HP Color Laserjet CP4020, Color LaserJet CP4520 service manual

5 (2)

COLOR LASERJET ENTERPRISE CP4020/CP4520

SERIES PRINTER

Service Manual

CP4025n CP4025dn CP4525n CP4525dn

CP4525xh

HP Color LaserJet Enterprise CP4020CP4520 Series Printers

Service Manual

Trademark Credits

, Acrobat®, and PostScript® are

Adobe trademarks of Adobe Systems Incorporated.

Reproduction, adaptation, or translation without prior written permission is prohibited, except as allowed under the copyright laws.

The information contained herein is subject to change without notice.

The only warranties for HP products and services are set forth in the express warranty statements accompanying such products and services. Nothing herein should be construed as constituting an additional warranty. HP shall not be liable for technical or editorial errors or omissions contained herein.

Part number: CC489-90936

Edition 1, 10/2009

Corel® is a trademark or registered trademark of Corel Corporation or Corel Corporation Limited.

Intel® Core™ is a trademark of Intel Corporation in the U.S. and other countries.

Java™ is a US trademark of Sun Microsystems, Inc.

Microsoft®, Windows®, Windows® XP, and Windows Vista® are U.S. registered trademarks of Microsoft Corporation.

PANTONE® is Pantone, Inc's checkstandard trademark for color.

is a registered trademark of The Open

UNIX Group.

ENERGY STAR and the ENERGY STAR mark are registered U.S. marks.

Conventions used in this guide

TIP: Tips provide helpful hints or shortcuts.

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

CAUTION: Cautions indicate procedures that you should follow to avoid losing data or damaging the

product.

WARNING! Warnings alert you to specific procedures that you should follow to avoid personal injury,

catastrophic loss of data, or extensive damage to the product.

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iv Conventions used in this guide ENWW

Table of contents

1 Theory of operation

Basic operation ..................................................................................................................................... 2

Sequence of operation ......................................................................................................... 3

Engine-control system .......................................................................................................................... 4

DC controller ........................................................................................................................ 5

Solenoids ............................................................................................................ 5

Clutches .............................................................................................................. 6

Switches .............................................................................................................. 6

Sensors ............................................................................................................... 7

Motors ................................................................................................................. 8

Fans ..................................................................................................................................... 9

High-voltage power supply ................................................................................................ 10

Low-voltage power supply ................................................................................................. 12

Overcurrent/overvoltage protection ................................................................... 13

Safety ................................................................................................................ 13

Voltage detection .............................................................................................. 13

Sleep (powersave) mode .................................................................................. 13

Low-voltage power supply failure ...................................................................... 13

Fuser control ...................................................................................................................... 14

Fuser temperature control ................................................................................. 15

Fuser sleeve temperature protection ................................................................ 15

Failure detection ................................................................................................ 16

Fuser unit identification ..................................................................................... 17

Fuser unit life detection ..................................................................................... 17

Laser/scanner system ........................................................................................................................ 18

Laser/scanner failure ......................................................................................................... 19

Protective-glass cleaners ................................................................................................... 19

Image-formation system ..................................................................................................................... 21

Image-formation process ................................................................................................... 22

Step 1: Pre-exposure ........................................................................................ 24

Step 2: Primary charging ................................................................................... 24

Step 3: Laser-beam exposure ........................................................................... 25

Step 4: Development ......................................................................................... 25

Step 5: Primary transfer .................................................................................... 26

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Step 6: Secondary transfer ............................................................................... 26

Step 7: Separation ............................................................................................ 27

Step 8: Fusing ................................................................................................... 27

Step 9: ITB cleaning .......................................................................................... 28

Step 10: Drum cleaning ..................................................................................... 28

Print cartridge .................................................................................................................... 28

Developing-roller engagement and disengagement .......................................................... 30

Intermediate transfer belt (ITB) unit ................................................................................... 31

Primary-transfer-roller engagement and disengagement .................................. 32

ITB cleaning ...................................................................................................... 34

Calibration .......................................................................................................................... 34

Color-misregistration control ............................................................................. 35

Image-stabilization control ................................................................................ 35

Pickup, feed, and delivery system ...................................................................................................... 37

Pickup-and-feed unit .......................................................................................................... 41

Cassette pickup ................................................................................................. 41

Cassette-presence detection ............................................................ 42

Cassette lift operation and cassette paper-presence detection ........ 43

Cassette multiple-feed prevention .................................................... 43

Multipurpose tray pickup ................................................................................... 44

Paper feed ......................................................................................................... 45

Skew-feed prevention ....................................................................... 46

Paper detection ................................................................................ 47

Feed speed control ........................................................................... 48

Fusing and delivery unit ..................................................................................................... 48

Loop control ...................................................................................................... 49

Pressure-roller pressurization control ............................................................... 50

Duplexing unit (HP Color LaserJet CP4525dn, HP Color LaserJet CP4025dn, and HP

Color LaserJet CP4525xh only) ......................................................................................... 52

Duplexing reverse and feed control .................................................................. 52

Duplex print operation ....................................................................................... 53

Jam detection ..................................................................................................................................... 55

Optional paper feeder ......................................................................................................................... 57

Motor control ...................................................................................................................... 59

Paper-feeder pickup and feed operation ........................................................................... 60

Paper-size detection and cassette-presence detection ..................................................... 62

Paper-feeder cassette lift operation ................................................................................... 63

Paper feeder jam detection ................................................................................................ 64

2 Removal and replacement

Introduction ......................................................................................................................................... 68

Removal and replacement strategy ................................................................................................... 68

Electrostatic discharge ....................................................................................................................... 69

Required tools ................................................................................................................................... 69

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Before performing service .................................................................................................................. 70

After performing service ..................................................................................................................... 70

Post-service test ................................................................................................................................. 71

Print-quality test ................................................................................................................. 71

Parts removal order ............................................................................................................................ 72

Customer self repair (CSR) components ........................................................................................... 74

Print cartridges ................................................................................................................... 74

Toner-collection unit .......................................................................................................... 76

Formatter PCA ................................................................................................................... 78

Hard drive .......................................................................................................................... 79

Remove the hard drive ...................................................................................... 79

Memory DIMM ................................................................................................................... 81

Remove the memory DIMM .............................................................................. 81

Enable memory ................................................................................ 82

Tray .................................................................................................................................... 84

Fuser ................................................................................................................................. 85

Feed and separation rollers (Trays 2-5) ............................................................................ 86

Pickup roller (Tray 1) ......................................................................................................... 87

Secondary transfer roller ................................................................................................... 90

Reinstall the transfer roller ................................................................................ 91

Intermediate transfer belt (ITB) .......................................................................................... 92

External panels, covers, and doors .................................................................................................... 95

Identification and location .................................................................................................. 95

Upper-left cover ................................................................................................................. 96

Power-supply cover ........................................................................................................... 98

Left cover ........................................................................................................................... 99

Remove the left cover ....................................................................................... 99

Front-top cover ................................................................................................................ 100

Remove the front-top cover ............................................................................. 100

Rear-top cover ................................................................................................................. 102

Remove the rear-top cover ............................................................................. 102

Right-front cover .............................................................................................................. 103

Remove the right-front cover ........................................................................... 103

Reinstall the power button .............................................................. 104

Control-panel assembly ................................................................................................... 105

Remove the control-panel assembly ............................................................... 105

Front-door assembly ........................................................................................................ 107

Remove the front-door assembly .................................................................... 107

Right-rear cover ............................................................................................................... 110

Remove the right-rear cover ........................................................................... 110

Rear cover ....................................................................................................................... 112

Remove the rear cover ................................................................................... 112

Right-door assembly ........................................................................................................ 113

