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hp color LaserJet
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HP Color LaserJet 4550/4550N/4550DN/ 4550HDN Printer and HP Color LaserJet 4500/ 4500 N/4500 DN Printer
Service Manual _____________
© Copyright 2000, Hewlett-Packard Company All Rights Reserved. Reproduction, adaptation, or translation without prior written permission is prohibited, except as allowed under the copyright laws. Part number: C7085-90921 First Edition, October 2000
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. CompuServeTM is a U.S. trademark of CompuServe, Inc. ENERGY 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 is a combined Service Manual for both the HP Color LaserJet 4500 series printer and the HP Color LaserJet 4550 series printer. The HP Color LaserJet 4550 series printer shares most characteristics of the HP Color LaserJet 4500 series printer, except where stated.
This manual uses the following conventions: COLoR is used to emphasize items that are important to the material under discussion. Bold is used for emphasis, particularly in situations where italic type 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 keyboard 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 WWW Note CAUTION WARNING! Hints are used to suggest an action that might simplify the process. World Wide Web references give Internet addresses for additional information and information updates. Notes contain important information set off from the text. Caution messages alert you to the possibility of damage to equipment or loss of data. Warning messages alert you to the possibility of personal injury.
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Contents
1 Printer description
Printer features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Printer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Printer assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Media requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Environmental Product Stewardship Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Regulatory statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2 Service approach
Service approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Parts and supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Warranty statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
3 Installation and configuration
Unpack the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Connecting to a network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Enhanced I/O (EIO) configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Printer drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Network configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Configuration tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Setting network security on the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
4 Printer maintenance
Cleaning the printer and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Approximate replacement intervals for consumable items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 Locating consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Replacing consumable items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 DIMM configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
5 Theory of operation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 Basic operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 Image formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Toner density. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Mechanical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 Paper path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 DC controller subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 Motors and fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133 Formatter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 Power supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Contents
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6 Removal and replacement
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Consumable assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Covers, drawers, and top and front assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Right side assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Left side assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Rear assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Internal assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
7 Troubleshooting
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 Troubleshooting process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 Printer error troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Paper path troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 Image formation troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 HP ColorSmart II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 Matching colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 Four-color printing (CMYK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 Image defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 Overhead transparency defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Repetitive defects troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 Interface troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 Control panel troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 Troubleshooting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 Service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
8 Parts and diagrams
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 Ordering parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 Illustrations and parts lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 Alphabetical parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 Numerical parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
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List of Figures
