HP 4500 DN, 4500 N Service Manual
4500, 4500 N, 4500 DN Printer
Service Manual
October 1999 Edition
HP Color LaserJet 4500,
4500 N, 4500 DN Printer
Service Manual _____________
© Copyright Hewlett-Packard
Company, 1999
All Rights Reserved.
Reproduction, adaptation, or
translation without prior written
permission is prohibited, except
as allowed under the copyright
laws.
Part number: C4084-91077
First Edition, October 1999
Warranty
The information contained in
this document is subject to
change without notice.
Hewlett-Packard makes no
warranty of any kind with
respect to this information.
HEWLETT-PACKARD
SPECIFICALLY DISCLAIMS
THE IMPLIED WARRANTY OF
MERCHANTABILITY AND
FITNESS FOR A PARTICULAR
PURPOSE.
Hewlett-Packard shall not be
liable for any direct, indirect,
incidental, consequential, or
other damage alleged in
connection with the furnishing or
use of this information.
Trademark Credits
Adobe is a trademark of Adobe
Systems Incorporated which
may be registered in certain
jurisdictions.
Arial is a U.S. registered
trademark of the Monotype
Corporation.
CompuServe(TM) is a U.S.
trademark of CompuServe, Inc.
E
NERGY STAR
is a U.S.
registered service mark of the
United States Environmental
Protection Agency.
®
Microsoft
is a U.S. registered
trademark of Microsoft
Corporation.
®
PANTONE
* *Pantone, Inc.’s
check-standard trademark for
color.
PostScript is a trademark of
Adobe Systems Incorporated
which may be registered in
certain jurisdictions.
TrueType is a U.S. trademark of
Apple Computer, Inc.
UNIX is a registered trademark
in the United States and other
countries, licensed exclusively
through X/Open Company
Limited.
Windows, MS Windows, and
Windows NT are U.S . registered
trademarks of Microsoft
Corporation.
Hewlett-Packard Company
11311 Chinden Boulevard
Boise, Idaho 83714 U.S.A.
Conventions
This manual uses the following conventions:
Color is used to emphasize items that are important to the material
under discussion.
italic
Bold is used for emphasis, particularly in situations where
would be confusing.
Italic
type is used to indicate related documents or emphasis.
DISPLAY type indicates text as seen on the printer control panel
display.
Commands you use on a computer k e yboard or on the printer control
panel are shown in [Keycap]. Two examples are [Select], and
[-[Value +].
COURIER type indicates text that you type on a computer keyboard
exactly as shown.
Hint Hints are used to suggest an action that may simplify the process.
Note Notes contain important information set off from the text.
type
CAUTION Caution messages alert you to the possibility of damage to equipment
or loss of data.
WARNING! Warning messages alert you to the possibility of personal injury.
iii
iv
Contents
List of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viii
List of tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xiii
1 Printer description
Printer features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Site requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Printer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Printer assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2
Media requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Environmental Product Stewardship Program . . . . . . . . . . . . . . . . .22
Regulatory statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
2 Service approach
Service approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Parts and supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Technical assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Warranty statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
3 Installation and configuration
Unpack the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Connecting to a network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Enhanced I/O (EIO) configuration . . . . . . . . . . . . . . . . . . . . . . . . . .62
Printer drivers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Network configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Configuration tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Setting network security on the printer. . . . . . . . . . . . . . . . . . . . . . .68
4 Printer maintenance
Cleaning the printer and accessories . . . . . . . . . . . . . . . . . . . . . . .72
Approximate replacement intervals for consumable items. . . . . . . .74
Locating consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Replacing consumable items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
DIMM configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Contents v
5 Theory of operation
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Basic operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Image formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Toner density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Mechanical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
DC controller subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Motors and fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Formatter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Power supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
6 Removal and replacement