Internal assemblies .......................................................................................................................... 118

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Cassette feed guide ......................................................................................................... 118

Secondary transfer assembly .......................................................................................... 119

Reinstall the secondary transfer assembly ..................................................... 120

Separation pad (Tray 1) ................................................................................................... 121

Remove the separation pad (Tray 1) .............................................................. 121

Registration density (RD) sensor assembly ..................................................................... 124

Remove the RD sensor assembly ................................................................... 124

Registration assembly ..................................................................................................... 128

Remove the registration assembly .................................................................. 129

Residual-toner-feed motor ............................................................................................... 133

Remove the residual-toner-feed motor ........................................................... 133

Residual-toner duct and feed assembly .......................................................................... 134

Remove the residual-toner duct and feed assembly ....................................... 134

Cartridge fan and environmental sensor .......................................................................... 137

Remove the cartridge fan and environmental sensor ..................................... 137

Toner-collection sensor and scanner-thermistor assembly ............................................. 141

Remove the toner-collection sensor and scanner-thermistor assembly ......... 141

Delivery fan ...................................................................................................................... 143

Remove the delivery fan ................................................................................. 143

Delivery assembly ............................................................................................................ 145

Remove the delivery assembly ....................................................................... 145

Reinstall the delivery assembly ...................................................... 149

Duplex-drive assembly .................................................................................................... 151

Remove the duplex-drive assembly ................................................................ 151

Power-supply fan ............................................................................................................. 152

Remove the power-supply fan ........................................................................ 152

Interconnect board (ICB) ................................................................................................. 153

Remove the ICB .............................................................................................. 153

DC controller PCA only .................................................................................................... 155

Remove the DC controller PCA only ............................................................... 155

Low-voltage power supply (LVPS) ................................................................................... 157

Remove the low-voltage power supply ........................................................... 157

DC controller PCA and tray ............................................................................................. 161

Remove the DC controller PCA and tray ........................................................ 161

High-voltage power supply lower (HVPS-D) .................................................................... 163

Remove the high-voltage power supply lower ................................................ 163

Reinstall the high-voltage power supply lower ............................... 167

Developing-disengagement motor ................................................................................... 168

Remove the developing-disengagement motor .............................................. 168

Exhaust fan and fan duct ................................................................................................. 169

Remove the exhaust fan and fan duct ............................................................ 169

Reinstall the exhaust fan and fan duct ............................................................ 171

Pickup motor .................................................................................................................... 172

Remove the pickup motor ............................................................................... 172

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Lifter-drive assembly ........................................................................................................ 173

Remove the lifter-drive assembly .................................................................... 173

Lifter base assembly ........................................................................................................ 175

Remove the lifter base assembly .................................................................... 175

Reinstall the lifter base assembly .................................................................... 176

Tray-pickup drive assembly ............................................................................................. 178

Remove the tray-pickup drive assembly ......................................................... 178

Tray-pickup assembly ...................................................................................................... 180

Remove the tray-pickup assembly .................................................................. 180

Laser/scanner assembly (Y/M) ........................................................................................ 186

Remove the laser/scanner assembly (Y/M) .................................................... 187

Laser/scanner assembly (C/Bk) ....................................................................................... 190

Remove the laser/scanner assembly (C/Bk) ................................................... 191

Reinstall the protective glass cleaner (PGC) actuators .................. 193

High-voltage power supply upper (HVPS-T) .................................................................... 196

Remove the high-voltage power supply upper ................................................ 196

Reinstall the high-voltage power supply upper ............................... 198

Yellow, magenta, cyan, and black drum motors .............................................................. 199

Remove the yellow, magenta, cyan, and black drum motors .......................... 199

Fuser motor ..................................................................................................................... 200

Remove the fuser motor .................................................................................. 201

ITB motor ......................................................................................................................... 202

Remove the ITB motor .................................................................................... 202

Main-drive assembly ........................................................................................................ 203

Remove the main-drive assembly ................................................................... 204

Reinstall the main-drive assembly .................................................. 207

Fuser-drive assembly ...................................................................................................... 211

Remove the fuser-drive assembly ................................................................... 212

Reinstall the fuser-drive assembly .................................................. 215

Optional paper feeder assemblies (1 x 500-sheet and 3 x 500-sheet) ............................................. 216

Front door (optional paper feeder) ................................................................................... 216

Rear cover (optional paper feeder) .................................................................................. 218

Right-front cover (optional paper feeder) ......................................................................... 219

Right door (optional paper feeder) ................................................................................... 220

Left cover (optional paper feeder) .................................................................................... 222

Remove the left cover (optional paper feeder) ................................................ 222

Right cover (optional paper feeder) ................................................................................. 224

Remove the right cover (optional paper feeder) .............................................. 224

Rear-right cover (optional paper feeder) .......................................................................... 225

Remove the rear-right cover (optional paper feeder) ...................................... 225

Pickup assembly (optional paper feeder) ........................................................................ 226

Remove the pickup assembly (optional paper feeder) .................................... 226

Lifter assembly (optional paper feeder) ........................................................................... 229

Remove the lifter assembly (optional paper feeder) ....................................... 229

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3 Solve problems

Solve problems checklist .................................................................................................................. 234

Menu map ........................................................................................................................................ 236

Troubleshooting process .................................................................................................................. 237

Tools for troubleshooting .................................................................................................................. 242

Lifter-drive assembly (optional paper feeder) .................................................................. 230

Remove the lifter-drive assembly (optional paper feeder) .............................. 230

Pickup motor assembly (optional paper feeder) ............................................................. 231

Remove the pickup motor (optional paper feeder) assembly .......................... 231

Controller PCA (optional paper feeder) ........................................................................... 232

Remove the controller PCA (optional paper feeder) ....................................... 232

Determine the problem source ........................................................................................ 237

Pre-troubleshooting checklist .......................................................................... 237

Troubleshooting flowchart ............................................................................... 239

Power subsystem ............................................................................................................ 240

Power-on checks ............................................................................................. 240

Power-on troubleshooting overview ............................................... 240

Individual component diagnostics .................................................................................... 242

LED diagnostics .............................................................................................. 242

Understand lights on the formatter ................................................. 242

Engine diagnostics .......................................................................................... 243

Defeating interlocks ........................................................................ 243

Disable cartridge check .................................................................. 244

Engine-test button .......................................................................... 244

Paper-path test ................................................................................................ 245

Manual sensor test (special-mode test) .......................................................... 246

A TOP (top of page) sensor ............................................................ 247

B and C loop sensors ..................................................................... 248

D fuser delivery sensor ................................................................... 249

E duplex re-pickup sensor .............................................................. 250

F output bin full sensor ................................................................... 251

I developer alienation ..................................................................... 252

J fuser pressure-release sensor .................................................... 253

K primary transfer-roller-disengagement sensor ............................ 254

L media sensor .............................................................................. 256

M front-door switch ......................................................................... 257

N right-door switch .......................................................................... 258

Manual sensor test 2 (special-mode test) ....................................................... 259

O Tray 1 paper present sensor ...................................................... 261

P Tray 2 paper present sensor ....................................................... 262

Q Tray 2 paper surface 1 and 2 sensors ........................................ 263

R Tray 2 paper size switches ........................................................ 264

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S Tray 3 paper present sensor ....................................................... 265

T Tray 3 feed sensor ...................................................................... 265

U Tray 3 paper surface 1 and 2 sensors ........................................ 265

V Tray 3 paper size switches .......................................................... 265

W Tray 4 paper present sensor ...................................................... 265

X Tray 4 feed sensor ...................................................................... 265

Y Tray 4 paper surface 1 and 2 sensors ........................................ 265