Figure 1-1 HP Color LaserJet 4500 family printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Figure 1-2 HP Color LaserJet 4550 series printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Figure 1-3 Model and Serial number information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Figure 1-4 Sample label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Figure 1-5 Space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Figure 1-6 Front view, HP Color LaserJet 4500 and HP Color LaserJet 4550 (shown with 500-sheet paper feeder and duplex unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Figure 1-7 Rear view, HP Color LaserJet 4500 (shown with 500-sheet paper feeder and duplex unit) . . . . .26 Figure 1-8 Rear view, HP Color LaserJet 4550 (shown with 500-sheet paper feeder and duplex unit) . . . . .27 Figure 3-1 Package contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Figure 3-2 Parallel cable with a "C" connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Figure 4-1 Imaging drum life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Figure 4-2 OPC life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Figure 4-3 Location of consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Figure 4-4 Removing the formatter board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 Figure 4-5 Do not remove the DIMM in slot #4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Figure 4-6 Do not remove the DIMM in slot #3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Figure 4-7 EDO and SDRAM memory modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Figure 5-1 Basic system operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 Figure 5-2 Image formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Figure 5-3 Primary charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 Figure 5-4 Laser exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Figure 5-5 Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Figure 5-6 Primary transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 Figure 5-7 Secondary transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 Figure 5-8 Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 Figure 5-9 ITB residual toner cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 Figure 5-10 Waste toner to waste toner reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 Figure 5-11 Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 Figure 5-12 Toner density sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Figure 5-13 Photosensitive drum cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 Figure 5-14 Waste toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 Figure 5-15 Transfer unit function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 Figure 5-16 Home position detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Figure 5-17 ITB unit life detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Figure 5-18 Secondary transfer roller unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Figure 5-19 ITB unit contact/separation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 Figure 5-20 Toner carousel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 Figure 5-21 Toner carousel operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 Figure 5-22 Toner cartridge contact/separation function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 Figure 5-23 Toner level detection/toner cartridge detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 Figure 5-24 Laser/scanner operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 Figure 5-25 Paper jam sensors (shown with the optional 500-sheet paper feeder and duplex unit installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 Figure 5-26 Tray 2 (cassette) operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123 Figure 5-27 Tray 1 manual feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 Figure 5-28 Laser paper detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 Figure 5-29 Overhead transparency sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 Figure 5-30 Pick-up and feed system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 Figure 5-31 Fusing and delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 Figure 5-32 Reversing and duplex pick-up operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 Figure 5-33 Reversing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Contents vii
Figure 5-34 Side registration adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Figure 5-35 Duplex feed roller pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Figure 5-36 DC controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Figure 5-37 Motors and fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Figure 6-1 Phillips and Posidriv screwdriver comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Figure 6-2 Top cover removal and replacement (rear view of printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Figure 6-3 Left side cover removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Figure 6-4 Right side cover removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Figure 6-5 Rear door removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Figure 6-6 Right rear cover removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Figure 6-7 Drum drawer (top drawer) cover removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Figure 6-8 Drum drawer (top drawer) cover tabs and levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Figure 6-9 ITB drawer (middle drawer) cover removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Figure 6-10 ITB drawer (middle drawer) removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Figure 6-11 Control panel removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Figure 6-12 Front right cover removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Figure 6-13 RFI shield removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Figure 6-14 Laser/scanner assembly removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Figure 6-15 DC controller removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Figure 6-16 Developing PCB removal and replacement (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Figure 6-17 Developing PCB removal and replacement (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Figure 6-18 Top cover switch assembly removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Figure 6-19 Top cover switch assembly removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Figure 6-20 Drum drawer (top drawer) switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Figure 6-21 Drum drawer (top drawer) assembly removal and replacement (1 of 3) . . . . . . . . . . . . . . . . . . 164 Figure 6-22 Drum drawer (top drawer) assembly removal and replacement (2 of 3) . . . . . . . . . . . . . . . . . . 