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1. For all your Home and Office PC Printer Plotter and Network Needs We are never far away Our goal is to ship what you need when you need it No gimmicks and No games We ship the same day you order when ever possible You can always find us on the Web at http www computercareonline com All the best parts for your systems printers and plotters We carry in stock hard to find Half Height and Low Profile Modems Network Cards Even AGP and PCI Video cards In Stock everyday hard to find HP DesignJet Plotter parts and Belts Of course we always keep inks ribbons and toners in stock We offer Free Ground Shipping See website for details Their Specials are more g ee 3 i FREE xthan our low Everyday Prices Epara s a 4 See website for details Order Online E iii Anytime Visa See COD MasterCard 979 764 8508 Check American Express yww computercareonline com _ Money Order Removal and Installation 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 Su
2. 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 both tabs up and slide Right Deflector to the left and lift up NOTE Please note that in some printers the Right Deflector Bracket does not exist In this case the new Right Deflector which has a new design needs to be modified by breaking the hook at the bottom right hand side which if installed will interfere with the Pinch Arm Sensor 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 NOTE In some printers the Left Deflector is secured to the Deflector Holder with 2 screws In this case you MUST remove these 2 screws before performing step 4 5 Remove all the Deflector Holders from the Printer and install new ones that are in the Media Deflector kit 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 Remove 1 T 20 screw Type
3. removing the Axle Spring because you could damage the Encoder Disc 26 Remove the Encoder Disc Cover 27 Release the levers on both ends of the Drive Roller 8 90 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 28 Lift Drive Roller out of the Printer Make sure you take care when lifting the Drive Roller because the Encoder Disc could get damaged NOTE After replacing the Drive Roller or the Encoder Disc make sure you perform the Factory Advance Calibration gt Page 5 11 HP DesignJets 500 and 800 Series Printers Service Manual 8 9 Removal and Installation Gear Assemblies Removal WARNING Switch off the printer and remove the power cord 1 Remove the Spindle 2 Remove the Left Hand Cover Refer to Page 8 5 3 Remove the Right Hand Cover Refer to Page 8 7 4 Remove the Left and Right Trims 5 Remove the Front Panel Refer to 10 11 12 13 14 15 16 Page 8 9 Remove the Top Cover and Window Refer to Page 8 10 Remove all the Media Deflectors Refer to Page 8 11 Remove the Back Platen make sure the Lever is in the UP position Refer to Page 8 17 Remove the Media Sensor Refer to Page 8 19 Remove the Spittoon Refer to Page 8 23 Remove the Cutter Assembly Refer to Page 8 32 Remove the Cutter Guide Bracket Refer to Page 8 36 Remove the Drive Roller Encoder Sensor Refer to Page 8 38 Rem
4. T 20 screw Type F from the back of the Right Hand Cover 3 Keep the Ink Cartridge Door open and remove 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 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 Remove the Right Hand Trim Disconnect Front Panel Connector from the ISS PCA 4 Unclip the 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 m 2 T 20 screws for the 24 model mE 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
5. lift each piece of the Print Platen from the Printer NOTE The Print Platen is split into 2 pieces on the 24 model and into 3 pieces on the 42 model 8 56 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Service Station Holder 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 Right Hand Trim 4 Remove the Front Panel Assembly Refer to Page 8 9 5 Remove the Interconnect PCA Refer to Page 8 50 6 Remove the Service Station Refer to Page 8 52 7 Remove the Fork Idler Tensioner and Idler Pulley Refer to Page 8 74 8 Remove the Encoder Strip Refer to Page 8 76 9 Remove T 15 screw Type E that secures the Service Station Holder to the sideplate HP DesignJets 500 and 800 Series Printers Service Manual 8 57 Removal and Installation 10 Remove 1 T 15 screw Type E that secures the Service Station Holder to the sideplate located underneath the Service Station Holder 11 Remove 4 T 20 screws Type C that secure the Service Station Holder to the Printer Chassis 12 Remove the Service Station Holder 8 58 HP DesignJets 500 and 800 Series Printers Service Manual Interconnect Cable Removal Removal and Installation WARNING Switch