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Consumable assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Covers, drawers, top, and front assemblies. . . . . . . . . . . . . . . . . .149
Right side assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Left side assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Rear assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
Internal assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
7 Troubleshooting
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Troubleshooting process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
Printer error troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
Paper path troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
Image formation troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .262
Image defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272
Overhead transparency defects . . . . . . . . . . . . . . . . . . . . . . . . . . .286
Repetitive defects troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .288
Interface troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
Control panel troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .297
Troubleshooting tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306
Service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311
Diagnostics mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330
vi Contents
8 Parts and diagrams
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .351
Ordering parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352
Illustrations and parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .357
Alphabetical parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386
Numerical parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Index
List of figures
Figure 1-1 HP Color LaserJet 4500 family printers . . . . . . . . . . . .2
Figure 1-2 Serial number information. . . . . . . . . . . . . . . . . . . . . . .5
Figure 1-3 Sample label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Figure 1-4 Space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Figure 1-5 Front view (shown with 500-sheet paper feeder
Figure 1-6 Rear view (shown with 500-sheet paper feeder
Figure 3-1 Package contents. . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Figure 3-2 Parallel cable with a “C” connector. . . . . . . . . . . . . . .53
Figure 4-1 Imaging drum life . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Figure 4-2 OPC life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Figure 4-3 Location of consumables . . . . . . . . . . . . . . . . . . . . . .78
Figure 4-4 Removing the formatter board . . . . . . . . . . . . . . . . . .92
Figure 4-5 Do not remove the DIMM in slot #4.. . . . . . . . . . . . . .93
Figure 4-6 EDO and SDRAM memory modules . . . . . . . . . . . . .93
Figure 5-1 Basic system operation. . . . . . . . . . . . . . . . . . . . . . . .97
Figure 5-2 Image formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Figure 5-3 Primary charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Figure 5-4 Laser exposure. . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Figure 5-5 Development. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Figure 5-6 Primary transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Figure 5-7 Secondary transfer . . . . . . . . . . . . . . . . . . . . . . . . . .103
Figure 5-8 Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Figure 5-9 ITB residual toner cleaning. . . . . . . . . . . . . . . . . . . .105
Figure 5-10 Waste toner to waste toner reservoir . . . . . . . . . . . .106
Figure 5-11 Fuser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Figure 5-12 Toner density sensor . . . . . . . . . . . . . . . . . . . . . . . .108
Figure 5-13 Photosensitive drum cartridge . . . . . . . . . . . . . . . . .109
Figure 5-14 Waste toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Figure 5-15 Transfer unit function . . . . . . . . . . . . . . . . . . . . . . . .111
Figure 5-16 Home position detection . . . . . . . . . . . . . . . . . . . . . .112
Figure 5-17 ITB unit life detection . . . . . . . . . . . . . . . . . . . . . . . .113
Figure 5-18 Secondary transfer roller unit . . . . . . . . . . . . . . . . . .114
Figure 5-19 ITB unit contact/separation unit . . . . . . . . . . . . . . . .115
Figure 5-20 Toner carousel assembly . . . . . . . . . . . . . . . . . . . . .116
Figure 5-21 Toner carousel operation . . . . . . . . . . . . . . . . . . . . .117
Figure 5-22 Toner cartridge contact/separation function . . . . . . .118
Figure 5-23 Toner level detection/toner cartridge detection. . . . .119
Figure 5-24 Laser/scanner operation. . . . . . . . . . . . . . . . . . . . . .120
Figure 5-25 Paper jam sensors . . . . . . . . . . . . . . . . . . . . . . . . . .122
Figure 5-26 Tray 2 (cassette) operation. . . . . . . . . . . . . . . . . . . .124
Figure 5-27 Tray 1 manual feed. . . . . . . . . . . . . . . . . . . . . . . . . .125
Figure 5-28 Laser paper detected . . . . . . . . . . . . . . . . . . . . . . . .126
and duplex unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
and duplex unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
List of figures vii
Figure 5-29 Overhead transparency sensor . . . . . . . . . . . . . . . .127
