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8
Removal and Installation
HP DesignJet 430, 450C and 455CA Printers
8-1
Section Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . . . . . . . Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing a RAM or ROM SIMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Bail Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Rollfeed Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Left End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Right End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Electronics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Encoder Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Right Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Carriage Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Spittoon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Cutter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Drive Roller Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Media Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Pinch Arm Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Primer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Service Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Bail Lift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Engaging Lever Support . . . . . . . . . . . . . . . . . . . . . . . . Removing the Trailing Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Trailing Cable Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Drive Belt Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Drive Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstalling the Drive Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Pinch Arm Lift Mechanism . . . . . . . . . . . . . . . . . . . . . . Removing the Overdrive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Entry Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page
83 83 83 84 85 86 87 88 89 8 10 8 11 8 12 8 13 8 15 8 17 8 18 8 20 8 21 8 22 8 23 8 24 8 25 8 26 8 28 8 32 8 34 8 36 8 37 8 41 8 42 8 44 8 45 8 47 8 50 8 52
8-2
HP DesignJet 430, 450C and 455CA Printers
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 the end of 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. 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.
Reassembly
Most of the procedures in this chapter describe how to remove parts from the Printer. Unless otherwise specified, reinstall the parts in the reverse order of removing them.
Safety Precautions
(Safety symbols ' Immediately after the table of contents.) Review WARNING and CAUTION symbols and instructions before you service the Printers. 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 protective earth (ground) terminal. Switch the Printer 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.
Removal and Installation
HP DesignJet 430, 450C and 455CA Printers
8-3
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. Printer.
4. Ground (earth) your body while disassembling and working on the 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.
8-4
HP DesignJet 430, 450C and 455CA Printers
Removal and Installation
Required Tools
The following tools are required to remove and install the printer.
Long Torx screwdriver with the indicated attachments.
T8
T9
T10
T15
T20
T25
Pozidrive PZ1 screwdriver.
Small flat blade screwdriver. Nut driver with the indicated attachments.
and 3/16 inch 5.5 mm
Removal and Installation
HP DesignJet 430, 450C and 455CA Printers
8-5
Installing a RAM or ROM SIMM
A RAM SIMM provides the Printer with extra memory. A ROM SIMM contains new firmware code to override the internal firmware code.
1. Make sure that the Printer is switched OFF and that neither the power
cord nor an interface cable is connected. remove it.
2. Unscrew the cover plate and the cable clip at the back of the Printer, and
Torx-10
or
Flat
Before handling a SIMM, either put on a grounding wrist strap and attach the end to the metal chassis of the Printer, or touch the outer metal surface of the Printer with your hand. Otherwise, static electricity from your body could damage the SIMM.
3. Take the SIMM out of its bag, holding the SIMM only by the edges. 4. With the SIMM's small notch on the left and the metallic edge away from
you, load the SIMM into the slot:
D D
nearest to you (RAM SIMM). furthest from you (ROM SIMM).
To do this, first hold the SIMM at an angle, and then gradually push it back until it clicks vertically into place.
Notch
2
1
5. Replace the cover plate, the cable clip (held by the left screw) and the screws.
8-6
HP DesignJet 430, 450C and 455CA Printers
Removal and Installation
Removing the Bail Assembly
Removal 1. Open the Top Cover.
2. Manually move the carriage assembly to the left side of the Printer. 3. Push one of the plastic ends of the bail assembly towards the center of the
Printer to release it from the hole in the sideplate, and lift the bail out of the Printer. If the Mark Encoder (the white plastic part installed on the left hand side of the Drive Roller) prevents you from removing the Bail Assembly, use the Media Axis Test (details ' page 4 16) to turn the Drive Roller to a position where the Bail Assembly can be removed easily.
4. Remove the star wheel assemblies (item 2) by pushing together the
retaining clips and pulling them off
Installation 1. Install the bail assembly by installing the left side first, then install the bail assembly into holes in the left and right hand side chassis.
2. Close the Top Cover. 3. Perform Bail Service Test ' page 4 23.
Removal and Installation
HP DesignJet 430, 450C and 455CA Printers
8-7
Removing the Top Cover
1. Open the top cover. 2. Push the right hand side of the cover slightly back, so that the rightmost
hinge uncouples.
3. Slide the cover to the left, so that the other hinges uncouple.
Reassembling: Close the cover and click each hinge into place.
4. Remove the cover from the Printer.
8-8
HP DesignJet 430, 450C and 455CA Printers
Removal and Installation
Removing the Rollfeed Assembly
Refer to figure 1. Removal 1. Remove one screw (Item 1) from the rear that attaches the Right Rollfeed Assembly (Item 2) to the Printer.
2. Slide the Right Rollfeed Assembly (Item 2) forward and remove it from
the Printer.
3. Remove one screw (Item 1) from the rear that attaches the Left Rollfeed
Assembly (Item 3) to the Printer. Printer.
4. Slide the Left Rollfeed Assembly (Item 3) forward and remove it from the
1
3
2 Figure 1: Rollfeed Assembly
Removal and Installation
HP DesignJet 430, 450C and 455CA Printers
8-9
Removing the Left End Cover
Removal 1. Remove the top cover ' page 8 8.
2. Remove the Left Rollfeed Assembly ' page 8 9. 3. Release the three clips at the bottom of the end cover: first the side clip,
then the front and back clips. These may be stiff.
B
A
C
4. Pull the end cover up, and remove it from the Printer.
Reassembling: It's not easy to reinstall the end covers on the Printer. With some practice, you should learn the knack. As a guide, before you replace an end cover, take a look at the various clips on its inside, and identify where they fit on the Printer. Make sure that the primer plunger is installed properly when reinstalling the end cover.
8-10
HP DesignJet 430, 450C and 455CA Printers
Removal and Installation
Removing the Right End Cover
Refer to figure 2. Removal 1. Remove the top cover ' page 8 8.
2. Remove the Right Rollfeed Assembly ' page 8 9. 3. Pull the Printer on/off switch (item 1) out of the right end cover (item 2). 4. Release the three clips at the bottom of the right end cover: first the side
clip, then the front and back clips. These may be stiff.
5. Pull the end cover up, taking care not to damage the front panel cables. 6. Inside the end cover, press the two tabs of the front panel towards each
other, and remove the front panel assembly from the end cover.
7. To be able to easily use the front panel, when the right end cover has been
removed, slide the front panel assembly onto the metal base of the Printer as shown. 1
B
A C
2
Figure 2: Right End Cover
Removal and Installation
HP DesignJet 430, 450C and 455CA Printers
8-11
Removing the Front Panel Assembly
Removal 1. Remove the left end cover ' page 8 10.
2. When removing the front panel, lift (but do not remove) the brown or
black clip in the J1 connector before removing the front panel (FP) cable. You don't need to use any force at all.
Be very careful when disconnecting the front panel connector from the Main PCA. If the cable is pulled too hard when removing the front panel it can damage the J1 front panel connector in the Main PCA which means that the complete electronics module has to be replaced. If you follow the instructions above, you will not damage the J1 connector: Remember that the clip must not be removed completely. If removed completely, the clip will be destroyed. Installation 1. When installing the front panel, pull the brown or black clip and insert the cable into the J1 connector. Once the cable is inside the connector, push the brown or black clip down to hold the cable in place. The conductive part (metallic part) of the cable must face the Main PCA.
REMEMBER THAT PULLING THE CABLE WITHOUT RELEASING THE BROWN OR BLACK CLIP WILL DAMAGE THE CONNECTOR IN WHICH CASE IT WILL DESTROY THE COMPLETE ELECTRONICS MODULE.
2. Make sure that the Front Panel cable is properly routed by the clips inside
the Right end cover and remains underneath the Spittoon at all times. If the Cable is not routed correctly, the Cutter Assembly can trap the cable and damage it.
8-12
HP DesignJet 430, 450C and 455CA Printers
Removal and Installation
Removing the Electronics Module
Refer to figure 3 ' page 14. Important Information The Printer firmware is contained either on a flash ROM SIMM at the back of the Printer or on a masked ROM inside the electronics module. The firmware revision level, for example A.01.03, is printed by the Printer on the setup sheet and on the service configuration plot. The revision level is also printed on a label on any flash ROM SIMM. Do not open the electronics module. Important: When replacing the electronics module, always remember to check the firmware revision level of the new electronics module. The revision level will be printed on the top surface of the module. Also, check the firmware revision level of the ROM SIMM installed in the old electronics module. With this information you must do the following: 1. If the firmware revision level of the ROM SIMM in the old electronics module is lower than the firmware revision level of the new electronics module, then you must not install the ROM SIMM into the module. 2. If the firmware revision level of the ROM SIMM in the old electronics module is higher than the firmware revision level of the new electronics module, then you must install the ROM SIMM into the module. Example 1: The ROM SIMM firmware revision level is A.01.03 and the firmware revision level of the electronics module is A.01.04. You would use the electronics module without the ROM SIMM installed. Example 2: The ROM SIMM firmware revision level is A.01.05 and the firmware revision level of the electronics module is A.01.04. You would use the electronics module with the ROM SIMM installed. Removal The electronics module is a field replaceable part. You do not need to open it. If it is faulty, exchange it for a new one.
1. Remove the right end cover ' page 8 11. 2. Disconnect the front panel assembly from the main PCA. 3. Unscrew the cover plate at the back of the Printer, and remove it. 4. Remove one screw (item 1) and washer (item 2) from the back cover.
Removal and Installation
HP DesignJet 430, 450C and 455CA Printers
8-13
5. Remove one screw (item 3) and washer (item 4) from the floor of the
electronics module (item 5).
6. Insert a flat head screwdriver in to the slot at the back of the Printer to
unlatch the electronics module from the back cover.
7. At the back of the Printer, ensure that the two small wire clamps of the
parallel port are positioned flush against the electronics module
8. Push the electronics module towards the front of the Printer. 9. Pull the electronics module to the right to easily access the connectors. 10. Disconnect all cables from the visible part of the main PCA.
Prevent tugging on the cables at the point of connection by leaving slack between the connectors and the clips.
11. Pull the electronics module further to the right and out of the Printer. 12. If you are changing the electronics module for a new one, remove the RAM
SIMM (if installed) from the old module and install it into the new one. Refer to page 8 13 before installing the ROM SIMM from the old module into the new module. 2 1
3
5
4
Figure 3: Electronics Module
8-14
HP DesignJet 430, 450C and 455CA Printers
Removal and Installation
Removing the Encoder Strip
Refer to figure 4 ' page 16. Removal 1. Move the cartridge carriage to the left, over the service station.
2. Remove the right end cover ' page 8 11. 3. Remove the left end cover ' page 8 10. 4. Disconnect the trailing cable from the main PCA and from the guides on
the right bracket. Fold the trailing cable upwards and store it on the trailing cable guide. encoder strip (item 2) to the encoder strip spring (item 3). to the left bracket (item 6).
5. On the right hand side, remove the two nuts (item 1) that secure the 6. Remove the screw (item 4) and washer (item 5) that secure the encoder strip 7. Compressing the encoder strip spring to release tension on the encoder
strip, carefully release the encoder strip from the pin on the spring.
8. Carefully release the encoder strip from the left bracket. 9. Carefully pull the encoder strip to the right, through and out of the
carriage assembly and lay it on a flat surface.
Installation 1. Move the cartridge carriage to the left, over the service station.
2. Ensure that the encoder strip is oriented with the transparent area up. 3. Feed the encoder strip through the cartridge carriage from right to left. 4. Temporarily, rest the loose strip safely on the drive roller. 5. Slip the left end of the strip over the plastic pin on the left bracket (item 6),
and press it right to the base of the pin. retain the encoder strip.
6. Loosely fit, but do not tighten, the washer (item 5) and screw (item 4) to 7. Slip the right side of the encoder strip (item 2) over the two pins on the
encoder strip spring (item 3) and replace the two nuts (item 1) on the right side, and slightly tighten the nuts.
8. Slightly tighten the screw (item 4) on the left side. 9. Slide the carriage back and forth the length of its travel to ensure free
movement. The encoder strip should not bind or rub on the carriage.
Removal and Installation
HP DesignJet 430, 450C and 455CA Printers
8-15
3
2
1
6 5 4
Figure 4: Encoder Strip
8-16
HP DesignJet 430, 450C and 455CA Printers
Removal and Installation
Removing the Right Bracket
Refer to figure 5. Removal 1. Remove the encoder strip ' page 8 15.
2. Remove the screw (item 1) that attaches the right bracket (item 2) to the
Printer chassis.
3. Pull the right bracket to the right, and remove it from the Printer.
2 1
Figure 5: Right Bracket
Removal and Installation
HP DesignJet 430, 450C and 455CA Printers
8-17
Removing the Carriage Motor
Removal 1. Remove the right bracket ' page 8 17.
2. Disconnect the carriage motor cable from the main PCA (connector MOT
Y),
and from the clip at the back of the Printer.
In the following step, take care not to break the black plastic tab on top of the motor.
3. Press the carriage motor towards the left, and remove the belt from the
motor shaft.
If you need greater maneuverability of the motor, press the black plastic tab on top very slightly downwards.