Z Tray 4 paper size switches .......................................................... 266

a Tray 5 paper present sensor ....................................................... 266

b Tray 5 feed sensor ....................................................................... 266

c Tray 5 paper surface 1 and 2 sensors ......................................... 266

d Tray 5 paper size switches .......................................................... 266 5V laser and 24V interlock and logic switches (and power

switch) ............................................................................................ 267

New ITB sensor .............................................................................. 271

Tray 3, 4, and 5 right door switch ................................................... 272

Paper-path sensors test .................................................................................. 273

Print/stop test .................................................................................................. 273

Component tests ............................................................................................. 274

Component test (special-mode test) ............................................... 274

Diagrams ......................................................................................................................... 277

Block diagrams ................................................................................................ 277

Plug/jack locations .......................................................................................... 280

Location of connectors .................................................................................... 281

DC controller connector locations ................................................... 281

Controller PCA (1 x 500-sheet and 3 x 500-sheet optional paper

feeders) ......................................................................................... 283

Locations of major components ...................................................................... 284

General timing chart ........................................................................................ 294

Circuit diagrams .............................................................................................. 294

HP Easy Printer Care ...................................................................................................... 298

Open the HP Easy Printer Care software ....................................................... 299

HP Easy Printer Care software sections ......................................................... 299

Internal print-quality test pages ........................................................................................ 302

Print-quality-troubleshooting pages ................................................................. 302

Diagnostics page ............................................................................................. 305

Cleaning page ................................................................................................. 306

Configuration page .......................................................................................... 307

Configuration page ......................................................................... 307

HP embedded Jetdirect page ......................................................... 309

Embedded protocol page ............................................................... 310

Finding important information on the configuration pages .............. 311

Color-band test ................................................................................................ 311

Print-quality troubleshooting tools .................................................................................... 312

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Repetitive defects ruler ................................................................................... 312

Calibrate the product ....................................................................................... 313

Control panel menus ........................................................................................................ 314

Control panel menus ....................................................................................... 314

Show Me How menu ...................................................................... 314

Retrieve job menu .......................................................................... 314

Information menu ............................................................................ 317

Paper handling menu ..................................................................... 317

Manage supplies menu .................................................................. 318

Configure device menu ................................................................... 321

Diagnostics menu ........................................................................... 342

Service menu .................................................................................. 344

Interpret control-panel messages .................................................................................... 345

Control-panel message types ......................................................................... 345

Control-panel messages ................................................................................. 345

Event log messages ........................................................................................................ 376

Print an event log ............................................................................................ 376

Show an event log ........................................................................................... 376

Sample event log ............................................................................................ 377

Clear the event log .......................................................................................... 377

Event log message table ................................................................................. 378

Clear paper jams .............................................................................................................................. 383

Common causes of jams ................................................................................................. 383

Jam locations ................................................................................................................... 386

Clear jams in the right door .............................................................................................. 387

Clear jams in the output bin area ..................................................................................... 390

Clear jams in Tray 1 ......................................................................................................... 390

Clear jams in Tray 2 or optional Trays 3, 4, or 5 .............................................................. 392

Clear jams in the lower right door (Tray 3, 4, or 5) .......................................................... 393

Jam causes and solutions ............................................................................................... 394

Jams in the output bin ..................................................................................... 394

Jams in the fuser and transfer area ................................................................ 394 Jams in the duplex area (HP Color LaserJet CP4525dn, HP Color LaserJet

CP4025dn, and HP Color LaserJet CP4525xh only) ...................................... 397

Jams in Tray 1, Tray 2 and internal paper path .............................................. 399

Jams in Tray 3, 4, and 5 .................................................................................. 400

Change jam recovery ....................................................................................................... 402

Solve paper-handling problems ........................................................................................................ 403

Product feeds multiple sheets .......................................................................................... 403

Product feeds incorrect page size ................................................................................... 403

Product pulls from incorrect tray ...................................................................................... 403

Paper does not feed automatically .................................................................................. 404

Paper does not feed from Tray 2, 3, 4, or 5 ..................................................................... 404

Transparencies or glossy paper will not feed .................................................................. 405

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Envelopes jam or will not feed in the product .................................................................. 405

Output is curled or wrinkled ............................................................................................. 406

Product will not duplex or duplexes incorrectly ................................................................ 406

Use manual print modes .................................................................................................................. 408

Solve image-quality problems .......................................................................................................... 410

Image defects table ......................................................................................................... 410

Clean the product ............................................................................................................................. 416

Clean the paper path ....................................................................................................... 416

Solve performance problems ........................................................................................................... 417

Solve connectivity problems ............................................................................................................. 418

Solve direct-connect problems ........................................................................................ 418

Solve network problems .................................................................................................. 418

Service mode functions .................................................................................................................... 420

Service menu ................................................................................................................... 420

Product resets .................................................................................................................. 423

Restore factory-set defaults ............................................................................ 423

Hard disk initialization (optional) ..................................................................... 423

NVRAM initialization ........................................................................................ 423

Product cold reset .......................................................................................... 424

Product updates ............................................................................................................................... 424

4 Parts and diagrams

Order parts, accessories, and supplies ............................................................................................ 426

Part numbers .................................................................................................................................... 427

Accessories ..................................................................................................................... 427

Print cartridges and toner collection unit .......................................................................... 427

Memory ............................................................................................................................ 427

Cables and interfaces ...................................................................................................... 427

Customer self repair (CSR) parts .................................................................................... 428

Service maintenance kits ................................................................................................. 428

Unique components ......................................................................................................... 429

Screws .............................................................................................................................................. 430

How to use the parts lists and diagrams .......................................................................................... 431

External covers, panels, and doors .................................................................................................. 432

Right door assembly ......................................................................................................................... 434

Front door assembly ......................................................................................................................... 436

Internal components ......................................................................................................................... 438

Internal components (1 of 7) ............................................................................................ 438

Internal components (2 of 7) ............................................................................................ 440

Internal components (3 of 7) ............................................................................................ 442

Internal components (4 of 7) ............................................................................................ 444

Internal components (5 of 7) ............................................................................................ 446

Internal components (6 of 7) ............................................................................................ 448

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Internal components (7 of 7) ............................................................................................ 450

Cassettes 2-5 ................................................................................................................... 452

Paper pickup assembly .................................................................................................... 454

Tray 1 paper pickup assembly ......................................................................................... 456

Registration assembly ..................................................................................................... 458

Secondary transfer assembly .......................................................................................... 460

Delivery assembly ............................................................................................................ 462

Fuser assembly ............................................................................................................... 464

PCAs ................................................................................................................................ 466

Assessories ...................................................................................................................................... 468

Paper feeders .................................................................................................................. 468

Paper feeder external covers, panels, and doors ............................................................ 470

1 X 500 paper feeder main body ..................................................................................... 472

3 X 500 paper feeder main body ..................................................................................... 474

Alphabetical parts list ....................................................................................................................... 476

Numerical parts list ........................................................................................................................... 484

Appendix A Service and support

Hewlett-Packard limited warranty statement .................................................................................... 494

HP's Premium Protection Warranty: LaserJet print cartridge limited warranty statement ................ 495

HP Color LaserJet Fuser Kit Limited Warranty Statement ............................................................... 496

End User License Agreement .......................................................................................................... 497

Customer self-repair warranty service .............................................................................................. 499

Customer support ............................................................................................................................. 500

Appendix B Product specifications

Physical specifications ..................................................................................................................... 502

Performance specifications .............................................................................................................. 502

Electrical specifications .................................................................................................................... 502

Acoustic specifications ..................................................................................................................... 503

Environmental specifications ............................................................................................................ 503

Skew specifications .......................................................................................................................... 504

