HP m521 Repair Manual

LASERJET PRO MFP

Repair Manual

M521

HP LaserJet Pro MFP M521 Printer

Repair Manual

Trademark Credits

, Acrobat®, and PostScript® are

Adobe trademarks of Adobe Systems Incorporated.

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

The information contained herein is subject to change without notice.

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

Edition 1, 12/2012

Part number: A8P79-90904

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 ...................................................................................... 11

Customer self repair (CSR) assemblies ....................................................................... 11

Toner cartridge ........................................................................................ 11

Tray 2 or Tray 3 assembly ......................................................................... 13

Document feeder rollers ............................................................................ 14

Document feeder pickup roller .................................................... 14

Document feeder separation roller ............................................... 16

Document feeder separation pad ............................................................... 17

External panels, covers, doors, and formatter ............................................................. 18

Formatter cover ........................................................................................ 18

Formatter PCA ......................................................................................... 19

Fax PCA and cable .................................................................................. 20

Interconnect board (ICB) ........................................................................... 21

Formatter stay .......................................................................................... 22

Dummy cover .......................................................................................... 23

Rear cover assembly ................................................................................. 24

Left cover ................................................................................................ 28

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Right-rear cover ........................................................................................ 30

Tray 1 cover ............................................................................................ 32

Cartridge-door assembly ........................................................................... 34

Right cover assembly ................................................................................ 36

Lower right cover ..................................................................................... 41

Reinstall the lower right cover ..................................................... 43

I/O plate ................................................................................................ 44

Document feeder assemblies and scanner .................................................................. 46

Document feeder/scanner assembly ........................................................... 46

Document feeder whole unit kit and scanner whole unit kit ............................ 52

Document feeder hinge assembly ............................................................... 57

Control-panel top-cover ............................................................................. 57

Control-panel assembly ............................................................................. 59

USB PCA ................................................................................................ 60

Control-panel FFC .................................................................................... 61

USB cable and USB grounding cable ......................................................... 64

Wi-Fi module and cable ............................................................................ 67

Main assemblies ..................................................................................................... 71

Tray 1 pickup roller .................................................................................. 71

Tray 1 separation pad .............................................................................. 73

Tray 2 or Tray 3 pickup roller .................................................................... 74

Tray 2 or Tray 3 separation pad ................................................................ 76

Tray 2 or Tray 3 base-plate roller assembly ................................................. 76

Transfer roller .......................................................................................... 78

Fuser ...................................................................................................... 80

Duplex paper-feed assembly ...................................................................... 83

Registration roller assembly ....................................................................... 86

Power-switch assembly .............................................................................. 88

Interlock-switch assembly ........................................................................... 89

Tray sensor PCA ...................................................................................... 91

Main fan ................................................................................................. 93

Top cover ................................................................................................ 95

Laser scanner ........................................................................................... 98

Tag holder assembly ............................................................................... 101

DC controller ......................................................................................... 102

Low-voltage power supply (LVPS) .............................................................. 106

Tray 2 paper pickup assembly ................................................................. 112

Tray 1 or Tray 2 pickup solenoid ............................................................. 118

Fuser motor ........................................................................................... 120

Pendulum assembly ................................................................................ 121

Sub fan and fan duct .............................................................................. 124

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Environmental sensor .............................................................................. 128

High-voltage power supply (HVPS) ........................................................... 130

2 Parts and diagrams ...................................................................................................... 139

Order parts by authorized service providers ............................................................................ 140

Order parts, accessories, and supplies .................................................................... 140

Supplies part numbers ........................................................................................... 140

Customer self-repair (CSR) and service kits ............................................................... 141

Related documentation and software ...................................................................................... 142

Fasteners used in this product ................................................................................................ 142

How to use the parts lists and diagrams .................................................................................. 143

Assembly locations ............................................................................................................... 143

Base product (no optional trays or accessories) ......................................................... 143

Base product (optional trays or accessories) ............................................................. 144

Covers ................................................................................................................................ 146

Document feeder and scanner assemblies ............................................................................... 148

Control-panel and USB PCA assemblies .................................................................................. 150

Document feeder assemblies .................................................................................................. 152

Internal assemblies (1 of 6) ................................................................................................... 154

Internal assemblies (2 of 6) ................................................................................................... 156

Internal assemblies (3 of 6) ................................................................................................... 158

Internal assemblies (4 of 6) ................................................................................................... 160

Internal assemblies (5 of 6) ................................................................................................... 162

Internal assemblies (6 of 6) ................................................................................................... 164

Input devices ....................................................................................................................... 166

500-sheet input tray (Tray 3) .................................................................................. 166

Alphabetical parts list ........................................................................................................... 168

Numerical parts list .............................................................................................................. 172

Index ............................................................................................................................... 177

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viii ENWW

1 Removal and replacement

Removal and replacement strategy

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Service approach

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Removal and replacement procedures

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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.