Figure 5-30 Pick-up and feed system . . . . . . . . . . . . . . . . . . . . .129
Figure 5-31 Fusing and delivery unit . . . . . . . . . . . . . . . . . . . . . .131
Figure 5-32 Reversing and duplex pick-up operation . . . . . . . . .133
Figure 5-33 Reversing operation . . . . . . . . . . . . . . . . . . . . . . . . .134
Figure 5-34 Side registration adjustment . . . . . . . . . . . . . . . . . . .135
Figure 5-35 Duplex feed roller pressure. . . . . . . . . . . . . . . . . . . .136
Figure 5-36 DC controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . .137
Figure 5-37 Motors and fans . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Figure 6-1 Phillips vs. Posidriv screwdrivers . . . . . . . . . . . . . . .146
Figure 6-2 Top cover removal and replacement (rear view of
printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Figure 6-3 Left side cover removal and replacement. . . . . . . . .150
Figure 6-4 Right side cover removal and replacement. . . . . . . .151
Figure 6-5 Rear door removal and replacement . . . . . . . . . . . .152
Figure 6-6 Right rear cover removal and replacement. . . . . . . .153
Figure 6-7 Drum drawer (top drawer) cover removal and
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Figure 6-8 Drum drawer (top drawer) cover tabs and levers . . .155
Figure 6-9 ITB drawer (middle drawer) cover removal and
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Figure 6-10 ITB drawer (middle drawer) removal and
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Figure 6-11 Control panel removal and replacement. . . . . . . . . .158
Figure 6-12 Front right cover removal and replacement . . . . . . .159
Figure 6-13 RFI shield removal and replacement . . . . . . . . . . . .160
Figure 6-14 Laser/scanner assembly removal and
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
Figure 6-15 DC controller removal and replacement . . . . . . . . . .162
Figure 6-16 Developing PCB removal and replacement (1 of 2) .163
Figure 6-17 Developing PCB removal and replacement (2 of 2) .164
Figure 6-18 Top cover switch assembly removal and
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
Figure 6-19 Top cover switch assembly removal and
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Figure 6-20 Drum drawer (top drawer) switch . . . . . . . . . . . . . . .168
Figure 6-21 Drum drawer (top drawer) assembly removal
and replacement (1 of 3). . . . . . . . . . . . . . . . . . . . . .169
Figure 6-22 Drum drawer (top drawer) assembly removal
and replacement (2 of 3). . . . . . . . . . . . . . . . . . . . . .170
Figure 6-23 Drum drawer assembly removal and
replacement (3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . .170
Figure 6-24 Densitometer removal and replacement (1 of 2). . . .171
Figure 6-25 Densitometer removal and replacement (2 of 2). . . .172
Figure 6-26 Formatter removal and replacement. . . . . . . . . . . . . 173
Figure 6-27 Formatter pan assembly removal and
replacement (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . .175
viii List of figures
Figure 6-28 Formatter pan assembly removal and
replacement (2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . .176
Figure 6-29 Formatter pan assembly removal and
replacement (3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . .177
Figure 6-30 Formatter pan assembly removal and
replacement (4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . .178
Figure 6-31 Power supply removal and replacement . . . . . . . . . .179
Figure 6-32 High-voltage power supply removal and
replacement (newer version printers). . . . . . . . . . . .181
Figure 6-33 High-voltage power supply removal and
replacement (older version printers). . . . . . . . . . . . .181
Figure 6-34 Drum drive assembly removal and replacement
(1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
Figure 6-35 Drum drive assembly removal and replacement
(2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
Figure 6-36 Drum drive assembly removal and replacement
(3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
Figure 6-37 Large fan removal and replacement (1 of 2). . . . . . .185
Figure 6-38 Large fan removal and replacement (2 of 2). . . . . . .186
Figure 6-39 Carousel drive assembly removal and
replacement (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . .187
Figure 6-40 Carousel drive assembly removal and
replacement (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . .188
Figure 6-41 Paper size switch removal and replacement . . . . . .189
Figure 6-42 Switch plate assembly removal and replacement. . .190
Figure 6-43 Paper feed PCB removal and replacement (1 of 3) .191
Figure 6-44 Paper feed PCB removal and replacement (2 of 3) .192
Figure 6-45 Paper feed PCB removal and replacement (3 of 3) .193
Figure 6-46 Fuser motor removal and replacement (1 of 2) . . . .194
Figure 6-47 Fuser motor removal and replacement (2 of 2) . . . .195
Figure 6-48 Paper path motor removal and replacement . . . . . .196
Figure 6-49 Paper pick solenoid removal and replacement. . . . .197
Figure 6-50 ITB cleaning roller clutch removal and replacement.198
Figure 6-51 ITB clutch assembly removal and replacement
(1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Figure 6-52 ITB clutch assembly removal and replacement
(2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