Appendix C Regulatory information

FCC regulations ............................................................................................................................... 506

Environmental product stewardship program ................................................................................... 507

Protecting the environment .............................................................................................. 507

Ozone production ............................................................................................................ 507

Power consumption ......................................................................................................... 507

Toner consumption .......................................................................................................... 507

Paper use ........................................................................................................................ 507

Plastics ............................................................................................................................ 507

HP LaserJet print supplies ............................................................................................... 507

xiv ENWW

Return and recycling instructions ..................................................................................... 508

United States and Puerto Rico ........................................................................ 508

Multiple returns (more than one cartridge) ..................................... 508

Single returns ................................................................................. 508

Shipping .......................................................................................... 508

Non-U.S. returns ............................................................................................. 508

Paper ............................................................................................................................... 508

Material restrictions .......................................................................................................... 509 Disposal of waste equipment by users in private households in the European

Union ............................................................................................................................... 509

Chemical substances ....................................................................................................... 509

Material Safety Data Sheet (MSDS) ................................................................................ 510

For more information ....................................................................................................... 510

Declaration of Conformity ................................................................................................................. 511

Safety statements ............................................................................................................................. 512

Laser safety ..................................................................................................................... 512

Canadian DOC regulations .............................................................................................. 512

VCCI statement (Japan) .................................................................................................. 512

Power cord instructions ................................................................................................... 512

Power cord statement (Japan) ......................................................................................... 512

EMC statement (China) ................................................................................................... 513

EMC statement (Korea) ................................................................................................... 513

EMI statement (Taiwan) ................................................................................................... 513

Laser statement for Finland ............................................................................................. 513

GS statement (Germany) ................................................................................................. 514

Substances Table (China) ............................................................................................... 514

Restriction on Hazardous Substances statement (Turkey) ............................................. 514

Index ................................................................................................................................................................. 515

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xvi ENWW

List of tables

Table 1-1 Sequence of operation ....................................................................................................................... 3

Table 1-2 Solenoids ........................................................................................................................................... 5

Table 1-3 Switches ............................................................................................................................................. 6

Table 1-4 Sensors .............................................................................................................................................. 7

Table 1-5 Motors ................................................................................................................................................ 8

Table 1-6 Fans ................................................................................................................................................... 9

Table 1-7 High-voltage power supply circuits ................................................................................................... 10

Table 1-8 Converted DC voltages .................................................................................................................... 12

Table 1-9 Fuser components ........................................................................................................................... 14

Table 1-10 Primary-transfer-roller engagement states ..................................................................................... 32

Table 1-11 Image-stabilization controls ............................................................................................................ 36

Table 1-12 Switches and sensors for the pickup, feed, and delivery system ................................................... 38

Table 1-13 Motors and solenoids for the pickup, feed, and delivery system ................................................... 39

Table 1-14 Print mode and feed speed ............................................................................................................ 48

Table 1-15 Paper sizes .................................................................................................................................... 53

Table 1-16 Jams that the product detects ........................................................................................................ 56

Table 1-17 Electrical components for the paper feeder ................................................................................... 59

Table 1-18 Pickup feed components (1 x 500-sheet paper feeder) ................................................................. 60

Table 3-1 Pre-troubleshooting checklist ......................................................................................................... 237

Table 3-2 Troubleshooting flowchart .............................................................................................................. 239

Table 3-3 Manual sensor diagnostic tests ...................................................................................................... 246

Table 3-4 Default state of bits ........................................................................................................................ 246

Table 3-5 Manual sensor test 2 diagnostic tests ............................................................................................ 259

Table 3-6 Default state of bits ........................................................................................................................ 260

Table 3-7 Paper-path sensors diagnostic tests .............................................................................................. 273

Table 3-8 Component test details .................................................................................................................. 274

Table 3-9 Formatter PCA ............................................................................................................................... 280

Table 3-10 DC controller connectors .............................................................................................................. 281

Table 3-11 Controller PCA connectors ........................................................................................................... 283

Table 3-12 Important information on the configuration pages ........................................................................ 311

Table 3-13 Embedded Jetdirect menu ........................................................................................................... 334

Table 3-14 Control-panel messages .............................................................................................................. 345

Table 3-15 Common causes of jams (by area) .............................................................................................. 385

Table 3-16 Causes and solutions for delivery delay jam ................................................................................ 394

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Table 3-17 Causes and solutions for fuser delivery delay jams ..................................................................... 394

Table 3-18 Causes and solutions for wrapping jams ..................................................................................... 394

Table 3-19 Causes and solutions for fuser delivery stationary jams .............................................................. 395

Table 3-20 Causes and solutions for residual media jams ............................................................................ 396

Table 3-21 Causes and solutions for pickup delay jams 2 ............................................................................. 396

Table 3-22 Causes and solutions for pickup stationary jams ......................................................................... 397

Table 3-23 Causes and solutions for duplexing reverse jams ...................................................................... 397

Table 3-24 Causes and solutions for duplex repick jams .............................................................................. 397

Table 3-25 Causes and solutions for residual media jams ............................................................................ 398

Table 3-26 Causes and solutions for pickup delay jam 1: tray pickup ........................................................... 399

Table 3-27 Causes and solutions for pickup stationary jams ......................................................................... 400

Table 3-28 Causes and solutions for pickup delay and pickup stationary jams ............................................. 400

Table 3-29 Causes and solutions for residual media jams ............................................................................ 401

Table 3-30 MP modes under the ADJUST PAPER TYPES sub menu ......................................................... 408

Table 3-31 MP modes under the OPTIMIZE submenu .................................................................................. 409

Table 4-1 Maintenance kits ............................................................................................................................ 428

Table 4-2 110V and 220V unique components .............................................................................................. 429

Table 4-3 Simplex and duplex unique components ....................................................................................... 429

Table 4-4 Common fasteners ........................................................................................................................ 430

Table 4-5 External covers, panels, and doors; .............................................................................................. 433

Table 4-6 Right door assembly ...................................................................................................................... 435

Table 4-7 Front door assembly ...................................................................................................................... 437

Table 4-8 Internal components (1 of 7) .......................................................................................................... 439

Table 4-9 Internal components (2 of 7) .......................................................................................................... 441

Table 4-10 Internal components (3 of 7) ........................................................................................................ 443

Table 4-11 Internal components (4 of 7) ........................................................................................................ 445

Table 4-12 Internal components (5 of 7) ........................................................................................................ 447

Table 4-13 Internal components 6 of 7 .......................................................................................................... 449

Table 4-14 Internal components 7 of 7 .......................................................................................................... 451

Table 4-15 Cassette ....................................................................................................................................... 453

Table 4-16 Paper pickup assembly ................................................................................................................ 455

Table 4-17 Tray 1 paper pickup assembly ..................................................................................................... 457

Table 4-18 Registration assembly .................................................................................................................. 459

Table 4-19 Secondary Transfer assembly ..................................................................................................... 461

Table 4-20 Delivery assembly ........................................................................................................................ 463

Table 4-21 Fuser assembly ............................................................................................................................ 465

Table 4-22 PCAs ............................................................................................................................................ 467

Table 4-23 Paper feeders ............................................................................................................................... 469

Table 4-24 Paper feeder external covers, panels, and doors ........................................................................ 471

Table 4-25 1 X 500 paper feeder main body .................................................................................................. 473

Table 4-26 3 X 500 paper feeder main body .................................................................................................. 475

Table 4-27 Alphabetical parts list ................................................................................................................... 476

Table 4-28 Numerical parts list ....................................................................................................................... 484

Table B-1 Product dimensions ....................................................................................................................... 502

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Table B-2 Product dimensions, with all doors and trays fully opened ............................................................ 502