6. off the printer and remove the power cord 1 HP DesignJets 500 and 800 Series Printers Service Manual Remove the Left Hand Cover Refer to Page 8 5 Remove the Right Hand Cover Refer to Page 8 7 Remove the Electronics Module Refer to Page 8 24 Remove the Left Encoder Holder Refer to Page 8 33 Remove the Service Station Refer to Page 8 52 Remove the Service Station Holder Refer to Page 8 57 Slide the Cable out of the Printer from the right hand side NOTE Make sure when removing the cable that it does NOT scratch against the edge of the beam NOTE Make sure that the Plastic Protector is NOT removed while removing the Cable 8 59 Removal and Installation Ink Supply Tubes Removal 1 Perform the Service Utility Change Ink Tubes Refer to Page 4 26 2 Open the Window and locate the Carriage Assembly 3 Release the latch and lift up the Carriage Cover 4 Remove all the Printheads 8 60 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 5 Open the Ink Cartridge Access Cover 6 Remove all the Ink Cartridges 7 Switch OFF the Printer and remove the power cord HP DesignJets 500 and 800 Series Printers Service Manual 8 61 Removal and Installation 8 Remove the Top Cover and Window Refer to Page 8 0 9 Loosen 1 T 8 screw that secures the Tubes to the Carriage 10 Unclip the Tubes from the Carriage and l
7. printer and remove the power cord 1 Remove the Left Hand Cover Refer to Page 8 5 2 Remove the Right Hand Cover Refer to Page 8 7 3 Release the tension from the right hand side of the Bell by pulling the Tensioner down and pushing it towards you to lock it into position 4 Release the Belt from the Scan Axis Motor on the left hand side 8 74 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 5 Pull out the from the right hand side of the Printer and remove the Idler Pulley 6 Unlock the Tensioner and remove from the Printer NOTE If it is too difficult to unlock the tensioner by hand try using a Screwdriver as a lever instead HP DesignJets 500 and 800 Series Printers Service Manual 8 75 Removal and Installation Encoder Strip 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 1 T 15 screw Type E that secures the Encoder Strip to the Left Encoder Holder 4 Release the from the left hand side NOTE The Encoder Stripjis sharp so be careful when touching it 8 76 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 5 Release the Encoder Strip from the Service Station Holder 6 Remove the from the Printe
8. to lock it into position HP DesignJets 500 and 800 Series Printers Service Manual 8 29 Removal and Installation 6 Remove the left hand side of the from the Scan Axis Motor 7 Remove 2 T 20 screws Type C from the Scan Axis Motor NOTE Make sure that you keep hold of the Scan Axis Motor when removing the screws otherwise the Motor could fall and be damaged 8 Remove the Scan Axis Motor 8 30 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Installing the Scan Axis Motor When installing the Scan Axis Motor make sure that you insert the notch in the Printer into the slot in the Scan Axis Motor HP DesignJets 500 and 800 Series Printers Service Manual 8 31 Removal and Installation Cutter Assembly Removal WARNING Switch off the printer and remove the power cord 1 Select the Change Cutter option from the Front Panel Menu 2 Open the Window 3 Lift Tab UP and pull out the Cutter Assembly 8 32 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Left Encoder Holder 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 15 screw Type E from the Left Encoder Holder attaches the Encoder Strip to the Holder 3 Release the Encoder Strip from the left hand si
9. Assembly that includes the Cartridge Holder top and Tray bottom The complete Assembly must be removed installed together HP DesignJets 500 and 800 Series Printers Service Manual 8 49 Removal and Installation Interconnect PCA 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 Disconnect all the cables connected to the Interconnect PCA 3 Remove 1 T 15 screw Type E from the Interconnect PCA 8 50 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 4 Lift the Interconnect PCA and remove HP DesignJets 500 and 800 Series Printers Service Manual 8 51 Removal and Installation Service Station and Aerosol Fan Removal NOTE Refer to the table on Page 8 4 for information on screw types 1 Perform the Service Utility Unlock Carriage Refer to Page 4 23 NOTE Switch off the Printer after performing this Utility 2 Remove the Right Hand Cover Refer to Page 8 7 Manually move the Carriage out of the Service Station 4 Disconnect the Service Station and Aerosol Fan Cables connectors P5 and P9 from the Interconnect PCA 8 52 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 5 Remove 2 T 15 screws Type E from inside the Service Station 6 Make sure you lift the Carriag
