HP Color Laserjet CP3525 service manual

HP Color LaserJet CP3525 Series Printer Service Manual

Theory of operation Removal and replacement Solve problems Parts list

www.hp.com/support/cljcp3525

HP Color LaserJet CP3525 Series Printers

Service Manual

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Part number: CC468-90963

Edition 1, 10/2008

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Table of contents

1 Product basics

Product comparison ............................................................................................................................. 2

Product features ................................................................................................................................... 3

Product view ......................................................................................................................................... 6

Front view ............................................................................................................................ 6

Back view ............................................................................................................................. 7

Interface ports ...................................................................................................................... 8

Serial number and model number location .......................................................................... 8

2 Control panel

Use the control panel ......................................................................................................................... 10

Control-panel layout ........................................................................................................... 10

Interpreting control panel indicator lights ........................................................................... 11

Control panel menus .......................................................................................................................... 12

Use the menus ................................................................................................................... 12

Menu hierarchy ................................................................................................................................... 13

Show Me How menu .......................................................................................................................... 14

Retrieve job menu .............................................................................................................................. 15

Information menu ............................................................................................................................... 17

Paper handling menu ......................................................................................................................... 18

Configure device menu ...................................................................................................................... 19

Printing menu ..................................................................................................................... 19

PCL sub-menu .................................................................................................. 20

Print Quality menu ............................................................................................................. 22

System setup menu ........................................................................................................... 25

I/O menu ............................................................................................................................ 32

Resets menu ...................................................................................................................... 39

Diagnostics menu ............................................................................................................................... 40

Service menu ..................................................................................................................................... 42

3 Paper and print media

Supported paper and print media sizes .............................................................................................. 44

Custom paper sizes ............................................................................................................................ 46

Supported paper and print media types ............................................................................................. 47

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Tray and bin capacity ......................................................................................................................... 48

Special paper or print media guidelines ............................................................................................. 49

Load trays ........................................................................................................................................... 50

Paper orientation for loading trays ..................................................................................... 50

Tray 1 ................................................................................................................ 50

Tray 2 or optional Tray 3 ................................................................................... 52

Load Tray 1 ........................................................................................................................ 53

Print envelopes ................................................................................................. 55

Load Tray 2 ........................................................................................................................ 55

Load the optional 500-sheet paper and heavy media tray (Tray 3) ................................... 57

Load standard-sized paper into Tray 3 ............................................................ 57

Load custom-size paper into Tray 3 .................................................................. 59

Load 4 x 6 inch (10 x 15 cm) size paper into Tray 3 ......................................... 61

Configure trays ................................................................................................................................... 65

Configure a tray when loading paper ................................................................................. 65

Configure a tray to match print job settings ....................................................................... 65

Configure a tray by using the Paper Handling menu ......................................................... 66

Automatic overhead transparency sensing (auto sense mode) ......................................... 66

Auto-sense settings ........................................................................................... 66

Select the media by source, type, or size .......................................................................... 67

Source ............................................................................................................... 67

Type and Size ................................................................................................... 67

4 Manage and maintain the product

Information pages ............................................................................................................................... 70

HP Easy Printer Care ......................................................................................................................... 71

Open the HP Easy Printer Care software .......................................................................... 71

HP Easy Printer Care software sections ............................................................................ 71

Embedded Web server ....................................................................................................................... 74

Open the embedded Web server by using a network connection ..................................... 74

Embedded Web server sections ........................................................................................ 75

Use HP Web Jetadmin software ........................................................................................................ 77

Security features ................................................................................................................................ 78

Secure the embedded Web server .................................................................................... 78

Secure Disk Erase (optional EIO hard drive) ..................................................................... 78

Data affected ..................................................................................................... 78

Additional Information ....................................................................................... 79

Job storage ....................................................................................................... 79

HP Encrypted High Performance Hard Disks .................................................................... 79

Lock the control-panel menus ............................................................................................ 79

Lock the formatter cage ..................................................................................................... 80

Manage supplies ................................................................................................................................ 81

Print-cartridge storage ....................................................................................................... 81

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HP policy on non-HP print cartridges ................................................................................. 81

HP fraud hotline and Web site ........................................................................................... 81

Replace supplies ............................................................................................................... 81

Supplies life ....................................................................................................... 81

Locate supplies ................................................................................................. 81

Supply replacement guidelines ......................................................................... 82

Change print cartridges ..................................................................................... 83

Change the toner collection unit ........................................................................ 86

Install memory ................................................................................................... 89

Install DDR2 memory DIMMs ........................................................... 89

Enable memory for Windows ............................................................ 92

Install an HP Jetdirect or EIO print server card or EIO hard disk ..... 92

Clean the product ............................................................................................................................... 96

Clean the exterior .............................................................................................................. 96

Clean spilled toner ............................................................................................................. 96

Clean the fuser .................................................................................................................. 96

Product updates ................................................................................................................................. 97

Determine the current firmware version ............................................................................. 97

Download new firmware from the HP Web site ................................................................. 97

Transfer the new firmware to the product .......................................................................... 97

Use the HP Easy Firmware Upgrade utility to update the firmware .................. 97

Use FTP to upload the firmware through a browser ......................................... 98

Use FTP to upgrade the firmware on a network connection ............................. 99

Use HP Web Jetadmin to upgrade the firmware ............................................... 99

Use Microsoft Windows commands to upgrade the firmware ......................... 100

Upgrade the HP Jetdirect firmware .................................................................................. 100

5 Theory of operation

Basic operation ................................................................................................................................. 104

Sequence of operation ..................................................................................................... 104

Engine-control system ...................................................................................................................... 106

DC controller .................................................................................................................... 107

Solenoids ........................................................................................................ 107

Clutches .......................................................................................................... 108

Switches .......................................................................................................... 108

Sensors ........................................................................................................... 109

Motors and fans .............................................................................................. 109

High-voltage power supply .............................................................................................. 111

Low-voltage power supply ............................................................................................... 113

Overcurrent/overvoltage protection ................................................................. 114

Safety .............................................................................................................. 114

Voltage detection ............................................................................................ 114

Sleep (powersave) mode ................................................................................ 114

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Low-voltage power supply failure .................................................................... 114

Fuser (fixing) control ........................................................................................................ 115

Fuser (fixing) temperature-control circuit ........................................................ 116

Fuser (fixing) over-temperature protection ...................................................... 116

Fuser (fixing)-failure detection ......................................................................... 117

Laser/scanner system ...................................................................................................................... 119

Image-formation system ................................................................................................................... 121

Image-formation process ................................................................................................. 122

Step 1: Pre-exposure ...................................................................................... 123

Step 2: Primary charging ................................................................................. 123

Step 3: Laser-beam exposure ......................................................................... 124

Step 4: Development ....................................................................................... 124

Step 5: Primary transfer .................................................................................. 124

Step 6: Secondary transfer ............................................................................. 125

Step 7: Separation .......................................................................................... 126

Step 8: Fusing ................................................................................................. 126

Step 9: ITB cleaning ........................................................................................ 127

Step 10: Drum cleaning ................................................................................... 127

Print cartridge .................................................................................................................. 127

Developing-roller engagement and disengagement ........................................................ 129

Intermediate transfer belt (ITB) unit ................................................................................. 130

Primary-transfer-roller engagement and disengagement ................................ 131

ITB cleaning .................................................................................................... 132

Calibration ........................................................................................................................ 133

Color-misregistration control ........................................................................... 134

Image-stabilization control .............................................................................. 135

Pickup, feed, and delivery system .................................................................................................... 136

Pickup-and-feed unit ........................................................................................................ 139

Cassette pickup ............................................................................................... 139

Cassette-presence detection .......................................................... 141

