HP LaserJet Enterprise MFP M525 Repair Manual
LASERJET ENTERPRISE 500 MFP
LASERJET ENTERPRISE FLOW MFP M525
Repair Manual
2
M525
2
M525c
HP LaserJet Enterprise 500 MFP M525
and HP LaserJet Enterprise flow MFP
M525
Repair Manual
Copyright and License
© 2012 Copyright Hewlett-Packard
Development Company, L.P.
Trademark Credits
®
, Acrobat®, and PostScript® are
Adobe
trademarks of Adobe Systems Incorporated.
Reproduction, adaptation, or translation
without prior written permission is
prohibited, except as allowed under the
copyright laws.
The information contained herein is subject
to change without notice.
The only warranties for HP products and
services are set forth in the express warranty
statements accompanying such products and
services. Nothing herein should be
construed as constituting an additional
warranty. HP shall not be liable for technical
or editorial errors or omissions contained
herein.
Edition 2, 11/2012
Part number: CF116-90902
Microsoft®, Windows®, Windows® XP,
and Windows Vista® are U.S. registered
trademarks of Microsoft Corporation.
ENERGY STAR and the ENERGY STAR mark
are registered U.S. marks.
Conventions used in this guide
TIP: Tips provide helpful hints or shortcuts.
NOTE: Notes provide important information to explain a concept or to complete a task.
CAUTION: Cautions indicate procedures that you should follow to avoid losing data or damaging
the product.
WARNING! Warnings alert you to specific procedures that you should follow to avoid personal
injury, catastrophic loss of data, or extensive damage to the product.
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iv Conventions used in this guide ENWW
Table of contents
1 Removal and replacement ................................................................................................ 1
Removal and replacement strategy ............................................................................................. 2
General cautions during removal and replacement ........................................................ 2
Electrostatic discharge ............................................................................................... 2
Required tools ........................................................................................................... 3
Types of screws ........................................................................................................ 3
Service approach ..................................................................................................................... 5
Before performing service .......................................................................................... 5
After performing service ............................................................................................. 5
Post-service test ......................................................................................................... 5
Print-quality test .......................................................................................... 5
Location of connectors ............................................................................................... 7
DC controller connections ............................................................................ 7
Formatter connections ................................................................................. 9
Parts removal order ................................................................................................. 10
Removal and replacement procedures ...................................................................................... 12
Customer self repair (CSR) components ...................................................................... 12
Toner cartridge ........................................................................................ 12
Tray 2, Tray 3, or Tray 4 assembly ............................................................. 14
Control-panel HIP cover ............................................................................ 15
Control-panel USB cover ........................................................................... 15
Control-panel assembly ............................................................................. 16
Control-panel assembly (M525c model) ...................................................... 19
Important removal considerations ................................................ 19
Remove the control-panel assembly .............................................. 21
Reinstall the control-panel assembly ............................................. 28
Control-panel assembly to keyboard FFC (M525c model) .............................. 35
Important considerations ............................................................ 35
Remove the control-panel assembly to keyboard FFC ..................... 36
Reinstall the control-panel assembly to keyboard FFC ..................... 37
Keyboard assembly (M525c model) ........................................................... 40
Remove the keyboard assembly .................................................. 40
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Keyboard overlay (M525c model) .............................................................. 45
Install a keyboard overlay .......................................................... 45
Back-side background selector assembly (M525c model) .............................. 49
Foam reflector .......................................................................................... 51
Document feeder pickup roller ................................................................... 56
Document feeder separation pad ............................................................... 58
Fax card and cable .................................................................................. 61
Disk drives (HDD and SSM) ....................................................................... 63
Remove the HDD ....................................................................... 63
Remove the SSM ....................................................................... 66
Install a replacement hard drive or SSM ....................................... 68
External panels, covers, doors, formatter, and stapler .................................................. 69
Formatter cover ........................................................................................ 69
Formatter PCA ......................................................................................... 70
Stapler cover ........................................................................................... 72
Substitute stapler cover ............................................................................. 74
Stapler assembly ...................................................................................... 75
Rear cover assembly ................................................................................. 76
Left cover ................................................................................................ 80
Right-rear cover ........................................................................................ 82
Tray 1 cover ............................................................................................ 84
Cartridge-door assembly ........................................................................... 86
Rear scanner cover ................................................................................... 88
Document feeder front cover ...................................................................... 89
Document feeder rear cover ...................................................................... 91
Right cover assembly ................................................................................ 93
Right handle cover and bracket .................................................................. 98
Reinstall the right handle cover and bracket ................................ 101
Document feeder assemblies and scanner ................................................................ 102
Deskew mylar and separation mylar ......................................................... 102
Document feeder tray extender ................................................................ 104
Document feeder PCA ............................................................................. 105
Document feeder jam-access cover ........................................................... 106
Document feeder roller cover ................................................................... 109
Scanner memory PCA (memory board) ..................................................... 112
Document feeder cable ........................................................................... 115
Document feeder whole unit (standard model) ............................................ 119
Reinstall the document feeder .................................................... 121
Image scanner (standard model) whole unit ............................................... 122
Remove the image scanner whole unit (standard model) ............... 122
Reinstall the image scanner ...................................................... 125
vi ENWW
Integrated scanner assembly (525c model) whole unit ................................ 130
Remove the ISA (525c model) ................................................... 130
Reinstall the ISA ...................................................................... 139
Document feeder hinge assembly ............................................................. 143
Control-panel cable ................................................................................ 144
