HP LaserJet 2100 Series Printers - Maintenance Kit Installation (US Only) bpl90282 2100 Maint kit _and TEA RDO WN.url In this document: Introduction Parts required Instructions Removal and replacement instructions Remove transfer roller Remove the I/O cover and the EIO card Remove the DIMMs Remove Tray 2 pickup roller Remove the rear cover. Remove the fusing assembly Remove the Tray 1 pickup roller assembly Remove the Tray 1 separation pad Remove Tray 2 separation pad Knowledgebase Document Number bpl90282 Last Updated: 02-April-2003 Minimum Skill Level 2 Introduction The HP LaserJet Maintenance Kit provides the parts most commonly used to repair the paper path wear components of the HP LaserJet 2100 series printers. Using the HP LaserJet Printer Maintenance kit helps provide convenience and cost savings by eliminating the need for individual subcomponent ordering where multiple parts needs exist. CAUTION: This kit is not for use by end users. It is intended for HP Authorized Service Providers or Help Desks in non-warranty applications in the US Only. Parts required Part description HP LaserJet 2100 part number Maintenance Kits 110V only H3974-60001 Maintenance Kit 220V only * H3974-60002 Fuser 110V (New) RG5-4132-170CN Part description HP LaserJet 2100 part number Fuser 220V (New) * RG5-4133-170CN Transfer Roller RG5-4164-000CN Pickup Roller (MP/Tray 1) RB2-2900-000CN Pickup Roller (Cassette/Tray 2) RB2-2891-000CN Separation Pad (MP Tray 1) RB2-6348-000CN Separation Pad (MP Tray 2) RB9-0695-020CN *These components may not be included depending on the voltage requirements. Instructions 1. Open the top cover and remove the print cartridge. 2. Remove paper Tray 2 from the unit. 3. Remove the transfer roller . 4. Remove the I/O cover and the EIO card . 5. Remove the DIMMs . 6. Remove and replace the Tray 2 pickup roller . 7. Remove the rear cover . 8. Remove the fusing assembly . 9. Remove the Tray 1 pickup roller assembly to replace the Tray 1 pickup roller . a. Remove the top cover . b. Remove the left cover . c. Remove Tray 1 . d. Remove the formatter PCB . e. Remove the printer drive assembly . 10. Remove and replace the Tray 1 separation pad . 11. Remove and replace the Tray 2 separation pad . 12. Reinstall the Tray 1 pickup roller assembly. a. Reinstall the printer drive assembly. b. Reinstall the formatter PCB. c. Reinstall Tray 1. d. Reinstall the left cover. e. Reinstall the top cover. 13. Install the new fusing assembly. 14. Reinstall the rear cover. 15. Reinstall the DIMMs, EIO Card, and I/O cover. 16. Install the new transfer roller. 17. Reinstall paper Tray 2 into the unit. 18. Reinstall the print cartridge, reconnect the power, and print a test page to verify printer function. Removal and replacement instructions Remove transfer roller CAUTION: Do not touch the new transfer roller’s sponge with bare skin because oils can damage the roller. Instead, grasp the transfer roller’s bushing and shaft. Open the print cartridge door and remove the print cartridge. Figure 1: Transfer roller Locate the transfer roller’s black bushing, which is on the left end of the transfer roller’s shaft and just behind the gear. 1 - Bushing 2 - Shaft Figure 2: Black bushing tabs Squeeze both of the black bushing’s tabs and then lift the transfer roller’s shaft to the left. Figure 3: Transfer roller shaft Figure 4: White retaining clip To reinstall: During replacement, securely insert the spring into the bushing’s boss so that the bushing pushes on the spring when the transfer roller is set. The white retaining clip on the right end of the transfer roller is also field replaceable. To remove the retaining clip squeeze both tabs on the retaining clip, and then lift it up. Remove the I/O cover and the EIO card Figure 5: I/O cover Pushing the two (2) tabs on the back of the I/O cover, swing the I/O cover away from the printer as shown. Pull out the I/O card. Remove the DIMMs Open the print cartridge door. Figure 6: DIMM cover release Press and hold the release button. Grasp the rear of the cover and pull it away from the printer until it stops. Figure 7: Right side cover Grasp the front and rear of the cover and swing it out from the printer. Figure 8: DIMM levers Rotate the levers shown in the figure at right to remove the DIMM(s). Remove Tray 2 pickup roller Figure 9: Tray 3 If