Cassette lift operation ..................................................................... 141

Cassette paper-presence detection ................................................ 142

Multifeed prevention ....................................................................... 143

Multipurpose tray pickup ................................................................................. 144

Paper feed ....................................................................................................... 145

Skew-feed prevention ..................................................................... 146

OHT detection ................................................................................ 146

Fusing and delivery unit ................................................................................................... 147

Loop control .................................................................................................... 147

Pressure-roller pressurization control ............................................................. 148

Duplexing unit (HP Color LaserJet CP3525dn and HP Color LaserJet CP3525x

only) ................................................................................................................................. 150

Duplexing reverse and feed control ................................................................ 151

Duplex pickup operation .................................................................................. 151

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Jam detection ................................................................................................................................... 152

Optional paper feeder ....................................................................................................................... 154

Paper-feeder pickup and feed operation ......................................................................... 156

Paper-size detection and cassette-presence detection ................................................... 156

Paper-feeder cassette lift operation ................................................................................. 158

Paper-feeder presence detection .................................................................................... 159

Paper-feeder multiple feed prevention ............................................................................. 160

Paper feeder jam detection .............................................................................................. 161

6 Removal and replacement

Introduction ....................................................................................................................................... 164

Removal and replacement strategy ................................................................................................. 164

Electrostatic discharge ..................................................................................................................... 164

Required tools ................................................................................................................................. 165

Before performing service ................................................................................................................ 165

After performing service ................................................................................................................... 166

Post-service test ............................................................................................................................... 166

Print-quality test ............................................................................................................... 166

DC controller connector locations .................................................................................................... 167

Parts removal order .......................................................................................................................... 168

Customer self repair (CSR) components ......................................................................................... 170

Print cartridges ................................................................................................................. 170

Duplex-reverse guide ....................................................................................................... 172

Toner-collection unit ........................................................................................................ 173

Formatter PCA ................................................................................................................. 175

Memory DIMM ................................................................................................................. 176

Tray cassette ................................................................................................................... 178

Fuser ............................................................................................................................... 179

Pickup roller (Tray 2) ....................................................................................................... 180

Pickup and feed rollers (Tray 3) ....................................................................................... 182

Separation roller (Tray 2) ................................................................................................. 183

Secondary transfer roller ................................................................................................. 184

Secondary transfer assembly .......................................................................................... 186

Intermediate transfer belt (ITB) ........................................................................................ 188

Right door (optional paper feeder) ................................................................................... 190

External panels, covers, and doors .................................................................................................. 192

Identification and location ................................................................................................ 192

Front-door assembly ........................................................................................................ 193

Right-door assembly ........................................................................................................ 194

Remove the memory DIMM ............................................................................ 176

Enable memory for Windows .......................................................... 177

Reinstall the transfer roller .............................................................................. 185

Reinstall the secondary transfer assembly ..................................................... 187

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Right-rear cover ............................................................................................................... 198

Left cover ......................................................................................................................... 200

Control-panel assembly ................................................................................................... 203

Right-front cover .............................................................................................................. 205

Remove the right-front cover ........................................................................... 205

Reinstall the power button .............................................................. 207

Front-top cover ................................................................................................................ 208

Remove the front-top cover ............................................................................. 208

Rear cover and upper-rear cover ..................................................................................... 209

Remove the rear cover and upper-rear cover ................................................. 209

Rear-top cover ................................................................................................................. 211

Remove the rear-top cover ............................................................................. 211

Internal assemblies .......................................................................................................................... 213

Pickup roller (Tray 1) ....................................................................................................... 213

Delivery fan, cartridge fan, and environmental sensor .................................................... 215

Remove the delivery fan, cartridge fan, and environmental sensor ................ 215

Toner-collection sensor .................................................................................................. 220

Remove the toner-collection sensor ................................................................ 220

Residual-toner-feed motor ............................................................................................... 222

Remove the residual-toner-feed motor ........................................................... 222

Reinstall the residual-toner collection door ..................................... 226

Registration density (RD) sensor assembly ..................................................................... 227

Remove the RD sensor assembly ................................................................... 227

Power-supply fan and fan duct ........................................................................................ 230

Remove the power-supply fan and fan duct .................................................... 230

Registration assembly ..................................................................................................... 233

Remove the registration assembly .................................................................. 233

Interconnect board (ICB) ................................................................................................. 238

Remove the ICB .............................................................................................. 238

DC controller PCA and tray ............................................................................................. 240

Remove the DC controller PCA ...................................................................... 240

Low-voltage power supply ............................................................................................... 243

Remove the low-voltage power supply ........................................................... 243

High-voltage power supply lower (HVPS-D) .................................................................... 248

Remove the high-voltage power supply lower ................................................ 248

Reinstall the high-voltage power supply lower ............................... 250

Developing-disengagement motor ................................................................................... 251

Remove the developing-disengagement motor .............................................. 251

Pickup motor .................................................................................................................... 253

Remove the pickup motor ............................................................................... 253

Lifter-drive assembly ........................................................................................................ 254

Remove the lifter-drive assembly .................................................................... 254

Cassette-pickup drive assembly ...................................................................................... 256

Remove the cassette-pickup drive assembly .................................................. 256

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Reinstall the cassette-pickup drive assembly ................................. 261

Cassette-pickup assembly ............................................................................................... 263

Remove the cassette-pickup assembly ........................................................... 263

Laser/scanner assembly (Y/M) ........................................................................................ 265

Remove the laser/scanner assembly (Y/M) .................................................... 265

Laser/scanner assembly (C/Bk) ....................................................................................... 272

Remove the laser/scanner assembly (C/Bk) ................................................... 273

Reinstall the protective glass cleaner (PGC) actuators .................. 276

High-voltage power supply upper (HVPS-T) .................................................................... 279

Remove the high-voltage power supply upper ................................................ 279

Reinstall the high-voltage power supply upper ............................... 282

Drum motor 1 ................................................................................................................... 2 83

Remove the drum motor 1 .............................................................................. 283

Drum motor 2 or drum motor 3 ........................................................................................ 284

Remove the drum motor 2 or drum motor 3 .................................................... 284

Fuser motor ..................................................................................................................... 285

Remove the fuser motor .................................................................................. 286

Main-drive assembly ........................................................................................................ 287

Remove the main-drive assembly ................................................................... 288

Reinstall the main-drive assembly .................................................. 292

Fuser-drive assembly ...................................................................................................... 298

Remove the fuser-drive assembly ................................................................... 299

Reinstall the fuser-drive assembly .................................................. 302

Delivery assembly ............................................................................................................ 303

Remove the delivery assembly ....................................................................... 304

Reinstall the delivery assembly ...................................................... 307

Duplex-drive assembly .................................................................................................... 308

Remove the duplex-drive assembly ................................................................ 309

Optional paper feeder assembly (Tray 3) ......................................................................................... 310

Drawer connector ........................................................................................................... 310

7 Solve problems

Solve problems checklist .................................................................................................................. 312

Menu map ........................................................................................................................................ 314

Troubleshooting process .................................................................................................................. 315

Determine the problem source ........................................................................................ 315

Pre-troubleshooting checklist .......................................................................... 315

Troubleshooting flowchart ............................................................................... 316

Power subsystem ............................................................................................................ 317

Power-on checks ............................................................................................. 317

Power-on troubleshooting overview ............................................... 317

Tools for troubleshooting .................................................................................................................. 319

Individual component diagnostics .................................................................................... 319

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LED diagnostics .............................................................................................. 319

Understand lights on the formatter ................................................. 319

Engine diagnostics .......................................................................................... 320

Diagnostics menu ........................................................................... 320

Diagnostics mode ........................................................................... 321