Remove the control-panel cable ................................................. 144
Main assemblies ................................................................................................... 146
Tray 1 pickup roller ................................................................................ 146
Tray 1 separation pad ............................................................................ 148
Tray 2, 3, or 4 pickup roller assembly ...................................................... 149
Remove the Tray 2, 3, or 4 pickup roller—whole unit .................. 150
Remove the Tray 2, 3, or 4 pickup roller—components ................ 152
Reassemble the Tray 2, 3, or 4 pickup roller assembly ................. 153
Reinstall the Tray 2, 3, or 4 pickup roller assembly ...................... 158
Tray 2, 3, or 4 separation pad ................................................................ 159
Tray 2, 3, or 4 base-plate roller assembly ................................................. 160
Transfer roller ........................................................................................ 161
Fuser .................................................................................................... 163
Duplex media-feed assembly ................................................................... 166
Registration roller assembly ..................................................................... 169
Power-switch assembly ............................................................................ 171
Interlock switch assembly ........................................................................ 172
Tray sensor PCA .................................................................................... 174
Main fan ............................................................................................... 176
Top cover .............................................................................................. 178
Laser scanner ......................................................................................... 181
Tag holder assembly ............................................................................... 184
DC controller ......................................................................................... 185
Low-voltage power supply (LVPS) .............................................................. 189
Tray 2 paper pickup assembly ................................................................. 196
Tray 1 or Tray 2 pickup solenoid ............................................................. 202
Fuser motor ........................................................................................... 205
Pendulum assembly ................................................................................ 207
Sub fan and fan duct .............................................................................. 210
Environmental sensor .............................................................................. 215
High-voltage power supply (HVPS) ........................................................... 217
2 Parts and diagrams ...................................................................................................... 225
Order parts by authorized service providers ............................................................................ 226
Order parts, accessories, and supplies .................................................................... 226
Supplies part numbers ........................................................................................... 227
ENWW vii
Customer self-repair (CSR) and service kits ............................................................... 227
Related documentation and software ...................................................................................... 232
Fasteners used in this product ................................................................................................ 232
How to use the parts lists and diagrams .................................................................................. 233
Assembly locations ............................................................................................................... 234
Base product (no optional trays or accessories) ......................................................... 234
Base product (optional trays or accessories) ............................................................. 235
Covers ................................................................................................................................ 236
Document feeder and scanner assemblies (525dn and 525f models) ......................................... 238
Document feeder and scanner assemblies (M525c model) ........................................................ 240
Keyboard (M525c model) ..................................................................................................... 242
Control panel assembly ........................................................................................................ 244
ADF assemblies ................................................................................................................... 246
Scanner assemblies .............................................................................................................. 248
Internal assemblies (1 of 6) ................................................................................................... 250
Internal assemblies (2 of 6) ................................................................................................... 252
Internal assemblies (3 of 6) ................................................................................................... 254
Internal assemblies (4 of 6) ................................................................................................... 256
Internal assemblies (5 of 6) ................................................................................................... 258
Internal assemblies (6 of 6) ................................................................................................... 260
Input devices ....................................................................................................................... 262
500-sheet input tray (Tray 3 and Tray 4) .................................................................. 262
Alphabetical parts list ........................................................................................................... 264
Numerical parts list .............................................................................................................. 269
Index ............................................................................................................................... 275
viii ENWW
List of tables
Table 2-1 Order parts, accessories, and supplies .................................................................................. 226
Table 2-2 Supplies part numbers ......................................................................................................... 227
Table 2-3 Customer self-repair (CSR) and service kits ............................................................................. 227
Table 2-4 Related documentation and software .................................................................................... 232
Table 2-5 Common fasteners ............................................................................................................. 232
Table 2-6 Optional 500-sheet input tray .............................................................................................. 235
Table 2-7 Covers .............................................................................................................................. 237
Table 2-8 Document feeder and scanner assemblies (525dn and 525f models) ........................................ 239
Table 2-9 Document feeder and scanner assemblies (525c models) ........................................................ 241
Table 2-10 Keyboard and brackets ..................................................................................................... 243
Table 2-11 Control panel assembly ..................................................................................................... 245
Table 2-12 ADF assemblies ................................................................................................................ 247
Table 2-13 Scanner assemblies .......................................................................................................... 249
Table 2-14 Internal assemblies (1 of 6) ................................................................................................ 251
Table 2-15 Internal assemblies (2 of 6) ................................................................................................ 253
Table 2-16 Internal assemblies (3 of 6) ................................................................................................ 255
Table 2-17 Internal assemblies (4 of 6) ................................................................................................ 257
Table 2-18 Internal assemblies (5 of 6) ................................................................................................ 259
Table 2-19 Internal assemblies (6 of 6) ................................................................................................ 261
Table 2-20 500-sheet input tray (Tray 3 and Tray 4) ............................................................................. 263
Table 2-21 Alphabetical parts list ....................................................................................................... 264
