Removing the print-cartridge carousel

Remove the following covers and assemblies:

Formatter cage (see Removing the formatter cage)
Fuser assembly (see Replacing the fuser assembly)
Left support assembly (see Removing the left support assembly)
Right support assembly (see Removing the right support assembly)
Air duct (see Removing the air duct and fan)
Rotary-drive assembly (see Removing the rotary-drive assembly)
Top plate (see Removing the top plate)

Remove two screws (callout 1) from the back of the device.

Figure 5-78 Remove the print-cartridge carousel (1 of 3)

Reinstallation tip Because the remainder of the print-cartridge carousel removal
procedures are performed from the left, right, and front of the device, it is easy to forget to
replace the two screws at the back of the device.

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Press the white plastic tab (callout 2) at the left side of the device to release the left swing-shaft
bushing, and then rotate the bushing to a vertical position.

Figure 5-79 Remove the print-cartridge carousel (2 of 3)

4

On the right side of the device, repeat step 3 on the right swing-shaft bushing.
Examine the positions of the left pressure-shaft holder (callout 3), the right pressure-shaft holder
(callout 4), and the pressure-shaft gear (callout 5) before you perform step 5. The pressure-shaft
holders must be reinstalled to their correct positions when reinstalling the print-cartridge carousel.

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Use the flatblade screwdriver to pry two white tabs on the pressure-shaft holders from their
seated positions in the rear frame assembly.

Figure 5-80 Remove the print-cartridge carousel (3 of 3)

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Lift the print-cartridge carousel out of the device.

Incorrect reinstallation of the "feet" is shown, followed by correct installation.

Figure 5-81 Installation of feet (1 of 2)

Figure 5-81 Installation of feet (2 of 2)

Also make sure that the tab on the pressure-shaft gear points down.

Figure 5-82 Correct gear placement

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202

After replacing the print-cartridge carousel, run a print-quality test (see Test 1 (print-quality test))
and a copy-quality test (see Test 2 (copy-quality test)).

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NOTE If you are servicing an HP Color LaserJet 2840 all-in-one, run a fax-quality test
(see Test 3 (fax-quality test)) and a memory-card test (see Test 4 (memory-card test)) as
well.

Aligning the carousel gears

Make sure that the gears in the print-cartridge carousel are aligned correctly before placing the
carousel back into the device.
1

Rotate the carousel so that the marker for the yellow print cartridge faces the front of the device.

Examine the gears: two marks on the smaller gear should line up with the single mark on the
larger gear (see the detail of the gears in Figure 5-83 Reinstall the print-cartridge carousel).
NOTE The single mark on the larger gear is adjacent to the slot for the black cartridge,
marked with a "K."

If the gears are not aligned correctly, locate the marks on the gears and realign the gears.

Figure 5-83 Reinstall the print-cartridge carousel

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Removing the registration-roller assembly

1

Remove two screws (callout 1) from the registration-shutter assembly.

Figure 5-84 Remove the registration-roller assembly

2

Rotate the registration-roller assembly toward the front of the device and then lift it towards the
rear of the device and up to remove it from the device.

After replacing the registration-roller assembly, run a print-quality test (see Test 1 (print-quality
test)).

Removing the toner-catch tray

The toner-catch tray is secured by two tabs underneath the tray (see Figure 5-85 Remove the tonercatch tray), toward the front of the tray.

204

Remove the print cartridges (see Replacing the print cartridges) and the imaging drum (see
Replacing the imaging drum).

Release one tab on either side of the toner-catch tray and then pull the tray approximately 2 or 3
mm (approximately 0.125 inch) toward the front of the device to make sure that the tab does not
reattach as you perform the next step.

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Release the tab on the other side and then lift the tray out of the device.

Figure 5-85 Remove the toner-catch tray

Removing the feed-drive shaft and belts

CAUTION This procedure requires turning the device over onto its top. The device is heavy.
Hewlett-Packard recommends that two people lift the device and turn it over onto a smooth,
soft surface.
1

Remove the following covers and assemblies:

Right rear cover (see Removing the right rear cover)
I/O cover (see Removing the input/output (I/O) cover)
ADF (see Replacing the ADF)
Fuser assembly (see Replacing the fuser assembly)
Toner-catch tray (see Removing the toner-catch tray)
Transfer-roller plate (see Removing the transfer-roller plate)
Transfer roller (see Removing the transfer roller)
Optional tray 2, if installed (see Removing optional tray 2 (250-sheet tray))
Print cartridges (see Replacing the print cartridges)
Imaging drum (see Replacing the imaging drum)

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Prepare a smooth, soft surface (with an ESD pad, if possible) on which the overturned device will
rest. Avoid placing small items such as screws or tools in this area.

Clean out loose toner from inside the device, and then turn the device over so that it rests on the
scanning assembly in the area that you prepared in step 2.

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Remove the power supply assembly (see Removing the power supply cover plate), and then
remove the plastic protector sheet from the bottom of the device.

Figure 5-86 Replacing the feed-drive shaft and belts (1 of 8)

5

206

Lay the device on its back.

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