Diagnostics that put the engine into the special diagnostics

mode ............................................................................................... 321

Defeating interlocks ........................................................................ 321

Disable cartridge check .................................................................. 323

Engine-test button .......................................................................... 323

Paper-path test ................................................................................................ 324

Manual sensor test (special-mode test) .......................................................... 325

A TOP (top of page) sensor ............................................................ 325

B and C loop sensors ..................................................................... 326

D fuser (fixing) delivery sensor ....................................................... 327

E duplex re-pickup sensor .............................................................. 328

F output bin full sensor ................................................................... 328

H fuser (fixing) pressure-release sensor ....................................... 329

I primary transfer-roller disengagement sensor .............................. 330

K right and front door interlock switches ......................................... 332

Manual sensor test 2 (special-mode test) ....................................................... 334

L Tray 1 media present sensor ...................................................... 334

M Tray 2 paper out sensor ............................................................. 335

N Tray 2 closed sensor ................................................................... 336

O Tray 2 stack-surface sensor ...................................................... 336

P optional Tray 3-empty sensor ...................................................... 337

Q optional Tray 3 media-feed sensor (Q) ....................................... 338

R optional Tray 3 stack-surface sensor (R) .................................... 338

S, T, and U optional Tray 3 media-size sensors ............................ 339

Paper-path sensors test .................................................................................. 340

Print/stop test .................................................................................................. 340

Component tests ............................................................................................. 341

Component test (special-mode test) ............................................... 341

Diagrams ......................................................................................................................... 343

Formatter PCA ................................................................................................ 343

Location of connectors .................................................................................... 344

DC controller PCA .......................................................................... 344

Paper feeder driver PCA ................................................................ 345

PCAs, motors, fans, switches, solenoids, and clutches .................................. 345

Base product .................................................................................. 346

1 x 500 paper feeder ...................................................................... 352

Sensors ........................................................................................................... 353

General timing chart ........................................................................................ 355

Circuit diagrams .............................................................................................. 355

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Print-quality troubleshooting tools .................................................................................... 358

Repetitive defects ruler ................................................................................... 358

Calibrate the product ....................................................................................... 359

Internal print-quality test pages ........................................................................................ 359

Print-quality-troubleshooting pages ................................................................. 359

Diagnostics page ............................................................................................. 362

Cleaning page ................................................................................................. 363

Configuration page .......................................................................................... 364

Configuration page ......................................................................... 364

HP embedded Jetdirect page ......................................................... 366

Embedded protocol page ............................................................... 367

Finding important information on the configuration pages .............. 368

Color-band test ................................................................................................ 368

Control-panel messages table .......................................................................................................... 369

Event log messages ......................................................................................................................... 395

Print an event log ............................................................................................................. 39 5

Show an event log ........................................................................................................... 395

Sample event log ............................................................................................................. 396

Clear the event log ........................................................................................................... 396

Event log message table ................................................................................................. 397

Clear paper jams .............................................................................................................................. 404

Common causes of jams ................................................................................................. 404

Jam locations ................................................................................................................... 405

Clear jams ........................................................................................................................ 405

Clear jams in the right door ............................................................................. 406

Clear jams in the output bin area .................................................................... 410

Clear jams in Tray 1 ........................................................................................ 411

Clear jams in Tray 2 ........................................................................................ 413

Clear jams in the optional 500-sheet paper and heavy media tray

(Tray 3) ............................................................................................................ 414

Clear jams in the lower right door (Tray 3) ...................................................... 414

Jam causes and solutions ............................................................................... 415

Jams in the output bin .................................................................... 415

Jams in the fuser and transfer area ................................................ 416

Jams in the duplex area (HP Color LaserJet CP3525dn and HP

Color LaserJet CP3525x only) ........................................................ 419

Jams in Tray 1, Tray 2 and internal paper path .............................. 421

Jams in Tray 3 ................................................................................ 423

Change jam recovery ....................................................................................................... 424

Solve paper-handling problems ........................................................................................................ 425

Product feeds multiple sheets .......................................................................................... 425

Product feeds incorrect page size ................................................................................... 425

Product pulls from incorrect tray ...................................................................................... 425

Paper does not feed automatically .................................................................................. 426

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Paper does not feed from Tray 2 or 3 .............................................................................. 426

Transparencies or glossy paper will not feed .................................................................. 427

Envelopes jam or will not feed in the product .................................................................. 427

Output is curled or wrinkled ............................................................................................. 428

Product will not duplex or duplexes incorrectly ................................................................ 428

Use manual print modes .................................................................................................................. 430

Solve image-quality problems .......................................................................................................... 432

Image defects table ......................................................................................................... 432

Solve performance problems ........................................................................................................... 438

Solve connectivity problems ............................................................................................................. 439

Solve direct-connect problems ........................................................................................ 439

Solve network problems .................................................................................................. 439

Service mode functions .................................................................................................................... 441

Service menu ................................................................................................................... 441

Product resets .................................................................................................................. 442

Restore factory-set defaults ............................................................................ 442

Hard disk initialization (optional) ..................................................................... 443

NVRAM initialization ........................................................................................ 443

Product cold reset .......................................................................................... 443

8 Parts and diagrams

Order parts, accessories, and supplies ............................................................................................ 446

Part numbers .................................................................................................................................... 447

Accessories ..................................................................................................................... 447

Print cartridges and toner collection unit .......................................................................... 447

Memory ............................................................................................................................ 447

Cables and interfaces ...................................................................................................... 448

Customer self repair (CSR) parts .................................................................................... 448

Maintenance kits .............................................................................................................. 450

Screws .............................................................................................................................................. 451

How to use the parts lists and diagrams .......................................................................................... 452

External covers, panels, and doors .................................................................................................. 454

.......................................................................................................................................... 454

Right door assembly ......................................................................................................................... 456

Internal components ......................................................................................................................... 458

Internal components (1 of 5) ............................................................................................ 458

Internal components (2 of 5) ............................................................................................ 460

Internal components (3 of 5) ............................................................................................ 462

Internal components (4 of 5) ............................................................................................ 464

Internal components (5 of 5) ............................................................................................ 466

Cassette ........................................................................................................................... 468

Cassette paper pickup assembly ..................................................................................... 470

MP paper pickup assembly .............................................................................................. 472

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Registration assembly ..................................................................................................... 474

Secondary transfer assembly .......................................................................................... 476

Delivery assembly ............................................................................................................ 478

Fusing (fixing) assembly ................................................................................................. 480

PCAs ................................................................................................................................ 484

Assessories ...................................................................................................................................... 486

1 x 500 paper feeder ........................................................................................................ 486

1 x 500 paper feeder ........................................................................................................ 487

Paper feeder main body .................................................................................................. 489

Cassette ........................................................................................................................... 491

Alphabetical parts list ....................................................................................................................... 493

Numerical parts list ........................................................................................................................... 500

Appendix A Service and support

Hewlett-Packard limited warranty statement .................................................................................... 508

HP's Premium Protection Warranty: LaserJet print cartridge limited warranty statement ................ 509

HP Color LaserJet Fuser Kit Limited Warranty Statement ............................................................... 510

End User License Agreement .......................................................................................................... 511

Customer self-repair warranty service .............................................................................................. 513

Customer support ............................................................................................................................. 514

Appendix B Product specifications

Physical specifications ..................................................................................................................... 516

Performance specifications .............................................................................................................. 516

Electrical specifications .................................................................................................................... 516

Acoustic specifications ..................................................................................................................... 517

Environmental specifications ............................................................................................................ 517

Paper and print media specifications ............................................................................................... 517

Skew specifications .......................................................................................................................... 517

Appendix C Regulatory information

FCC regulations ............................................................................................................................... 520

Declaration of Conformity ................................................................................................................. 521