Tray 3 is installed, lift the printer off the paper cassette assembly. Remove the print cartridge and remove Tray 2. Figure 10: Tray 2 pickup roller Place the printer top-down with the infrared port facing forward. Be careful not to scratch the printer or the surface. Tilting the lever to the left, rotate the white bushing. Stop when the Figure 11: White bushing bushing’s tab is aligned with the opening on the carriage. Figure 12: Bushing tabs Align the bushing’s tab with the opening on the carriage, and then slide the white bushing to the left. Figure 13: Black bushing Tilting the lever to the right, rotate the black bushing. If necessary, grasp the bushing’s lever with the needle nose pliers. Figure 14: Pickup roller shaft black Remove the black bushing from bushing the pickup roller’s shaft. Figure 15: Pickup roller white bushing Slide the pickup roller to the right so that its shaft is removed from the white bushing. Figure 16: Pickup roller shaft To remove the pickup roller from its carriage grasp the left end of its shaft and then lift up the roller. Remove the two (2) rollers from Figure 17: Two White locking rollers the pickup roller. Figure 18: Replace white rollers Place the two (2) rollers on the ends of the new pickup roller. Figure 19: Pickup roller insertion Replace the pickup roller in its carriage as follows: 1. Insert the non- slotted end of the roller’s shaft through the right- side carriage opening while holding the roller at a slight angle. 2. Lower the other end of the pickup roller until it rests on the bottom of the carriage. Slide the slotted end of the pickup roller’s shaft into the Figure 20: Pickup roller slotted end white bushing. Rotate the roller while sliding it so that its slotted haft rests over the drive shaft. CAUTION: The black bushing will not fit if the slotted end of the pickup roller’s shaft is not properly inserted over the drive shaft. Figure 21: Non-slotted end of pickup Slide the black bushing through shaft the carriage opening and over the non-slotted end of the pickup roller’s shaft. The tab on the black bushing must be oriented so that it will fit through the keyed opening on the carriage. If the black bushing does not fit, the slotted end of the pickup roller’s shaft is not properly inserted over the drive shaft. If necessary, repeat the previous step. Figure 22: Black bushing lock mechanism Rotate the black bushing forward until it locks in place. Slide the white bushing to the right until it goes through the Figure 23: White bushing orientation carriage opening. The tab on the white bushing must be oriented so that it will fit through the keyed opening on the carriage. Rotate the white bushing forward until it locks in place. Turn the printer upright and install the print cartridge and any removed paper trays. Remove the rear cover. Remove the DIMM cover. Figure 24: Rear output bin door Open the rear output bin until it stops, and then pull it again so that it rests parallel with the floor. Remove the two (2) screws from Figure 25: Rear cover screws the back of the unit. Figure 26: Rear cover, bottom left Pull the bottom-left corner of the rear cover. Figure 27: Rear cover movement Pull the rear cover down and then out to remove it. Remove the fusing assembly CAUTION: Turn the power off and unplug the power cord before removing the fusing assembly. After turning the power off, let the fusing assembly cool down for several minutes. Figure 28: PE Opening Do not insert metallic objects into the opening shown at right. Figure 29: Engine test button location The print engine test button is located on the back of the printer as shown at right. Remove the DIMM cover and the rear cover. Figure 30: Two Wire connectors To disconnect the left wire connector pull it straight out. To disconnect the right wire connector, press a flat blade screwdriver on the connector and then pull out the connector. Figure 31: Two Grounding plate screws Remove the two (2) grounding plate screws. Figure 32: Fusing assembly screws Remove the two (2) screws which fasten the fuser assembly to the printer. Figure 33: Fusing assembly Remove the fuser assembly from the printer. To reinstall: When replacing Figure 34: Fusing assembly guide pins the fusing assembly, use the guide pins to correctly align it. Remove the Tray 1 pickup roller assembly