10. 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 8 17 Removal and Installation 4 Unclip the Media Sensor from underneath the Bac
11. d to the Electronics HP DesignJets 500 and 800 Series Printers Service Manual 8 21 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 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 3 Remove 1 T 10 screw Type B from the top of the Electronics Module 8 24 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 4 Remove 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 8 25 Removal and Installation Installing the Electronics Module NOTE When insta
12. de NOTE The Encoder Stripjis sharp so be careful when touching it HP DesignJets 500 and 800 Series Printers Service Manual 8 33 Removal and Installation 4 Disconnect the Trailing Cable jand unclip the Ferrite and remove 5 Remove the Electronics Module Refer to Page 8 24 6 Remove 2 T 20 screws Type A from the Left Encoder Holder 7 Remove the Left Encoder Holder making sure that you first unclip both the Trailing Cable and the Interconnect Cable 8 34 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Cutter Bushing Removal WARNING Switch off the printer and remove the power cord 1 Remove the Left Hand Cover Refer to Page 8 5 2 Remove the Electronics Module Refer to Page 8 24 3 Remove the Cutter Assembly Refer to Page 8 32 4 Remove the Left Encoder Holder Refer to Page 8 33 5 Slide the Cutter Bushing to the Left and remove from the Printer HP DesignJets 500 and 800 Series Printers Service Manual 8 35 Removal and Installation Cutter Guide Bracket 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 Cutter from its position 3 Remove the Vacuum Fan Cable from the Cutter Guide Bracket 8 36 HP DesignJets 500 and 800 Series Printers Service Manual Removal and I
13. e Lock before sliding out the Service Station out of the Printer 7 Slide the Assembly towards you to the right and remove HP DesignJets 500 and 800 Series Printers Service Manual 8 53 Removal and Installation Installing the Service Station Aerosol Fan NOTE When installing the Service Station make sure that you line up the tabs on the Service Station with the structure of the Service Station Holder 8 54 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Cutter Guide Removal WARNING Switch off the printer and remove the power cord 1 Remove the Left Hand Cover Refer to Page 8 5 2 Remove the Cutter Assembly Refer to Page 8 32 3 Remove the Cutter Guide Bracket Refer to Page 8 36 4 Slide the Cutter Guide out of the Printer as shown in the drawing This 1s a cross sectional view of the Printer showing how the Cutter Guide is seated HP DesignJets 500 and 800 Series Printers Service Manual 8 55 Removal and Installation Print 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 Cutter Assembly Refer to Page 8 32 2 Remove the Cutter Guide Refer to Page 8 55 3 Remove the following screws Type G from the Print Platen m 24 Screws T 8 for the 24 model E 36 Screws T 8 for the 42 model 4 Pull the tabs out slightly and
14. ervice Manual Removal and Installation 18 Remove the Plastic Holder from the Printer 19 Release the Trailing Cable clips 20 Disconnect the Trailing Cable from the Electronics Module HP DesignJets 500 and 800 Series Printers Service Manual 8 45 Removal and Installation 21 Unclip the Ferrite and remove 22 Slide the Trailing Cable through the Carriage Assembly and remove 8 46 HP DesignJets 500 and 800 Series Printers Service Manual Installing the Trailing Cable HP DesignJets 500 and 800 Series Printers Service Manual NOTE Removal and Installation When installing the Trailing Cable make sure that you align the red lines on the Trailing Cable as shown in these drawings 8 47 Removal and Installation Ink Supply Station 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 Remove the Ink Cartridges 2 Remove the Right Hand Cover Refer to Page 8 7 3 Disconnect the Ink Supply Station Cables Connectors P2 and P4 from the Interconnect PCA 4 Release the Tubes Bracket from the Ink Supply Station by pushing the clips inwards and lifting up the Bracket 8 48 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 5 Remove T 15 screw Type E from the top of the Assembly 6 Remove the Ink Supply Station from the Printer NOTE The ISS is a complete