Certificate of volatility ....................................................................................................................... 522

Safety statements ............................................................................................................................. 523

Laser safety ..................................................................................................................... 523

Canadian DOC regulations .............................................................................................. 523

VCCI statement (Japan) .................................................................................................. 523

Power cord statement (Japan) ......................................................................................... 523

EMC statement (Korea) ................................................................................................... 523

Laser statement for Finland ............................................................................................. 523

Substances Table (China) ............................................................................................... 524

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Index ................................................................................................................................................................. 525

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List of tables

Table 2-1 Embedded Jetdirect and EIO <X> Jetdirect menus ......................................................................... 32

Table 3-1 Supported paper and print media sizes ........................................................................................... 44

Table 5-1 Sequence of operation ................................................................................................................... 105

Table 5-2 Solenoids ....................................................................................................................................... 107

Table 5-3 Switches ......................................................................................................................................... 108

Table 5-4 Sensors .......................................................................................................................................... 109

Table 5-5 Motors ............................................................................................................................................ 110

Table 5-6 Fans ............................................................................................................................................... 111

Table 5-7 High-voltage power supply circuits ................................................................................................. 112

Table 5-8 Converted DC voltages .................................................................................................................. 113

Table 5-9 Fuser (fixing) components .............................................................................................................. 115

Table 5-10 Primary-transfer-roller engagement states ................................................................................... 131

Table 5-11 Image-stabilization controls .......................................................................................................... 135

Table 5-12 Switches and sensors for the pickup, feed, and delivery system ................................................. 136

Table 5-13 Motors and solenoids for the pickup, feed, and delivery system ................................................. 137

Table 5-14 Jams that the product detects ...................................................................................................... 152

Table 5-15 Electrical components for the paper feeder ................................................................................. 155

Table 6-1 DC controller connectors ................................................................................................................ 167

Table 7-1 Pre-troubleshooting checklist ......................................................................................................... 315

Table 7-2 Troubleshooting flowchart .............................................................................................................. 316

Table 7-3 Manual sensor diagnostic tests ...................................................................................................... 325

Table 7-4 Manual sensor test 2 diagnostic tests ............................................................................................ 334

Table 7-5 Paper-path sensors diagnostic tests .............................................................................................. 340

Table 7-6 Component test details .................................................................................................................. 341

Table 7-7 Formatter PCA ............................................................................................................................... 343

Table 7-8 DC controller connectors ................................................................................................................ 344

Table 7-9 Paper feeder driver PCA connectors ............................................................................................. 345

Table 7-10 PCAs, motors, fans, switches, solenoids, and clutches ............................................................... 350

Table 7-11 Sensors ........................................................................................................................................ 353

Table 7-12 Important information on the configuration pages ........................................................................ 368

Table 7-13 Control-panel messages .............................................................................................................. 369

Table 7-14 Causes and solutions for delivery delay jam ................................................................................ 415

Table 7-15 Causes and solutions for fuser delivery delay jams ..................................................................... 416

Table 7-16 Causes and solutions for wrapping jams ..................................................................................... 416

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Table 7-17 Causes and solutions for fuser delivery stationary jams .............................................................. 416

Table 7-18 Causes and solutions for residual media jams ............................................................................ 417

Table 7-19 Causes and solutions for pickup delay jams 2 ............................................................................. 418

Table 7-20 Causes and solutions for pickup stationary jams ......................................................................... 419

Table 7-21 Causes and solutions for duplexing reverse jams ...................................................................... 419

Table 7-22 Causes and solutions for duplex repick jams .............................................................................. 420

Table 7-23 Causes and solutions for residual media jams ............................................................................ 420

Table 7-24 Causes and solutions for pickup delay jam 1: tray pickup ........................................................... 421

Table 7-25 Causes and solutions for pickup stationary jams ......................................................................... 422

Table 7-26 Causes and solutions for pickup delay jam 1; MP tray pickup ..................................................... 422

Table 7-27 Causes and solutions for pickup delay and pickup stationary jams ............................................. 423

Table 7-28 MP modes under the ADJUST PAPER TYPES sub menu .......................................................... 430

Table 7-29 MP modes under the OPTIMIZE submenu .................................................................................. 431

Table 8-1 Common fasteners ........................................................................................................................ 451

Table 8-2 External covers, panels, and doors; .............................................................................................. 455

Table 8-3 Right door assembly ...................................................................................................................... 457

Table 8-4 Internal components (1 of 5) .......................................................................................................... 459

Table 8-5 Internal components (2 of 5) .......................................................................................................... 461

Table 8-6 Internal components (3 of 5) .......................................................................................................... 463

Table 8-7 Internal components (4 of 5) .......................................................................................................... 465

Table 8-8 Internal components (5 of 5) .......................................................................................................... 467

Table 8-9 Cassette ......................................................................................................................................... 469

Table 8-10 Cassette paper pickup assembly ................................................................................................. 471

Table 8-11 MP paper pickup assembly .......................................................................................................... 473

Table 8-12 Registration assembly .................................................................................................................. 475

Table 8-13 Secondary Transfer assembly ..................................................................................................... 477

Table 8-14 Delivery assembly ........................................................................................................................ 479

Table 8-15 Fusing assembly .......................................................................................................................... 483

Table 8-16 PCAs ............................................................................................................................................ 485

Table 8-17 1 x 500 paper feeder .................................................................................................................... 488

Table 8-18 Paper feeder main body ............................................................................................................... 490

Table 8-19 Cassette ....................................................................................................................................... 492

Table 8-20 Alphabetical parts list ................................................................................................................... 493

Table 8-21 Numerical parts list ....................................................................................................................... 500

Table B-1 Product dimensions ....................................................................................................................... 516

Table B-2 Product dimensions, with all doors and trays fully opened ............................................................ 516

Table B-3 Power requirements ....................................................................................................................... 516

Table B-4 Power consumption (average, in watts) ........................................................................................ 517

Table B-5 HP Color LaserJet CP3525 Series ................................................................................................ 517

Table B-6 Media registration and image placement accuracy ....................................................................... 517

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List of figures

Figure 4-1 Slot for the security cable ................................................................................................................ 80

Figure 4-2 Supply item locations ...................................................................................................................... 82

Figure 5-1 Relationship between the main product systems ......................................................................... 104

Figure 5-2 Engine-control system .................................................................................................................. 106

Figure 5-3 DC controller block diagram .......................................................................................................... 107

Figure 5-4 High-voltage power supply circuits ............................................................................................... 111

Figure 5-5 Low-voltage power-supply circuit .................................................................................................. 113

Figure 5-6 Fuser (fixing) components ............................................................................................................ 115

Figure 5-7 Fuser temperature-control circuit .................................................................................................. 116

Figure 5-8 Laser/scanner system ................................................................................................................... 119

Figure 5-9 Image-formation system ............................................................................................................... 121

Figure 5-10 Image-formation process ............................................................................................................ 122

Figure 5-11 Pre-exposure .............................................................................................................................. 123

Figure 5-12 Primary charging ......................................................................................................................... 123

Figure 5-13 Laser-beam exposure ................................................................................................................. 124

Figure 5-14 Development ............................................................................................................................... 124

Figure 5-15 Primary transfer .......................................................................................................................... 125

Figure 5-16 Secondary transfer ...................................................................................................................... 125

Figure 5-17 Separation ................................................................................................................................... 126

Figure 5-18 Fusing ......................................................................................................................................... 126

Figure 5-19 ITB cleaning ................................................................................................................................ 127

Figure 5-20 Drum cleaning ............................................................................................................................. 127

Figure 5-21 Print-cartridge system ................................................................................................................. 128

Figure 5-22 Developing-roller engagement and disengagement control ....................................................... 129