Remove the top cover Remove the print cartridge, the DIMM cover, and the rear cover. Figure 35: print cartridge door swing arm Release the swing arm from the print cartridge door, and push it down in the opening. Remove the two (2) screws from Figure 36: Two top screws the top of the unit. Figure 37: Two rear screws Remove the two (2) screws from the rear of the unit. Figure 38: Tray 1 Open Tray 1. Release the latch on the top, left Figure 39: Top, left latch of the unit. Figure 40: Top cover Lift the top cover to remove it. Figure 41: Positioning of top four screws To reinstall: Two (2) of the four (4) screws removed in the above procedure are longer than the other two (2). When replacing the top cover, these screws go in the holes as shown at left. Remove the left cover Remove the print cartridge, DIMM cover, rear cover, and top cover. Figure 42: Top latch release Release the latch on the top of the unit. Simultaneously lift the cover up and outward. Remove Tray 1 Remove the print cartridge, DIMM cover, the rear cover, the top cover, and the left cover. Figure 43: Tray 1 springs Disconnect the springs from the printer on the left and right side of Tray 1. Disconnect the pivot arms from Figure 44: Tray 1 pivot arms Tray 1 on the left and right side of the tray. Figure 45: Tray 1 bottom piece Remove the bottom piece of Tray 1 by sliding it to the left. Figure 46: Pivot arm positions Rotate the pivot arms to the upward position and remove the top piece of Tray 1. Remove the pivot arms. Figure 47: Pivot arm removal NOTE: Each pivot arm is marked with either the letter L or R, to indicate which side of the printer to replace it on. Remove the formatter PCB Remove the print cartridge, DIMM cover, and EIO card. Figure 48: Ribbon and power cables Disconnect the ribbon and power cables (call-out 1) and remove the four (4) screws (call-out 2). 1 - Ribbon and power cables 2 - Four screws Remove one (1) screw and then Figure 49: Formatter PCB screw remove the formatter PCB. Remove the printer drive assembly Remove the print cartridge, the DIMM cover, the rear cover, the top cover, and the formatter PCB. Figure 50: Ribbon cable and main motor cable Disconnect the ribbon cable and the main motor cable. Remove the two (2) ground Figure 51: Printer drive assembly screws (call-out 1) and five (5) self- tapping (call-out 2) screws. 1 - Two Ground screws 2 - Five Self-tapping screws Lift out the printer drive assembly to remove it. Remove Tray 1 assembly and replace pickup roller Remove the print cartridge, the DIMM cover, the rear cover, the top cover, the left cover, Tray 1, the formatter PCB, and the printer drive assembly. Figure 52: Pickup roller gears Remove the gear in the figure at right, rotating to move it past the solenoid. While facing the black bushing, pull out its lever and rotate it Figure 53: Keyed opening for bushing counter-clockwise until the tab clears the keyed opening to remove the bushing. 1 - Pull out lever 2 - Rotate counterclockwise Figure 54: White tab by bushing keyed opening While facing the white bushing, pull out its lever and rotate it counter-clockwise until the tab clears the keyed opening to remove the bushing. 1 - Pull out lever 2 - Rotating counterclockwise Slide the assembly to the right until the left end of the shaft Figure 55: Tray 1 assembly clears the opening, and then slide the assembly back to the left to remove it. Remove the Tray 1 separation pad Remove the print cartridge, the DIMM cover, the rear cover, the top cover, the left cover, Tray 1, and the Tray 1 pickup roller assembly. Figure 56: Tray 1 separation pad Simultaneously lift up and to the left to rotate the separation pad forward. 1 - Lifting up and left 2 - Rotating forward Figure 57: Tray 1 separation pad Remove the screw and then lift assembly the assembly to remove it. Remove Tray 2 separation pad Remove Tray 2 from the unit. Figure 58: Tray 2 separation pad Turn the tray over to access the release tabs for the separation pad. 1 - Separation pad 2 - Separation pad spring Using a flat blade screwdriver, release the two black plastic tabs Figure 59: Tray 2 plastic tabs on the underside of the paper tray. Figure 60: Tray 2 separation pad Lift out the separation pad. To reinstall: Align the two black plastic tabs with the notches in the paper tray and click back into place.