165 Figure 6-23 Drum drawer assembly removal and replacement (3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Figure 6-24 Densitometer removal and replacement (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Figure 6-25 Densitometer removal and replacement (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Figure 6-26 Formatter removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Figure 6-27 Formatter pan assembly removal and replacement (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Figure 6-28 Formatter pan assembly removal and replacement (2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Figure 6-29 Formatter pan assembly removal and replacement (3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Figure 6-30 Formatter pan assembly removal and replacement (4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Figure 6-31 Power supply removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Figure 6-32 High-voltage power supply removal and replacement (newer version HP Color LaserJet 4500 and HP Color LaserJet 4550 printers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Figure 6-33 High-voltage power supply removal and replacement (older version HP Color LaserJet 4500 printers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Figure 6-34 Drum drive assembly removal and replacement (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Figure 6-35 Drum drive assembly removal and replacement (2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Figure 6-36 Drum drive assembly removal and replacement (3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Figure 6-37 Large fan removal and replacement (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Figure 6-38 Large fan removal and replacement (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Figure 6-39 Toner level sensor assembly removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Figure 6-40 Carousel drive assembly removal and replacement (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Figure 6-41 Carousel drive assembly removal and replacement (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Figure 6-42 Paper size switch removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Figure 6-43 Switch plate assembly removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Figure 6-44 Paper feed PCB removal and replacement (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Figure 6-45 Paper feed PCB removal and replacement (2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Figure 6-46 Paper feed PCB removal and replacement (3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Figure 6-47 Fuser motor removal and replacement (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Figure 6-48 Fuser motor removal and replacement (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Figure 6-49 Paper path motor removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Figure 6-50 Paper pick solenoid removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Figure 6-51 ITB cleaning roller clutch removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 Figure 6-52 ITB clutch assembly removal and replacement (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Figure 6-53 ITB clutch assembly removal and replacement (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 viii
Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure
6-54 Transfer roller cam clutch removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192 6-55 Left side gears removal and replacement (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194 6-56 Left side gears removal and replacement (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194 6-57 Large right side fan removal and replacement (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195 6-58 Large right side fan removal and replacement (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196 6-59 Left side fan removal and replacement (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197 6-60 Left side fan removal and replacement (2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198 6-61 Left side fan removal and replacement (3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198 6-62 Rear paper path assembly removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199 6-63 Cartridge carousel replacement - formatter pan assembly (1 of 6) . . . . . . . . . . . . . . . . . . . . . .200 6-64 Cartridge carousel replacement - continuous toner level sensor assembly (2 of 6) . . . . . . . . .201 6-65 Cartridge carousel replacement - carousel brake (3 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201 6-66 Cartridge carousel replacement - face-down delivery rod (4 of 6) . . . . . . . . . . . . . . . . . . . . . . .202 6-67 Cartridge carousel replacement - right-side carousel mounting plate (5 of 6) . . . . . . . . . . . . . .202 6-68 Cartridge carousel replacement - lift out the cartridge carousel (6 of 6) . . . . . . . . . . . . . . . . . .203 6-69 Paper transport assembly removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204 6-70 Paper pick rollers removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 6-71 Star wheel assembly removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206 6-72 Transfer roller removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207 6-73 Cam shaft removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208 7-1 Troubleshooting flowchart (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214 7-2 Troubleshooting flowchart (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215 7-3 Jam sensors (shown with the optional 500-sheet paper feeder and duplex unit installed) . . . . .237 7-4 Jam locations (shown with the optional 500-sheet paper feeder and duplex unit installed) . . . .238 7-5 Jam locations by error message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239 7-6 Image formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243 7-7 Color balance calibration page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251 7-8 Repetitive defect ruler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266 7-9 Imaging drum exposed to light (proportions not to scale) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267 7-10 HP EIO configuration page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268 7-11 4500 series menu map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271 7-12 4550 series menu map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272 7-13 4500 series (left) and 4550 series (right) printer configuration page . . . . . . . . . . . . . . . . . . . . .287 7-14 Supplies status page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290 7-15 Usage page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .291 7-16 Hard disk file directory page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292 7-17 Service mode menu map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293 7-18 HP Color LaserJet 4500 series Service menu map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294 7-19 HP Color LaserJet 4550 series Service menu map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295 7-20 Registration page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298 7-21 Location of the engine test button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306 7-22 Sensor locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308 7-23 Printer solenoids and clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .309 7-24 Printer motors and fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310 7-25 Miscellaneous sensors and clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310 7-26 