Figure 6-53 Transfer roller cam clutch removal and
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
Figure 6-54 Left side gears removal and replacement (1 of 2) . .203
Figure 6-55 Left side gears removal and replacement (2 of 2) . .203
Figure 6-56 Large right side fan removal and replacement
(1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
Figure 6-57 Large right side fan removal and replacement
(2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
Figure 6-58 Left side fan removal and replacement (1 of 3) . . . .206
Figure 6-59 Left side fan removal and replacement (2 of 3) . . . .207
List of figures ix
Figure 6-60 Left side fan removal and replacement (3 of 3) . . . .207
Figure 6-61 Rear paper path assembly removal and
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
Figure 6-62 Carousel housing assembly removal and
replacement (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . .209
Figure 6-63 Carousel housing assembly removal and
replacement (2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . .211
Figure 6-64 Carousel housing assembly removal and
replacement (left side view when facing printer)
(3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
Figure 6-65 Carousel housing assembly removal and
replacement (right side view when facing printer)
(4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
Figure 6-66 Paper transport assembly removal and
replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
Figure 6-67 Paper pick rollers removal and replacement. . . . . . .214
Figure 7-1 Troubleshooting flowchart (1 of 2) . . . . . . . . . . . . . .222
Figure 7-2 Troubleshooting flowchart (2 of 2) . . . . . . . . . . . . . .223
Figure 7-3 Paper jam sensors . . . . . . . . . . . . . . . . . . . . . . . . . .255
Figure 7-4 Paper jam locations . . . . . . . . . . . . . . . . . . . . . . . . .256
Figure 7-5 Paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
Figure 7-6 Image formation . . . . . . . . . . . . . . . . . . . . . . . . . . . .262
Figure 7-7 Color balance calibration page . . . . . . . . . . . . . . . . .269
Figure 7-8 Imaging drum exposed to light (not to scale) . . . . . .291
Figure 7-9 Menu map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298
Figure 7-10 Printer configuration page. . . . . . . . . . . . . . . . . . . . .307
Figure 7-11 Service mode menu map . . . . . . . . . . . . . . . . . . . . .311
Figure 7-12 Service menu map . . . . . . . . . . . . . . . . . . . . . . . . . .312
Figure 7-13 Registration page . . . . . . . . . . . . . . . . . . . . . . . . . . .317
Figure 7-15 Sensor locations . . . . . . . . . . . . . . . . . . . . . . . . . . . .330
Figure 7-16 Printer solenoids and clutches . . . . . . . . . . . . . . . . .332
Figure 7-17 Printer motors and fans . . . . . . . . . . . . . . . . . . . . . .333
Figure 7-18 Miscellaneous sensors and clutches . . . . . . . . . . . .334
Figure 7-19 Intermediate transfer belt sensors . . . . . . . . . . . . . .335
Figure 7-20 Miscellaneous sensors (with tray 1 front cover
removed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .336
Figure 7-21 PS6 and PS7 sensor location . . . . . . . . . . . . . . . . . .337
Figure 7-22 Miscellaneous switches . . . . . . . . . . . . . . . . . . . . . .338
Figure 7-23 Miscellaneous switches and sensors . . . . . . . . . . . .339
Figure 7-24 PS14 sensor location . . . . . . . . . . . . . . . . . . . . . . . .340
Figure 7-25 Miscellaneous parts . . . . . . . . . . . . . . . . . . . . . . . . .341
Figure 7-26 Imaging drum connector . . . . . . . . . . . . . . . . . . . . . .342
Figure 7-27 Rear door interlock switch defeat . . . . . . . . . . . . . . .343
Figure 7-28 Right rear fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .344
Figure 7-29 Fuse (F1) and CB101 . . . . . . . . . . . . . . . . . . . . . . . .345
Figure 7-30 Fusing assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .346
Figure 7-31 DC controller PCB connectors . . . . . . . . . . . . . . . . .347
x List of figures
Figure 7-32 Location of connectors . . . . . . . . . . . . . . . . . . . . . . .348
Figure 7-33 Location of duplexer and 500-sheet paper feeder
connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .349
Figure 7-34 500-sheet feeder wiring diagram . . . . . . . . . . . . . . .350
Figure 8-1 Assembly location diagram (1 of 2) . . . . . . . . . . . . .358
Figure 8-2 Assembly location diagram (2 of 2) . . . . . . . . . . . . .359
Figure 8-3 PCB locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .360
Figure 8-4 External covers, panels, etc.. . . . . . . . . . . . . . . . . . .362
Figure 8-5 Top cover assembly . . . . . . . . . . . . . . . . . . . . . . . . .364
Figure 8-6 Internal components (1 of 3). . . . . . . . . . . . . . . . . . .366
Figure 8-7 Internal components (2 of 3). . . . . . . . . . . . . . . . . . .368
Figure 8-8 Internal components (3 of 3). . . . . . . . . . . . . . . . . . .370
Figure 8-9 Developing carousel assembly. . . . . . . . . . . . . . . . .372
Figure 8-10 Paper pick-up assembly (1 of 3). . . . . . . . . . . . . . . .374
Figure 8-11 Paper pick-up assembly (2 of 3). . . . . . . . . . . . . . . .376
Figure 8-12 Paper pick-up assembly (3 of 3). . . . . . . . . . . . . . . .378
