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HP COLOR LASERJET CP5220SERIES PRINTER Service Manual
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HP Color LaserJet CP5220 Series PrinterService Manual
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Copyright and License© 2009 Copyright Hewlett-PackardDevelopment Company, L.P.Reproduction, adaptation, or translationwithout prior written permission is prohibited,except as allowed under the copyright laws.The information contained herein is subjectto change without notice.The only warranties for HP products andservices are set forth in the express warrantystatements accompanying such productsand services. Nothing herein should beconstrued as constituting an additionalwarranty. HP shall not be liable for technicalor editorial errors or omissions containedherein.Part number: CE710-90910Edition 1, 9/2009Trademark CreditsAdobe®, Acrobat®, and PostScript® aretrademarks of Adobe Systems Incorporated.Corel® is a trademark or registeredtrademark of Corel Corporation or CorelCorporation Limited.Microsoft®, Windows®, Windows® XP, andWindows Vista® are U.S. registeredtrademarks of Microsoft Corporation.UNIX® is a registered trademark of The OpenGroup.ENERGY STAR and the ENERGY STARmark are registered U.S. marks.
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Table of contents1 Theory of operationBasic operation ..................................................................................................................................... 2Major product systems ......................................................................................................... 2Product block diagram ......................................................................................................... 2Sequence of operation ......................................................................................................... 3Normal sequence of operation ............................................................................ 3Formatter-control system ..................................................................................................................... 5Sleep mode .......................................................................................................................... 5Input/output .......................................................................................................................... 5CPU ..................................................................................................................................... 6Memory ................................................................................................................................ 6Firmware ............................................................................................................. 6Nonvolatile memory ............................................................................................ 6PJL overview ....................................................................................................................... 6PML ..................................................................................................................................... 6Control panel ....................................................................................................................... 6Engine-control system .......................................................................................................................... 7DC controller ........................................................................................................................ 8Motors ............................................................................................................... 11Fans .................................................................................................................. 13Fuser-control circuit ........................................................................................... 14Fuser temperature control ................................................................ 15Fuser protective function .................................................................. 16Fuser failure detection ...................................................................... 17Low-voltage power supply ................................................................................. 18Overcurrent/overvoltage protection .................................................. 20High-voltage power supply ................................................................................ 21Laser scanner system ........................................................................................................ 23Laser failure detection ....................................................................................... 24Image-formation system ..................................................................................................................... 25Electrophotographic process ............................................................................................. 25Image formation process ................................................................................................... 27Latent-image formation block ............................................................................ 28Pre-exposure .................................................................................... 28ENWWiii
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Primary charging .............................................................................. 28Laser beam exposure ....................................................................... 29Developing block ............................................................................................... 30Transfer block ................................................................................................... 31Primary transfer ................................................................................ 31Secondary transfer ........................................................................... 31Separation ........................................................................................ 32Fusing block ...................................................................................................... 32ITB cleaning block ............................................................................................. 33Drum cleaning block .......................................................................................... 33Print cartridges ................................................................................................................... 34Memory tag ....................................................................................................... 35Cartridge presence detection ............................................................................ 35Toner level detection ......................................................................................... 35Cartridge life detection ...................................................................................... 35Developing unit engagement and disengagement control ................................ 35ITB unit .............................................................................................................................. 37Primary transfer roller engagement and disengagement control ...................... 38ITB unit presence detection .............................................................................. 39ITB cleaning mechanism ................................................................................... 39Calibration .......................................................................................................................... 40Color-misregistration control ............................................................................. 40Environment change control ............................................................................. 41Image stabilization control ................................................................................. 41Image density control (DMAX) .......................................................... 42Image halftone control (DHALF) ....................................................... 42Pickup, feed, and delivery system ...................................................................................................... 43Photo sensors .................................................................................................................... 44Motors and solenoids ......................................................................................................... 45Pickup and feed block ........................................................................................................ 45Cassette pickup ................................................................................................. 45Cassette multiple-feed prevention ..................................................................... 46Tray 1 (MP tray) paper pickup ........................................................................................... 47Tray 1 (MP tray) last-paper detection ................................................................................ 48Paper feed ......................................................................................................................... 49Skew-feed prevention ....................................................................................... 50Feed-speed control ........................................................................................... 51Fusing and delivery block .................................................................................................. 52Loop control ...................................................................................................... 52Pressure roller pressurization and depressurization control ............................. 53Output bin full detection .................................................................................... 55Duplex block (duplex models only) .................................................................................... 56Jam detection .................................................................................................................... 57Paper feeder ....................................................................................................................................... 59ivENWW
