HP 2500 L Service Manual

							EN 5 Removal and replacement119
Density sensor and top-of-page sensor 
1Remove the following covers:
right- and left-side covers (see page 93)
 front cover (see page 118)
2 Press the tab (callout 1) on the sensor cover to release the cover, and then lift the cover up 
and away from the printer.
Figure 66. Removing the density sensor cover
3Unplug one connector (callout 2).
4 Remove the two screws (callout 3).
5 Lift the density sensor straight up to remove it from the printer.
6 Unplug one connector (callout 4) from the top-of-page sensor.
7 Remove one screw (callout 5) and then lift the top-of-page sensor straight up and away from 
the printer.
Figure 67. Removing the density sensor
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							120Removal and replacement C9706-90926
E-label reader (for imaging-drum E-labels)
1Remove the following covers and assemblies:
right- and left-side covers (see page 93)
 interface cover (see page 98)
 formatter cage (see page 99)
 front cover (see page 118).
2 Use the small flatblade screwdriver to lift two tabs, one on each side of the E-label reader 
housing.
3 Slide the E-label reader off of its rails.
Figure 68. Removing the E-label reader (1 of 2)
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							EN 5 Removal and replacement121
4
Unplug the E-label reader connector (callout 2) from the dc controller.
Note Examine the cable routing as you lift the E-label reader from the printer.
Figure 69. Removing the E-label reader (2 of 2)
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							122Removal and replacement C9706-90926
Tray 1 (multipurpose tray)
1Remove the following covers:
right- and left-side covers (see page 93)
 front lower cover (see page 109)
2 Open tray 1.
3 Press the multipurpose-roller cover (not shown) inward toward the printer, and then grasp 
the top edge to remove it.
4 Lift tray 1 slightly to align the notch (callout 1) in the tray 1 cover (callout 2) with the hinge 
pins of the tray 1 hinges (callout 3).
5 Push the left tray 1 hinge to the right while pulling the tray 1 cover to the left to carefully 
disengage the hinge pin from the tray 1 cover.
6 Disengage the right tray 1 hinge (callout 4) from the tray 1 cover.
7 Close the tray 1 guide (callout 5), open the tray 1 cover, and then slide the tray 1 cover to the 
left to remove it from its pins.
Figure 70. Removing tray 1 (1 of 2)
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							EN 5 Removal and replacement123
8
Disengage the left and right hinges from the tray 1 guide and then slide both of the hinges off 
of their keyed holes (callout 6) in the printer.
9 Use needle-nose pliers to unhook two springs (callout 7), one at each side of the tray 1 
guide, and then remove the tray 1 guide.
Figure 71. Removing tray 1 (2 of 2)
Reinstall note
The two springs should remain attached to two pegs inside the printer. If the springs are not 
attached, use needle-nose pliers to reattach them before reinstalling the tray 1 guide.
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							124Removal and replacement C9706-90926
Tray 1 separation pad assembly
1Remove tray 1 (see page 122).
2 Remove one screw (callout 1) from the separation pad assembly, and then remove the 
separation pad assembly.
Figure 72. Removing the tray 1 separation pad assembly
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							EN 5 Removal and replacement125
Gear assembly
1Remove the following covers and assemblies:
right- and left-side covers (see page 93)
 interface cover (see page 98)
 formatter cage (see page 99)
 back cover (see page 110)
 top cover (see page 111)
2 Disconnect one connector (callout 1, hidden —it is the connector to the main motor).
3 Disconnect two connectors (callout 2) from the dc controller.
Note The dc controller is removed from the printer in figure 73. If it was not, then the connectors in 
callout 2 would still be attached to the dc controller.
4 Pinch the cable holder (callout 3) and then unwind the cable.
CAUTION Do not attempt to disconnect the clutch cable from the clutch. Doing so can damage the cable.
5 Remove the e-clip (callout 4) from the clutch, and then pull the clutch away from the printer.
6 From inside the printer, press the small tab on the gear (see callout 1 in figure 58 on page 
111) to disengage the inside and outside gears (callout 5) from each other.
Note To reinstall the gear, lower the vertical rack (callout 6) to its lowest position, and then align the 
gear with the vertical rack.
Figure 73. Removing the gear assembly (1 of 2)
Note Routing of the clutch cable is different in more recent versions of the printer from the routing shown 
in figure 73. Examine the routing to make sure that it is reinstalled correctly.
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							126Removal and replacement C9706-90926 7
Remove eight screws (callout 6) from the gear plate.
8 Rotate the gear assembly away from the printer, beginning with the front edge.
Note A grounding spring (callout 7, hidden) should remain attached to the printer chassis. If it does 
not, then either reattach it to the chassis or place it with the gear assembly to prevent misplacing it.
Figure 74. Removing the gear assembly (2 of 2)
Reinstall note
A grounding wire at the lower-back corner of the gear assembly must be hooked around the 
chassis at reinstallation. Callout 2 in figure 75 on page 127 shows the grounding wire. Callout 3 
in figure 75 shows the grounding spring attached to the chassis.
Align the following parts with the printer chassis:

gear assembly shaft

grounding spring

grounding wire
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							EN 5 Removal and replacement127
Waste-toner sensor
1Unroute the cable from several cable holders.
2 Remove one screw (callout 1).
3 Lift the waste toner-sensor away from the printer.
Note Callout 2 shows the grounding wire that must be hooked around the printer chassis upon 
reinstallation of the gear assembly. Callout 3 shows the grounding spring.
Figure 75. Removing the waste toner sensor
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							128Removal and replacement C9706-90926
Rotary-drive assembly
Note The rotary-drive assembly includes the developer motor, the brake solenoid, and the encoder 
motor.
1 Remove the following covers:
right- and left-side covers (see page 93)
 interface cover (see page 98)
 formatter cage (see page 99)
 back cover (see page 110)
 top cover (see page 111)
2 Unplug three cable connectors (callout 1) from the dc controller and unplug the flat laser/
scanner cable (callout 2) from the laser/scanner.
Figure 76. Removing the rotary-drive assembly (1 of 3)
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