HP Laserjet 5 Service Manual

3Disconnect the AC voltage to the Heating Element by releasing the connector
located on the DC Controller. Press down on the connector release with a small,
flathead screwdriver (Figure 6-14, callout 1). (Since this is a small space, it is much
easier to reach the connector with a screwdriver.) Pull straight out (Figure 6-14,
callout 2).
Heating Element Removal (2 of 3)
Figure 6-14
6 - 18 Removal and Replacement 

4Remove the wire from the wire guides along the right-side of the printer.
5Disconnect the thermistor feedback connector in the left front side of the Fusing
Assembly (Figure 6-15).
Heating Element Removal (3 of 3)
6Lift the Heating Element out.
To reinstall
Make sure the connectors are properly reattached.
Figure 6-15
6
Removal and
Replacement
Removal and Replacement 6 - 19 

Pressure Roller
1Remove Printer Covers, Delivery Assembly (Figures 6-9 and 6-10), Fuser Pressure
Plate (Figure 6-11), and Heating Element (Figures 6-13 through 6-15).
2Remove the Pressure Roller guide by lifting the edge (Figure 6-16, callout 1) and
then rolling it gently backward (Figure 6-16, callout 2).
Pressure Roller Guide Removal
3Lift the right end of the Pressure Roller up and out of the printer chassis.
NoteThe right end of the Pressure Roller is greased.
4The left side will follow easily with...

Face-Up/Face-Down Lever
1Remove Printer Covers, Delivery Assembly (Figures 6-9 and 6-10), Fuser Pressure
Plate (Figure 6-11), and Heating Element (Figures 6-13 through 6-15), and Pressure
Roller (Figure 6-16).
2Rotate the lever forward 90 degrees (past the spring) and pull it straight out the front
of the printer.
To reinstall
1Make sure the lever arm is on the left and is initially pointing downward.
2Pull the spring forward using needlenose pliers.
3Slide the short, round tabs into the grooves on the...

Fuser Exit Roller Assembly
1Remove Printer Covers, Delivery Assembly (Figures 6-9 and 6-10), Fuser Pressure
Plate (Figure 6-11), and Heating Element (Figures 6-13 through 6-15), Pressure
Roller (Figure 6-16), and Face-Up/Face-Down Lever (Figure 6-17).
2Remove the gear from the left end of the roller shaft by pressing down on the
catching mechanism with the small flathead screwdriver and pulling the gear away.
3Remove the Exit Roller Assembly by pressing the small, white tab upward (Figure
6-18, callout...

Paper Exit Sensor Flag
1Remove the Printer Covers, Delivery Assembly (Figures 6-9 and 6-10), and Fuser
Pressure Plate (Figure 6-11).
CautionBefore proceeding to Step 2, examine the Paper Exit Sensor flag. It is important to
note the position of the spring mechanism on the flag. The spring must be
reinstalled to exactly this position.
2Remove the Paper Exit Sensor flag by pressing down on the left side and pulling up
on the right side.
To reinstall
NoteIt is important that you reinstall the flag...

Top Assemblies
Laser/Scanner Assembly
1Remove the Printer Covers.
2Remove both Laser/Scanner connectors (Figure 6-20, callout 1).
3Remove all (4) screws and lift the assembly straight off (Figure 6-20, callout 2).
NoteOne of the four screws is longer than the other three. Upon reinstallation, the longer
screw must be replaced in its original location.
Laser/Scanner Assembly Removal
Figure 6-20
6 - 24 Removal and Replacement 

Solenoid
1Remove the Printer Covers.
2On the left side of the printer, remove the paper pickup gear (Figure 6-21, callout 1)
by pressing the tabs in the center of the gear outward and pulling the gear off
(Figure 6-21).
Solenoid Removal (1 of 2)
Figure 6-21
6
Removal and
Replacement
Removal and Replacement 6 - 25 

3Remove the Solenoid connector (J204) from the DC Controller (Figure 6-22,
callout 1).
4Remove the self-tapping screw that holds the Solenoid in place (Figure 6-22, callout
2).
5Unthread the wires from the printer chassis.
6Lift the Solenoid off.
Solenoid Removal (2 of 2)
NoteWhen reinstalling this part, the Paper Pickup Gear is keyed to go on the shaft in
only one way.
Figure 6-22
6 - 26 Removal and Replacement 

Pickup Roller Assembly
1Remove the Printer Covers.
2Remove the paper pickup gear (Figure 6-21).
NoteThis gear is keyed to go on the shaft in only one way.
3Remove the pickup roller grounding clip on the right of the printer by lifting each
end of the clip up and over the two metal guides and sliding the clip off. Figure 6-23
depicts the clip from an HP LaserJet 5L. The clip from an HP LaserJet 6L (and
some HP LaserJet 5Ls) is shaped differently.
Pickup Roller Assembly Removal (1 of 2)
Figure 6-23
6...