15. i i the indicated attachments Ts 710 715 Teo T15L Oo Nut driver with the indicated attachments ad DE 416 5 5 Inch mm a Small flat blade screwdriver HP DesignJets 500 and 800 Series Printers Service Manual 8 3 Removal and Installation Screw Types eff 80 Pantie os 0 pf o s rowe pese 015205 o o s ee Mind ossa 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 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
16. ift up 8 62 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 11 Unclip the tubes from the Tubes Guide 12 Release the Tubes Bracket from the Ink Supply Station by pushing the clips inwards and lifting up the Bracket 13 Remove the complete Ink Suppl Assembly from the Printer HP DesignJets 500 and 800 Series Printers Service Manual 8 63 Removal and Installation Vacuum Fan Removal WARNING Switch off the printer and remove the power cord 1 Remove the Left Hand Cover Refer to Page 8 5 2 Remove ALL the Media Deflectors Refer to Page 8 ey 3 Disconnect the Vacuum Fan Cable j from the Electronics Module 1 W Wy a a E bz i t I AA T a 7 57 4 Remove the Vacuum Fan Cable from the Cutter Guide Bracket 8 64 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 5 Unclip the Vacuum Fan Assembly from underneath the Printer NOTE Push in the clips of the Vacuum Fan starting from the right hand side 6 Remove the Vacuum Fan Assembly from the Printer NOTE When removing the Vacuum Fan Assembly make sure you pull the Vacuum Fan cable through the hole in the Chassis HP DesignJets 500 and 800 Series Printers Service Manual 8 65 Removal and Installation Pinch Arm Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for informa
17. k 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 attached to the Back Platen to prevent pulling the cable and breaking the sensor 8 18 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 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 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 to the Electronics 3 Remove the 8 20 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 the 2 screws that attach the LAN Car
18. lling the Electronics Module make sure that you insert the tab on the Printer into the slot in the Electronics Module 8 26 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 3 Disconnect the Power Supply Cable from the Electronics Module HP DesignJets 500 and 800 Series Printers Service Manual 8 27 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 8 28 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 VAVA SOCOLA 5 Release the tension from the right hand side of the Belt by pulling the Tensioner down and pushing it towards you
19. nstallation 4 Remove T 10 screw Type B from the Cutter Guide Bracket 5 Slide the Cutter Guide Bracket out of the Printer HP DesignJets 500 and 800 Series Printers Service Manual 8 37 Removal and Installation Drive Roller Encoder Sensor 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 Spittoon Refer to Page 8 23 3 Remove the Cutter Guide Bracket Refer to Page 8 36 4 Disconnect the Encoder Sensor Cable from the Electronics Module 5 Remove T 8 screw Type G from the Encoder Sensor Cover 8 38 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 6 Depress the clip and remove the Encoder Sensor Cover 7 Remove 1 T 8 screw Type G from the Encoder Sensor 8 Move the Encoder Sensor to the left and remove including the Encoder Sensor Cable HP DesignJets 500 and 800 Series Printers Service Manual 8 39 Removal and Installation Trailing Cable Removal NOTE Refer to the table on Page 8 4 for information on screw types 1 Perform the Service Utility Unlock Carriage Refer to Page 4 23 NOTE Switch off the Printer after performing this Utility 2 Remove the Left Hand Cover Refer to Page 8 5 3 Remove the Top Cover and Window Refer to Page 8 10 4 Manually move the carriage to
20. ove the Drive Roller Encoder Sensor Refer to Page 8 38 Remove the Ink Supply Station Refer to Page 8 48 Remove the Cutter Guide Refer to Page 8 55 8 86 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 16 Disconnect the Pinch Arm Sensor Cable from the Interconnect PCA 17 Disconnect the Paper Axis Motor Cables and the Vacuum Fan Cable from the Electronics Module 18 Remove 1 screw T 10 from the Grounding Strip HP DesignJets 500 and 800 Series Printers Service Manual 8 87 Removal and Installation 19 Remove screw T 15 from the Right Back Trim and remove trim 20 Remove screw T 15 from the Left Back Trim and remove trim 21 Remove 4 screws T 25 that secure the Top Part of the Printer to the Bottom Part from the Left Hand Side 8 88 HP DesignJets 500 and 800 Series Printers Service Manual HP DesignJets 500 and 800 Series Printers Service Manual 22 23 24 Removal and Installation Remove 4 screws T 25 that secure the Top Part of the Printer to the Bottom Part from the right hand side Make sure the Media Lever is in the UP Position and lift the complete Top Part of the Printer away from the Bottom Part NOTE The Top Part of the Printer is very heavy so 2 people should perform this step Remove 1 screw T 15 from the Axle Spring 8 89 Removal and Installation 25 Remove the Axle Spring NOTE Be very careful when