Table B-3 Power requirements ....................................................................................................................... 503 Table B-4 Power consumption (average, in watts) Table B-5 HP Color LaserJet Enterprise CP4020-CP4520 Series

1246

.................................................................................... 503

.............................................................. 503

Table B-6 Media registration and image placement accuracy ....................................................................... 504

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List of figures

Figure 1-1 Relationship between the main product systems ............................................................................. 2

Figure 1-2 Engine-control system ...................................................................................................................... 4

Figure 1-3 DC controller block diagram .............................................................................................................. 5

Figure 1-4 High-voltage power supply circuits ................................................................................................. 10

Figure 1-5 Low-voltage power-supply circuit .................................................................................................... 12

Figure 1-6 Fuser components .......................................................................................................................... 14

Figure 1-7 Fuser temperature-control circuit .................................................................................................... 15

Figure 1-8 Laser/scanner system ..................................................................................................................... 18

Figure 1-9 Protective-glass cleaners (PGCs) ................................................................................................... 20

Figure 1-10 Image-formation system ............................................................................................................... 21

Figure 1-11 Image-formation drive system ....................................................................................................... 22

Figure 1-12 Image-formation process .............................................................................................................. 23

Figure 1-13 Pre-exposure ................................................................................................................................ 24

Figure 1-14 Primary charging ........................................................................................................................... 24

Figure 1-15 Laser-beam exposure ................................................................................................................... 25

Figure 1-16 Development ................................................................................................................................. 25

Figure 1-17 Primary transfer ............................................................................................................................ 26

Figure 1-18 Secondary transfer ........................................................................................................................ 26

Figure 1-19 Separation ..................................................................................................................................... 27

Figure 1-20 Fusing ........................................................................................................................................... 27

Figure 1-21 ITB cleaning .................................................................................................................................. 28

Figure 1-22 Drum cleaning ............................................................................................................................... 28

Figure 1-23 Print-cartridge system ................................................................................................................... 29

Figure 1-24 Developing-roller engagement and disengagement control ......................................................... 30

Figure 1-25 ITB unit .......................................................................................................................................... 31

Figure 1-26 Three states of primary-transfer-roller engagement and disengagement ..................................... 33

Figure 1-27 ITB cleaning process .................................................................................................................... 34

Figure 1-28 Toner patterns for calibration ........................................................................................................ 35

Figure 1-29 Paper path .................................................................................................................................... 37

Figure 1-30 Switches and sensors for the pickup, feed, and delivery system ................................................. 38

Figure 1-31 Motors and solenoids for the pickup, feed, and delivery system .................................................. 39

Figure 1-32 Three main units of the pickup, feed, and delivery system ........................................................... 40

Figure 1-33 Pickup-and-feed unit ..................................................................................................................... 41

Figure 1-34 Cassette-pickup mechanism ......................................................................................................... 42

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Figure 1-35 Cassette lift mechanism ................................................................................................................ 43

Figure 1-36 Multiple-feed prevention ................................................................................................................ 44

Figure 1-37 Multipurpose tray pickup mechanism ............................................................................................ 45

Figure 1-38 Paper-feed mechanism ................................................................................................................. 46

Figure 1-39 Skew-feed prevention ................................................................................................................... 47

Figure 1-40 Fuser and delivery unit .................................................................................................................. 49

Figure 1-41 Loop-control mechanism ............................................................................................................... 50

Figure 1-42 Pressure-roller pressurization control ........................................................................................... 51

Figure 1-43 Duplexing unit ............................................................................................................................... 52

Figure 1-44 Duplex reverse and feed control ................................................................................................... 53

Figure 1-45 Jam detection sensors .................................................................................................................. 55

Figure 1-46 1 x 500 optional paper feeder ....................................................................................................... 57

Figure 1-47 3 x 500-sheet optional paper feeder ............................................................................................. 58

Figure 1-48 Signals for the paper feeder ......................................................................................................... 58

Figure 1-49 Paper-feeder pickup and feed operation ...................................................................................... 60

Figure 1-50 Paper-feeder cassette lift ............................................................................................................. 63

Figure 1-51 Jam detection (1 x 500-sheet paper feeder) ................................................................................. 64

Figure 1-52 Jam detection (3 x 500-sheet paper feeder) ................................................................................. 65

Figure 2-1 Phillips and pozidrive screwdriver comparison ............................................................................... 69

Figure 2-2 Parts removal order (1 of 2) ............................................................................................................ 72

Figure 2-3 Parts removal order (2 of 2) ............................................................................................................ 73

Figure 2-4 Remove the print cartridge (1 of 2) ................................................................................................. 74

Figure 2-5 Remove the print cartridge (2 of 2) ................................................................................................. 75

Figure 2-6 Remove the toner-collection unit (1 of 4) ........................................................................................ 76

Figure 2-7 Remove the toner-collection unit (2 of 4) ........................................................................................ 76

Figure 2-8 Remove the toner-collection unit (3 of 4) ........................................................................................ 77

Figure 2-9 Remove the toner-collection unit (4 of 4) ........................................................................................ 77

Figure 2-10 Remove the formatter ................................................................................................................... 78

Figure 2-11 Remove the hard drive (1 of 3) ..................................................................................................... 79

Figure 2-12 Remove the hard drive (2 of 3) ..................................................................................................... 79

Figure 2-13 Remove the hard drive (3 of 3) ..................................................................................................... 80

Figure 2-14 Remove the memory DIMM (1 of 2) .............................................................................................. 81

Figure 2-15 Remove the memory DIMM (2 of 2) .............................................................................................. 82

Figure 2-16 Remove the tray (1 of 2) ............................................................................................................... 84

Figure 2-17 Remove the tray (2 of 2) ............................................................................................................... 84

Figure 2-18 Remove the fuser (1 of 2) ............................................................................................................. 85

Figure 2-19 Remove the fuser (2 of 2) ............................................................................................................. 85

Figure 2-20 Remove the Pickup and feed rollers (Trays 2-5) .......................................................................... 86

Figure 2-21 Remove the pickup roller (Tray 1) (1 of 5) .................................................................................... 87

Figure 2-22 Remove the pickup roller (Tray 1) (2 of 5) .................................................................................... 87

Figure 2-23 Remove the pickup roller (Tray 1) (3 of 5) .................................................................................... 88

Figure 2-24 Remove the pickup roller (Tray 1) (4 of 5) .................................................................................... 88

Figure 2-25 Remove the pickup roller (Tray 1) (5 of 5) .................................................................................... 89

Figure 2-26 Remove the transfer roller (1 of 3) ................................................................................................ 90

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Figure 2-27 Remove the transfer roller (2 of 3) ................................................................................................ 90

Figure 2-28 Remove the transfer roller (3 of 3) ................................................................................................ 91

Figure 2-29 Reinstall the transfer roller ............................................................................................................ 91

Figure 2-30 Remove the intermediate transfer belt (1 of 4) ............................................................................. 92

Figure 2-31 Remove the intermediate transfer belt (2 of 4) ............................................................................. 92

Figure 2-32 Remove the intermediate transfer belt (3 of 4) ............................................................................. 93

Figure 2-33 Remove the intermediate transfer belt (4 of 4) ............................................................................. 94

Figure 2-34 External panels, covers, and doors; identification and location .................................................... 95

Figure 2-35 Remove the upper-left cover (1 of 3) ............................................................................................ 96

Figure 2-36 Remove the upper-left cover (2 of 3) ............................................................................................ 96

Figure 2-37 Remove the upper-left cover (3 of 3) ............................................................................................ 97

Figure 2-38 Remove the power-supply cover .................................................................................................. 98

