HP Designjet 500 and 800 Series Removal and Installation Guide

Removal and Installation8

Screw Types 8-4 Left Hand Cover 8-5 Right Hand Cover 8-7 Front Panel 8-9 Window and Top Cover 8-10 Media Deflectors 8-11 Left End Roll-Feed 8-13 Right End Roll-Feed 8-15 Back Platen 8-17 Media Sensor 8-19 Formatter 8-20 LAN Card 8-21 Spittoon 8-23 Electronics Module 8-24 Power Supply 8-27 Scan-Axis Motor Assembly 8-29 Cutter Assembly 8-32 Left Encoder Holder 8-33 Cutter Bushing 8-35 Cutter Guide Bracket 8-36 Drive Roller Encoder Sensor 8-38 Trailing Cable 8-40 Ink Suppl y St ation 8-48 Interconnect PCA 8-50 Service Station and Aerosol Fan 8-52 Cutter Guide 8-55 Print Platen 8-5 6 Service Station Holder 8-57 Interconnect Cable 8-59 Ink Supply Tubes 8-60 Vacuum Fan 8-64 Pinch-Arm 8-66 Pinch-Arm Mechanism 8-67 Pinch-Arm Lever 8-69 Pinch-Arm Sensor 8-71 Fork Idler, Tensioner an d Idler Pulley 8-74 Encoder Strip 8-76 Carriage Assembly (Including Belt) 8-78 Paper-Axis Motor 8-84 Drive Roller 8-86 Gear Assemblies 8-92

HP DesignJets 500 and 800 Series Printers Service Manual

8-1

Removal and Installation

Introduction

This chapter is a step by step guide to the removal and installation of the key components in the printer. You may find it useful to tick off the steps as they are performed. Use the illustration at each procedure to identify the parts referred to in the text.

The procedures appear in order of removal. So the whole machine can be stripped down by starting at the beginning of this chapter and working through the subsequent procedures.

NOTE Before using this chapter to remove and install a new component,

always make sure that you have performed the relevant service test from Chapter 4. If the test passes you will not need to r eplace the component.

Safety Precautions

Review WARNING and CAUTION symbols and instructions before you service the printer. Follow these warnings and cautions for your protection and to avoid damaging the printer.

WARNING Serious shock hazard leading to death or injury may result if you

do not take the following precautions: Ensure that the ac power outlet (mains) has a prote ctive earth

(ground) terminal. Switch the plotter off, and disconnect it from the power source

prior to performing any maintenance. Prevent water or other liquids from running onto electrical

components or circuits, or through openings in the module.

8-2

HP DesignJets 500 and 800 Series Printers Service Manual

Removal and Installation

Electrostatic Discharge (ESD) Precautions

To prevent damage to the Printer circuits from high-voltage electrostatic discharge (ESD):

1. Do not wear clothing that is subject to static build-up.

2. Do not handle integrated circuits (ICs) in carpeted areas.

3. Do not remove an IC or a printed circuit assembly (PCA) from its conductive foam

pad or conductive packaging until you are ready to install it.

4. Ground (earth) your body while disassembling and working on the Printer.

5. After removing a cover from the Printer, attach an earthing (ground) lead between the

PCA common and earth ground. Touch all tools to earth ground to remove static charges before using them on the Printer.

6. After removing any PCA from the Printer, place it on a conductive foam pad or into

its conductive packaging to prevent ESD damage to any ICs on the PCA.

Required Tools

The following tools are required to disassemble and repair the Printer.

Long Torx Screwdriver with the indicated attachments

Nut driver with the

indicated attachments

Small flat-blade screwdriver

HP DesignJets 500 and 800 Series Printers Service Manual

8-3

Removal and Installation

Screw Types

T ype Torx Length

(mm)

Head Type Thread Type Part Number

A T-20 17 Pan Taptite 0515-1743 B T-10 8.0 Pan Taptite 0515-2200 C T-20 10 Pan Taptite 0515-2282 D T-10 17.5 Pan Washer Plastite 0515-2675 E T-15 12.7 Pan Plastite 0624-0769

F T-15 20 Pan Plastite 0624-0771 G T-8 12.7 Pan Plastite 0624-0768 H T-20 35 Pan Taptite 0515-2521

I T-15 9.5 Pan Plastite 0515-2981 J T-10 8 Pan Machined 0515-2246

8-4

HP DesignJets 500 and 800 Series Printers Service Manual

Removal and Installation

Left Hand Cover

Removal

WARNING Switch off the printer and remove the power cable.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove the Spindle.