21. ove the Ink Supply Station Refer to Page 8 48 Remove the Cutter Guide Refer to Page 8 55 Remove the Paper Axis Motor Refer to Page 8 84 8 92 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 17 Remove the Drive Roller Refer to Page 8 86 18 Remove the 2 locking pins from the Gears 19 Remove the Gears HP DesignJets 500 and 800 Series Printers Service Manual 8 93 Removal and Installation 8 94 HP DesignJets 500 and 800 Series Printers Service Manual
22. pply Station 8 48 Interconnect PCA 8 50 Service Station and Aerosol Fan 8 52 Cutter Guide 8 55 Print Platen 8 56 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 and 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 replace 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
23. r HP DesignJets 500 and 800 Series Printers Service Manual 8 77 Removal and Installation Carriage Assembly Including Belt Removal L Perform the Service Utility Unlock Carriage Refer to Page 4 23 NOTE Switch off the Printer after 2 10 performing this Utility Remove the Left Hand Cover Refer to Page 8 5 Remove the Right Hand Cover Refer to Page 8 7 Remove the Top Cover and Window Refer to Page 8 10 Remove the Front Panel Assembly Refer to Page 8 9 Remove the Service Station Refer to Page 8 52 Remove the Fork Idler Tensioner and Idler Pulley Refer to Page 8 74 Remove the Encoder Strip Refer to Page 8 76 Remove the Service Station Holder Refer to Page 8 57 Manually move the carriage to the correct position to remove the Tubes Assembly from the Carriage 8 78 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 11 Release the latch and lift up the Carriage cover 12 Remove all the Printheads 13 Loosen 1 T 8 screw that secures the Tubes to the Carriage HP DesignJets 500 and 800 Series Printers Service Manual 8 79 Removal and Installation 14 Unclip the Tubes from the Carriage and lift up 15 Move the Tubes Assembly clear from the Carriage Assembly 16 Close the Carriage Cover 8 80 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 17 Unclip the Carriage Co
24. the correct position to remove the Tubes Assembly from the Carriage 5 Release the latch and lift up the Carriage Cover 8 40 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 6 Remove all the Printheads 7 Loosen 1 T 8 screw that secures the Tubes to the Carriage 8 Unclip the Tubes from the Carriage and lift up HP DesignJets 500 and 800 Series Printers Service Manual 8 41 Removal and Installation 9 Move the Tubes Assembly clear from the Carriage Assembly 10 Close the Carriage Cover 11 Unclip the Carriage Cover clip located on the left hand side of the Carriage use a screwdriver if necessary 8 42 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Se 12 Remove the clip securing the Remove SWN 13 Disconnect the Trailing Cable from the Carriage Assembly 14 Slide the Trailing Cablejout of the clip inside the Carriage Assembly and then lift up to free it from the Carriage HP DesignJets 500 and 800 Series Printers Service Manual 8 43 Removal and Installation 15 Move the Carriage Assembly to the right so that the Trailing Cable clips on the beam are visible 16 Release ALL the clips on the beam that secure the Trailing Cable 17 Slide the Plastic Holder that kept the Trailing Cable flat to the right to release it from the retaining clip 8 44 HP DesignJets 500 and 800 Series Printers S
25. tion on screw types 1 Remove the Spindle 2 Remove the Back Platen make sure the Pinch Arm Lever is in the UP Position Refer to Page 8 17 3 Remove 2 T 20 screws Type H from each Pinch Arm NOTE There 5 Pinch Arms in the 4 42 Model and 3 in the 24 Model 4 Remove the Pinch Arm s 8 66 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Pinch Arm Mechanism 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 Back Platen make sure the Pinch Arm Lever is in the UP Position Refer to Page 8 17 2 Remove ALL the Pinch Arms Refer to Page 8 66 3 Remove 1 T 15 screw Type E that attaches the Cam to the Lever 4 Remove 1 T 15 screw from the left hand side of the Cam HP DesignJets 500 and 800 Series Printers Service Manual 8 67 Removal and Installation 5 Open the Media Guide by unclipping it 6 While pulling the Media Clip down move the complete assembly to the left towards you and then to the right and remove completely 8 68 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Pinch Arm Lever 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 Make sure the Pinch Arm Le