HP does not support repairing individual subassemblies or troubleshooting to the component level.

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 must fully seat all FFCs in their connectors. Failure to fully seat an FFC into a connector can cause a short circuit in a PCA.

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 before touching an ESD-sensitive part.

Protect the ESD-sensitive parts by placing them in ESD pouches when they are out of the product.

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-tip 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 M3X6 0515-2908 Used to secure metal

components to metal components (for example, a ground wire to the frame)

Screw M3X8 0515-4681

Screw, tapping P-M3X6 0515-5621

Screw, tapping, truss head

M4X14 0515-4672 Used to secure

anything to plastic

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Removal and replacement strategy

14 mm

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, the server, or the product).

2. Troubleshoot the problem by using the procedures in the solve problems chapter of the

Troubleshooting Manual.

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 chassis before 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 11.

Tray 2 or Tray 3 assembly on page 13.

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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. 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.

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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 paper 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

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 switch

J2201 Paper feeder

connector

J2301 CST paper 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

(SW501)

J2704 Cartridge door switch

(SW501)

8 Chapter 1 Removal and replacement ENWW

Formatter connections

TAZ

Figure 1-3 Formatter connections

J18 WIFI

J17 THUMB

J19

J21 ADF SCAN

SCANNER

J20

J27

POWER

J24 SNAPPER FAX

J22 ADF MOTOR

J8 LAN

J16 USB DEVICE

Item Description Item Description

J3 Control panel J19 Flatbed scanner

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J7 Power J20 Flatbed motor

J8 LAN J21 ADF/Scanner

J16 USB Device J22 ADF motor

J17 USB J24 Snapper Fax

J18 Wifi J27 Video

Service approach

Parts removal order

Figure 1-4 Parts removal order: covers and customer-replaceable assemblies

1. covers and customer replaceable assemblies

Assembly

Toner cartridge Tray2,3 Formatter cover Formatter PCA ICB Fax card and cable Dummy cover Rear cover assy Left cover Right-rear cover Tray 1 cover Cartridge-door assy

Right cover Lower right cover

Top cover

I/O Plate

ADF pickup & separation roller

2. ADF/Scanner assembly

Assembly

Control Panel top cover

Control Panel sub cover

Control Panel Control Panel

USB PCA

Control Panel FFC cable

USB cable & grounding cable

Wifi module and cable

ADF whole unit

Scanner whole unit

ADF hinge assembly

3. Main assemblies

Assembly

Tray 1 pickup roller

Tray 1 separation pad

Tray 2, 3 pickup roller

Tray 2, 3 separation pad

Tray 2, 3 base-plate roller assy

Transfer roller

Fuser

Duplex media-feed assy

Registration roller assy

Power-switch assy Interlock switch assy Tray sensor PCA Main fan DC controller

Top cover Laser scanner Tag holder assy

LVPS (Low-voltage power supply)

Tray 1, 2 pickup solenoid

Fuser motor Pendulum assy Sub fan and fan duct

Environmental sensor

Tray 2 paper pickup

HVPS

Remove

Formatter cover Formatter cover Formatter cover Formatter cover

Rear cover assy Formatter cover

Rear cover assy

Formatter cover Dummy cover Rear cover assy Left cover

Formatter cover

Remove Remove

Control Panel top cover

top cover

Control Panel top cover

Formatter cover

Dummy cover

Rear cover assy

Left cover

ADF/Scanner assy

Remove Remove

Rear cover assy Right-rear cover

Rear cover assy

Rear cover assy Left cover

Formatter cover

Dummy cover

Rear cover assy

Left cover

Formatter cover

Dummy cover

Rear cover assy

Left cover

Right-rear cover

Tray 1 cover

Cartridge-door assy

Remove

Rear cover assy

Left cover Tray 1 cover

Tray 1 cover (could choose not remove)

ADF/Scanner assy

Formatter PCA ICB Fax card

Control Panel sub cover

USB bracket (sheet metal)

Scanner lower cover

Scanner rear cover

Right-rear cover

Tray 1 cover Tray 1 cover Tray 1 cover Tray 1 cover Tray 1 cover

ADF/Scanner assy ADF/Scanner assy ADF/Scanner assy

Right cover

Right cover Right cover Right cover

Right cover

Duplex media-feed assy

Remove

Cartridge-door assy (could choose not remove, only open)

Formatter Stay (sheet metal)

Remove Remove

Control Panel top cover

Remove Remove

Cartridge-door assy Cartridge-door assy Cartridge-door assy Cartridge-door assy Cartridge-door assy

Top cover

Lower right cover

Lower right cover Lower right cover Lower right cover

Lower right cover

Right cover

Remove

ADF/Scanner assy ADF/Scanner assy

I/O Plate assembly

Control Panel sub cover

Right cover Right cover Right cover Right cover Right cover Lower right cover

ADF/Scanner assy

ADF/Scanner assy ADF/Scanner assy ADF/Scanner assy

ADF/Scanner assy

Lower right cover

Remove

Right cover

Remove

(if removing sheet metal plate)