Table 2-22 Numerical parts list ........................................................................................................... 269
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x ENWW
List of figures
Figure 1-1 Phillips and Pozidriv screwdriver comparison ............................................................................ 3
Figure 1-2 DC controller connections ....................................................................................................... 7
Figure 1-3 Formatter connections ............................................................................................................ 9
Figure 1-4 Parts removal order: covers and customer-replaceable assemblies ............................................. 10
Figure 1-5 Parts removal order: document feeder assemblies and scanner ................................................. 11
Figure 1-6 Parts removal order: main assemblies .................................................................................... 11
Figure 1-7 Remove the toner cartridge (1 of 2) ....................................................................................... 12
Figure 1-8 Remove the toner cartridge (2 of 2) ....................................................................................... 13
Figure 1-9 Remove the tray .................................................................................................................. 14
Figure 1-10 Remove the control-panel HIP cover ..................................................................................... 15
Figure 1-11 Remove control-panel USB cover ......................................................................................... 15
Figure 1-12 Remove the control-panel assembly (1 of 5) .......................................................................... 16
Figure 1-13 Remove the control-panel assembly (2 of 5) .......................................................................... 16
Figure 1-14 Remove the control-panel assembly (3 of 5) .......................................................................... 17
Figure 1-15 Remove the control-panel assembly (4 of 5) .......................................................................... 17
Figure 1-16 Remove the control-panel assembly (5 of 5) .......................................................................... 18
Figure 1-17 Reinstall the control-panel assembly ..................................................................................... 18
Figure 1-18 Raising the control panel to access the FFC connector (1 of 2) ................................................ 19
Figure 1-19 Raise the control panel to access the FFC connector (2 of 2) ................................................... 20
Figure 1-20 Check the control panel FFC for damage (1 of 2) .................................................................. 20
Figure 1-21 Check the control panel FFC for damage (2 of 2) .................................................................. 21
Figure 1-22 Remove the control-panel assembly (1 of 13) ........................................................................ 21
Figure 1-23 Remove the control-panel assembly (2 of 13) ........................................................................ 22
Figure 1-24 Remove the control-panel assembly (3 of 13) ........................................................................ 22
Figure 1-25 Remove the control-panel assembly (4 of 13) ........................................................................ 23
Figure 1-26 Remove the control-panel assembly (5 of 13) ........................................................................ 23
Figure 1-27 Remove the control-panel assembly (6 of 13) ........................................................................ 24
Figure 1-28 Remove the control-panel assembly (7 of 13) ........................................................................ 24
Figure 1-29 Remove the control-panel assembly (8 of 13) ........................................................................ 25
Figure 1-30 Remove the control-panel assembly (9 of 13) ........................................................................ 26
Figure 1-31 Remove the control-panel assembly (10 of 13) ...................................................................... 26
Figure 1-32 Remove the control-panel assembly (11 of 13) ...................................................................... 27
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Figure 1-33 Remove the control-panel assembly (12 of 13) ...................................................................... 27
Figure 1-34 Remove the control-panel assembly (13 of 13) ...................................................................... 28
Figure 1-35 Reinstall the control-panel assembly (1 of 13) ........................................................................ 28
Figure 1-36 Reinstall the control-panel assembly (2 of 13) ........................................................................ 29
Figure 1-37 Reinstall the control-panel assembly (3 of 13) ........................................................................ 29
Figure 1-38 Reinstall the control-panel assembly (4 of 13) ........................................................................ 30
Figure 1-39 Reinstall the control-panel assembly (5 of 13) ........................................................................ 30
Figure 1-40 Reinstall the control-panel assembly (6 of 13) ........................................................................ 31
Figure 1-41 Reinstall the control-panel assembly (7 of 13) ........................................................................ 31
Figure 1-42 Reinstall the control-panel assembly (8 of 13) ........................................................................ 32
Figure 1-43 Reinstall the control-panel assembly (9 of 13) ........................................................................ 32
Figure 1-44 Reinstall the control-panel assembly (10 of 13) ...................................................................... 33
Figure 1-45 Reinstall the control-panel assembly (11 of 13) ...................................................................... 33
Figure 1-46 Reinstall the control-panel assembly (12 of 13) ...................................................................... 34
Figure 1-47 Remove the control-panel assembly (13 of 13) ...................................................................... 34
Figure 1-48 Control-panel assembly to keyboard FFC .............................................................................. 35
Figure 1-49 Remove the control-panel assembly to keyboard FFC (1 of 3) .................................................. 36
Figure 1-50 Remove the control-panel assembly to keyboard FFC (2 of 3) .................................................. 36
Figure 1-51 Remove the control-panel assembly to keyboard FFC (3 of 3) .................................................. 37
Figure 1-52 Reinstall the control-panel assembly to keyboard FFC (1 of 4) ................................................. 37
Figure 1-53 Reinstall the control-panel assembly to keyboard FFC (2 of 4) ................................................. 38
Figure 1-54 Reinstall the control-panel assembly to keyboard FFC (3 of 4) ................................................. 38
Figure 1-55 Reinstall the control-panel assembly to keyboard FFC (4 of 4) ................................................. 39
Figure 1-56 Remove the keyboard assembly (1 of 7) ............................................................................... 40
Figure 1-57 Remove the keyboard assembly (2 of 7) ............................................................................... 41
Figure 1-58 Remove the keyboard assembly (3 of 7) ............................................................................... 41
Figure 1-59 Remove the keyboard assembly (4 of 7) ............................................................................... 42
Figure 1-60 Remove the keyboard assembly (5 of 7) ............................................................................... 43
Figure 1-61 Remove the keyboard assembly (6 of 7) ............................................................................... 43
Figure 1-62 Remove the keyboard assembly (7 of 7) ............................................................................... 44
Figure 1-63 Install a keyboard overlay (1 of 6) ....................................................................................... 45
Figure 1-64 Install a keyboard overlay (2 of 6) ....................................................................................... 45
Figure 1-65 Install a keyboard overlay (3 of 6) ....................................................................................... 46
Figure 1-66 Install a keyboard overlay (4 of 6) ....................................................................................... 46
Figure 1-67 Inst
Figure 1-68 Install a keyboard overlay (6 of 6) ....................................................................................... 48
Figure 1-69 Remove the back-side background selector assembly (1 of 3) ................................................. 49
Figure 1-70 Remove the back-side background selector assembly (2 of 3) ................................................. 49
Figure 1-71 Remove the back-side background selector assembly (3 of 3) ................................................. 50
