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
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							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 the Pressure Roller gear still attached.
NoteWhen reinstalling the Pressure Roller, apply a drop of grease to the grounding plate
on the right side of the shaft. (Refer to Chapter 8 for a part number.)
Figure 6-16
6 - 20 Removal and Replacement 
						

							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 Separation Guide Assembly. The
machined ridges on the lever will face you.
4Release the spring so it falls in place in front of the square tab (Figure 6-17).
NoteWhile the shape of the lever was changed for the HP LaserJet 6L (a stiffening rod
was also added), these procedures for Face-Up/Face-Down Lever removal remain
unchanged. Figure 6-17 shows the lever from an HP LaserJet 5L.
Face-Up/Face-Down Lever Replacement
NoteYou can tell when the lever is in place because there are two plastic grooves that fit
precisely in front of the Exit Rollers, and you should be able to feel the spring’s
release mechanism.
Figure 6-17
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Removal and Replacement 6 - 21 
						

							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 1) and rotating it around (Figure 6-18, callout 2).
NoteWhile the shape of the white tab was changed for the HP LaserJet 6L, these
procedures for Fuser Exit Roller Assembly removal remain unchanged. Figure 6-18
shows the white tab from an HP LaserJet 5L.
4Slide the Exit Roller Assembly forward and out to the right of the printer.
Fuser Exit Roller Removal
Figure 6-18
6 - 22 Removal and Replacement 
						

							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 correctly, because installing it incorrectly
will cause the Control Panel to display an error with the Paper Exit Sensor (PS201).
Place the left side of the flag in the correct position first, then slide the right side
into place, making certain the spring is on top of the flag (Figure 6-19). If the spring
exerts no pressure on the flag, it may require “respringing” by giving the spring an
extra turn before reinstalling. The flag should fit snugly in place.
Paper Exit Sensor Flag Replacement
Figure 6-19
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Removal and Replacement 6 - 23 
						

							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
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							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
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Removal and Replacement 6 - 27