SERVICE

UPDATE No. P1542

Fuser Replacement
HLL5000D, HLL5100DN, HLL5200DW, HLL5200DWT, HLL6200DW, HLL6200DWT,
HLL6250DW, HLL6300DW, HLL6400DW, HLL6400DWT

Recommendation for fuser replacement:

1. Remove the R Cover.

2. Remove the Taptite bind B M4x12 screw and fuser unit line cover R.
3. Remove the Rear nip release link. Lift the lower portion of the nip in the direction of 4b.
Slide the lower rear nip release in the direction of the arrow 4a while pulling it in the
direction of 4b.
4. Remove the taptite pan B M4x14 screw. Remove Fuser unit line cover L.

IMAGE 1
5. Disconnect the center and side thermistor harness and heater harness.
NOTE: Make sure to pull the thermistor harnesses straight from the eject sensor PCB by
bracing the PCB and unplugging. If removed at an angle the connectors could be damaged.

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 SERVICE
UPDATE No. P1542
Fuser Replacement
HLL5000D, HLL5100DN, HLL5200DW, HLL5200DWT, HLL6200DW, HLL6200DWT,
HLL6250DW, HLL6300DW, HLL6400DW, HLL6400DWT

IMAGE 2
6. Remove the Taptite pan B M4x14 from the left side of the fuser and remove the fuser.
NOTE: Make sure the front cover is closed when removing or installing the fuser unit.

IMAGE 3

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 SERVICE
UPDATE No. P1542
Fuser Replacement
HLL5000D, HLL5100DN, HLL5200DW, HLL5200DWT, HLL6200DW, HLL6200DWT,
HLL6250DW, HLL6300DW, HLL6400DW, HLL6400DWT

7. Install the new fuser unit.

8. Reconnect the fuser wire harness and thermistor harness.

NOTE: Make sure the thermistor and heater harnesses are seated properly. Otherwise they
may be pinched or damaged.

9. Place the Taptite pan B M4x14 back in the left side of the fuser.
10. Replace the Fuser unit line cover L using the Taptite pan B M4x14 screw.
11. Reinstall the Rear nip release link.
a. Keep the nip at an angle. (Image 4)
b. Place the protruding hook on the rear nip into the slot just below the slight rise in
the frame.
c. Lift the nip and slide into positon till it is flush.

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 SERVICE
UPDATE No. P1542
Fuser Replacement
HLL5000D, HLL5100DN, HLL5200DW, HLL5200DWT, HLL6200DW, HLL6200DWT,
HLL6250DW, HLL6300DW, HLL6400DW, HLL6400DWT

IMAGE 4

12. Reinstall the Fuser unit line Cover R and the Taptite bind B M4x12 screw.

NOTE: When reinstalling the Fuser unit line Cover R, place the lower portion with the nip
in where the fuser harness is resting first. Then rock the cover into position making sure
the hook on the left seats properly. (See Image 5)

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 SERVICE
UPDATE No. P1542
Fuser Replacement
HLL5000D, HLL5100DN, HLL5200DW, HLL5200DWT, HLL6200DW, HLL6200DWT,
HLL6250DW, HLL6300DW, HLL6400DW, HLL6400DWT

IMAGE 5
13. Reinstall the fuser cover and rear paper guide.
14. When reinstalling the Rear Cover, place the rear cover extension underneath the
exposed portion of Rear nip release link. Then slide the left side of the cover onto the
boss. (See Image 6).

IMAGE 6

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 SERVICE
UPDATE No. P1542
Fuser Replacement
HLL5000D, HLL5100DN, HLL5200DW, HLL5200DWT, HLL6200DW, HLL6200DWT,
HLL6250DW, HLL6300DW, HLL6400DW, HLL6400DWT
NOTE: Make sure to open the front cover to verify the Rear Nip was installed correctly. If
you are unable to open the front cover fully, the Rear Nip was not installed correctly.

15. Follow the instructions below to reset the fuser life count.
HLL5000D, HLL5100DN, HLL5200DW, HLL5200DWT, HLL6200DW, HLL6200DWT,
HLL6250DW
a. Press the OK, GO,, , ,  to enter Maintenance Mode.
b. Press the  to display Maintenance 88, then press OK. "Reset-Laser Unit" will be
displayed. Press the or  to display "Reset-Fuser Unit" then press OK.
c. "Reset-Fuser Unit OK?" will be displayed. Press OK. The display will go back to "Reset-
Laser Unit"
d. Press the CANCEL button. Then display return to Maintenance.
e. Press the or  to display Maintenance 77, then press OK. The Maintenance report
will print after a few moments. Verify the Remailing life of the fuser is 100%
f. Press the or  to display Maintenance 99, then press OK.

HLL6300DW, HLL6400DW, HLL6400DWT

a. Press and hold Home for approximately five seconds.

b. Press and release the blank section at the very bottom of the LCD.
c. Press >>, *, <<, 2,8,6,4.
d. Press 8, 8.
e. "Reset-Laser Unit" will be displayed. Press the or  to display "Reset-Fuser Unit"
then press the Mono key.
f. Press X to exit.
g. Press 7, 7. The Maintenance report will print after a few moments. Verify the Remailing
life of the fuser is 100%.
h. Press 9, 9 to exit Maintenance Mode.

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