Figure 1-72 Remove the foam reflector (1 of 3) ....................................................................................... 51
Figure 1-73 Remove the foam reflector (2 of 3) ....................................................................................... 51
all a keyboard overlay (5 of 6) ....................................................................................... 47
xii ENWW
Figure 1-74 Remove the foam reflector (3 of 3) ....................................................................................... 52
Figure 1-75 Install the foam reflector (1 of 7) .......................................................................................... 52
Figure 1-76 Install the foam reflector (2 of 7) .......................................................................................... 53
Figure 1-77 Install the foam reflector (3 of 7) .......................................................................................... 53
Figure 1-78 Install the foam reflector (4 of 7) .......................................................................................... 54
Figure 1-79 Install the foam reflector (5 of 7) .......................................................................................... 54
Figure 1-80 Install the foam reflector (6 of 7) .......................................................................................... 55
Figure 1-81 Install the foam reflector (7 of 7) .......................................................................................... 55
Figure 1-82 Remove the document feeder pickup roller (1 of 4) ................................................................ 56
Figure 1-83 Remove the document feeder pickup roller (2 of 4) ................................................................ 56
Figure 1-84 Remove the document feeder pickup roller (3 of 4) ................................................................ 57
Figure 1-85 Remove the document feeder pickup roller (4 of 4) ................................................................ 57
Figure 1-86 Remove the document feeder separation pad (1 of 5) ............................................................ 58
Figure 1-87 Remove the document feeder separation pad (2 of 5) ............................................................ 58
Figure 1-88 Remove the document feeder separation pad (3 of 5) ............................................................ 59
Figure 1-89 Remove the document feeder separation pad (4 of 5) ............................................................ 59
Figure 1-90 Remove the document feeder separation pad (5 of 5) ............................................................ 60
Figure 1-91 Reinstall the document feeder separation pad spring ............................................................. 60
Figure 1-92 Remove the fax card and cable (1 of 4) ............................................................................... 61
Figure 1-93 Remove the fax card and cable (2 of 4) ............................................................................... 61
Figure 1-94 Remove the fax card and cable (3 of 4) ............................................................................... 62
Figure 1-95 Remove the fax card and cable (4 of 4) ............................................................................... 62
Figure 1-96 Remove the HDD (1 of 5) ................................................................................................... 63
Figure 1-97 Remove the HDD (2 of 5) ................................................................................................... 64
Figure 1-98 Remove the HDD (3 of 5) ................................................................................................... 64
Figure 1-99 Remove the HDD (4 of 5) ................................................................................................... 65
Figure 1-100 Remove the HDD (5 of 5) ................................................................................................. 65
Figure 1-101 Remove the SSM (1 of 4) .................................................................................................. 66
Figure 1-102 Remove the SSM (2 of 4) .................................................................................................. 66
Figure 1-103 Remove the SSM (3 of 4) .................................................................................................. 67
Figure 1-104 Remove the SSM (4 of 4) .................................................................................................. 67
Figure 1-105 Re
Figure 1-106 Remove the formatter PCA (1 of 4) .................................................................................... 70
Figure 1-107 Remove the formatter PCA (2 of 4) .................................................................................... 70
Figure 1-108 Remove the formatter PCA (3 of 4) .................................................................................... 71
Figure 1-109 Remove the formatter PCA (4 of 4) .................................................................................... 71
Figure 1-110 Remove the substitute cover (1 of 4) ................................................................................... 72
Figure 1-111 Remove the stapler cover (2 of 4) ...................................................................................... 72
Figure 1-112 Remove the stapler cover (3 of 4) ...................................................................................... 73
Figure 1-113 Remove the stapler cover (4 of 4) ...................................................................................... 73
Figure 1-114 Remove the substitute stapler cover (1 of 2) ........................................................................ 74
move the formatter cover .............................................................................................. 69
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Figure 1-115 Remove the substitute stapler cover (2 of 2) ........................................................................ 74
Figure 1-116 Remove the stapler assembly ............................................................................................ 75
Figure 1-117 Remove the rear cover assembly (1 of 8) ............................................................................ 76
Figure 1-118 Remove the rear cover assembly (2 of 8) ............................................................................ 76
Figure 1-119 Remove the rear cover assembly (3 of 8) ............................................................................ 77
Figure 1-120 Remove the rear cover assembly (4 of 8) ............................................................................ 77
Figure 1-121 Remove the rear cover assembly (5 of 8) ............................................................................ 78
Figure 1-122 Remove the rear cover assembly (6 of 8) ............................................................................ 78
Figure 1-123 Remove the rear cover assembly (7 of 8) ............................................................................ 79
Figure 1-124 Remove the rear cover assembly (8 of 8) ............................................................................ 79
Figure 1-125 Remove the left cover (1 of 3) ........................................................................................... 80
Figure 1-126 Remove the left cover (2 of 3) ........................................................................................... 81
Figure 1-127 Remove the left cover (3 of 3) ........................................................................................... 81
Figure 1-128 Remove the right-rear cover (1 of 2) ................................................................................... 82
Figure 1-129 Remove the right-rear cover (2 of 2) ................................................................................... 82
Figure 1-130 Reinstall the right-rear cover .............................................................................................. 83
Figure 1-131 Remove Tray 1 cover (1 of 3) ........................................................................................... 84
Figure 1-132 Remove Tray 1 cover (2 of 3) ........................................................................................... 84
Figure 1-133 Remove Tray 1 cover (3 of 3) ........................................................................................... 85
Figure 1-134 Remove the cartridge-door assembly (1 of 3) ...................................................................... 86
Figure 1-135 Remove the cartridge-door assembly (2 of 3) ...................................................................... 87
Figure 1-136 Remove the cartridge-door assembly (3 of 3) ...................................................................... 87
Figure 1-137 Remove the Rear scanner cover ......................................................................................... 88
Figure 1-138 Remove the document feeder front cover (1 of 4) ................................................................. 89
Figure 1-139 Remove the document feeder front cover (2 of 4) ................................................................. 89
Figure 1-140 Remove the document feeder front cover (3 of 4) ................................................................. 90
Figure 1-141 Remove the document feeder front cover (4 of 4) ................................................................. 90
Figure 1-142 Remove the document feeder rear cover (1 of 4) ................................................................. 91