Figure 2-39 Remove the left cover (1 of 2) ....................................................................................................... 99

Figure 2-40 Remove the left cover (2 of 2) ....................................................................................................... 99

Figure 2-41 Remove the front-top cover (1 of 3) ............................................................................................ 100

Figure 2-42 Remove the front-top cover (2 of 3) ............................................................................................ 100

Figure 2-43 Remove the front-top cover (3 of 3) ............................................................................................ 101

Figure 2-44 Remove the rear-top cover (1 of 2) ............................................................................................. 102

Figure 2-45 Remove the rear-top cover (2 of 2) ............................................................................................. 102

Figure 2-46 Remove the right-front cover (1 of 3) .......................................................................................... 103

Figure 2-47 Remove the right-front cover (2 of 3) .......................................................................................... 103

Figure 2-48 Remove the right-front cover (3 of 3) .......................................................................................... 104

Figure 2-49 Reinstall the power button .......................................................................................................... 104

Figure 2-50 Remove the control-panel assembly (1 of 2) .............................................................................. 105

Figure 2-51 Remove the control-panel assembly (2 of 2) .............................................................................. 106

Figure 2-52 Remove the front-door assembly (1 of 5) ................................................................................... 107

Figure 2-53 Remove the front-door assembly (2 of 5) ................................................................................... 108

Figure 2-54 Remove the front-door assembly (3 of 5) ................................................................................... 108

Figure 2-55 Remove the front-door assembly (4 of 5) ................................................................................... 109

Figure 2-56 Remove the front-door assembly (5 of 5) ................................................................................... 109

Figure 2-57 Remove the right-rear cover (1 of 2) ........................................................................................... 110

Figure 2-58 Remove the right-rear cover (2 of 2) ........................................................................................... 111

Figure 2-59 Remove the rear cover ............................................................................................................... 112

Figure 2-60 Remove the right-door assembly (1 of 9) ................................................................................... 113

Figure 2-61 Remove the right-door assembly (2 of 9) ................................................................................... 113

Figure 2-62 Remove the right-door assembly (3 of 9) ................................................................................... 114

Figure 2-63 Remove the right-door assembly (4 of 9) ................................................................................... 114

Figure 2-64 Remove the right-door assembly (5 of 9) ................................................................................... 115

Figure 2-65 Remove the right-door assembly (6 of 9) ................................................................................... 115

Figure 2-66 Remove the right-door assembly (7 of 9) ................................................................................... 116

Figure 2-67 Remove the right-door assembly (8 of 9) ................................................................................... 116

Figure 2-68 Remove the right-door assembly (9 of 9) ................................................................................... 117

Figure 2-69 Remove the cassette feed guide (1 of 2) .................................................................................... 118

Figure 2-70 Remove the cassette feed (2 of 2) .............................................................................................. 118

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Figure 2-71 Remove the secondary transfer assembly (1 of 3) ..................................................................... 119

Figure 2-72 Remove the secondary transfer assembly (2 of 3) ..................................................................... 119

Figure 2-73 Remove the secondary transfer assembly (3 of 3) ..................................................................... 120

Figure 2-74 Reinstall the secondary transfer assembly ................................................................................. 120

Figure 2-75 Remove the separation pad (1 of 6) ........................................................................................... 121

Figure 2-76 Remove the separation pad (2 of 6) ........................................................................................... 121

Figure 2-77 Remove the separation pad (3 of 6) ........................................................................................... 122

Figure 2-78 Remove the separation pad (4 of 6) ........................................................................................... 122

Figure 2-79 Remove the separation pad (5 of 6) ........................................................................................... 123

Figure 2-80 Remove the separation pad (6 of 6) ........................................................................................... 123

Figure 2-81 Remove the RD sensor assembly (1 of 7) .................................................................................. 124

Figure 2-82 Remove the RD sensor assembly (2 of 7) .................................................................................. 124

Figure 2-83 Remove the RD sensor assembly (3 of 7) .................................................................................. 125

Figure 2-84 Remove the RD sensor assembly (4 of 7) .................................................................................. 125

Figure 2-85 Remove the RD sensor assembly (5 of 7) .................................................................................. 126

Figure 2-86 Remove the RD sensor assembly (6 of 7) .................................................................................. 126

Figure 2-87 Remove the RD sensor assembly (7 of 7) .................................................................................. 127

Figure 2-88 Remove the registration assembly (1 of 8) ................................................................................. 129

Figure 2-89 Remove the registration assembly (2 of 8) ................................................................................. 129

Figure 2-90 Remove the registration assembly (3 of 8) ................................................................................. 130

Figure 2-91 Remove the registration assembly (4 of 8) ................................................................................. 130

Figure 2-92 Remove the registration assembly (5 of 8) ................................................................................. 131

Figure 2-93 Remove the registration assembly (6 of 8) ................................................................................. 131

Figure 2-94 Remove the registration assembly (7 of 8) ................................................................................. 132

Figure 2-95 Remove the registration assembly (8 of 8) ................................................................................. 132

Figure 2-96 Remove the residual-toner-feed motor ....................................................................................... 133

Figure 2-97 Remove the residual-toner duct and feed assembly (1 of 4) ...................................................... 134

Figure 2-98 Remove the residual-toner duct and feed assembly (2 of 4) ...................................................... 135

Figure 2-99 Remove the residual-toner duct and feed assembly (3 of 4) ...................................................... 135

Figure 2-100 Remove residual-toner duct and feed assembly (4 of 4) .......................................................... 136

Figure 2-101 Remove the cartridge fan and environmental sensor (1 of 7) ................................................... 137

Figure 2-102 Remove the cartridge fan and environmental sensor (2 of 7) ................................................... 138

Figure 2-103 Remove the cartridge fan and environmental sensor (3 of 7) ................................................... 138

Figure 2-104 Remove the cartridge fan and environmental sensor (4 of 7) ................................................... 139

Figure 2-105 Remove the cartridge fan and environmental sensor (5 of 7) ................................................... 139

Figure 2-106 Remove the cartridge fan and environmental sensor (6 of 7) ................................................... 140

Figure 2-107 Remove the cartridge fan and environmental sensor (7 of 7) ................................................... 140

Figure 2-108 Remove the toner-collection sensor and scanner-thermistor assembly (1 of 3) ....................... 141

Figure 2-109 Remove the toner-collection sensor and scanner-thermistor assembly (2 of 3) ....................... 142

Figure 2-110 Remove the toner-collection sensor and scanner-thermistor assembly (3 of 3) ....................... 142

Figure 2-111 Remove the delivery fan (1 of 2) ............................................................................................... 143

Figure 2-112 Remove the delivery fan (2 of 2) ............................................................................................... 144

Figure 2-113 Remove the delivery assembly (1 of 7) .................................................................................... 145

Figure 2-114 Remove the delivery assembly (2 of 7) .................................................................................... 146

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Figure 2-115 Remove the delivery assembly (3 of 7) .................................................................................... 146

Figure 2-116 Remove the delivery assembly (4 of 7) .................................................................................... 147

Figure 2-117 Remove the delivery assembly (5 of 7) .................................................................................... 147

Figure 2-118 Remove the delivery assembly (6 of 7) .................................................................................... 148

Figure 2-119 Remove the delivery assembly (7 of 7) .................................................................................... 148

Figure 2-120 Reinstall the delivery assembly (1 of 4) .................................................................................... 149

Figure 2-121 Reinstall the delivery assembly (2 of 4) .................................................................................... 149

Figure 2-122 Reinstall the delivery assembly (3 of 4) .................................................................................... 150

Figure 2-123 Reinstall the delivery assembly (4 of 4) .................................................................................... 150

Figure 2-124 Remove the duplex-drive assembly ......................................................................................... 151

