity/environmen t/productinfo/s afety . For mor e inform ation To obt ain informat ion about these environme[...]

Declarati on of Conformity Declaration of Conformity according to ISO/ IEC 17050–1 and EN 1 7050–1, DoC#: BOISB-0806-00- rel.1.0 Manufact urer's Name: Hewlett- Packard Company Manufacturer's Address: 11311 Chinden Boulevard, Boise, Idaho 83714-1021, USA declares that the product Produc t Name: HP Color LaserJet CP 4525/CP4025 series R[...]

Safety statement s Laser safety The Center for Devices and Radiologica l Health (CDRH) of t he U.S. Food and Drug Adminis tration has implem ented regulatio ns for laser produ cts manufactured since August 1, 19 76. Compliance is mand atory for pro ducts mark eted in the United Stat es. The de vice is ce rtified as a “Class 1” laser p roduct un[...]

EMC statement (China) EMC statement (Korea) EMI statement (Taiw an) Laser statement for Finland Luokan 1 lase rlaite Klass 1 Laser Appar at HP Col or LaserJ et CP4025n, CP 4025dn, C P4525n, CP4 525dn, CP 4525xh, las erkirjoitin on käyttäj än kannal ta turvalline n luokan 1 laserl aite. Norma alissa käyt össä kirjoitti men suoja koteloint i es[...]

Mikäli kirjoitt imen suoja kotelo ava taan, olet al ttiina näky mättömällel asersäte ilylle laitt een olless a toiminn assa. Älä katso sä teeseen. VARNING ! Om laserpr interns skydds hölje öppnas då ap paraten är i funk tion, utsättas anv ändaren för osy nlig laser strålning. Be trakta ej strå len. Tied ot laitteessa k äytettäv?[...]

Index Symbols/Numeri cs 500-she et paper and heav y media tra y specif ications, phy sical 50 1 A AC to DC conversi on 12 access ories ordering 426 part numbers 427 scre ws 43 0 access ories ins talled, infor matio n 311 acousti c specificat ions 503 after- serv ice chec klist 7 0 AppleTalk informatio n 310 B bands, tr oubleshooti ng 411 batterie s[...]

PCA l ocatio ns xxvii i pickup, fee d, and delivery 37 print c artridg e 28 protection for 13, 1 5 configur ation page 242 configur ation pages informat ion 311 pri nti ng 307 configur e device menu 321 conn ectors controll er PCA ( optional paper feed er) 28 3 DC cont rolle r PCA 281, xxviii control panel cleaning page, p rinting 416 I/O menu 33 4[...]

drive c ircuit power-s upply frequ ency range 17 drum cl eaning 28 duplex p rinting (do uble-sided) Show Me Ho w menu 31 4 duplexe r specif ications, phy sical 50 1 duplexi ng unit componen ts 52 duplex- drive ass embly, removi ng 151 ja m caus es 39 7 motors 8 print o peration 53 See also pickup, feed, and delive ry E EIO ca rds part number 427 re[...]

I I/O (inpu t/output) menu 33 4 I/O menu 334 image p lacement a ccuracy xi x image quality issues ex ample s and soluti ons 239 image sta bilization c ontrols 35 image-fo rmation proce ss developm ent process 25 drum clea ning 28 fusing pr ocess 27 ITB clea ning 28 laser-b eam exposu re 25 pre-expos ure 24 primary c harging 24 primary tr ansfer pro[...]

main -drive assem bly remo ving 20 3 manage sup plies menu 318 manual p rint mo des 408 material restrictions 5 09 Material Safe ty Data Sheet (MSDS) 5 10 media Show Me Ho w menu 31 4 media re gistrati on accuracy x ix media s ensor va lue Serv ice menu re set 422 memo ry informa tion 3 07 insuffic ient 346, 3 62 NVRAM initializa tion 42 3 part num[...]

lifter-d rive ass embly, removi ng 230 motor c ontrol 5 9 mu ltif eed pr even tion 43 optional 1 x 500-sh eet 57 optional 3 x 500-sh eet 57 paper d etection 4 7 pickup and fee d operation 60 pick up asse mbly, removi ng 226 pick up m otor asse mbly , removi ng 231 rear cover , remo ving 218 rear-r ight cove r, removing 225 right cove r, remov ing 2[...]

Q qualit y. See print quality R recycli ng HP printi ng supplies returns a nd envi ronmental pr ogram 5 08 reform at product hard disk 423 registr ation asse mbly remo ving 12 8 registr ation roll er Serv ice menu re set 422 regulato ry statemen ts Decl ara tion of Con formi ty 511 environ mental produ ct stewa rdship prog ram 507 remo ving part s [...]

secu rity settin gs 334 security setti ngs information 309 secu rity s lot lo cating 280 sensor tests man ual 5V laser and 24V interloc k and logic sw itches 2 67 developer alienation s ensor (I) 252 duplex re -pickup sensor (E) 250 front-door switch (M) 257 fuser de livery sensor (D) 249 fuser pr essure-rele ase sens or (J) 253 loop sens ors (B an[...]

TCP/IP settings 334 tech nical suppo rt online 500 temp erat ure control for fuser 15 thresholds fo r fuser compon ents 15, 16 val ues, prin ted 3 05 temperat ure requir ements 503 tests color band 311 componen t tests list a nd descr iptions xvii disable c artridge ch eck 244 engine 240 manual s ensor 24 6 network s 338 paper pa th 245 pape r- pat[...]

Material Sa fety Data Sh eet (MSDS) 5 10 ordering supplies 4 26 white spots , troubleshoo ting 411 wrinkl es, troub leshooting 4 15 524 I ndex ENWW[...]

[...]

© 20 1 0 Hewlett-P ackar d De velopment C ompan y , L.P . www .hp.com *CC489-90936* *CC489-90936* CC489-9093 6[...]