Intermediate transfer belt sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311 7-27 Miscellaneous sensors (with tray 1 front cover removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 7-28 PS6 and PS7 sensor location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 7-29 Miscellaneous switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313 7-30 Miscellaneous switches and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313 7-31 PS14 sensor location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .314 7-32 Miscellaneous parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .314 7-33 Imaging drum connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .315 7-34 Rear door interlock switch defeat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .316 7-35 Right rear fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .316 7-36 Fuse (F1) and CB101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317 7-37 Fusing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317 7-38 DC controller PCB connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .318 7-39 Location of connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .319 ix
Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure
7-40 Location of duplexer and 500-sheet paper feeder connectors . . . . . . . . . . . . . . . . . . . . . . . . . 320 7-41 500-sheet feeder wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 8-1 Assembly location diagram (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 8-2 Assembly location diagram (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 8-3 PCB locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332 8-4 External covers, panels, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 8-5 Top cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 8-6 Internal components (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 8-7 Internal components (2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 8-8 Internal components (3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 8-9 Developing carousel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342 8-10 Paper pick-up assembly (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344 8-11 Paper pick-up assembly (2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 8-12 Paper pick-up assembly (3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 8-13 Upper drawer assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 8-14 MP tray paper pick-up assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 8-15 250-sheet cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 8-16 500-sheet paper feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353 8-17 Duplex unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
x
List of Tables
Table 1-1 Printer features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Table 1-2 Model names and numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Table 1-3 Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Table 1-4 Environmental specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Table 1-5 Consumable storage requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Table 1-6 Printer dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Table 1-7 Acoustic emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Table 1-8 Supported media specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Table 1-9 Printing on transparencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Table 2-1 Related documentation and software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Table 3-1 Printer security levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Table 4-1 Cleaning the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Table 4-2 Approximate replacement interval for consumable items . . . . . . . . . . . . . . . . . . .83 Table 5-1 Toner carousel assembly components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 Table 5-2 Motors, solenoids, sensors, and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 Table 5-3 Motors, solenoids, clutches, and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 Table 5-4 Solenoids, sensors, switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 Table 5-5 Paper size detection switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 Table 5-6 Fusing and delivery unit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 Table 5-7 Motors, solenoids, and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Table 5-8 Motor and fan locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133 Table 6-1 Types of screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141 Table 6-2 Approximate replacement interval for consumable items . . . . . . . . . . . . . . . . . .142 Table 7-1 Pre-troubleshooting checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213 Table 7-2 Alphabetical printer error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217 Table 7-3 Numerical printer error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226 Table 7-4 HP Color LaserJet 4500 jam locations and associated error messages . . . . . . .239 Table 7-5 HP Color LaserJet 4550 jam locations and associated error messages . . . . . . .240 Table 7-6 Explanation of alternating message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240 Table 7-7 Image defect table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253 Table 7-9 Defect spacing chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267 Table 7-10 Communications check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268 Table 7-11 HP Color LaserJet 4500 Information Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . .273 Table 7-12 HP Color LaserJet 4550 Information Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . .273 Table 7-13 HP Color LaserJet 4500 Paper Handling Menu . . . . . . . . . . . . . . . . . . . . . . . . .274 Table 7-14 HP Color LaserJet 4550 Paper Handling Menu . . . . . . . . . . . . . . . . . . . . . . . . .275 Table 7-15 HP Color LaserJet 4500 Configuration settings . . . . . . . . . . . . . . . . . . . . . . . . .276 Table 7-16 HP Color LaserJet 4550 Configuration settings . . . . . . . . . . . . . . . . . . . . . . . . .277 Table 7-17 HP Color LaserJet 4500 Printing Menu settings . . . . . . . . . . . . . . . . . . . . . . . .278 Table 7-18 HP Color LaserJet 4550 Printing Menu settings . . . . . . . . . . . . . . . . . . . . . . . .279 Table 7-19 HP Color LaserJet 4500 I/O Menu settings . . . . . . . . . . . . . . . . . . . . . . . . . . . .280 Table 7-20 HP Color LaserJet 4550 I/O Menu settings . . . . . . . . . . . . . . . . . . . . . . . . . . . .280 Table 7-21 HP Color LaserJet 4500 Calibration Menu settings . . . . . . . . . . . . . . . . . . . . . .281 Table 7-22 HP Color LaserJet 4550 Calibration Menu settings . . . . . . . . . . . . . . . . . . . . . .281 Table 7-23 HP Color LaserJet 4500 Resets Menu settings . . . . . . . . . . . . . . . . . . . . . . . . .282 Table 7-24 HP Color LaserJet 4550 Resets Menu settings . . . . . . . . . . . . . . . . . . . . . . . . .282 Table 7-25 HP Color LaserJet 4550 Quick Copy Jobs menu . . . . . . . . . . . . . . . . . . . . . . . .283 Table 7-26 HP Color LaserJet 4550 Private/Stored Jobs menu . . . . . . . . . . . . . . . . . . . . .284 Table 7-27 Formatter diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300 Table 7-28 Engine diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302 Table 7-29 Paper path sensors and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303 Table 7-30 Paper size settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304 Contents xi