Figure 2-125 Remove the power-supply fan .................................................................................................. 152

Figure 2-126 Remove the ICB (1 of 2) ........................................................................................................... 153

Figure 2-127 Remove the ICB (2 of 2) ........................................................................................................... 154

Figure 2-128 Remove the DC controller PCA only (1 of 2) ............................................................................ 155

Figure 2-129 Remove the DC controller PCA only (2 of 2) ............................................................................ 156

Figure 2-130 Remove the low-voltage power supply (1 of 6) ......................................................................... 157

Figure 2-131 Remove the low-voltage power supply (1 of 6) ......................................................................... 158

Figure 2-132 Remove the low-voltage power supply (2 of 6) ......................................................................... 158

Figure 2-133 Remove the low-voltage power supply (3 of 6) ......................................................................... 159

Figure 2-134 Remove the low-voltage power supply (4 of 6) ......................................................................... 159

Figure 2-135 Remove the low-voltage power supply (5 of 6) ......................................................................... 160

Figure 2-136 Remove the low-voltage power supply (6 of 6) ......................................................................... 160

Figure 2-137 Remove the DC controller PCA and tray (1 of 3) ...................................................................... 161

Figure 2-138 Remove the DC controller PCA and tray (2 of 3) ...................................................................... 162

Figure 2-139 Remove the DC controller PCA and tray (3 of 3) ...................................................................... 162

Figure 2-140 Remove the high-voltage power supply lower (1 of 7) .............................................................. 163

Figure 2-141 Remove the high-voltage power supply lower (2 of 7) .............................................................. 164

Figure 2-142 Remove the high-voltage power supply lower (3 of 7) .............................................................. 165

Figure 2-143 Remove the high-voltage power supply lower (4 of 7) .............................................................. 165

Figure 2-144 Remove the high-voltage power supply lower (5 of 7) .............................................................. 166

Figure 2-145 Remove the high-voltage power supply lower (6 of 7) .............................................................. 166

Figure 2-146 Remove the high-voltage power supply lower (7 of 7) .............................................................. 167

Figure 2-147 Reinstall the high-voltage power supply lower .......................................................................... 167

Figure 2-148 Remove the developing-disengagement motor ........................................................................ 168

Figure 2-149 Remove the exhaust fan and fan duct (1 of 3) .......................................................................... 169

Figure 2-150 Remove the exhaust fan and fan duct (2 of 3) .......................................................................... 170

Figure 2-151 Remove the exhaust fan and fan duct (3 of 3) .......................................................................... 170

Figure 2-152 Reinstall the exhaust fan and fan duct ..................................................................................... 171

Figure 2-153 Remove the pickup motor ......................................................................................................... 172

Figure 2-154 Remove the lifter-drive assembly (1 of 2) ................................................................................. 173

Figure 2-155 Remove the lifter-drive assembly (2 of 3) ................................................................................. 174

Figure 2-156 Remove the lifter-drive assembly (3 of 3) ................................................................................. 174

Figure 2-157 Remove the lifter base assembly (1 of 2) ................................................................................. 175

Figure 2-158 Remove the lifter base assembly (2 of 2) ................................................................................. 176

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Figure 2-159 Reinstall the lifter base assembly (1 of 2) ................................................................................. 176

Figure 2-160 Reinstall the lifter base assembly (2 of 2) ................................................................................. 177

Figure 2-161 Remove the tray-pickup drive assembly (1 of 3) ...................................................................... 178

Figure 2-162 Remove the tray-pickup drive assembly (2 of 3) ...................................................................... 179

Figure 2-163 Remove the tray-pickup drive assembly (3 of 3) ...................................................................... 179

Figure 2-164 Remove the tray-pickup assembly (1 of 11) ............................................................................. 180

Figure 2-165 Remove the tray-pickup assembly (2 of 11) ............................................................................. 181

Figure 2-166 Remove the tray-pickup assembly (3 of 11) ............................................................................. 181

Figure 2-167 Remove the tray-pickup assembly (4 of 11) ............................................................................. 182

Figure 2-168 Remove the tray-pickup assembly (5 of 11) ............................................................................. 182

Figure 2-169 Remove the tray-pickup assembly (6 of 11) ............................................................................. 183

Figure 2-170 Remove the tray-pickup assembly (7 of 11) ............................................................................. 183

Figure 2-171 Remove the tray-pickup assembly (8 of 11) ............................................................................. 184

Figure 2-172 Remove the tray-pickup assembly (9 of 11) ............................................................................. 184

Figure 2-173 Remove the tray-pickup assembly (10 of 11) ........................................................................... 185

Figure 2-174 Remove the tray-pickup assembly (11 of 11) ........................................................................... 185

Figure 2-175 Remove the laser/scanner assembly (Y/M) (1 of 5) ................................................................. 187

Figure 2-176 Remove the laser/scanner assembly (Y/M) (2 of 5) ................................................................. 187

Figure 2-177 Remove the laser/scanner assembly (Y/M) (3 of 5) ................................................................. 188

Figure 2-178 Remove the laser/scanner assembly (Y/M) (4 of 5). ................................................................ 189

Figure 2-179 Remove the laser/scanner assembly (Y/M) (5 of 5) ................................................................. 189

Figure 2-180 Remove the laser/scanner assembly (C/Bk) (1 of 5) ................................................................ 191

Figure 2-181 Remove the laser/scanner assembly (C/Bk) (2 of 5) ................................................................ 191

Figure 2-182 Remove the laser/scanner assembly (C/Bk) (3 of 5) ................................................................ 192

Figure 2-183 Remove the laser/scanner assembly (C/Bk) (4 of 5) ................................................................ 192

Figure 2-184 Remove the laser/scanner assembly (C/Bk) (5 of 5) ................................................................ 193

Figure 2-185 Reinstall the PGC actuators (1 of 5) ......................................................................................... 193

Figure 2-186 Reinstall the PGC actuators (2 of 5) ......................................................................................... 194

Figure 2-187 Reinstall the PGC actuators (3 of 5) ......................................................................................... 194

Figure 2-188 Reinstall the PGC actuators (4 of 5) ......................................................................................... 195

Figure 2-189 Reinstall the PGC actuators (5 of 5) ......................................................................................... 195

Figure 2-190 Remove the high-voltage power supply upper (1 of 2) ............................................................. 196

Figure 2-191 Remove the high-voltage power supply upper (2 of 2) ............................................................. 197

Figure 2-192 Reinstall the high-voltage power supply upper ......................................................................... 198

Figure 2-193 Remove the yellow, magenta, cyan, and black drum motors ................................................... 199

Figure 2-194 Remove the fuser motor ........................................................................................................... 201

Figure 2-195 Remove the ITB motor (1 of 2) ................................................................................................. 202

Figure 2-196 Remove the main-drive assembly (1 of 6) ................................................................................ 204

Figure 2-197 Remove the main-drive assembly (2 of 6) ................................................................................ 204

Figure 2-198 Remove the main-drive assembly (3 of 6) ................................................................................ 205

Figure 2-199 Remove the main-drive assembly (4 of 6) ................................................................................ 205

Figure 2-200 Remove the main-drive assembly (5 of 6) ................................................................................ 206

Figure 2-201 Remove the main-drive assembly (6 of 6) ................................................................................ 206

Figure 2-202 Reinstall the main-drive assembly (1 of 7) ................................................................................ 207

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Figure 2-203 Reinstall the main-drive assembly (2 of 7) ................................................................................ 207

Figure 2-204 Reinstall the main-drive assembly (3 of 7) ................................................................................ 208

Figure 2-205 Reinstall the main-drive assembly (4 of 7) ................................................................................ 209