Figure 5-23 ITB unit ........................................................................................................................................ 130

Figure 5-24 Three states of primary-transfer-roller engagement and disengagement ................................... 132

Figure 5-25 ITB cleaning process .................................................................................................................. 133

Figure 5-26 Toner patterns for calibration ...................................................................................................... 134

Figure 5-27 Switches and sensors for the pickup, feed, and delivery system ............................................... 136

Figure 5-28 Motors and solenoids for the pickup, feed, and delivery system ................................................ 137

Figure 5-29 Three main units of the pickup, feed, and delivery system ......................................................... 138

Figure 5-30 .................................................................................................................................................... 139

Figure 5-31 Cassette-pickup mechanism ....................................................................................................... 140

Figure 5-32 Cassette presence sensor .......................................................................................................... 141

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Figure 5-33 Cassette lift mechanism .............................................................................................................. 142

Figure 5-34 Paper-level-detection mechanism .............................................................................................. 143

Figure 5-35 Multifeed prevention .................................................................................................................... 143

Figure 5-36 Multipurpose tray pickup mechanism .......................................................................................... 144

Figure 5-37 Paper-feed mechanism ............................................................................................................... 145

Figure 5-38 Skew-feed prevention ................................................................................................................. 146

Figure 5-39 Fuser and delivery unit ................................................................................................................ 147

Figure 5-40 Loop-control mechanism ............................................................................................................. 148

Figure 5-41 Pressure-roller pressurization control ......................................................................................... 149

Figure 5-42 Duplexing unit ............................................................................................................................. 150

Figure 5-43 Jam detection sensors ................................................................................................................ 152

Figure 5-44 Optional paper feeder ................................................................................................................. 154

Figure 5-45 Signals for the paper feeder ....................................................................................................... 155

Figure 5-46 Paper-feeder pickup and feed operation .................................................................................... 156

Figure 5-47 Paper size detection ................................................................................................................... 157

Figure 5-48 Paper-feeder cassette lift ........................................................................................................... 159

Figure 5-49 Paper-feeder multiple feed prevention ........................................................................................ 160

Figure 5-50 Jam detection .............................................................................................................................. 161

Figure 6-1 Phillips and pozidrive screwdriver comparison ............................................................................. 165

Figure 6-2 DC controller connector locations ................................................................................................. 167

Figure 6-3 Parts removal order (1 of 2) .......................................................................................................... 168

Figure 6-4 Parts removal order (2 of 2) .......................................................................................................... 169

Figure 6-5 Remove the print cartridge (1 of 2) ............................................................................................... 170

Figure 6-6 Remove the print cartridge (2 of 2) ............................................................................................... 171

Figure 6-7 Remove the duplex-reverse guide (1 of 2) ................................................................................... 172

Figure 6-8 Remove the duplex-reverse guide (2 of 2) ................................................................................... 172

Figure 6-9 Remove the toner-collection unit (1 of 4) ...................................................................................... 173

Figure 6-10 Remove the toner-collection unit (2 of 4) .................................................................................... 173

Figure 6-11 Remove the toner-collection unit (3 of 4) .................................................................................... 174

Figure 6-12 Remove the toner-collection unit (4 of 4) .................................................................................... 174

Figure 6-13 Remove the formatter ................................................................................................................. 175

Figure 6-14 Remove the memory DIMM (1 of 2) ............................................................................................ 176

Figure 6-15 Remove the memory DIMM (2 of 2) ............................................................................................ 177

Figure 6-16 Remove the tray cassette (1 of 2) ............................................................................................... 178

Figure 6-17 Remove the tray cassette (2 of 2) ............................................................................................... 178

Figure 6-18 Remove the fuser (1 of 2) ........................................................................................................... 179

Figure 6-19 Remove the fuser (2 of 2) ........................................................................................................... 179

Figure 6-20 Remove the pickup roller (Tray 2) (1 of 4) .................................................................................. 180

Figure 6-21 Remove the pickup roller (Tray 2) (2 of 4) .................................................................................. 180

Figure 6-22 Remove the pickup roller (Tray 2) (3 of 4) .................................................................................. 181

Figure 6-23 Remove the pickup roller (Tray 2) (4 of 4) .................................................................................. 181

Figure 6-24 Remove the Pickup and feed rollers (Tray 3) (1 of 2) ................................................................. 182

Figure 6-25 Remove the Pickup and feed rollers (Tray 3) (2 of 2) ................................................................. 182

Figure 6-26 Remove the separation roller (Tray 2) ........................................................................................ 183

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Figure 6-27 Remove the transfer roller (1 of 3) .............................................................................................. 184

Figure 6-28 Remove the transfer roller (2 of 3) .............................................................................................. 184

Figure 6-29 Remove the transfer roller (3 of 3) .............................................................................................. 185

Figure 6-30 Reinstall the transfer roller .......................................................................................................... 185

Figure 6-31 Remove the transfer roller (2 of 3) .............................................................................................. 186

Figure 6-32 Remove the secondary transfer assembly (1 of 2) ..................................................................... 186

Figure 6-33 Remove the secondary transfer assembly (2 of 2) ..................................................................... 187

Figure 6-34 Reinstall the secondary transfer assembly ................................................................................. 187

Figure 6-35 Remove the intermediate transfer belt (1 of 3) ........................................................................... 188

Figure 6-36 Remove the intermediate transfer belt (2 of 3) ........................................................................... 188

Figure 6-37 Remove the intermediate transfer belt (3 of 3) ........................................................................... 189

Figure 6-38 Remove the right door; optional paper feeder (1 of 3) ................................................................ 190

Figure 6-39 Remove the right door; optional paper feeder (2 of 3) ................................................................ 190

Figure 6-40 Remove the right door; optional paper feeder (3 of 3) ................................................................ 191

Figure 6-41 External panels, covers, and doors; identification and location .................................................. 192

Figure 6-42 Remove the front-door assembly (1 of 2) ................................................................................... 193

Figure 6-43 Remove the front-door assembly (2 of 2) ................................................................................... 193

Figure 6-44 Remove the right-door assembly (1 of 8) ................................................................................... 194

Figure 6-45 Remove the right-door assembly (2 of 8) ................................................................................... 194

Figure 6-46 Remove the right-door assembly (3 of 8) ................................................................................... 195

Figure 6-47 Remove the right-door assembly (4 of 8) ................................................................................... 195

Figure 6-48 Remove the right-door assembly (5 of 8) ................................................................................... 196

Figure 6-49 Remove the right-door assembly (6 of 8) ................................................................................... 196

Figure 6-50 Remove the right-door assembly (7 of 8) ................................................................................... 197

Figure 6-51 Remove the right-door assembly (8 of 8) ................................................................................... 197

Figure 6-52 Remove the right-rear cover (1 of 3) ........................................................................................... 198

Figure 6-53 Remove the right-rear cover (2 of 3) ........................................................................................... 198

Figure 6-54 Remove the right-rear cover (3 of 3) ........................................................................................... 199

Figure 6-55 Remove the left cover (1 of 5) ..................................................................................................... 200

Figure 6-56 Remove the left cover (2 of 5) ..................................................................................................... 200

Figure 6-57 Remove the left cover (3 of 5) ..................................................................................................... 201

Figure 6-58 Remove the left cover (4 of 5) ..................................................................................................... 201

Figure 6-59 Remove the left cover (5 of 5) ..................................................................................................... 202

Figure 6-60 Remove the control-panel assembly (1 of 4) .............................................................................. 203

Figure 6-61 Remove the control-panel assembly (2 of 4) .............................................................................. 203

Figure 6-62 Remove the control-panel assembly (3 of 4) .............................................................................. 204