Figure 1-143 Remove the document feeder rear cover (2 of 4) ................................................................. 91
Figure 1-144 Remove the document feeder rear cover (3 of 4) ................................................................. 92
Figure 1-145 Remove the document feeder rear cover (4 of 4) ................................................................. 92
Figure 1-146 Remo
Figure 1-147 Remove the right cover assembly (2 of 4) ........................................................................... 94
Figure 1-148 Remove the right cover assembly (3 of 4) ........................................................................... 95
Figure 1-149 Remove the right cover assembly (4 of 4) ........................................................................... 95
Figure 1-150 Reinstall the right cover assembly: correct alignment ............................................................ 96
Figure 1-151 Reinstall the right cover assembly: incorrect alignment ......................................................... 96
Figure 1-152 Reinstall the right cover assembly ...................................................................................... 97
Figure 1-153 Remove the right handle cover and bracket (1 of 5) ............................................................. 98
Figure 1-154 Remove the right handle cover and bracket (2 of 5) ............................................................. 99
Figure 1-155 Remove the right handle cover and bracket (3 of 5) ............................................................. 99
ve the right cover assembly (1 of 4) ........................................................................... 93
xiv ENWW
Figure 1-156 Remove the right handle cover and bracket (4 of 5) ........................................................... 100
Figure 1-157 Remove the right handle cover and bracket (5 of 5) ........................................................... 100
Figure 1-158 Reinstall the right handle cover and bracket (1 of 2) .......................................................... 101
Figure 1-159 Remove the right handle cover and bracket (2 of 2) ........................................................... 101
Figure 1-160 Remove the deskew mylar and separation mylar (1 of 3) .................................................... 102
Figure 1-161 Remove the deskew mylar and separation mylar (2 of 3) .................................................... 102
Figure 1-162 Remove the deskew mylar and separation mylar (3 of 3) .................................................... 103
Figure 1-163 Remove the document feeder tray extender (1 of 2) ........................................................... 104
Figure 1-164 Remove the document feeder tray extender (2 of 2) ........................................................... 104
Figure 1-165 Remove the document feeder PCA ................................................................................... 105
Figure 1-166 Remove the document feeder jam-access cover (1 of 5) ...................................................... 106
Figure 1-167 Remove the document feeder jam-access cover (2 of 5) ...................................................... 106
Figure 1-168 Remove the document feeder jam-access cover (3 of 5) ...................................................... 107
Figure 1-169 Remove the document feeder jam-access cover (4 of 5) ...................................................... 107
Figure 1-170 Remove the document feeder jam-access cover (5 of 5) ...................................................... 108
Figure 1-171 Remove the document feeder roller cover (1 of 4) .............................................................. 109
Figure 1-172 Remove the document feeder roller cover (2 of 4) .............................................................. 109
Figure 1-173 Remove the document feeder roller cover (3 of 4) .............................................................. 110
Figure 1-174 Remove the document feeder roller cover (4 of 4) .............................................................. 110
Figure 1-175 Reinstall the document feeder roller cover ......................................................................... 111
Figure 1-176 Remove the scanner memory PCA (1 of 4) ........................................................................ 112
Figure 1-177 Remove the scanner memory PCA (2 of 4) ........................................................................ 112
Figure 1-178 Remove the scanner memory PCA (3 of 4) ........................................................................ 113
Figure 1-179 Remove the scanner memory PCA (4 of 4) ........................................................................ 114
Figure 1-180 Remove the document feeder cable (1 of 6) ...................................................................... 115
Figure 1-181 Remove the document feeder cable (2 of 5) ...................................................................... 116
Figure 1-182 Remove the document feeder cable (2 of 5) ...................................................................... 116
Figure 1-183 Remove the document feeder cable (3 of 5) ...................................................................... 117
Figure 1-184 Remove the document feeder cable (4 of 5) ...................................................................... 117
Figure 1-185 Remove the document feeder cable (5 of 5) ...................................................................... 118
Figure 1-186 Remove the document feeder whole unit (1 of 4) ............................................................... 119
Figure 1-187 Remove the document feeder whole unit (2 of 4) ............................................................... 119
Figure 1-188 Remove the document feeder whole unit (3 of 4) ............................................................... 120
Figure 1-189 R
Figure 1-190 Remove the image scanner (standard model) whole unit (1 of 6) ......................................... 122
Figure 1-191 Remove the image scanner (standard model) whole unit (2 of 6) ......................................... 123
Figure 1-192 Remove the image scanner (standard model) whole unit (3 of 6) ......................................... 123
Figure 1-193 Remove the image scanner (standard model) whole unit (4 of 6) ......................................... 124
Figure 1-194 Remove the image scanner (standard model) whole unit (5 of 6) ......................................... 124
Figure 1-195 Remove the image scanner (standard model) whole unit (6 of 6) ......................................... 125
Figure 1-196 Transfer the control-panel cable (1 of 7) ........................................................................... 125
emove the document feeder whole unit (4 of 4) ............................................................... 120
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Figure 1-197 Transfer the control-panel cable (2 of 7) ........................................................................... 126
Figure 1-198 Transfer the control-panel cable (3 of 7) ........................................................................... 126
Figure 1-199 Transfer the control-panel cable (4 of 7) ........................................................................... 127
Figure 1-200 Transfer the control-panel cable (5 of 7) ........................................................................... 127
Figure 1-201 Transfer the control-panel cable (6 of 7) ........................................................................... 128
Figure 1-202 Transfer the control-panel cable (7 of 7) ........................................................................... 128
Figure 1-203 Remove the ISA (525c model) whole unit (1 of 9) .............................................................. 130
Figure 1-204 Remove the ISA (525c model) whole unit (2 of 9) .............................................................. 131
Figure 1-205 Remove the ISA (525c model) whole unit (3 of 9) .............................................................. 131
Figure 1-206 Remove the ISA (525c model) whole unit (4 of 9) .............................................................. 132
Figure 1-207 Remove the ISA (525c model) whole unit (5 of 9) .............................................................. 132
Figure 1-208 Remove the ISA (525c model) whole unit (6 of 9) .............................................................. 133
Figure 1-209 Remove the ISA (525c model) whole unit (7 of 9) .............................................................. 133
Figure 1-210 Remove the ISA (525c model) whole unit (8 of 9) .............................................................. 134
Figure 1-211 Remove the ISA (525c model) whole unit (9 of 9) .............................................................. 134
Figure 1-212 Separate the ISA assemblies (525c model; 1 of 7) ............................................................ 135
Figure 1-213 Separate the ISA assemblies (525c model; 2 of 7) ............................................................ 135
Figure 1-214 Separate the ISA assemblies (525c model; 3 of 7) ............................................................ 136
Figure 1-215 Separate the ISA assemblies (525c model; 4 of 7) ............................................................ 136
Figure 1-216 Separate the ISA assemblies (525c model; 5 of 7) ............................................................ 137