2. Remove 3 T-20 screws (Type F) from

the Rear of the Left Hand Cover.

3. Remove the LAN Card Cover from

the back of the Left Hand Cover.

HP DesignJets 500 and 800 Series Printers Service Manual

8-5

Removal and Installation

4. Remove 1 T-20 screw (Type F) from

the front of Left Hand Cover.

5. Open the Window and remove 1 T-20 screw (Type F) from the side-plate.

NOTE Be careful not to drop the

screw into the Printer.

6. Remove the Left Hand Cover.

8-6

HP DesignJets 500 and 800 Series Printers Service Manual

Removal and Installation

Right Hand Cover

Removal

WARNING Switch off the printer and remove the power cable.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove 1 T-20 screw (Type F) from

the back of the Right Hand Cover.

2. Open the Ink Cartridge Door and

remove 1 T-20 screw (Type F) from the back of the Right Hand Cover.

3. Keep the Ink Cartridge Door open and

remove 1 T-20 screw (Type F) from the top of the Right Hand Cover.

HP DesignJets 500 and 800 Series Printers Service Manual

8-7

Removal and Installation

4. Remove 1 T-20 screw (Type F) from the front of the Right Hand Cover.

5. Open the Window and remove 1 T-20 screw (Type F) from the side plate.

6. Remove the Right Hand Cover.

NOTE Always keep the Ink

Cartridge door open when removing/installing the Right Hand Cover.

8-8

HP DesignJets 500 and 800 Series Printers Service Manual

Removal and Installation

Front Panel

Removal

WARNING Switch off the printer and remove the power cable.

1. Remove the the Right Hand Cover -

Refer to Page 8-7.

2. Remove the Right Hand Trim.

Disconnect

3. Disconnect Front Panel Connector

from the ISS PCA.

4. Unclip the Front Panel and remove

from the Printer.

HP DesignJets 500 and 800 Series Printers Service Manual

8-9

Removal and Installation

Window and Top Cover

Removal

WARNING Switch off the printer and remove the power cord.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove the following screws

(Type A) from the rear that attach the Top Cover to the Printer:

n 2 T-20 screws for the 24" model. n 3 T-20 screws for the 42" model.

2. Raise Window and unclip at both ends.

3. Lift up complete assembly (Window and Top Cover) and remove from Printer.

8-10

HP DesignJets 500 and 800 Series Printers Service Manual

Removal and Installation

Media Deflectors

Removal

WARNING Switch off the printer and remove the power cord.

1. Make sure the Media Lever is in the

UP Position.

2. Lift tab up and slide Right Deflector

to the left and lift up.

HP DesignJets 500 and 800 Series Printers Service Manual

8-11

Removal and Installation

3. Lift tab up and slide Middle Deflector to the right and lift up.

4. Lift tab up and slide Left Deflector to the right and lift up.

8-12

HP DesignJets 500 and 800 Series Printers Service Manual

Removal and Installation

Left End Roll-Feed

Removal

WARNING Switch off the printer and remove the power cord.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove the Left Hand Cover - Refer

to Page 8-5

2. Remove the Spindle.

3. Remove 1 T-20 screw (Type F) from

the Left Hand Roll-Feed (located on the inside next to the Electronics Module).

4. Remove 2 T-20 screws (Type F) from

the Left End Roll-Feed.

HP DesignJets 500 and 800 Series Printers Service Manual

8-13

Removal and Installation

5. Move Left End Roll-Feed down and remove from Printer.

8-14

HP DesignJets 500 and 800 Series Printers Service Manual

Removal and Installation

Right End Roll-Feed

Removal

WARNING Switch off the printer and remove the power cord.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove the Right Hand Cover - Refer

to Page 8-7.

2. Remove the Spindle.

3. Remove 1 T-20 screw (Type F) from

the Right Hand Roll-Feed.

4. Remove 2 T-20 screws (Type F) from

the Right Hand Roll-Feed (located on the inside).

HP DesignJets 500 and 800 Series Printers Service Manual

8-15

Removal and Installation

5. Remove Right Hand Roll-Feed.

8-16

HP DesignJets 500 and 800 Series Printers Service Manual

Removal and Installation

Back Platen

Removal

WARNING Switch off the printer and remove the power cord.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove the Spindle.

2. Make sure the Media Lever is in the

UP Position.

3. Unclip the Media Sensor Cover and

remove from the Printer.