Table 7-31 Sensor status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 Table 7-32 Sensor function and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 Table 7-33 Solenoid and clutch functions and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 309 Table 7-34 Printer motors and fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 Table 7-35 Miscellaneous sensors and clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 Table 7-36 Intermediate transfer belt sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 Table 7-37 PS3 and PS4 description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 Table 7-38 PS6 and PS7 description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 Table 7-39 Switch description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 Table 7-40 SW2, SW5, and PS13 description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 Table 7-41 Density sensor location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 Table 7-42 Miscellaneous parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 Table 7-43 Imaging drum connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 Table 7-44 Fuse F1 and CB101 location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Table 7-45 110-volt fusing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Table 8-1 Consumables, accessories, and supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 Table 8-2 Types of screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 Table 8-3 PCB assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333 Table 8-4 Printer cover and door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 Table 8-5 Top cover components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 Table 8-6 Internal components (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 Table 8-7 Internal components (2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 Table 8-8 Internal components (3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 Table 8-9 Developing carousel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343 Table 8-10 Paper pick-up assembly (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 Table 8-11 Paper pick-up assembly (2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Table 8-12 Paper pick-up assembly (3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 Table 8-13 Upper drawer assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 Table 8-14 MP tray paper pick-up assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 Table 8-15 250-sheet cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 Table 8-16 500-sheet paper feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353 Table 8-17 Duplex unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 Table 8-18 Alphabetical parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 Table 8-19 Numerical parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
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Printer description
Chapter contents
Printer features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Model and serial numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Power and regulatory information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Electrical specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Environmental specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Consumable storage requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Printer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Printer assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Media requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Selecting print media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Media specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Supported media weights and sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Non-supported media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Printing on special media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Environmental Product Stewardship Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Regulatory statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 HP Color LaserJet 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 HP Color LaserJet 4550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Laser safety statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Material Safety Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Toner safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Laser statement for Finland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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Chapter 1 Printer description 13
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 contains 32 MB of RAM. The HP LaserJet 4500 N printer is the base model with an HP JetDirect 600N print server (network card) and 64 MB of RAM. The HP LaserJet 4500 DN printer is 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.
Figure 1-1
14 Printer description
1 1 2
2
HP Color LaserJet 4500 family printers HP Color LaserJet 4500 and 4500 N printers HP Color LaserJet 4500 DN printer
The HP LaserJet 4550 printer family pictured in Figure 1-2 has four models. The HP LaserJet 4550 printer is the base model; it includes 64 MB of RAM. The HP LaserJet 4550N printer is the base model with an HP JetDirect 610N print server (network card) and 64 MB of RAM. The HP LaserJet 4550N printer is the base model with an HP JetDirect 610N print server (network card), a 500-sheet paper feeder, a duplex unit, and 64 MB of RAM. The HP LaserJet 4550N printer is the base model with a 6 GB hard drive, an HP JetDirect 610N print server (network card), a 500-sheet paper feeder, a duplex unit, and 64 MB of RAM.
C7085-90921
1
2
Figure 1-2
HP Color LaserJet 4550 series printers 1 2 HP Color LaserJet 4550 and 4550N printers HP Color LaserJet 4550DN and 4550HDN printers
This printer series combines the quality and reliability of Hewlett-Packard printers with the features listed in Table 1-1. WWW For more information about printer features, refer to the Hewlett-Packard website at http://www.hp.com.