Figure 1-217 Separate the ISA assemblies (525c model; 6 of 7) ............................................................ 137
Figure 1-218 Separate the ISA assemblies (525c model; 7 of 7) ............................................................ 138
Figure 1-219 Remove the document feeder hinge assembly ................................................................... 143
Figure 1-220 Remove the control-panel cable (1 of 2) ........................................................................... 144
Figure 1-221 Remove the control-panel cable (2 of 2) ........................................................................... 145
Figure 1-222 Remove the Tray 1 pickup roller (1 of 2) .......................................................................... 146
Figure 1-223 Remove the Tray 1 pickup roller (2 of 2) .......................................................................... 147
Figure 1-224 Remove the Tray 1 separation pad (1 of 2) ...................................................................... 148
Figure 1-225 Remove the Tray 1 separation pad (2 of 2) ...................................................................... 148
Figure 1-226 Tray 2, 3, or 4 pickup roller assembled ........................................................................... 149
Figure 1-227 Tr
Figure 1-228 Remove the Tray 2, 3, or 4 pickup roller (1 of 2) ............................................................... 150
Figure 1-229 Remove the Tray 2, 3, or 4 pickup roller (2 of 2) ............................................................... 151
Figure 1-230 Remove the Tray 2, 3, or 4 pickup roller (1 of 3) ............................................................... 152
Figure 1-231 Remove the Tray 2, 3, or 4 pickup roller (2 of 3) ............................................................... 152
Figure 1-232 Remove the Tray 2, 3, or 4 pickup roller (3 of 3) ............................................................... 153
Figure 1-233 Reassemble the Tray 2, 3, or 4 pickup roller assembly (1 of 9) ........................................... 153
Figure 1-234 Reassemble the Tray 2, 3, or 4 pickup roller assembly (2 of 9) ........................................... 154
Figure 1-235 Reassemble the Tray 2, 3, or 4 pickup roller assembly (3 of 9) ........................................... 154
Figure 1-236 Reassemble the Tray 2, 3, or 4 pickup roller assembly (4 of 9) ........................................... 155
Figure 1-237 Reassemble the Tray 2, 3, or 4 pickup roller assembly (5 of 9) ........................................... 155
ay 2, 3, or 4 pickup roller disassembled ....................................................................... 149
xvi ENWW
Figure 1-238 Reassemble the Tray 2, 3, or 4 pickup roller assembly (6 of 9) ........................................... 156
Figure 1-239 Reassemble the Tray 2, 3, or 4 pickup roller assembly (7 of 9) ........................................... 156
Figure 1-240 Reassemble the Tray 2, 3, or 4 pickup roller assembly (8 of 9) ........................................... 157
Figure 1-241 Reassemble the Tray 2, 3, or 4 pickup roller assembly (9 of 9) ........................................... 157
Figure 1-242 Reinstall the Tray 2, 3, or 4 pickup roller assembly (1 of 2) ................................................ 158
Figure 1-243 Reinstall the Tray 2, 3, or 4 pickup roller assembly (2 of 2) ................................................ 158
Figure 1-244 Remove the Tray 2, 3, or 4 separation pad ...................................................................... 159
Figure 1-245 Tray 2, 3, or 4 base plate roller assembly (1 of 2) ............................................................ 160
Figure 1-246 Tray 2, 3, or 4 base plate roller assembly (2 of 2) ............................................................ 160
Figure 1-247 Remove the transfer roller (1 of 3) ................................................................................... 161
Figure 1-248 Remove the transfer roller (2 of 3) ................................................................................... 161
Figure 1-249 Remove the transfer roller (3 of 3) ................................................................................... 162
Figure 1-250 Remove the fuser (1 of 4) ............................................................................................... 163
Figure 1-251 Remove the fuser (2 of 4) ............................................................................................... 164
Figure 1-252 Removing the fuser (3 of 4) ............................................................................................. 164
Figure 1-253 Removing the fuser (4 of 4) ............................................................................................. 165
Figure 1-254 Remove the duplex media-feed assembly (1 of 5) .............................................................. 166
Figure 1-255 Remove the duplex media-feed assembly (2 of 5) .............................................................. 167
Figure 1-256 Remove the duplex media-feed assembly (3 of 5) .............................................................. 167
Figure 1-257 Remove the duplex media-feed assembly (4 of 5) .............................................................. 168
Figure 1-258 Remove the duplex media-feed assembly (5 of 5) .............................................................. 168
Figure 1-259 Remove the registration roller assembly (1 of 3) ................................................................ 169
Figure 1-260 Remove the registration roller assembly (2 of 3) ................................................................ 169
Figure 1-261 Removing the registration roller assembly (3 of 3) .............................................................. 170
Figure 1-262 Remove the power-switch assembly .................................................................................. 171
Figure 1-263 Remove the Interlock switch assembly (1 of 3) ................................................................... 172
Figure 1-264 Remove the Interlock switch assembly (2 of 3) ................................................................... 173
Figure 1-265 Remove the Interlock switch assembly (3 of 3) ................................................................... 173
Figure 1-266 Remove the tray sensor PCA (1 of 3) ................................................................................ 174
Figure 1-267 Remove the tray sensor PCA (2 of 3) ................................................................................ 175
Figure 1-268 Remove the tray sensor PCA (3 of 3) ................................................................................ 175
Figure 1-269 Remove the main fan (1 of 3) .................................
Figure 1-270 Remove the main fan (2 of 3) .......................................................................................... 177
Figure 1-271 Remove the main fan (3 of 3) .......................................................................................... 177
Figure 1-272 Remove the top cover (1 of 4) ......................................................................................... 178
Figure 1-273 Remove the top cover (2 of 4) ......................................................................................... 179
Figure 1-274 Remove the top cover (3 of 4) ......................................................................................... 179
Figure 1-275 Remove the top cover (4 of 4) ......................................................................................... 180
Figure 1-276 Reinstall the top cover .................................................................................................... 180
Figure 1-277 Remove the laser scanner (1 of 5) ................................................................................... 181
Figure 1-278 Remove the laser scanner (2 of 5) ................................................................................... 182
......................................................... 176
ENWW xvii
Figure 1-279 Remove the laser scanner (3 of 5) ................................................................................... 182
Figure 1-280 Remove the laser scanner (4 of 5) ................................................................................... 183
Figure 1-281 Remove the laser scanner (5 of 5) ................................................................................... 183
Figure 1-282 Remove the tag holder assembly ..................................................................................... 184
Figure 1-283 Remove the DC controller (1 of 6) .................................................................................... 185
Figure 1-284 Remove the DC controller (2 of 6) .................................................................................... 186
Figure 1-285 Remove the DC controller (3 of 6) .................................................................................... 186
Figure 1-286 Remove the DC controller (4 of 6) .................................................................................... 187
Figure 1-287 Remove the DC controller (5 of 6) .................................................................................... 187
Figure 1-288 Remove the DC controller (6 of 6) .................................................................................... 188
Figure 1-289 Remove the LVPS (1 of 10) ............................................................................................. 190