Figure 8-13 Upper drawer assembly . . . . . . . . . . . . . . . . . . . . . .380
Figure 8-14 MP tray paper pick-up assembly . . . . . . . . . . . . . . .381
Figure 8-15 250-sheet cassette . . . . . . . . . . . . . . . . . . . . . . . . . .382
Figure 8-16 500-sheet paper feeder . . . . . . . . . . . . . . . . . . . . . .384
Figure 8-17 Duplex unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .385
List of figures xi
List of tables
Table 1-1 Printer features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Table 1-2 Model names and numbers . . . . . . . . . . . . . . . . . . . . .5
Table 1-3 Electrical specifications. . . . . . . . . . . . . . . . . . . . . . . . .9
Table 1-4 Environmental specifications . . . . . . . . . . . . . . . . . . . .9
Table 1-5 Consumable storage requirements. . . . . . . . . . . . . . .10
Table 1-6 Printer dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Table 1-7 Acoustic emissions . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Table 1-8 Supported media specifications . . . . . . . . . . . . . . . . .15
Table 1-9 Printing on transparencies . . . . . . . . . . . . . . . . . . . . .18
Table 2-1 Related documentation and software . . . . . . . . . . . . .35
Table 4-1 Cleaning the printer . . . . . . . . . . . . . . . . . . . . . . . . . .73
Table 4-2 Approximate replacement interval for consumable
Table 5-1 Toner carousel assembly components. . . . . . . . . . .116
Table 5-2 Motors, solenoids, sensors, and switches . . . . . . . .124
Table 5-3 Motors, solenoids, clutches, and sensors. . . . . . . . .125
Table 5-4 Solenoids, sensors, switches . . . . . . . . . . . . . . . . . .129
Table 5-5 Paper size detection switches . . . . . . . . . . . . . . . . .130
Table 5-6 Fusing and delivery unit components . . . . . . . . . . . .131
Table 5-7 Motors, solenoids, and sensors . . . . . . . . . . . . . . . .133
Table 5-8 Motor and fan locations . . . . . . . . . . . . . . . . . . . . . .138
Table 6-1 Types of screws . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Table 6-2 Approximate replacement interval for consumable
Table 7-1 Pre-troubleshooting checklist . . . . . . . . . . . . . . . . . .220
Table 7-2 Alphabetical printer error messages. . . . . . . . . . . . .226
Table 7-3 Numerical printer error messages. . . . . . . . . . . . . . .239
Table 7-4 Paper jam locations and associated error
Table 7-5 Explanation of alternating message . . . . . . . . . . . . .258
Table 7-6 Image defect table . . . . . . . . . . . . . . . . . . . . . . . . . .272
Table 7-7 Defect spacing chart. . . . . . . . . . . . . . . . . . . . . . . . .290
Table 7-8 Communications checks. . . . . . . . . . . . . . . . . . . . . .292
Table 7-9 Information Menu . . . . . . . . . . . . . . . . . . . . . . . . . . .299
Table 7-10 Paper Handling Menu . . . . . . . . . . . . . . . . . . . . . . . .300
Table 7-11 Configuration settings . . . . . . . . . . . . . . . . . . . . . . . .301
Table 7-12 Printing Menu settings . . . . . . . . . . . . . . . . . . . . . . .302
Table 7-13 I/O Menu settings . . . . . . . . . . . . . . . . . . . . . . . . . . .303
Table 7-14 Calibration Menu settings . . . . . . . . . . . . . . . . . . . . .304
Table 7-15 Resets Menu settings . . . . . . . . . . . . . . . . . . . . . . . .305
Table 7-16 Formatter diagnostics . . . . . . . . . . . . . . . . . . . . . . . .321
Table 7-17 Engine diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . .322
Table 7-18 Paper path sensors and switches. . . . . . . . . . . . . . .325
Table 7-19 Paper size settings . . . . . . . . . . . . . . . . . . . . . . . . . .326
items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
xii List of tables
Table 7-20 Sensor status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327
Table 7-21 Sensor function and locations. . . . . . . . . . . . . . . . . .331
Table 7-22 Solenoid and clutch functions and locations. . . . . . .332
Table 7-23 Printer motors and fans . . . . . . . . . . . . . . . . . . . . . .333
Table 7-24 Miscellaneous sensors and clutches . . . . . . . . . . . .334
Table 7-25 Intermediate transfer belt sensors . . . . . . . . . . . . . .335
Table 7-26 PS3 and PS4 description . . . . . . . . . . . . . . . . . . . . .336
Table 7-27 PS6 and PS7 description . . . . . . . . . . . . . . . . . . . . .337
Table 7-28 Switch description. . . . . . . . . . . . . . . . . . . . . . . . . . .338
Table 7-29 SW2, SW5, and PS13 description . . . . . . . . . . . . . .339
Table 7-30 Density sensor location. . . . . . . . . . . . . . . . . . . . . . .340
Table 7-31 Miscellaneous parts . . . . . . . . . . . . . . . . . . . . . . . . .341
Table 7-32 Imaging drum connector. . . . . . . . . . . . . . . . . . . . . .342
Table 7-33 Fuse F1 and CB101 location . . . . . . . . . . . . . . . . . .345
Table 7-34 110-volt fusing assembly . . . . . . . . . . . . . . . . . . . . .346
Table 8-1 Consumables, accessories, and supplies . . . . . . . .353
Table 8-2 Types of screws . . . . . . . . . . . . . . . . . . . . . . . . . . . .356
Table 8-3 PCB assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361
Table 8-4 Printer cover and door . . . . . . . . . . . . . . . . . . . . . . .362
Table 8-5 Top cover components. . . . . . . . . . . . . . . . . . . . . . .365
