Wednesday, October 5, 2011

HP LaserJet 5 -- Routine Teardown/Overhaul

The LaserJet 5 is an excellent machine -- well worth what it may take to keep one going. Following is the order of work for a thorough teardown and cleaning/overhaul.


- - -

1) Cartridge

2) Tray 2

3) Right Side Cover
- One captive M4 screw at the upper rear.
- Slide the cover rearward a bit to free it.

4) Back Door

5) Top Cover
- Two M3x8mm pan head YZD screws w/captive washers at the upper rear.
- One M3x8mm pan head YZD screw w/captive washers under the toner cartridge access door.
- Tray 1 open.
- Two forward-gripping claws in front (rectangular openings -- 5mm x 17mm).
- Lift cover and tip up its left side.
- One cable connection at the control panel.

6) Tray 1 Door w/Platform Extension
- Pry gently at the inner platform ways to free the door from the inner platform.
- Slide the door rightward off its hinge pins.
- Flex the platform extension A/R to free it from its ways.

7) Left Side Cover
- One claw at upper rear near the front corner of the delivery assembly.
- Pry at the front lip to free it.

8) Right Front Cover
- One M3x8mm pan head YZD screw w/captive washers.
- One claw visible high up.
- One claw visible at the right side.
- One claw below the switch rocker -- accessible via an opening in the sheet metal.
- One claw at the lower left corner.

9) Delivery Assembly
- Ground continuity clip at upper left.
- Two claws low down at rear. Tip the unit up and remove it rearward.
- NOTE the two hooks at the lower front that must engage openings in the sheet metal on reinstallation.

10) Fuser
- Two M4x8mm hex head (7mm A/F) screws w/captive star washers.
- Tug the unit rearward to unplug/remove it.

11) Cross-Brace Below Tray 1 Platform
- Two M3x6mm bright washerhead screws.

12) Tray 1 Platform
- Unhook the torsion spring at the left side hinge.
- Tilt the item downward until it can slip off its flatted hinge pins.

13) Envelope Feeder Slot Cover
- Tug the arrow-marked 'handle' downward to free the cover.

14) Paper Input Unit
- Two cable connectors at the right front.
- Two M3x8mm YZD pan head screws w/captive washers at the right front.
- Three M3x6mm bright washerhead screws at the left side.
- Slide the unit out the front.

15) Memory Access Door
- One captive 4mm screw.

16) Formatter Assembly
- Six M3x6mm bright pan head screws w/captive washers.
- Pull the assembly rightward straight off its connector.

17) Right Side Lower Front Perforated Sheet Metal
- NOTE how this item supports the switch rod at its upper rear corner.
- Two M3x6mm bright washerhead screws.

18) Switch Rod
- NOTE that the longer bent-over end engages the switch in the power supply; the shorter end engages the rocker in front.

19) Power Supply
- Two cable connections.
- Two M3x6mm bright pan head screws w/captive star washers.
- Pull the assembly rightward to unplug it from the fuser AC connector.

20) Printhead (It's self-aligning. No adjustment is disturbed by removing it.)
- NOTE the black plastic shutter actuator at the front left corner of the printhead. The actuator's tip goes behind the shutter's projection.
- Three cable connections.
- Free the cabling from the two upper restraints.
- Four M3x14mm YZD pan head screws w/captive washers.

21) HVPS (The 'Black Box' underneath.)
- Two M3x8mm YZD pan head screws w/captive washers.
- Two claws at the rear.
- Pull the item straight off.

22) Motor
- One cable connection.
- Four M3x10mm YZD pan head screws w/captive washers.

23) Gearbox
- Two M3x6mm bright washerhead screws.
- NOTE: At reinstallation, take care to ensure that this item is correctly and fully seated before running in and tightening the two screws.

22) Right Side Tray 2 Way
- One M3x8mm YZD pan head screw w/captive washers.
- On claw below the fuser AC connector.

23) Left Side Tray 2 Way
- One M3x8mm black pan head threading screw.
- One lock-button. Press it in until the item can be slid rearward.



- - -
24) Blow out the chassis w/compressed air.

25) Reassemble w/replacement parts A/R.


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