Figure 1-290 Remove the LVPS (2 of 10) ............................................................................................. 190
Figure 1-291 Remove the LVPS (3 of 10) ............................................................................................. 191
Figure 1-292 Remove the LVPS (4 of 10) ............................................................................................. 191
Figure 1-293 Remove the LVPS (5 of 10) ............................................................................................. 192
Figure 1-294 Remove the LVPS (6 of 10) ............................................................................................. 192
Figure 1-295 Remove the LVPS (7 of 10) ............................................................................................. 193
Figure 1-296 Remove the LVPS (8 of 8) ............................................................................................... 193
Figure 1-297 Remove the LVPS (9 of 10) ............................................................................................. 194
Figure 1-298 Remove the LVPS (10 of 10) ........................................................................................... 194
Figure 1-299 Reinstall the LVPS .......................................................................................................... 195
Figure 1-300 Remove the Tray 2 paper pickup assembly (1 of 10) ......................................................... 197
Figure 1-301 Remove the Tray 2 paper pickup assembly (2 of 10) ......................................................... 197
Figure 1-302 Remove the Tray 2 paper pickup assembly (3 of 10) ......................................................... 198
Figure 1-303 Remove the Tray 2 paper pickup assembly (4 of 10) ......................................................... 198
Figure 1-304 Remove the Tray 2 paper pickup assembly (5 of 10) ......................................................... 199
Figure 1-305 Remove the Tray 2 paper pickup assembly (6 of 10) ......................................................... 199
Figure 1-306 Remove the Tray 2 paper pickup assembly (7 of 10) ......................................................... 200
Figure 1-307 Remove the Tray 2 paper pickup assembly (8 of 10) ......................................................... 200
Figure 1-308 Remove the Tray 2 paper pickup assembly (9 of 10) ......................................................... 201
Figure 1-309 Remove the Tray 2 paper pickup assembly (10 of 10) ....................................................... 201
Figure 1-310 Tray 1 or Tray 2 pickup solenoid (1 of 3) ......................................................................... 203
Figure 1-311 Tr
Figure 1-312 Tray 1 or Tray 2 pickup solenoid (3 of 3) ......................................................................... 204
Figure 1-313 Removing the fuser motor ............................................................................................... 206
Figure 1-314 Remove the pendulum assembly (1 of 4) .......................................................................... 208
Figure 1-315 Remove the pendulum assembly (2 of 4) .......................................................................... 208
Figure 1-316 Remove the pendulum assembly (3 of 4) .......................................................................... 209
Figure 1-317 Remove the pendulum assembly (4 of 4) .......................................................................... 209
Figure 1-318 Removing the sub fan and fan duct (1 of 5) ...................................................................... 211
Figure 1-319 Removing the sub fan and fan duct (2 of 5) ...................................................................... 211
ay 1 or Tray 2 pickup solenoid (2 of 3) ......................................................................... 203
xviii ENWW
Figure 1-320 Removing the sub fan and fan duct (3 of 5) ...................................................................... 212
Figure 1-321 Remove the sub fan and fan duct (4 of 5) ......................................................................... 212
Figure 1-322 Remove the sub fan and fan duct (5 of 5) ......................................................................... 213
Figure 1-323 Reinstall the sub fan (1 of 2) ........................................................................................... 214
Figure 1-324 Reinstall the sub fan (2 of 2) ........................................................................................... 214
Figure 1-325 Removing the environmental sensor (1 of 2) ...................................................................... 216
Figure 1-326 Removing the environmental sensor (2 of 2) ...................................................................... 216
Figure 1-327 Remove the HVPS (1 of 12) ............................................................................................ 218
Figure 1-328 Remove the HVPS (2 of 12) ............................................................................................ 218
Figure 1-329 Remove the HVPS (3 of 12) ............................................................................................ 219
Figure 1-330 R
Figure 1-331 R
Figure 1-332 R
Figure 1-333 R
Figure 1-334 R
Figure 1-335 R
Figure 1-336 Remove the HVPS (10 of 12) .......................................................................................... 222
Figure 1-337 R
Figure 1-338 R
Figure 1-339 R
Figure 2-1 Base
Figure 2-2 Base product (optional trays or accessories) .......................................................................... 235
Figure 2-3 Covers ............................................................................................................................. 236
Figure 2-4 Document feeder and scanner assemblies (525dn and 525f models) ....................................... 238
Figure 2-5 Document feeder and scanner assemblies (525c models) ....................................................... 240
Figure 2-6 Keyboard and brackets ...................................................................................................... 242
Figure 2-7 Control panel assembly ...................................................................................................... 244
Figure 2-8 ADF assemblies ................................................................................................................. 246
Figure 2-9 Scanner assemblies ........................................................................................................... 248
Figure 2-10 Internal assemblies (1 of 6) ............................................................................................... 250
Figure 2-11 Internal assemblies (2 of 6) ............................................................................................... 252
Figure 2-12 Internal as
Figure 2-13 Internal assemblies (4 of 6) ............................................................................................... 256
Figure 2-14 Internal assemblies (5 of 6) ............................................................................................... 258
Figure 2-15 Internal assemblies (6 of 6) ............................................................................................... 260
Figure 2-16 500-sheet input tray (Tray 3 and Tray 4) ............................................................................ 262
emove th
emove th
emove th
emove th
emove th
emove th
emove
emove
einstall the HVPS ......................................................................................................... 224
product (no optional trays or accessories) ..................................................................... 234
e HVPS (4 of 12) ............................................................................................ 219
e HVPS (5 of 12) ............................................................................................ 220
e HVPS (6 of 12) ............................................................................................ 220
e HVPS (7 of 12) ............................................................................................ 221
e HVPS (8 of 12) ............................................................................................ 221
e HVPS (9 of 12) ............................................................................................ 222
the HVPS (11 of 12) .......................................................................................... 223
the HVPS (12 of 12) .......................................................................................... 223
semblies (3 of 6) ............................................................................................... 254
ENWW xix
xx ENWW
1 Removal and replacement
Removal and replacement strategy
●
Service approach
●
Removal and replacement procedures
●
ENWW 1
Removal and replacement strategy
General cautions during removal and replacement
This chapter describes the removal and replacement of field-replaceable units (FRUs) only.
Replacing FRUs is generally the reverse of removal. Occasionally, notes and tips are included to
provide directions for difficult or critical replacement procedures.
not
HP does
WARNING! Turn the product off, wait 5 seconds, and then remove the power cable before
attempting to service the product. If this warning is not followed, severe injury can result, in addition to
damage to the product. The power must be on for certain functional checks during troubleshooting.
However, disconnect the power supply during parts removal.