Table 8-6 Internal components (1 of 3). . . . . . . . . . . . . . . . . . .366
Table 8-7 Internal components (2 of 3). . . . . . . . . . . . . . . . . . .369
Table 8-8 Internal components (3 of 3). . . . . . . . . . . . . . . . . . .371
Table 8-9 Developing carousel assembly. . . . . . . . . . . . . . . . .372
Table 8-10 Paper pick-up assembly (1 of 3). . . . . . . . . . . . . . . .375
Table 8-11 Paper pick-up assembly (2 of 3). . . . . . . . . . . . . . . .376
Table 8-12 Paper pick-up assembly (3 of 3). . . . . . . . . . . . . . . .378
Table 8-13 Upper drawer assembly . . . . . . . . . . . . . . . . . . . . . .380
Table 8-14 MP tray paper pick-up assembly . . . . . . . . . . . . . . .381
Table 8-15 250-sheet cassette . . . . . . . . . . . . . . . . . . . . . . . . . .383
Table 8-16 500-sheet paper feeder . . . . . . . . . . . . . . . . . . . . . .384
Table 8-17 Duplex unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .385
Table 8-18 Alphabetical parts list . . . . . . . . . . . . . . . . . . . . . . . .386
Table 8-19 Numerical parts list . . . . . . . . . . . . . . . . . . . . . . . . . .393
List of tables xiii
xiv List of tables
1
Printer description
Chapter contents
Printer features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Model and serial numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Power and regulatory information . . . . . . . . . . . . . . . . . . . . . . . .6
Site requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Space requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Environmental specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Consumable storage requirements . . . . . . . . . . . . . . . . . . . . . .10
Printer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Printer assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Media requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Selecting print media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Media specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Supported media weights and sizes . . . . . . . . . . . . . . . . . . . . .15
Non-supported media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Printing on special media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Environmental Product Stewardship Program . . . . . . . . . . . . . . . . .22
Regulatory statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
FCC regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Canadian DOC regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
VCCI statement (Japan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Korean EMI statement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Laser safety statement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Material Safety Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Toner safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Laser statement for Finland. . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Chapter 1 Printer description 1
Printer features
The HP LaserJet 4500 printer family pictured in Figure 1-1 has three
models.
The HP LaserJet 4500 printer is the base model; it includes
32 MB of RAM.
The HP LaserJet 4500 N printer includes the base model with an
HP JetDirect 600N print server (network card) and 64 MB of
RAM.
The HP LaserJet 4500 DN printer includes the base model with
an HP JetDirect 600N print server (network card), a 500-sheet
paper feeder, a duplex unit, and 64 MB of RAM.
1
Figure 1-1 HP Color LaserJet 4500 family printers
1 HP Color LaserJet 4500 and 4500 N printers
2 HP Color LaserJet 4500 DN printer
2
2 Printer features
This printer combines the quality and reliability of Hewlett-Packard
printers with the features listed in Table 1-1 below. For more
information on printer features, refer to the Hewlett-Packard website
at http://www.hp.com.
Table 1-1 Printer features
Feature Description
Connectivity
Duplex
Environmental
Fonts
Memory—standard
●
Bidirectional parallel port (requires a “C” connector)
●
Two enhanced input/output (EIO) slots
●
Optional HP JetDirect 600N print server (network card)
(included with the HP Color LaserJet 4500 N and 4500 DN
printers)
●
Optional duplex unit; mounts directly beneath the printer for
two-sided printing (duplex unit is standard with the HP Color
LaserJet 4500 DN)
●
Requires 40 MB of memory. 64 MB of memory is
recommended for optimal duplex printing.
Note:
If the 500-sheet paper feeder (Tray 3) is installed, the
duplex unit must be positioned between the printer and Tray 3.
●
PowerSave setting (meets E
●
High content of recyclable components and materials
●
80 internal fonts
●
HP FontSmart software
●
32 MB RAM (Base)
●
64 MB RAM (HP Color LaserJet 4500 N/4500 DN)
●
Memory Enhancement T echnolog y (MEt), which automatically
NERGY STAR
guidelines)
compresses data to use RAM more efficiently
Memory—optional
●
Install 4, 8, 16, 32, or 64 MB DIMMs into the printer’s three
DIMM slots. Synchronous SDRAM modules do not need to be
configured in pairs (in corresponding left and right slots). The
printer will only recognize 208 MB of RAM. If you install more
than 208 MB of RAM, it will not be used by the printer.
CAUTION:
The HP Color LaserJet printer uses 100-pin,
non-parity, synchronous SDRAM DIMMs. Extended Data
Output (EDO) DIMMs are not supported.
