DeskJet 65x Disassembly Procedures

Removal and Replacement

Chapter Contents
REMOVING CASE PARTS............................................................................................ 1
1. REMOVING THE ACCESS DOOR .................................................................................... 1
2. REMOVING THE TOP COVER......................................................................................... 1
3. REMOVING THE WINGS ................................................................................................ 2
4. REMOVING THE OUTPUT TRAY .................................................................................... 2
5. DISASSEMBLING THE OUTPUT TRAY ............................................................................ 3
REMOVING INTERNAL ASSEMBLIES ..................................................................... 4
6. REMOVING THE KEYPAD .............................................................................................. 4
7. REMOVING THE PRESSURE PLATE .......................................................................... 5
8. REMOVING THE MECHANISM ASSEMBLY ..................................................................... 5
9. REMOVING THE LOGIC PCA ........................................................................................ 5
10. REMOVING THE GROUND PLANE AND SENSOR PCA .................................................. 6
11. REMOVING THE ACCESS DOOR SENSOR LEVER .......................................................... 6
REMOVING MECHANISM CARRIAGE PATH COMPONENTS .......................... 7
12. REMOVING THE TENSION BRACKET, SPRING, IDLER PULLEY, AND IDLER SHAFT ...... 7
13. REMOVING THE ENCODER STRIP ................................................................................ 7
14. REMOVING THE CARRIAGE ROD AND RETAINER ........................................................ 8
15. REMOVING THE CARRIAGE ASSEMBLY AND CARRIAGE BELT .................................... 9
16. REMOVING THE REAR RAIL ....................................................................................... 9
17. REMOVING THE CARRIAGE MOTOR ......................................................................... 10
REMOVING MECHANISM PAPER FEED COMPONENTS ................................. 10
18. REMOVING THE PAPER MOTOR AND CLUSTER GEAR ............................................... 10
19. REMOVING THE PAPER GUIDE ASSEMBLY, UPPER AND LOWER PINCH ROLLERS,
SPITTOON, CLUTCH ACTUATOR, PRELOADER, PIVOT ASSEMBLY, PIVOT ADJUSTER, AND
PAPER SEPARATOR ........................................................................................................ 11
20. REMOVING THE SERVICE STATION ASSEMBLY ........................................................ 12
REMOVING SERVICE STATION COMPONENTS ................................................ 13
21. REMOVING THE WIPERS AND PEN CAPS ................................................................... 13
22. REMOVING THE ABSORBER ...................................................................................... 13

Removing Case Parts

1. