4

Removal and Replacement

1. Back Case...................................................................................4-3
2. Main PCA....................................................................................4-4
3. Front Case ..................................................................................4-6
4. Access Door ...............................................................................4-8
5. Input Tray ...................................................................................4-9
6. Key Panel PCA .........................................................................4-10
7. Spittoon Foam .........................................................................4-11
8. Service Station Wipers and Caps...........................................4-12

Mechanism Removal and Replacement

9. Carriage Motor.......................................................................4-13
10. Encoder Strip and Carriage Belt .........................................4-15
11. Carriage ..................................................................................4-17
12. Pinch Plate .............................................................................4-19
13. Pressure Plate Lever, Pressure Plate and
Service Station.......................................................................4-22
14. Output Roller Assembly, Platen Assembly, Paper Trough,
Paper Size Adjustment Bracket and In-Pinch Rollers ......4-25
15. Feed Roller Assembly and Left Support Assembly...........4-27
16. Service Station Motor ...........................................................4-29

Thi d t t d ith F M k 402

DeskJet 400 Hardware Training Guide
Removal and Replacement

This manual numbers each removal and replacement procedure to help you easily
locate procedures. For example, if a procedure requires you to first do another
procedure given elsewhere in the manual the text may say, “First remove the front
case, using removal procedure 1.”

N O T E
The procedures in this chapter are removal procedures. To do the replacement
procedure, reverse the removal procedure, unless stated otherwise.

Removal and Replacement Tools

• phillips screwdriver
• electrostatic grounding heel strap
• needle-nose pliers
• flat blade screwdriver
• #13 knitting needle
• feed roller spring compression tool
• E-clip applicator ETH-5 O-type

Before You Begin

Before starting a removal procedure, do the following:

1. Remove the print cartridge. You may place the print cartridge in a plastic bag to
reduce the possibility of ink clogs in the nozzles and ink loss due to
evaporation.

2. Turn off the printer and disconnect the power adapter.

3. Disconnect the interface cable.

C A U T I O N
Before working with the printer, be sure to wear electrostatic grounding heel
straps to prevent damage to the electronic components.

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1. Back Case

1. Be sure the clips on the Centronics plug do not block the 2. Push down on the top of the back case with the heel of
case removal. Position them to stick straight out from the your hand and move it towards the back.
plug.

3. This should release the five catches holding the back

case to the front case, and the back case will pop off.

Replacement: Be sure the Centronics connector cover plate is attached to the mechanism and that the
Centronics connector cover plate slides into the slot in the back case.

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2. Main PCA
Tool required: Phillips screwdriver.

1. First remove the back case, removal procedure 1. 2. Push the Centronics connector cover plate in towards
the Centronics connector and pry it up and out of the
notch in the chassis.

3. Remove the six connectors to the Main PCA. 4. Pull up on both ends of the two clamps holding in the two
flat cables.

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5. Remove the two flat cables. 6. Unscrew the five screws holding the Main PCA to the
chassis. The PCA will come off when you remove the last
screw.

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3. Front Case
Tools required: Flat blade screwdriver.

1. First remove the back case, removal procedure 1. 2. If you have not removed the Main PCA, disconnect the
key panel connector from the Main PCA.

3. To release the catches at the bottom sides of the front 4. To release the two catches at the top of the front case,
case, pull out and up on each left and right side. push back and pull up on each left and right side of the
front case.

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5. To release the tab at the bottom of the front case from the 6. Be sure the envelope lever is down and does not block
slot in the printer’s base, pry up on the tab with a flat removal. Lift the front case away from the mechanism.
blade screwdriver.

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4. Access Door

1. With the front case on the printer, open the access door. 2. Hold the access door by its sides and push down with
your thumbs on the printer’s front cover. The access door
pops off.

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Removal and Replacement

5. Input Tray

1. First remove the back case, access door and front case, 2. Stand the front case on its left side, with the input tray
removal procedures 1, 4 and 3. open at a 90 degree angle.

3. Push down on the side of the input tray with one hand 4. When the front case pin is clear of the slot in the input
and twist up and back on the side of the front case with tray, remove the input tray by pulling it to the side.
the other hand.

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6. Key Panel PCA

1. First remove the back case and front case, removal 2. Lay down the front case with its front side down.
procedures 1, and 3.

3. Release the catch on one side of the key panel PCA with 4. Repeat step 3 for the catch on the other side of the key
the fingernail of one hand and pull that side slightly up panel PCA. Pull the key panel PCA up and out of the front
with the thumb and forefinger of the other hand. case.

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Removal and Replacement

7. Spittoon Foam
Tools required: Needle-nose pliers and flat blade screwdriver.

1. To remove the spittoon foam without removing the front 2. If the print cartridge carriage is locked in the service
case, open the printer access door and move the print station, use a flat blade screwdriver to turn the service
cartridge carriage to the left. station gear through the slot in the printer’s base. Turn
the gear until it unlocks the carriage. (See note below.)

3. You can use the needle-nose pliers to pull the spittoon

foam out of the spittoon.

N O T E
Be careful not to damage the plastic service station gear with the screwdriver.

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8. Service Station Wipers and Caps

Tools required: Needle-nose pliers and flat blade screwdriver.

1. First remove the back case and front case, removal 2. If the service station is locked in position, use a flat blade
procedures 1, and 3. screwdriver to unlock it, by rotating the service station
gear through the slot in the bottom of the printer. (See
note on previous page.)

3. With the service station unlocked, rotate it with your 4. Remove a wiper or cap by pulling up with the needle-
finger until the wiper or cap shows. nose pliers.

Replacement: When replacing wipers or caps, be sure the service station is correctly aligned, see the
first “Solution” in the table on page 2-18. When replacing the color cap, be sure the beveled edge is up to
ensure correct cartridge sealing.

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Removal and Replacement

Mechanism Removal and Replacement

9. Carriage Motor
Tool required: Phillips screwdriver.

1. First remove the back case and front case, removal 2. Remove the two connectors for the carriage and paper
procedures 1, and 3. motors from the Main PCA.

3. Remove the carriage and paper motor wires from the 4. Untwist the carriage motor wires from the paper motor
wire holders on the chassis. wires.

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Removal and Replacement

5. Use the Phillips screwdriver to unscrew the two screws 6. Unhook the carriage motor bracket and remove the
holding the carriage motor. motor from the chassis.

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Removal and Replacement

10. Encoder Strip and Carriage Belt

Tool required: Flat blade screwdriver.

1. First remove the back case, front case, and carriage 2. Press on the left end of the upper carriage rod to release
motor, removal procedures 1, 3 and 9. the pressure on the E-clip; then remove the E-clip with
the flat blade screwdriver.

3. Slide out the upper carriage rod to the left. Be sure to 4. Remove the left end of the encoder strip from the
save the wave washer at the right end of the rod. encoder spring.

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5. Turn the encoder strip to remove it from the hook on the 6. With the flat blade screwdriver, remove the E-clip from
right side of the printer. the left end of the lower carriage rod.

7. Push on the right end of the lower carriage rod and free 8. Remove the carriage belt from the carriage.
the carriage rod.

Replacement: Whenever you remove and replace a carriage belt, you must adjust the pen to paper
spacing. To do the pen to paper spacing adjustment, you must centre the lower carriage rod bushings
before replacing the lower carriage rod. See chapter 5, Calibrations.
When replacing the upper carriage rod, be sure to first move the carriage to the far left. This allows the
rod to immediately slide into the carriage and prevents grease on the rod from contaminating the
encoder strip.

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11. Carriage

1. First remove the back case, Main PCA, front case, 2. Unhook the clip holding the back flex cable holder to the
carriage motor, and carriage belt, removal procedures 1, chassis.
2, 3, 9 and 10.

3. Remove the flex cable from the back flex cable holder. 4. Unhook the clip holding the front flex cable holder to the
chassis.

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DeskJet 400 Hardware Training Guide
Removal and Replacement

5. Remove the sleeve and bushing from the left end of the 6. Slide the carriage to the left off the lower carriage rod.
carriage rod.

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12. Pinch Plate

Tool required: Phillips screwdriver.

1. First remove the back case, Main PCA, and front case, 2. Remove the carriage motor and paper motor wires from
removal procedures 1, 2, and 3. the wire holders on the chassis.

3. Untwist the carriage motor wires from the paper motor 4. Remove the service station and OOPS flag wires from the
wires. wire holders on the back of the chassis.

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Removal and Replacement

5. Unscrew the five screws holding the base to the chassis 6. From the back, unscrew the four self-taping screws
and remove the base. holding the print zone to the chassis.

7. From the front, unscrew the four machine screws 8. Unhook the pinch plate springs from the hooks on the
holding the print zone to the chassis, and remove the chassis.
print zone from the chassis.

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Removal and Replacement

9. Slide the pinch plate rod to the left, until the right side of 10.Slide the pinch plate rod to the right and remove the
the pinch plate comes loose. pinch plate.

Replacement: When replacing the pinch plate, do not hook the pinch plate springs to their hooks on the
chassis until after replacing the print zone. When you do hook on the pinch plate springs, use a #13
knitting needle to more easily hook the springs onto their hooks on the chassis.

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Removal and Replacement

13. Pressure Plate Lever, Pressure Plate, and

Service Station
Tool required: Phillips screwdriver.

1. First remove the back case, Main PCA, and front case, 2. Remove the carriage motor and paper motor wires from
removal procedures 1, 2, and 3. the wire holders on the chassis.

3. Untwist the carriage motor wires from the paper motor 4. Remove the service station and OOPS flag wires from the
wires. wire holders on the back of the chassis.

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5. Unscrew the five screws holding the base to the chassis 6. From the back, unscrew the four self-taping screws
and remove the base. holding the print zone to the chassis.

7. From the front, unscrew the four machine screws 8. Remove the loose pressure plate and pressure plate
holding the print zone to the chassis, and remove the lever.
print zone from the chassis.

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Removal and Replacement

9. Untwist the service station wires from the OOPS wires

and remove the service station to the right.

Replacement: When replacing the base:

1. Remove the paper adjust lever from the base.
2. Use tweezers to hold back the paper size adjustment bracket spring while you push the lever into the
clip on the paper size adjustment bracket, as shown in the figure below:

3. With the lever in place, fit the base on to the lever and the chassis; then screw the base to the chassis.

Be sure the hook on the base fits into the hook on the pressure plate. The pressure plate should be free
to move and will rattle when you shake the mechanism.

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Removal and Replacement

14. Output Roller Assembly, Platen Assembly,

Paper Trough, Paper Size Adjustment Bracket, and
Pinch Rollers
Tool required: Phillips screwdriver and flat blade screwdriver.

1. First remove the back case, Main PCA, front case, and 2. Use a Phillips screwdriver to unscrew and remove the
service station, removal procedures 1, 2, 3, and 13. paper size adjustment bracket spring and spring holder
from the left support assembly.

3. With the paper size adjustment bracket to the right, pry 4. Remove the platen assembly and the paper trough from
out the clip with the flat blade screwdriver and lift out the the left support assembly.
output roller assembly.

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5. Remove the paper size adjustment bracket. 6. Lift the in-pinch rollers from the paper trough.

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15. Feed Roller Assembly and

Left Support Assembly
Tool required: Flat blade screwdriver.

1. First remove the back case, Main PCA, front case, 2. Pull out the bushing to the right.
service station, and output roller assembly..., removal
procedures 1, 2, 3, 13, and 14.

3. Bend the left wall of the left support assembly to the left 4. Pull the feed roller assembly up and out of the left
with the flat blade screwdriver to release the feed roller support assembly.
assembly.

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Removal and Replacement

Replacement of Feed Roller Assembly

Tool required: Feed Roller spring compression tool.

1. Compress the feed roller spring with the feed roller 2. Pull back the pivot lever of the left support assembly and
spring compression tool. position the feed roller assembly under it.

3. Ensure the washer on the feed roller assembly is to the 4. Pull out the feed roller spring compression tool; then
left of the transmission plate; then push the feed roller push the bushing on the feed roller assembly to the left
assembly down into the left support assembly. into the left support assembly.

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16. Service Station Motor

Tool required: Phillips screwdriver.

1. First remove the back case, Main PCA, front case, and 2. Unscrew the two screws holding the service station
service station, removal procedures 1, 2, 3, and 13. motor to the service station assembly.

3. Slide out the service station motor from the slot in the
service station assembly.

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