Figure 6-63 Remove the control-panel assembly (4 of 4) .............................................................................. 204

Figure 6-64 Remove the right-front cover (1 of 5) .......................................................................................... 205

Figure 6-65 Remove the right-front cover (2 of 5) .......................................................................................... 205

Figure 6-66 Remove the right-front cover (3 of 5) .......................................................................................... 206

Figure 6-67 Remove the right-front cover (4 of 5) .......................................................................................... 206

Figure 6-68 Remove the right-front cover (5 of 5) .......................................................................................... 207

Figure 6-69 Reinstall the power button .......................................................................................................... 207

Figure 6-70 Remove the front-top cover (1 of 2) ............................................................................................ 208

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Figure 6-71 Remove the front-top cover (2 of 2) ............................................................................................ 208

Figure 6-72 Remove the rear cover and upper-rear cover (1 of 4) ................................................................ 209

Figure 6-73 Remove the rear cover and upper-rear cover (2 of 4) ................................................................ 209

Figure 6-74 Remove the rear cover and upper-rear cover (3 of 4) ................................................................ 210

Figure 6-75 Remove the rear cover and upper-rear cover (4 of 4) ................................................................ 210

Figure 6-76 Remove the rear-top cover (1 of 2) ............................................................................................. 211

Figure 6-77 Remove the rear-top cover (2 of 2) ............................................................................................. 212

Figure 6-78 Remove the pickup roller (Tray 1) (1 of 2) .................................................................................. 213

Figure 6-79 Remove the pickup roller (Tray 1) (2 of 2) .................................................................................. 214

Figure 6-80 Remove the delivery fan, cartridge fan, and environmental sensor (1 of 9) ............................... 215

Figure 6-81 Remove the delivery fan, cartridge fan, and environmental sensor (2 of 9) ............................... 215

Figure 6-82 Remove the delivery fan, cartridge fan, and environmental sensor (3 of 9) ............................... 216

Figure 6-83 Remove the delivery fan, cartridge fan, and environmental sensor (4 of 9) ............................... 216

Figure 6-84 Remove the delivery fan, cartridge fan, and environmental sensor (5 of 9) ............................... 217

Figure 6-85 Remove the delivery fan, cartridge fan, and environmental sensor (6 of 9) ............................... 217

Figure 6-86 Remove the delivery fan, cartridge fan, and environmental sensor (7 of 9) ............................... 218

Figure 6-87 Remove the delivery fan, cartridge fan, and environmental sensor (8 of 9) ............................... 218

Figure 6-88 Remove the delivery fan, cartridge fan, and environmental sensor (9 of 9) ............................... 219

Figure 6-89 Remove the toner-collection sensor (1 of 4) ............................................................................... 220

Figure 6-90 Remove the toner-collection sensor (2 of 4) ............................................................................... 220

Figure 6-91 Remove the toner-collection sensor (3 of 4) ............................................................................... 221

Figure 6-92 Remove the toner-collection sensor (4 of 4) ............................................................................... 221

Figure 6-93 Remove the residual-toner-feed motor (1 of 7) ........................................................................... 222

Figure 6-94 Remove the residual-toner-feed motor (2 of 7) ........................................................................... 223

Figure 6-95 Remove the residual-toner-feed motor (3 of 7) ........................................................................... 223

Figure 6-96 Remove the residual-toner-feed motor (4 of 7) ........................................................................... 224

Figure 6-97 Remove the residual-toner-feed motor (5 of 7) ........................................................................... 224

Figure 6-98 Remove the residual-toner-feed motor (6 of 7) ........................................................................... 225

Figure 6-99 Remove the residual-toner-feed motor (7 of 7) ........................................................................... 225

Figure 6-100 Reinstall the residual-toner collection door ............................................................................... 226

Figure 6-101 Remove the RD sensor assembly (1 of 6) ................................................................................ 227

Figure 6-102 Remove the RD sensor assembly (2 of 6) ................................................................................ 227

Figure 6-103 Remove the RD sensor assembly (3 of 6) ................................................................................ 228

Figure 6-104 Remove the RD sensor assembly (4 of 6) ................................................................................ 228

Figure 6-105 Remove the RD sensor assembly (5 of 6) ................................................................................ 229

Figure 6-106 Remove the RD sensor assembly (6 of 6) ................................................................................ 229

Figure 6-107 Remove the power-supply fan (1 of 4) ...................................................................................... 230

Figure 6-108 Remove the power-supply fan (2 of 4) ...................................................................................... 231

Figure 6-109 Remove the power-supply fan (3 of 4) ...................................................................................... 231

Figure 6-110 Remove the power-supply fan (4 of 4) ...................................................................................... 232

Figure 6-111 Remove the registration assembly (1 of 8) ............................................................................... 233

Figure 6-112 Remove the registration assembly (2 of 8) ............................................................................... 234

Figure 6-113 Remove the registration assembly (3 of 8) ............................................................................... 234

Figure 6-114 Remove the registration assembly (4 of 8) ............................................................................... 235

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Figure 6-115 Remove the registration assembly (5 of 8) ............................................................................... 235

Figure 6-116 Remove the registration assembly (6 of 8) ............................................................................... 236

Figure 6-117 Remove the registration assembly (7 of 8) ............................................................................... 236

Figure 6-118 Remove the registration assembly (8 of 8) ............................................................................... 237

Figure 6-119 Remove the ICB (1 of 3) ........................................................................................................... 238

Figure 6-120 Remove the ICB (2 of 3) ........................................................................................................... 239

Figure 6-121 Remove the ICB (3 of 3) ........................................................................................................... 239

Figure 6-122 Remove the DC controller PCA and tray (1 of 4) ...................................................................... 240

Figure 6-123 Remove the DC controller PCA and tray (2 of 4) ...................................................................... 241

Figure 6-124 Remove the DC controller PCA and tray (3 of 4) ...................................................................... 241

Figure 6-125 Remove the DC controller PCA and tray (4 of 4) ...................................................................... 242

Figure 6-126 Remove the low-voltage power supply (1 of 8) ......................................................................... 243

Figure 6-127 Remove the low-voltage power supply (2 of 8) ......................................................................... 244

Figure 6-128 Remove the low-voltage power supply (3 of 8) ......................................................................... 244

Figure 6-129 Remove the low-voltage power supply (4 of 8) ......................................................................... 245

Figure 6-130 Remove the low-voltage power supply (5 of 8) ......................................................................... 245

Figure 6-131 Remove the low-voltage power supply (6 of 8) ......................................................................... 246

Figure 6-132 Remove the low-voltage power supply (7 of 8) ......................................................................... 246

Figure 6-133 Remove the low-voltage power supply (8 of 8) ......................................................................... 247

Figure 6-134 Remove the high-voltage power supply lower (1 of 4) .............................................................. 248

Figure 6-135 Remove the high-voltage power supply lower (2 of 4) .............................................................. 249

Figure 6-136 Remove the high-voltage power supply lower (3 of 4) .............................................................. 249

Figure 6-137 Remove the high-voltage power supply lower (4 of 4) .............................................................. 250

Figure 6-138 Reinstall the high-voltage power supply lower .......................................................................... 250

Figure 6-139 Remove the developing-disengagement motor (1 of 2) ............................................................ 251

Figure 6-140 Remove the developing-disengagement motor (2 of 2) ............................................................ 252

Figure 6-141 Remove the pickup motor ......................................................................................................... 253

Figure 6-142 Remove the lifter-drive assembly (1 of 2) ................................................................................. 254

Figure 6-143 Remove the lifter-drive assembly (2 of 2) ................................................................................. 255

Figure 6-144 Remove the cassette-pickup drive assembly (1 of 10) ............................................................. 256