Table 1-1 Printer features Feature
Connectivity
Description
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 HP JetDirect 610N print server (network card) (included with the HP Color LaserJet 4550N, 4550DN and 4550HDN printers) HP Color LaserJet 4550 series: Infrared receiver port HP Color LaserJet 4550 series: Embedded Web server Optional duplex unit; mounts directly beneath the printer for two-sided printing (duplex unit is standard with the HP Color LaserJet 4500DN, 4550DN and 4550HDN) Requires 40 MB of memory; 64 MB of memory is recommended for optimal duplex printing. If the 500-sheet paper feeder (Tray 3) is installed, the duplex unit must be positioned between the printer and Tray 3.
C7085-90921
Fonts
Environmental
Duplex
Note
PowerSave setting High content of recyclable components and materials 80 internal fonts
Chapter 1 Printer description 15
Table 1-1 Printer features (continued) Feature
CPU
Description
The Color LaserJet 4500 series formatter PCB incorportates a 133 MHz RISC processor The Color LaserJet 4550 series formatter PCB incorporates a 233 MHz RISC processor
Memory--standard
HP Color LaserJet 4500 series: 32 MB RAM (Base) 64 MB RAM (HP Color LaserJet 4500 N/4500 DN) Memory Enhancement Technology (MEt), which automatically compresses data to use RAM more efficiently HP Color LaserJet 4550 series: 64 MB RAM (Base) 128 MB RAM (HP Color LaserJet 4550DN and HDN) Memory Enhancement Technology (MEt), which automatically compresses data to use RAM more efficiently
16 Printer description
Memory--optional
HP Color LaserJet 4500 series: Install 4, 8, 16, 32, or 64 MB DIMMs into the three DIMM slots to a possible total 208 MB. Synchronous SDRAM modules do not need to be configured in pairs (in corresponding left and right slots). If you install more than 208 MB of RAM, it will not be used by the printer. HP Color LaserJet 4550 series: Install 64 or 128 MB DIMMS into the two DIMM slots to a possible total of 192 MB. If you install more than 192 MB of RAM, it will not be used by the printer. HP Color LaserJet 4550 series: 5 GB hard disk drive (Included wit the HP Color LaserJet 4550HDN printer). CAUTION: The HP Color LaserJet 4500 series uses 100-pin, non-parity, SDRAM DIMMs. The HP Color LaserJet 4550 series uses 168-pin, non-parity, synchronous DRAM DIMMs. Extended Data Output (EDO) DIMMs are not supported.
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Table 1-1 Printer features (continued) Feature
Paper handling--input tray capacity
Description
The capacities will vary depending on the media being used (for example, transparencies, labels, heavy media, and envelopes). Quantities based on 75 g/m2 (20 lb) media for both the HP Color LaserJet 4500 and 4550 printers: Tray 1: 150-sheet multipurpose tray Tray 2: 250-sheet standard cassette Tray 3: Optional 500-sheet paper feeder (included with the HP Color LaserJet 4500DN, 4550DN and HDN models)
Printer-language support
HP Color LaserJet 4500 series: HP PCL5c PostScriptTM Emulation Automatic language switching HP Color LaserJet 4550 series: HP PCL 5c HP PCL 6 PostScriptTM 3 Emulation Automatic language switching
Standard interfaces
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Print speed-- color printing
Print speed-- monochrome printing
Paper sizes supported
Paper handling--output (face-down, correct-order output)
Top output bin holds up to 250 sheets of standard paper. Rear output bin holds up to 100 sheets of standard paper. (The output of the rear output bin is in reverse order, facing up.)
A4/Letter Legal Executive JIS B5 A5 Custom (B5 ISO) 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
The printer comes equipped with two 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.
Chapter 1 Printer description 17
Identification
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 1-3). For information on determining the version of printer you are servicing, see page 140.
printer version production code country of origin production number
Figure 1-3
Model and Serial number information
Table 1-2 Model names and numbers Model Name
HP Color LaserJet 4500 HP Color LaserJet 4500 N HP Color LaserJet 4500 DN HP Color LaserJet 4550 HP Color LaserJet 4550N HP Color LaserJet 4550DN HP Color LaserJet 4550HDN
Model Number
C4084A C4089A C4094A C7085A C7086A C7087A C7088A
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 140. The HP Color LaserJet 4550 series printer, unless otherwise specified, is equivalent to the later version of the HP Color LaserJet 4500 series printer.