Chapter 1 Printer description 3
Table 1-1 Printer features (continued)
Feature Description
Paper handling—input
(tray capacity)
Paper handling—output
(face-down, correct order
output)
Printer language support
Paper sizes supported
The capacities will vary depending on the media being used (for
example, transparencies, labels, heavier media, and envelopes):
●
Tray 1:*
●
Tray 2:*
●
Tray 3:*
*
●
Top output bin holds up to 250 sheets of standard paper
●
Rear output bin holds up to 100 sheets of standard paper.
150-sheet multipurpose tray
250-sheet standard cassette
Optional 500-sheet paper feeder
Quantities based on 75 g/m
2
(20 lb) media.
(The output of the rear output bin is in reverse order, facing
up.)
●
HP PCL5c
●
PostScript™ Emulation
●
Auto language switching
●
A4/Letter
●
Legal
●
Executive
●
JIS B5
●
A5
●
Custom (B5 ISO)
Print speed—
monochrome printing
Print speed—
color printing
●
16 pages per minute (ppm)
●
8 ppm for transparencies, heavy paper, and glossy paper
●
4 ppm
●
2 ppm for transparencies, heavy paper, and glossy paper
Standard interfaces The printer comes equipped with two enhanced
input/output (EIO) slots
Note:
If the printer is not configured with a network interface card,
connect the printer using a bidirectional parallel cable (IEEE-1284
compliant) with a “C” connector.
4 Printer features
Identification
r
Model and serial numbers
The model number and serial numbers are listed on identification
labels located on the rear of the printer. The model number is
alphanumeric, such as C4084A for the HP Color LaserJet 4500. The
serial number contains information about the country of origin; the
printer version; production code; and the production number of the
printer (see Figure 1-2). For information on determining the version of
printer you are servicing, see page 146.
Country
of origin
printer version
production code
production numbe
Figure 1-2 Serial number information
Table 1-2 Model names and numbers
Model Name Model Number
HP Color LaserJet 4500 C4084A
HP Color LaserJet 4500 N C4089A
HP Color LaserJet 4500 DN C4094A
Note Two versions of the HP Color LaserJet 4500 series printers are
available. Before servicing the printer or ordering parts, you will need
to identify which printer version you are servicing. For more information,
see page 146.
Chapter 1 Printer description 5
Power and regulatory information
The identification labels on the rear of the printer also contain power
rating and regulatory information as shown in Figure 1-3.
CAUTION Converting the voltage on the printer can damage the printer. Do not
use any voltage other than the operating voltage. Any attempt to
convert operating voltages will v oid the product warranty (f or e xample,
attempting to change a 110V printer to a 220V printer).
Figure 1-3 Sample label
6 Identification
Site requirements
The printer must be kept in a proper location to maintain the
performance level that has been set at the factory. In particular, be
sure that the environment adheres to the specifications listed in this
chapter.
Below are recommendations for the printer location and placement.
Make sure the printer has the following:
a well-ventilated, dust-free area
a hard, level surface (not more than a 2° angle):
• for the HP Color LaserJet 4500 and 4500 N, the surface must
support 51 kg (112 lb)
• for the HP Color LaserJet 4500 DN, the surface must support
77 kg (169 lb)
a level surface that supports all four corners of the 500-sheet
paper feeder
a constant temperature and humidity. (Do not install near water
sources, humidifiers, air conditioners, refrigerators, or other major
appliances.)
Make sure to keep the printer:
away from direct sunlight, dust, open flames, or ammonia fumes
away from walls or other objects. There must be enough space
around the printer for proper access and ventilation. See Figure
1-4 on page 8.
away from the direct flow of exhaust from air ventilation systems
Chapter 1 Printer description 7
Space requirements
1
2
The printer must have the following amounts of space above and
around it.
Figure 1-4 Space requirements
1 Top view
2 Side view
8 Site requirements
Electrical specifications
Table 1-3 lists the electrical specifications required to run the printer
safely.
Table 1-3 Electrical specifications
Item 110-volt models 220-volt models
Power requirements 100-127 V (+/- 10%)
50/60 Hz (+/- 2 Hz)
Power consumption
(typical)
During printing
During standby
During PowerSave
Minimum recommended
circuit capacity for typical
product
1
When
the printer is in standby (off) mode, a minimal amount of energy is
still consumed.
1
470 W (average)
80 W (average)
< 45 W
16.0 A at 120 V 7.1 A at 220 V
220-240 V (+/- 10%)
50/60 Hz (+/- 2 Hz)
480 W (average)
90 W (average)
< 45 W
En vironmental specifications
Keep the printer within the environmental conditions shown in
Table 1-4 for optimum performance.