Figure 6-145 Remove the cassette-pickup drive assembly (2 of 10) ............................................................. 257

Figure 6-146 Remove the cassette-pickup drive assembly (3 of 10) ............................................................. 257

Figure 6-147 Remove the cassette-pickup drive assembly (4 of 10) ............................................................. 258

Figure 6-148 Remove the cassette-pickup drive assembly (5 of 10) ............................................................. 258

Figure 6-149 Remove the cassette-pickup drive assembly (6 of 10) ............................................................. 259

Figure 6-150 Remove the cassette-pickup drive assembly (7 of 10) ............................................................. 259

Figure 6-151 Remove the cassette-pickup drive assembly (8 of 10) ............................................................. 260

Figure 6-152 Remove the cassette-pickup drive assembly (9 of 10) ............................................................. 260

Figure 6-153 Remove the cassette-pickup drive assembly (10 of 10) ........................................................... 261

Figure 6-154 Reinstall the cassette-pickup drive assembly (1 of 3) ............................................................... 261

Figure 6-155 Reinstall the cassette-pickup drive assembly (2 of 3) ............................................................... 262

Figure 6-156 Reinstall the cassette-pickup drive assembly (3 of 3) ............................................................... 262

Figure 6-157 Remove the cassette-pickup assembly (1 of 3) ........................................................................ 263

Figure 6-158 Remove the cassette-pickup assembly (2 of 3) ........................................................................ 264

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Figure 6-159 Remove the cassette-pickup assembly (3 of 3) ........................................................................ 264

Figure 6-160 Remove the laser/scanner assembly (Y/M) (1 of 12) ............................................................... 265

Figure 6-161 Remove the laser/scanner assembly (Y/M) (2 of 12) ............................................................... 266

Figure 6-162 Remove the laser/scanner assembly (Y/M) (3 of 12) ............................................................... 266

Figure 6-163 Remove the laser/scanner assembly (Y/M) (4 of 12) ............................................................... 267

Figure 6-164 Remove the laser/scanner assembly (Y/M) (5 of 12) ............................................................... 267

Figure 6-165 Remove the laser/scanner assembly (Y/M) (6 of 12) ............................................................... 268

Figure 6-166 Remove the laser/scanner assembly (Y/M) (7 of 12) ............................................................... 268

Figure 6-167 Remove the laser/scanner assembly (Y/M) (8 of 12) ............................................................... 269

Figure 6-168 Remove the laser/scanner assembly (Y/M) (9 of 12) ............................................................... 269

Figure 6-169 Remove the laser/scanner assembly (Y/M) (10 of 12) ............................................................. 270

Figure 6-170 Remove the laser/scanner assembly (Y/M) (11 of 12) ............................................................. 270

Figure 6-171 Remove the laser/scanner assembly (Y/M) (12 of 12) ............................................................. 271

Figure 6-172 Remove the laser/scanner assembly (C/Bk) (1 of 7) ................................................................ 273

Figure 6-173 Remove the laser/scanner assembly (C/Bk) (2 of 7) ................................................................ 273

Figure 6-174 Remove the laser/scanner assembly (C/Bk) (3 of 7) ................................................................ 274

Figure 6-175 Remove the laser/scanner assembly (C/Bk) (4 of 7) ................................................................ 274

Figure 6-176 Remove the laser/scanner assembly (C/Bk) (5 of 7) ................................................................ 275

Figure 6-177 Remove the laser/scanner assembly (C/Bk) (6 of 7) ................................................................ 275

Figure 6-178 Remove the laser/scanner assembly (C/Bk) (7 of 7) ................................................................ 276

Figure 6-179 Reinstall the PGC actuators (1 of 5) ......................................................................................... 276

Figure 6-180 Reinstall the PGC actuators (2 of 5) ......................................................................................... 277

Figure 6-181 Reinstall the PGC actuators (3 of 5) ......................................................................................... 277

Figure 6-182 Reinstall the PGC actuators (4 of 5) ......................................................................................... 278

Figure 6-183 Reinstall the PGC actuators (5 of 5) ......................................................................................... 278

Figure 6-184 Remove the high-voltage power supply upper (1 of 5) ............................................................. 279

Figure 6-185 Remove the high-voltage power supply upper (2 of 5) ............................................................. 280

Figure 6-186 Remove the high-voltage power supply upper (3 of 5) ............................................................. 280

Figure 6-187 Remove the high-voltage power supply upper (4 of 5) ............................................................. 281

Figure 6-188 Remove the high-voltage power supply upper (5 of 5) ............................................................. 281

Figure 6-189 Reinstall the high-voltage power supply upper ......................................................................... 282

Figure 6-190 Remove the drum motor 1 ........................................................................................................ 283

Figure 6-191 Remove the drum motor 2 or drum motor 3 .............................................................................. 284

Figure 6-192 Remove the fuser motor ........................................................................................................... 286

Figure 6-193 Remove the main-drive assembly (1 of 7) ................................................................................ 288

Figure 6-194 Remove the main-drive assembly (2 of 7) ................................................................................ 288

Figure 6-195 Remove the main-drive assembly (3 of 7) ................................................................................ 289

Figure 6-196 Remove the main-drive assembly (4 of 7) ................................................................................ 289

Figure 6-197 Remove the main-drive assembly (5 of 7) ................................................................................ 290

Figure 6-198 Remove the main-drive assembly (6 of 7) ................................................................................ 290

Figure 6-199 Remove the main-drive assembly (7 of 7) ................................................................................ 291

Figure 6-200 Reinstall the main-drive assembly (1 of 11) .............................................................................. 292

Figure 6-201 Reinstall the main-drive assembly (2 of 11) .............................................................................. 292

Figure 6-202 Reinstall the main-drive assembly (3 of 11) .............................................................................. 293

xxii ENWW

Figure 6-203 Reinstall the main-drive assembly (4 of 11) .............................................................................. 293

Figure 6-204 Reinstall the main-drive assembly (5 of 11) .............................................................................. 294

Figure 6-205 Reinstall the main-drive assembly (6 of 11) .............................................................................. 294

Figure 6-206 Reinstall the main-drive assembly (7 of 11) .............................................................................. 295

Figure 6-207 Reinstall the main-drive assembly (8 of 11) .............................................................................. 295

Figure 6-208 Reinstall the main-drive assembly (9 of 11) .............................................................................. 296

Figure 6-209 Reinstall the main-drive assembly (10 of 11) ............................................................................ 296

Figure 6-210 Reinstall the main-drive assembly (11 of 11) ............................................................................ 297

Figure 6-211 Remove the fuser-drive assembly (1 of 6) ................................................................................ 299

Figure 6-212 Remove the fuser-drive assembly (2 of 6) ................................................................................ 299

Figure 6-213 Remove the fuser-drive assembly (3 of 6) ................................................................................ 300

Figure 6-214 Remove the fuser-drive assembly (4 of 6) ................................................................................ 300

Figure 6-215 Remove the fuser-drive assembly (5 of 6) ................................................................................ 301

Figure 6-216 Remove the fuser-drive assembly (6 of 6) ................................................................................ 301

Figure 6-217 Reinstall the fuser-drive assembly ............................................................................................ 302

Figure 6-218 Remove the delivery assembly (1 of 5) .................................................................................... 304

Figure 6-219 Remove the delivery assembly (2 of 5) .................................................................................... 304

Figure 6-220 Remove the delivery assembly (3 of 5) .................................................................................... 305

Figure 6-221 Remove the delivery assembly (4 of 5) .................................................................................... 305

Figure 6-222 Remove the delivery assembly (5 of 5) .................................................................................... 306

Figure 6-223 Reinstall the delivery assembly (1 of 2) .................................................................................... 307

