How to Remove and Replace the Registration Assembly

The following instructions detail how to remove and replace the Registration Assembly for the HP Color LaserJet 9500 series printers. This information can also be found in Chapter 6 of the service manual. This procedure involves major disassembly of the printer as several assemblies must be removed in order to remove and replace the registration assembly.

Registration Assembly

RG5-6016-000CN

The following assemblies will need to be removed in the order listed to access the registration assembly.
Black Process Cartridge (Image Drum)
Paper Pickup Unit (PIU)
High Voltage Power Supply (HVPS)
Registration Motor
Registration Drive Assembly
Two Wire Harness Covers
Right Back ITB Lift Link
Disconnect Registration Assembly Connectors
Registration Assembly Plate

General cautions during removal and replacement

Before removing or replacing assemblies and parts note the following:
Make sure the printer is turned off
Disconnect all cables and cords
If the printer has been running continuously prior to servicing, turn the power off but allow the printer to remain plugged in with the cooling fans running for at least 10 minutes before unplugging the power cord.
Always remove the image drums before removing or replacing assemblies and parts near the drums.

CAUTION: Put the image drums in the original protective plastic sleeves, or, if the sleeves are not available, place the image drums right-side up on a hard, flat, clean surface. Do not place the image drums on carpet or a dusty surface because contaminants (for instance, dust, fibers) can stick to the OPC and diminish print quality. Light can damage the image drums.

Initial disassembly instructions

Before beginning printer disassembly remove the Black Image Drum to prevent it from being damaged. Then proceed with the following removal instructions in the order listed.
Remove the PIU.
Next, remove the HVPS.
Now, disconnect one connector (see figure below, call-out 1) and remove three screws (call-out 2).

NOTE: Mark the screw holes on the chassis before removing the screws.

Figure 1: Disconnect the registration assembly motor 1-Connector 2-Three screws to be removed

Remove the registration motor
Remove three screws (see figure below, call-out 1) from the registration drive assembly.

Figure 2: Remove the registration assembly motor 1-Three screws

Remove two covers (see figure below, call-out 1).

Figure 3: Remove two wire harness covers 1-Two harness covers

Open the front doors of the printer to access the green handle, see figure below.

Figure 4: Open the front doors (right door already removed in this figure)

Push the green handle (ITB release lever) down, see figure below.

Figure 5: Lower the green handle (ITB release lever)

Advanced disassembly instructions

CAUTION: Be sure to cover the top of the PIU and registration assembly with a cloth to avoid dropping the link clip into these components.
CAUTION: Do not remove the e-ring (see figure below, call-out 1) from the claw assembly.

Remove the retainer clip and washer by using needlenose pliers, see call-out 2 below.
Use a small flatblade screwdriver to unclip the claw, see call-out 3 below.

Figure 6: Release the right back ITB lifting link 1-E-ring NOT to be removed 2-Retainer clip and washer to be removed 3-Unclip this claw

Slide off the right back ITB lift link to the left.

CAUTION: Make sure not to bend the right back ITB claw by pulling out too far.

Figure 7: Remove the right back ITB lifting link

Disconnect one wire connector, see call-out 1 below.
Remove the registration drive assembly , see call-out 2 below.

Figure 8: Disconnect the registration assembly connector 1-Wire connector 2-Registration drive assembly

Remove two screws, see call-out 1 below.

Figure 9: Remove the registration assembly plate mounting screws 1-Mounting screws

Slide the plate toward the back of the printer, see figure below.

Figure 10: Remove the registration assembly plate (1 of 2)

Lift up the left side of the plate, slide it toward the front of the printer and remove it, see figure below.

Figure 11: Remove the registration assembly plate (2 of 2)

Remove three screws, see call-out 1 below.

CAUTION: Make sure that the black image drum (process cartridge) is removed. The handle of a long-blade screw driver can damage the image drum if it contacts the cartridge when removing these screws.

Figure 12: Remove the registration assembly mounting screws 1-Three screws

Disconnect two connectors, see call-out 1 below.

Figure 13: Disconnect the registration assembly connectors 1-Two connectors

Lift the front of the registration assembly and unhook two white claws, see call-out 1 below.
Remove the registration assembly.

Figure 14: Remove the registration assembly 1-Registration assembly

© 2005 Hewlett-Packard