Figure 2-206 Reinstall the main-drive assembly (5 of 7) ................................................................................ 209

Figure 2-207 Reinstall the main-drive assembly (6 of 7) ................................................................................ 210

Figure 2-208 Reinstall the main-drive assembly (7 of 7) ................................................................................ 210

Figure 2-209 Remove the fuser-drive assembly (1 of 7) ................................................................................ 212

Figure 2-210 Remove the fuser-drive assembly (2 of 7) ................................................................................ 212

Figure 2-211 Remove the fuser-drive assembly (3 of 7) ................................................................................ 213

Figure 2-212 Remove the fuser-drive assembly (4 of 7) ................................................................................ 213

Figure 2-213 Remove the fuser-drive assembly (5 of 7) ................................................................................ 214

Figure 2-214 Remove the fuser-drive assembly (6 of 7) ................................................................................ 214

Figure 2-215 Remove the fuser-drive assembly (7 of 7) ................................................................................ 215

Figure 2-216 Reinstall the fuser-drive assembly ............................................................................................ 215

Figure 2-217 Remove the front door (optional paper feeder) (1 of 2) ............................................................ 216

Figure 2-218 Remove the front door (optional paper feeder) (2 of 2) ............................................................ 217

Figure 2-219 Remove the rear cover (optional paper feeder) ........................................................................ 218

Figure 2-220 Remove the right-front cover (optional paper feeder) .............................................................. 219

Figure 2-221 Remove the right door (optional paper feeder) (1 of 3) ............................................................ 220

Figure 2-222 Remove the right door (optional paper feeder) (2 of 3) ............................................................ 220

Figure 2-223 Remove the right door (optional paper feeder) (3 of 3) ............................................................ 221

Figure 2-224 Remove the left cover (optional paper feeder) (1 of 3) ............................................................. 222

Figure 2-225 Remove the left cover (optional paper feeder) (2 of 3) ............................................................. 223

Figure 2-226 Remove the left cover (optional paper feeder) (3 of 3) ............................................................. 223

Figure 2-227 Remove the right cover (optional paper feeder) ...................................................................... 224

Figure 2-228 Remove the rear-right cover (optional paper feeder) ............................................................... 225

Figure 2-229 Remove the pickup assembly (optional paper feeder) (1 of 5) ................................................. 226

Figure 2-230 Remove the pickup assembly (optional paper feeder) (2 of 5) ................................................. 227

Figure 2-231 Remove the pickup assembly (optional paper feeder) (3 of 5) ................................................. 227

Figure 2-232 Remove the pickup assembly (optional paper feeder) (4 of 5) ................................................. 228

Figure 2-233 Remove the pickup assembly (optional paper feeder) (5 of 5) ................................................. 228

Figure 2-234 Remove the lifter assembly (optional paper feeder) (1 of 2) ..................................................... 229

Figure 2-235 Remove the lifter assembly (optional paper feeder) (2 of 2) ..................................................... 229

Figure 2-236 Remove the lifter-drive assembly (optional paper feeder) (1 of 2) ............................................ 230

Figure 2-237 Remove the lifter-drive assembly (optional paper feeder) (2 of 2) ............................................ 230

Figure 2-238 Remove the pickup motor assembly (optional paper feeder) (1 of 2) ....................................... 231

Figure 2-239 Remove the pickup motor assembly (optional paper feeder) (2 of 2) ....................................... 231

Figure 2-240 Remove the controller PCA (optional paper feeder) (1 of 2) .................................................... 232

Figure 2-241 Remove the controller PCA (optional paper feeder) (2 of 2) .................................................... 232

Figure 3-1 Diagnostic test (1 of 2) .................................................................................................................. 243

Figure 3-2 Diagnostic test (2 of 2) .................................................................................................................. 244

Figure 3-3 Engine-test button ......................................................................................................................... 245

Figure 3-4 Test the TOP sensor (1 of 2) ........................................................................................................ 247

Figure 3-5 Test the TOP sensor (2 of 2) ........................................................................................................ 247

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Figure 3-6 Test the loop sensors .................................................................................................................... 248

Figure 3-7 Test the fuser delivery sensor (1 of 2) .......................................................................................... 249

Figure 3-8 Test the fuser delivery sensor (2 of 2) .......................................................................................... 249

Figure 3-9 Test the duplex re-pickup sensor .................................................................................................. 250

Figure 3-10 Test the output-bin-full sensor .................................................................................................... 251

Figure 3-11 Test the fuser pressure-release sensor ...................................................................................... 253

Figure 3-12 Test the primary transfer-roller-disengagement sensor (1 of 4) ................................................. 254

Figure 3-13 Test the primary transfer-roller-disengagement sensor (2 of 4) ................................................. 254

Figure 3-14 Test the primary transfer-roller-disengagement sensor (3 of 4) ................................................. 255

Figure 3-15 Test the primary transfer-roller-disengagement sensor (4 of 4) ................................................. 255

Figure 3-16 Media sensor .............................................................................................................................. 256

Figure 3-17 Test the front-door switch ........................................................................................................... 257

Figure 3-18 Test the right door switch ............................................................................................................ 258

Figure 3-19 Test the Tray 1 media-present sensor ....................................................................................... 261

Figure 3-20 Test the tray 2 paper-present sensor ......................................................................................... 262

Figure 3-21 Tray 2 paper surface 1 and 2 ...................................................................................................... 263

Figure 3-22 Test the Tray 2 paper size switches ........................................................................................... 264

Figure 3-23 Test the Tray 3 feed sensor ........................................................................................................ 265

Figure 3-24 Test the new ITB sensor ............................................................................................................. 271

Figure 3-25 Test the new ITB sensor ............................................................................................................. 271

Figure 3-26 Test the right door switch ............................................................................................................ 272

Figure 3-27 Product cross section .................................................................................................................. 277

Figure 3-28 Optional paper feeder (1 x 500-sheet) ........................................................................................ 278

Figure 3-29 Optional paper feeder (3 x 500-sheet) ........................................................................................ 279

Figure 3-30 Formatter PCA ............................................................................................................................ 280

Figure 3-31 DC controller connector locations ............................................................................................... 281

Figure 3-32 Controller PCA connectors ......................................................................................................... 283

Figure 3-33 External component locations ..................................................................................................... 284

Figure 3-34 Major component locations (1 of 3) ............................................................................................ 285

Figure 3-35 Major component locations (2 of 3) ............................................................................................ 286

Figure 3-36 Major component locations (3 of 3) ............................................................................................ 287

Figure 3-37 Motors, fans, and rollers component locations ........................................................................... 288

Figure 3-38 PCA component locations .......................................................................................................... 289

Figure 3-39 Optional paper feeder (1 x 500-sheet) component locations (1 of 2) ......................................... 290

Figure 3-40 Optional paper feeder (1 x 500-sheet) component locations (2 of 2) ......................................... 291

Figure 3-41 Optional paper feeder (3 x 500-sheet) component locations (1 of 2) ......................................... 292

Figure 3-42 Optional paper feeder (3 x 500-sheet) component locations (2 of 2) ......................................... 293

Figure 3-43 General timing chart .................................................................................................................... 294

Figure 3-44 General circuit diagram (1 of 2) .................................................................................................. 295

Figure 3-45 General circuit diagram (1 of 2) .................................................................................................. 295

Figure 3-46 Paper feeder circuit diagram (1 X 500-sheet) ............................................................................. 296

Figure 3-47 Paper feeder circuit diagram (3 X 500-sheet) ............................................................................. 297

Figure 3-48 Print-quality troubleshooting procedure ...................................................................................... 302

Figure 3-49 Yellow print-quality troubleshooting page ................................................................................... 303

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