Never operate or service the product with the protective cover removed from the laser scanner
assembly. The reflected beam, although invisible, can damage your eyes.
The sheet-metal parts can have sharp edges. Be careful when handling sheet-metal parts.
CAUTION: Do not bend or fold the flat flexible cables (FFCs) during removal or installation. Also, do
not straighten prefolds in the FFCs. You
an FFC into a connector can cause a short circuit in a PCA.
support repairing individual subassemblies or troubleshooting to the component level.
must
fully seat all FFCs in their connectors. Failure to fully seat
Incorrectly routed or loose wire harnesses can interfere with other internal components and can become
damaged or broken. Frayed or pinched harness wires can be difficult to find. When replacing wire
harnesses, always use the provided wire loops, lance points, or wire-harness guides and retainers.
NOTE: To install a self-tapping screw, first turn it counterclockwise to align it with the thread pattern,
and then carefully turn it clockwise to tighten. Do not overtighten. If a self-tapping screw-hole becomes
stripped, repair the screw-hole or replace the affected assembly.
Note the length, diameter, color, type, and location of each screw. Be sure to return each screw to its
original location during reassembly.
TIP: For clarity, some photos in this chapter might show components removed that would not be
removed to service the product. If necessary, remove the components listed at the beginning of a
procedure before proceeding to service the product.
Electrostatic discharge
CAUTION: Some parts are sensitive to electrostatic discharge (ESD). Look for the ESD reminder
when removing product parts. Always perform service work at an ESD-protected workstation or mat, or
use an ESD strap. If an ESD workstation, mat, or strap is not available, ground yourself by touching the
sheet-metal chassis
Protect the ESD-sensitive parts by placing them in ESD pouches when they are out of the product.
before
touching an ESD-sensitive part.
2 Chapter 1 Removal and replacement ENWW
Required tools
#2 Phillips 152 mm (6 in) screwdriver with magnetic tip
●
#2 Phillips 76 mm (3 in) screwdriver with magnetic tip
●
Small flat blade screwdriver
●
Small needle-nose pliers
●
ESD mat
●
Penlight
●
CAUTION: Always use a Phillips screwdriver (callout 1). Do not use a Pozidriv® screwdriver
(callout 2) or any motorized screwdriver. These can damage screws or screw threads.
Figure 1-1 Phillips and Pozidriv screwdriver comparison
Types of screws
NOTE: The illustration in this section are for reference only. The screws in your product might look
slightly different.
Illustration Description Size Part number Use
Screw with washer M3X6 XB2-7300-000CN Used to secure metal
components to metal
components (for
example, a ground
wire to the frame)
Screw, tapping M3X6 XA9-1503-000CN
Screw D-M3X6 XA9-1671-000CN
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Removal and replacement strategy
3
Screw P-M3X8 XB4-5300-807CN
Screw, tapping, truss
head
M4X10 XB4-7401-005CN Used to secure
anything to plastic
4 Chapter 1 Removal and replacement ENWW
Service approach
Product repair normally begins by using the product internal diagnostics and the following two-step
process:
1. Isolate the problem to the major system (for example, the network or server, or the product).
2. Troubleshoot the problem by using the procedures in the solve problems chapter.
After you find a faulty part, the product can usually be repaired at the assembly level by replacing fieldreplaceable units (FRUs). Some mechanical assemblies might need to be repaired at the subassembly
level.
Before performing service
Remove all paper from the product.
●
Turn off the power using the power switch.
●
Disconnect the power cable and interface cable or cables.
●
Place the product on an ESD workstation or mat, or use an ESD strap (if one is available). If an
●
ESD workstation, mat, or strap is not available, ground yourself by touching the sheet-metal
before
chassis
touching an ESD-sensitive part.
Remove the toner cartridges. See
●
Remove the tray or trays. See
●
After performing service
Connect the power cable.
●
Reinstall the toner cartridges.
●
Reinstall the tray or trays.
●
If an optional paper feeder was installed, place the product on the feeder.
●
Post-service test
Perform the following test to verify that the repair or replacement was successful.
Print-quality test
1. Verify that you have completed the necessary reassembly steps.
2. Make sure that the tray contains clean, unmarked paper.
Toner cartridge on page 12.
Tray 2, Tray 3, or Tray 4 assembly on page 14.
ENWW
3. Attach the power cable and interface cable or interface cables, and then turn on the product.
4. Verify that the expected start-up sounds occur. The fans start.
Service approach
5
5. Print a configuration page, and then verify that the expected printing sounds occur. The fans start
and the rollers turn.
6. Print a demo page, and then verify that the print quality is as expected.
7. Send a print job from the host computer, and then verify that the output meets expectations.
8. If necessary, restore any customer-specified settings.
9. Clean the outside of the product with a damp cloth.
6 Chapter 1 Removal and replacement ENWW
Location of connectors
DC controller connections
Figure 1-2 DC controller connections
J2400
J2103J2104 J2102
J2704
J2703
J2311
J2301
J2302
J2310
J2306
J2105
J2307
J2304
J2702
FT1
FT2
J2308 J2401 J2303
J2100
J2201
J2701
J2700
J2200
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Item Description Item Description Item Description
J2100 Not used J2302 MPT media out
sensor (PS205)
J2102 Fuser motor
(M8002)
J2103 Main motor
(M8003)
J2303 Face-up sensor
(PS1)
Output bin full
sensor (PS4)
J2304 Environmental
sensor (TH3)
J2400 Fuser output sensor
(PS2)
TH1/TH2
J2401
J2700 LVPS
Service approach
7
Item Description Item Description Item Description
J2104 Subfan (FM2)
Rear door sensor
(PS8001)
Scanner motor
(M3)
J2105 Power switch
(SW240)
J2200 HVPS J2308 Main fan (FM1) J2703 Cartridge door
J2201 Paper feeder
connector
J2301 CST media out
sensor (PS3)
J2306 Interlock switch
(SW260)
J2307 Tray detection
switch (SW235)
J2310 CST pickup
solenoid (SL2)
J2311 MPT pickup
solenoid (SL1)
J2701 LVPS
J2702 LVPS
switch (SW501)
J2704 Cartridge door
switch (SW501)
8 Chapter 1 Removal and replacement ENWW
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