CP3525 59.F0 error

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HP CP3525dn – successful repair following 59.F0 error message – replacement of the Fuser Drive Gear Assembly

History of this problem:

Having encountered the 59.F0 error in my original printer, I attempted to repair the fault by accessing and adapting the solenoid, as discussed in: https://www.metrofuser.com/post/hp-color-laserjet-cp3525-cp4525-cm4540-59-f0-error-code This repair attempt was time consuming and failed, but it did spur my interest in trying to figure out why. I also bought a few other secondhand machines displaying the same fault.

I then purchased this duplex machine in full working order with no history of 59.F0 error messages. This machine had printed about 60,000 pages while the other faulty machine typically had a print history of over 80,000 pages.

While investigating the situation, I swapped the intermediate transfer belt from one of the other machines with the working machine – but inadvertently this caused the working machine to develop the 59.F0 fault, which was quite annoying.

My analysis of this situation is that the new fault was probably not related to a sticking solenoid since the machine was working fine previously. This suggests that an old transfer belt from a faulty machine placed too much strain on the fuser drive gear assembly and thus created a mechanical rather than an electrical problem.

Solution to the problem:

Given the time consuming nature of this repair, my choice was to replace the entire fuser drive gear assembly (part number for a duplex machine) with a new model. This was ordered from China, arrived a few weeks later and has just been installed (after another patient time consuming disassembly and re-assembly process).

RESULT: The duplex machine now works perfectly again. Yeah!

Visual summary of repair steps – will upload this separately

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Diagrams and comments:

Figure 1 - Disassembled printer prior to part replacement - no comments

Figure 2: Side by side comparison - Outer view - no comments

Figure 3: Side by side comparison - Edge view, bottom - highlight similar evidence at gear matching, small difference in movable hinge point

Figure 4: Side by side comparison - Edge view, top  - note difference in solenoid base spring tension (but I may have accidentally damaged this myself in the initial repair attempt)

Summary: There were very few visual clues indicating a difference between the faulty old part and the new replacement part. On rotating the NIDEC motor by hand, one can cause the gears to spin and mesh with one another in a logical sequence. The solenoid motor performs an essential function in manipulating a spring-loaded metal lever which may be important in regulating this logical sequence, by inhibiting rotation of the alienation drive hub that should move the intermediate transfer belt (when the device is working properly). If I get another chance to carry out this repair I will take a closer look at this.

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Close-up of twin gears regulated by the solenoid's magnetised arm - barely visible in the lower oval highlighter shape. Note that there are two large gears which appear out of sync in the faulty assembly (pictured above in the upper oval highlighter shape). In the working assembly, both of these gears were perfectly in sync at all times.

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CP3525 CM3530 and CP4025 Fuser Drive Duplex Simplex Conversion RM1-5001 RM1-4974 Service Note (metro...

This article from Metrofuser provides detail on the differences between the fuser driver assembly parts available for CP3525.

I have also now ordered a replacement solenoid (not the full fuser driver assembly), which is a much cheaper attempt to effect a repair. Will report back once this second repair attempt gets completed.

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Where did you get the solenoid and did just that solve the problem? I took my printer out of duplex mode, and it prints fine. I want duplex back. Where did you get the whole assembly and are you happy with it?

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I purchased a used solenoid from eBay, which came from a Dell printer. It had a part number of TDS-F06B-10C. Unfortunately, while the body of the solenoid was identical to the part that I needed, the suffix "10C" turned out to mean a different base and spring. Thus, replacing the solenoid was not practical.

On reflection, I also decided that stripping the machine down and re-assembling it was extremely time consuming. I therefore abandoned the replacement solenoid route and chose instead to purchase an entire new fuser drive assembly (see previous posts for part numbers, which differ between simplex and duplex). I bought this (a duplex model) from China via AliExpress for about $40 plus delivery.

Before installing the new duplex fuser drive assembly, I scrutinised the new assembly next to the old assembly (see photos). I could not see any obvious mechanical difference. There was a subtle difference in the solenoid spring, but I may have inadvertently stretched this when removing the faulty assembly.

Front view (new assembly to the left)Rear view (new assembly to the left)Top viewBottom viewAnother bottom viewSide view of repair

On replacing the whole assembly, the printer sprang back into life and has been working well ever since. There are some streaks on the page, but I have not yet had time to clean the rollers. I am very happy with this repair job. Since I have built up a small collection of these printers (5 in all), I want to get more of them working.

Apart from the "repair-it-yourself" scenario, I also discovered that the second hand market (i.e. eBay) often features HP Cp3525 printers for sale. Many have the 59.F0 error, but some do not. If you are lucky, you may be able to replace your faulty machine with a fully working substitute. This does, however, require luck and patience.