HP DesignJets 500 and 800 Series Printers Service Manual

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Removal and Installation

4. Unclip the Media Sensor from underneath the Back Platen.

5. Remove 2 T -15 screws (Type E) from the Back Platen.

6. Remove the Back Platen by pulling it evenly towards you.

NOTE Make sure that the Media

Sensor is not atta ched to the Back Platen to prevent pulling the cable and breaking the sensor.

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HP DesignJets 500 and 800 Series Printers Service Manual

Removal and Installation

Media Sensor

Removal

WARNING Switch off the printer and remove the power cord.

1. Remove the Right Hand Cover - Refer

to Page 8-7.

2. Remove the Spindle.

3. Disconnect the Media Sensor Cable

from the ISS PCA.

4. Unclip the Media Sensor Cover and

remove from the Printer.

5. Unclip the Media Sensor from

underneath the Back Platen. Route the Media Sensor cable out where necessary and remove the Media Sensor.

HP DesignJets 500 and 800 Series Printers Service Manual

8-19

Removal and Installation

Formatter

Removal

WARNING Switch off the printer and remove the power cord.

1. Remove the LAN Card Cover from

the back of the Left Hand Cover.

2. With a flat end screwdriver, unscrew the 2 screws that attach the Formatter to the Electronics.

8-20

3. Remove the Formatter.

HP DesignJets 500 and 800 Series Printers Service Manual

Removal and Installation

LAN Card

Removal

WARNING Switch off the printer and remove the power cord.

1. Remove the LAN Card Cover from

the back of the Left Hand Cover.

2. Disconnect the LAN Cable from the

LAN Card

3. With a flat end screwdriver, unscrew

HP DesignJets 500 and 800 Series Printers Service Manual

the 2 screws that attach the LAN Card to the Electronics.

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Removal and Installation

4. Remove the LAN Card from the Printer.

8-22

HP DesignJets 500 and 800 Series Printers Service Manual

Removal and Installation

Spittoon

Removal

WARNING Switch off the printer and remove the power cord.

1. Remove the Left Hand Cover - Refer

to Page 8-5.

2. Release the cables that are attached to

Release

the Spittoon.

3. Press in the 2 clips to release the

Spittoon.

4. Lift up the Spittoon and remove from

the Printer.

HP DesignJets 500 and 800 Series Printers Service Manual

8-23

Removal and Installation

Electronics Module

Removal

WARNING Switch off the printer and remove the power cord.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove the Left Hand Cover - Refer

to Page 8-5.

2. Disconnect ALL the cables from the Electronics Module.

Disconnect

3. Remove 1 T-10 screw (Type B) from the top of the Electronics Module.

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HP DesignJets 500 and 800 Series Printers Service Manual

Loosen Only

Removal and Installation

4. Remove 1 T-10 screw (Type B) from

the back of the Electronics Module.

5. Loosen 1 T-10 screw (Type B) just

below the Electronics Module.

6. Lift the Electronics Module up and

towards the right and remove from

Printer.

HP DesignJets 500 and 800 Series Printers Service Manual

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Removal and Installation

Installing the Electronics Module

NOTE When installing the

Electronics Module, make sure that you insert the tab on the Printer into the slot in the Electronics Module.

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HP DesignJets 500 and 800 Series Printers Service Manual

Removal and Installation

Power Supply

Removal

WARNING Switch off the printer and remove the power cord.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove the Left Hand Cover - Refer

to Page 8-5.

2. Remove 1 T-10 (Type B) screw from

the Power Switch on the front of the Printer.

Disconnect

3. Disconnect the Power Supply Cable

from the Electronics Module.

HP DesignJets 500 and 800 Series Printers Service Manual

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Removal and Installation

4. Remove 2 T-10 screws (Type B) that secure Power Supply to the Bracket.

5. Remove the Power Supply as one assembly (Power Switch and Power Supply Unit).

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HP DesignJets 500 and 800 Series Printers Service Manual

Removal and Installation

Scan-Axis Motor Assembly

Removal

WARNING Switch off the printer and remove the power cord.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove the Left Hand Cover - Refer

to Page 8-5.

2. Remove the Right Hand Cover - Refer

to Page 8-7.

3. Remove the Power Supply - Refer to

Page 8-27.

4. Disconnect the Scan-Axis Motor

Cable from the Electronics Module.

5. Release the tension from the right

HP DesignJets 500 and 800 Series Printers Service Manual

hand side of the Belt by pulling the Tensioner down and pushing it towards you to lock it into position.

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