Top cover

Top cover Top cover Top cover

Top cover

ADF/Scanner assy

Remove

DC controller

DC controller DC controller LVPS Fuser motor DC controller

DC controller with plate

Top cover

Remove Remove

LVPS

DC controller

LVPS

10 Chapter 1 Removal and replacement ENWW

Removal and replacement procedures

Customer self repair (CSR) assemblies

Toner cartridge

CAUTION: If toner gets on your clothing, wipe it off with a dry cloth and wash clothing in cold

water. Hot water sets toner into fabric.

1. Press the cartridge-door release button, and then open the cartridge door. Make sure that the door

is completely open.

Figure 1-5 Remove the toner cartridge (1 of 2)

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Removal and replacement procedures

2. Grasp the toner-cartridge handle and pull it out of the product.

CAUTION: Do not touch the green roller. Doing so can damage the cartridge. Do not expose

the cartridge to strong light. Cover the cartridge with a sheet of paper to protect it from light.

Reinstallation tip Align the toner cartridge with its slot and insert the toner cartridge until it

clicks into place.

Figure 1-6 Remove the toner cartridge (2 of 2)

12 Chapter 1 Removal and replacement ENWW

Tray 2 or Tray 3 assembly

NOTE: Use this procedure to remove the Tray 2 or Tray 3 assembly.

Pull the tray straight out of the product until it stops. Carefully lift up on the tray to release it, and

▲

then remove the tray.

Figure 1-7 Remove the tray

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Removal and replacement procedures

Document feeder rollers

Document feeder pickup roller

CAUTION: Do not touch the surface of the roller. Skin oils deposited on the roller might cause print-

quality problems.

NOTE: If you did not remove Tray 2 or 3 before servicing the product, remove them now.

1. Carefully place the product front-side up, so that you can see into the opening where the tray

would be installed.

NOTE: Debris can scratch or damage the back of the product. Before you place the product

front-side up, remove any debris from the work surface. If possible, set the product on a clean, dry cloth to prevent scratching and damage.

2. Open the document feeder cover.

Figure 1-8 Remove the document feeder pickup roller (1 of 2)

14 Chapter 1 Removal and replacement ENWW

3. Release one tab, and then rotate the roller out and away from the product to remove it.

TIP: It might be easier to release the tab by using a small flat-tip screwdriver.

Figure 1-9 Remove the document feeder pickup roller (2 of 2)

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Removal and replacement procedures

Document feeder separation roller

CAUTION: Do not touch the surface of the roller. Skin oils deposited on the roller might cause print-

quality problems.

1. Open the document feeder cover.

Figure 1-10 Remove the document feeder separation roller (1 of 2)

2. Release one tab, and then rotate the roller out and away from the product to remove it.

TIP: It might be easier to release the tab by using a small flat-tip screwdriver.

Figure 1-11 Remove the document feeder separation roller (2 of 2)

16 Chapter 1 Removal and replacement ENWW

Document feeder separation pad

CAUTION: Do not touch the surface of the pad. Skin oils deposited on the roller might cause paper-

handling problems.

1. Open the document feeder cover.

Figure 1-12 Remove the document feeder separation pad (1 of 2)

2. Press down on the document feeder separation pad to release the pad, and then remove the

separation pad.

Figure 1-13 Remove the document feeder separation pad (2 of 2)

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Removal and replacement procedures

External panels, covers, doors, and formatter

Formatter cover

Slide the formatter cover toward the rear of the product to remove.

▲

Figure 1-14 Remove the formatter cover

18 Chapter 1 Removal and replacement ENWW

Formatter PCA

WARNING! ESD sensitive component.

1. Before proceeding, remove the following:

Formatter cover. See

●

2. Disconnect 10 cables/FFCs (M521dw) or 9 cables/FFCs (M521dn).

NOTE: To locate the formatter connector locations, see Formatter connections on page 9.

Figure 1-15 Remove the formatter PCA (1 of 2)

Formatter cover on page 18.

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3. Remove five screws and then carefully remove the formatter PCA.

Figure 1-16 Remove the formatter PCA (2 of 2)

Removal and replacement procedures

Fax PCA and cable

WARNING! ESD sensitive component.

1. Before proceeding, remove the following:

Formatter cover. See

●

2. Disconnect one connector on the fax PCA.

Figure 1-17 Remove the fax PCA and cable (1 of 2)

3. Remove four screws, and then remove the fax PCA from the product.

Formatter cover on page 18.

Figure 1-18 Remove the fax PCA and cable (2 of 2)

20 Chapter 1 Removal and replacement ENWW

+ 160 hidden pages