Table 1-4 Environmental specifications
Item Operating
Temperature
Recommended
Allowed
Humidity
Recommended
Allowed
Altitude
Allowed 0 to 3100 m
20 to 26° C (68 to 79° F)
15 to 30° C (59 to 86° F)
20 to 50% RH
10 to 80% RH
(0 to 10,000 ft)
Chapter 1 Printer description 9
Consumable storage requirements
The life of consumables is greatly affected by their storage
environment. Use Table 1-5 to determine the shelf life of stored
consumables.
Table 1-5 Consumable storage requirements
Item Storage time Storage condition
Temperature Normal (maximum of
2.5 years)
Severe (maximum of
18 days)
Maximum temperature
change rate
Humidity Normal (maximum of
Atmospheric pressure 460 to 760 mm Hg (18.1 to 29.9 in Hg)
Average storage time 1 year
40 to 15° C (104 to 59° F) within 3 minutes
-20 to 25° C (-4 to 77° F) within 3 minutes
2.5 years)
Severe (maximum of
18 days)
0 to 35° C (32 to 95° F)
High 35 to 40° C (95 to
104° F)
Low 0 to -20° C (32 to
-4° F)
35 to 85% RH
High 85 to 95% RH
Low 10 to 35% RH
10 Site requirements
Printer specifications
Table 1-6 describes the dimensions of the printer.
Table 1-6 Printer dimensions
HP Color LaserJet
4500, 4500 N
Height 395 mm (15.6 inches) 578 mm (22.8 inches)
Width 500 mm (19.7 inches) 500 mm (19.7 inches)
Depth 559 mm (22 inches) 709 mm (27.9 inches)
Weight 57 kg (125 lb) 75 kg (165 lb)
HP Color LaserJet
4500 DN
Table 1-7 lists the acoustic emissions of the printer when it is printing
and when it is in standby mode.
Table 1-7 Acoustic emissions
Operating position
Printing
Standby
Bystander 1m
Printing
Standby
Sound power
Printing
Standby
Per ISO 9296, DIN 45635, T.19
58 dB(A)
L
PA
L
49 dB(A)
PA
Per ISO 7779, DIN 45635, T.19
52 dB(A)
L
PA
L
45 dB(A)
PA
Per ISO 9296
L
= 6.6 bels(A)
WAd
L
= 5.8 bels(A)
WAd
Note This product emits a sound intensity level,
printing. Do not place the printer in close proximity to users.
Maximum duty cycles is 35,000 pages per month.
Chapter 1 Printer description 11
, at 6.4 bel during
L
WAd
Printer assemblies
2
1
3
4
5
6
7
8
9
10
11
Figures 1-5 and 1-6 show the location of each major assembly in the
printer. These assemblies are described in Chapter 3.
Figure 1-5 Front view
12 Printer assemblies
(shown with 500-sheet paper feeder and duplex unit)
1 Top output bin
2 Printer control panel
3 Power switch (standby button)
4 Duplex unit drawer (optional on 4500 and 4500 N models)
5 Tray 3 (500-sheet paper feeder, optional on 4500 and 4500 N
models)
6 Tray 2 (250 sheets of standard paper)
7 ITB drawer (transfer belt access)
8 Tray 1 (150-sheet multipurpose tray)
9 Drum drawer (imaging drum access)
10 Top cover release (toner access) button
11 Toner cartridge access cover
8
9
1
7
Figure 1-6 Rear view
1 Rear door (fuser access)
2 Rear output bin door
3 Cover for duplex unit
4 Power receptacle for duplex unit
5 Duplex unit power cord to the printer
6
5
(shown with 500-sheet paper feeder and duplex unit)
4
2
3
6 Printer power receptacle
7 EIO slots
8 Parallel connector (“C” connector)
9 Memory access
Chapter 1 Printer description 13
Media requirements
Selecting print media
You can use many types of paper and other print media with this
printer. This section provides guidelines and specifications for
selecting and using different print media.
Before purchasing any media or specialized forms in quantity, verify
that your paper supplier obtains and understands the print media
requirements specified in the
. The guide is available through HP Direct. See the online user
Guide
guide for ordering information.
It is possible that media could meet all of the guidelines in this chapter
and still not print satisfactorily. This may be due to abnormal
characteristics of the printing environment or to other variables over
which Hewlett-Packard has no control (for example, extremes in
temperature and humidity).
Hewlett-Pac kar d recommends testing any media bef ore b uying it
in large quantities.
CAUTION Using media that does not conform to the specifications listed here and
HP LaserJet Family Paper Specification Guide
in the
problems that require service. This service is not covered by the
Hewlett-Packard warranty or service agreements.
HP LaserJet Family Paper Specification
can cause
Media specifications
For optimum results, use conventional 75 g/m2 (20 lb) xerographic
paper. Verify that the paper is of good quality and is free of cuts,
nicks, tears, spots, loose particles, dust, wrinkles, curls, or bent
edges. Avoid fanning the print media before loading it into the paper
trays.
14 Media requirements
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