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Paper-feeder motors .......................................................................................................... 60Paper-feeder paper pickup and feed ................................................................................. 61Paper-feeder cassette lift operation ................................................................................... 61Paper-feeder jam detection ............................................................................................... 622 Removal and replacementIntroduction ......................................................................................................................................... 64Removal and replacement strategy ................................................................................................... 65Electrostatic discharge ....................................................................................................................... 66Required tools ................................................................................................................................... 67Service approach ............................................................................................................................... 68Before performing service .................................................................................................. 68After performing service ..................................................................................................... 68Post-service test ................................................................................................................ 68Print-quality test ................................................................................................ 68Removal and replacement procedures .............................................................................................. 69Customer self repair (CSR) components ........................................................................... 69Print cartridges .................................................................................................. 69Toner-collection unit .......................................................................................... 72Memory DIMM ................................................................................................... 74Product memory ............................................................................... 74Install memory and font DIMMs ........................................................ 74Enable memory ................................................................................ 78Check DIMM installation ................................................................... 78Fuser ................................................................................................................ 79Pickup roller (Tray 1) ......................................................................................... 80Separation pad (Tray 1) .................................................................................... 81Separation roller assembly (Tray 2) .................................................................. 82Pickup roller (Tray 2) ......................................................................................... 84Pickup roller, separation roller, and feed roller (Tray 3) .................................... 85Secondary transfer roller ................................................................................... 86Intermediate transfer belt (ITB) ......................................................................... 87External panels, covers, and doors ................................................................................... 89Identification and location .................................................................................. 89Right-front cover and control-panel assembly ................................................... 90Left cover .......................................................................................................... 92Rear cover ......................................................................................................... 93Remove the rear cover ..................................................................... 93Toner collection unit access door ...................................................................... 93Right-rear cover ................................................................................................ 95Top cover .......................................................................................................... 96Remove the top cover ...................................................................... 96Front-door assembly ......................................................................................... 98ENWWv
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Right-door assembly ....................................................................................... 102Internal assemblies .......................................................................................................... 104Laser scanner assembly ................................................................................. 105Remove the laser scanner assembly ............................................. 105Cassette pickup drive assembly ...................................................................... 108Remove the cassette pickup drive assembly ................................. 108Registration sensor assembly ......................................................................... 112Remove the registration sensor assembly ..................................... 112Lifter-drive assembly ....................................................................................... 115Remove the lifter-drive assembly ................................................... 115ITB front guide assembly ................................................................................ 117ITB rear guide assembly ................................................................................. 119Residual toner full sensor ............................................................................... 120Remove the residual toner full sensor ............................................ 121Formatter case ................................................................................................ 123Delivery assembly ........................................................................................... 124Remove the delivery assembly ....................................................... 124Duplex drive assembly (duplex models) ......................................................... 127Remove the duplex-drive assembly ............................................... 127Delivery drive assembly (simplex models) ...................................................... 129Remove the delivery drive assembly .............................................. 129Residual-toner-feed assembly ........................................................................ 130Remove the residual-toner-feed assembly ..................................... 130ITB motor ........................................................................................................ 132Remove the ITB motor ................................................................... 132Drum motor ..................................................................................................... 134Remove the drum motor ................................................................. 134Developing motor ............................................................................................ 135Remove the developing motor ........................................................ 135Fuser motor ..................................................................................................... 136Remove the fuser motor ................................................................. 136Developing-disengagement motor .................................................................. 137Remove the developing-disengagement motor .............................. 137Power-supply fan ............................................................................................ 139Remove the power-supply fan ........................................................ 139Fuser fan ......................................................................................................... 142Remove the fuser fan ..................................................................... 142Formatter PCA ................................................................................................ 144Formatter resets ............................................................................. 144DC controller PCA ........................................................................................... 146Remove the DC controller PCA ...................................................... 146Low-voltage power supply ............................................................................... 148Remove the low-voltage power supply ........................................... 148Imaging (developing) high-voltage power supply ............................................ 152viENWW