26. to death or injury may result if you do not take the following precautions Ensure that the ac power outlet mains has a protective 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 x 1r Long Torx Screwdriver with i i i i
27. ve the power cord 1 Remove the Spindle 2 Remove the Left Hand Cover Refer to Page 8 5 3 Remove the Back Platen make sure the Lever is in the UP position Refer to Page 8 17 4 Disconnect the Paper Axis Motor Cables from the Electronics Module 5 Remove 2 T 15 screws Type J from the Paper Axis Motor NOTE Make sure that you keep hold of the Paper Axis Motor when removing the screws otherwise the Motor could fall and be damaged 8 84 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 6 Remove the Paper Axis Motor including the cables HP DesignJets 500 and 800 Series Printers Service Manual 8 85 Removal and Installation Drive Roller Removal WARNING Switch off the printer and remove the power cord 1 Remove the Spindle 2 Remove the Left Hand Cover Refer to Page 8 5 3 Remove the Right Hand Cover Refer to Page 8 7 4 Remove the Left and Right Trims 5 Remove the Front Panel Refer to 10 11 12 13 14 15 Page 8 9 Remove the Top Cover and Window Refer to Page 8 10 Remove all the Media Deflectors Refer to Page 8 11 Remove the Back Platen make sure the Lever is in the UP position Refer to Page 8 17 Remove the Media Sensor Refer to Page 8 19 Remove the Spittoon Refer to Page 8 23 Remove the Cutter Assembly Refer to Page 8 32 Remove the Cutter Guide Bracket Refer to Page 8 36 Rem
28. ver clip located on the left hand side of the Carriage use a screwdriver if necessary 18 Remove the clip securing the Trailing Cable 19 Disconnect the Trailing Cable from the Carriage Assembly HP DesignJets 500 and 800 Series Printers Service Manual 8 8 Removal and Installation 20 Slide the Trailing Cable out of the clip inside the Carriage Assembly and then lift up to free it from the Carriage 21 Slide the carriage including the to the right and out of the Printer 22 The Belt can then be slipped off the Carriage Clips 8 82 HP DesignJets 500 and 800 Series Printers Service Manual Installing the Carriage Assembly a n fie ENT ai a i lit m a i va ou wi Make sure that you insert these parts preload slider and slider when you you reassemble the Carriage Assembly 1 it En iii mij iamnm miam Lite cei tail miiia PO mii mii i ampaian niena ia eia Hill UHI Tey I il rene HEN kii lt Scan Axis Motor HP DesignJets 500 and 800 Series Printers Service Manual NOTE NOTE Removal and Installation When connecting the Trailing Cable to the Carriage make sure that you align the red lines on the Trailing Cable as shown in this drawing When installing the Belf make sure that you insert it into the Carriage as shown in this drawing Tensioner 8 83 Removal and Installation Paper Axis Motor Removal WARNING Switch off the printer and remo
29. ver is in the UP Position 3 Remove 1 T 15 screw Type I and washer that secures the Lever to the chassis HP DesignJets 500 and 800 Series Printers Service Manual 8 69 Removal and Installation 4 Remove T 15 screw Type E that secures the Lever to the Cam 5 Lower the Pinch Arm Lever and remove from the Printer including the lever bushing 8 70 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Pinch Arm Sensor 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 Raise the Media Lever 3 Lift tab up and slide Right Deflector to the left and lift up HP DesignJets 500 and 800 Series Printers Service Manual 8 71 Removal and Installation 4 Remove T 20 screw Type C from the Right Deflector Bracket 6 Remove 1 T 8 screw Type G from the Pinch Arm Sensor 8 72 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 7 Disconnect the Pinch Arm Sensor Cable from the Interconnect PCA Aittce ASE SOAS Beak cele PIRAT R A 4 a Coe 4 Ce Chee 8 Remove the Pinch Arm Sensor including the cable HP DesignJets 500 and 800 Series Printers Service Manual 8 73 Removal and Installation Fork Idler Tensioner and Idler Pulley Removal WARNING Switch off the

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