Figure 6-224 Reinstall the delivery assembly (2 of 2) .................................................................................... 307

Figure 6-225 Remove the duplex-drive assembly (1 of 2) ............................................................................. 309

Figure 6-226 Remove the duplex-drive assembly (2 of 2) ............................................................................. 309

Figure 6-227 Remove the drawer connector; optional paper feeder .............................................................. 310

Figure 7-1 Diagnostic test (1 of 3) .................................................................................................................. 322

Figure 7-2 Diagnostic test (2 of 3) .................................................................................................................. 322

Figure 7-3 Diagnostic test (3 of 3) .................................................................................................................. 323

Figure 7-4 Engine-test button ......................................................................................................................... 324

Figure 7-5 Test the TOP sensor ..................................................................................................................... 326

Figure 7-6 Test the loop sensors .................................................................................................................... 326

Figure 7-7 Test the fuser delivery sensor (1 of 2) .......................................................................................... 327

Figure 7-8 Test the fuser (fixing) delivery sensor (2 of 2) ............................................................................... 327

Figure 7-9 Test the duplex re-pickup sensor .................................................................................................. 328

Figure 7-10 Test the output-bin-full sensor .................................................................................................... 329

Figure 7-11 Test the fuser (fixing) pressure-release sensor (1 of 2) .............................................................. 329

Figure 7-12 Test the fuser (fixing) pressure-release sensor (2 of 2) .............................................................. 330

Figure 7-13 Test the primary transfer-roller disengagement sensor (1 of 2) .................................................. 330

Figure 7-14 Test the primary transfer-roller disengagement sensor (2 of 2) .................................................. 331

Figure 7-15 Test the right- and front-door interlock switches (1 of 4) ............................................................ 332

Figure 7-16 Test the right- and front-door interlock switches (2 of 4) ............................................................ 332

Figure 7-17 Test the right- and front-door interlock switches (3 of 4) ............................................................ 333

Figure 7-18 Test the right- and front-door interlock switches (4 of 4) ............................................................ 333

Figure 7-19 Test the Tray 1 media-present sensor ....................................................................................... 335

ENWW xxiii

Figure 7-20 Test the tray 2 paper-out sensor ................................................................................................ 335

Figure 7-21 Test the Tray 2 closed sensor (1 of 2) ........................................................................................ 336

Figure 7-22 Test the Tray 2 closed sensor (2 of 2) ........................................................................................ 336

Figure 7-23 Test the Tray 2 stack-surface sensor .......................................................................................... 337

Figure 7-24 Test the optional Tray 3-empty sensor ....................................................................................... 337

Figure 7-25 Test the optional Tray 3 media-feed sensor .............................................................................. 338

Figure 7-26 Test the optional Tray 3 stack-surface sensor ........................................................................... 339

Figure 7-27 Test the optional Tray 3 media-size sensors .............................................................................. 339

Figure 7-28 Formatter PCA ............................................................................................................................ 343

Figure 7-29 DC controller PCA ....................................................................................................................... 344

Figure 7-30 Paper feeder driver PCA ............................................................................................................ 345

Figure 7-31 Component locations (1 of 5) ...................................................................................................... 346

Figure 7-32 Component locations (2 of 5) ...................................................................................................... 346

Figure 7-33 Component locations (3 of 5) ...................................................................................................... 347

Figure 7-34 Component locations (4 of 5) ...................................................................................................... 348

Figure 7-35 Component locations (5 of 5) ...................................................................................................... 349

Figure 7-36 1 x 500 paper feeder ................................................................................................................... 352

Figure 7-37 Sensors ...................................................................................................................................... 353

Figure 7-38 General timing chart .................................................................................................................... 355

Figure 7-39 General circuit diagram .............................................................................................................. 356

Figure 7-40 Paper feeder circuit diagram ....................................................................................................... 357

Figure 7-41 Repetitive defects ruler ............................................................................................................... 358

Figure 7-42 Print-quality troubleshooting procedure ...................................................................................... 360

Figure 7-43 Yellow print-quality troubleshooting page ................................................................................... 360

Figure 7-44 Yellow comparison page ............................................................................................................. 361

Figure 7-45 Black print-quality troubleshooting page ..................................................................................... 362

Figure 7-46 Configuration page ..................................................................................................................... 364

Figure 7-47 HP embedded Jetdirect page ..................................................................................................... 366

Figure 7-48 Embedded protocol page ........................................................................................................... 367

Figure 7-49 Sample event log ........................................................................................................................ 396

Figure 7-50 Jam locations .............................................................................................................................. 405

Figure 8-1 External covers, panels, and doors .............................................................................................. 454

Figure 8-2 Right door assembly ..................................................................................................................... 456

Figure 8-3 Internal components 1 of 5 ........................................................................................................... 458

Figure 8-4 Internal components 2 of 5 ........................................................................................................... 460

Figure 8-5 Internal components 3 of 5 ........................................................................................................... 462

Figure 8-6 Internal components 4 of 5 ........................................................................................................... 464

Figure 8-7 Internal components 5 of 5 ........................................................................................................... 466

Figure 8-8 Cassette ........................................................................................................................................ 468

Figure 8-9 Cassette paper pickup assembly .................................................................................................. 470

Figure 8-10 MP paper pickup assembly ......................................................................................................... 472

Figure 8-11 Registration assembly ................................................................................................................ 474

Figure 8-12 Secondary transfer assembly .................................................................................................... 476

Figure 8-13 Delivery assembly ...................................................................................................................... 478

xxiv ENWW

Figure 8-14 Fusing (fixing) assembly (1 of 2) ................................................................................................. 480

Figure 8-15 Fusing (fixing) assembly (2 of 2) ................................................................................................. 482

Figure 8-16 PCAs ........................................................................................................................................... 484

Figure 8-17 1 x 500 paper feeder ................................................................................................................... 486

Figure 8-18 1 x 500 paper feeder ................................................................................................................... 487

Figure 8-19 Paper feeder main body ............................................................................................................. 489

Figure 8-20 Cassette ..................................................................................................................................... 491

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xxvi ENWW

1 Product basics

Product comparison

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Product features

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Product view

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ENWW 1

Product comparison

Model Features

HP Color LaserJet CP3525

HP Color LaserJet CP3525n

HP Color LaserJet CP3525dn

100-sheet multipurpose input tray (Tray 1)

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250-sheet input tray (Tray 2)

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250-sheet, face-down output bin

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Hi-speed USB 2.0 port

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256 megabytes (MB) of random access memory (RAM)

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100-sheet multipurpose input tray (Tray 1)

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250-sheet input tray (Tray 2)

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250-sheet, face-down output bin

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Hi-speed USB 2.0 port

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HP Jetdirect embedded print server for connecting to a 10/100Base-TX network

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256 megabytes (MB) of random access memory (RAM)

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100-sheet multipurpose input tray (Tray 1)

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250-sheet input tray (Tray 2)

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250-sheet, face-down output bin

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HP Color LaserJet CP3525x

Hi-speed USB 2.0 port

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HP Jetdirect embedded print server for connecting to a 10/100Base-TX network

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384 megabytes (MB) of random access memory (RAM)

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Automatic two-sided printing

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100-sheet multipurpose input tray (Tray 1)

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250-sheet input tray (Tray 2)

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250-sheet, face-down output bin

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500-sheet paper and heavy media tray (Tray 3), including HP postcard media insert

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for 101.6 x 152.4 mm (4 x 6 in) paper

Hi-speed USB 2.0 port

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HP Jetdirect embedded print server for connecting to a 10/100Base-TX network

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512 megabytes (MB) of random access memory (RAM)

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Automatic two-sided printing

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2 Chapter 1 Product basics ENWW

+ 534 hidden pages