B
A
4. Slightly rotate the motor on its hinge until the indicated part of the black
plastic is parallel with the side of the chassis beam.
Beam
Black Plastic
5. Pull the motor out to the right of the Printer.
8-18
HP DesignJet 430, 450C and 455CA Printers
Removal and Installation
The motor may be stiff.
Installation 1. There is one spring on the motor assembly which fits onto the protruding plastic part on top of the motor. Position this part inside the chassis beam.
Also, make sure the belt is correctly positioned on the grooves of the shaft.
Removal and Installation
HP DesignJet 430, 450C and 455CA Printers
8-19
Removing the Spittoon
Refer to figure 6. Removal 1. Remove the right end cover ' page 8 11.
2. Remove the screw (item 1) and washer (item 2) that attaches the spittoon
(item 3) to the right side plate. the Printer.
3. Rotate the Spittoon slightly and Slide it to the right, and remove it from
3
2
1
Figure 6: Spittoon
8-20
HP DesignJet 430, 450C and 455CA Printers
Removal and Installation
Removing the Cutter Assembly
Refer to figure 7. Removal 1. Remove the Spittoon ' page 8 20.
2. Remove the right bracket ' page 8 17. 3. Slide the Cutter Assembly (item 1) (including the Cutter Bushing) out of
the right side of the printer.
1
Figure 7: Cutter Assembly
Removal and Installation
HP DesignJet 430, 450C and 455CA Printers
8-21
Removing the Drive Roller Gear
Removal 1. Remove the spittoon ' page 8 20.
2. Remove the two screws that secure the drive roller gear to the drive roller
shaft.
Torx-10
3. Remove the drive roller gear from the drive roller shaft.
The gear may be stiff.
Reassembling: The worm pinion and drive roller gear mesh slightly during use. Don't install a new motor and an old gear, or vice versa: install the gear that comes with the motor. Apply the grease that comes with the new motor to the worm pinion and drive roller gear. Reassembling: Push the gear onto the shaft as far as it will go. Align the holes on the gear with the holes on the shaft. Always calibrate the X axis after reassembling the motor or the gear ' page 5 2.
8-22
HP DesignJet 430, 450C and 455CA Printers
Removal and Installation
Removing the Media Motor Assembly
Refer to figure 8. Removal 1. Remove the spittoon ' page 8 20.
2. Remove the Drive Roller Gear ' page 8 22. 3. Disconnect the media motor cable and the flat media axis encoder cable
from the main PCA (connectors labeled MOT X and ENC X respectively), and from the clip at the back of the Printer. mounting bracket (item 3) to the Printer Chassis.
4. Remove the three screws (item 1) and washers (item 2) that secure the 5. Remove the Mounting Bracket complete with the Media Motor Assembly.
Reassembling: The worm pinion and drive roller gear mesh slightly during use. Don't install a new motor and an old gear, or vice versa: install the gear that comes with the motor. Apply the grease that comes with the new motor to the worm pinion and drive roller gear. Calibration: After having reassembled the Printer, perform the accuracy calibration (Details ' chapter 5.)
3 2 1
Figure 8: Media Motor Assembly
Removal and Installation
HP DesignJet 430, 450C and 455CA Printers
8-23
Removing the Pinch Arm Mechanism
Refer to figure 9. Removal 1. Remove the Media Motor ' page 8 23.
2. Remove one screw (item 1) and washer (item 2) that attaches the
pinch arm sensor (item 3) to the right side plate. Remove the Pinch arm sensor (item 3).
3. Remove the spring (Item 4). 4. Remove one screw (item 5) that attaches the Pinch arm lever (item 6) to the
left piece of the right cam journal assembly (item 7). Remove the Pinch arm lever (item 6). (item 9) to the Pinch arm Bar Cam (item 10).
5. Loosen one screw (item 8) that attaches the right cam journal assembly 6. Remove the three parts of the right cam journal assembly (items 7, 9 and 11).
10
3
2 1
6
8 7 5 4 11 9
Figure 9: Pinch arm Mechanism
8-24
HP DesignJet 430, 450C and 455CA Printers
Removal and Installation
Removing the Primer Assembly
Removal 1. Remove the left end cover ' page 8 10.
2. Disconnect the four short tubes from the ink separator.
3. Remove the screw that attaches the primer to the left side plate.
Torx-20
4. Slide the primer to the left, and remove it from the Printer.
Removal and Installation
HP DesignJet 430, 450C and 455CA Printers
8-25