18 Printer description
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Power and regulatory information
The identification labels on the rear of the printer also contain power rating and regulatory information as shown in Figure 1-4. 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 void the product warranty (for example, attempting to change a 110V printer to a 220V printer).
Figure 1-4
Sample label
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Chapter 1 Printer description 19
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 4500N, the surface must support 51 kg (112 lb) · for the HP Color LaserJet 4500DN, the surface must support 77 kg (169 lb) · for the HP Color LaserJet 4550 and 4550N, the surface must support 51 kg (112 lb) · for the HP Color LaserJet 4550DN and 4550HDN, 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)
20 Printer description
Make sure to keep the printer: away from direct sunlight, dust, open flames, or ammonia fumes. away from the direct flow of exhaust from air ventilation systems. away from walls or other objects. There must be enough space around the printer for proper access and ventilation. See Figure 1-5 on page 21.
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Space requirements
The printer must have the following amounts of space above and around it.
Figure 1-5
Space requirements 1 2 Top view Side view
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Chapter 1 Printer description 21
Electrical specifications
Table 1-3 lists the electrical specifications required to run the printer safely. Table 1-3 Electrical specifications Item
Power requirements Power consumption (typical) During printing During standby* During PowerSave Off
110-volt models
100-127 V (+/- 10%) 50/60 Hz (+/- 2 Hz)
220-volt models
220-240 V (+/- 10%) 50/60 Hz (+/- 2 Hz)
470 W (average) 80 W (average) 4500: 32 W 4550: 0 W
480 W (average) 90 W (average) 4500: 32W 4550: 0 W 4500: 7.1 A at 220 V 4550: 5.1 A at 220 V
Minimum recommended 4500: 16.0 A at 120 V circuit capacity for typical 4550: 10.2 A at 120 V product
*
When the printer is in standby (off) mode, it continues to consume a minimal amount of energy.
Note
This information is preliminary and might not be current. Please see http://www.hp.com/support/ lj4550 for current information.
Environmental specifications
Keep the printer within the environmental conditions shown in Table 1-4 for optimum performance. Table 1-4 Environmental specifications Item
Temperature Recommended Allowed Humidity Recommended Allowed Altitude Allowed
Operating
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 3100 m (0 to 10,000 ft)
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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
Temperature
Storage time
Normal (maximum of 2.5 years) Severe (maximum of 18 days)
Storage condition
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)
Maximum temperature change rate Humidity
40° to 15° C (104° to 59° F) within 3 minutes -20° to 25° C (-4° to 77° F) within 3 minutes Normal (maximum of 2.5 years) Severe (maximum of 18 days) 35% to 85% RH High 85% to 95% RH Low 10% to 35% RH
Atmospheric pressure Average storage time
460 to 760 mm Hg (18.1 to 29.9 in Hg) 1 year
Printer specifications
Table 1-6 describes the dimensions of the printer. Table 1-6 Printer dimensions HP Color LaserJet 4500, 4500N
Height Width Depth Weight 395 mm (15.6 inches) 500 mm (19.7 inches) 559 mm (22 inches) 57 kg (125 lb)
HP Color LaserJet 4500 DN
578 mm (22.8 inches) 500 mm (19.7 inches) 709 mm (27.9 inches) 75 kg (165 lb)
HP Color LaserJet 4550, 4500N
395 mm (15.6 inches) 500 mm (19.7 inches) 559 mm (22 inches) 57 kg (125 lb)
HP Color LaserJet 4550DN, 4550HDN
578 mm (22.8 inches) 500 mm (19.7 inches) 709 mm (27.9 inches) 75 kg (165 lb)
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 HP Color LaserJet 4500 Series
Operating position Printing Standby Bystander 1m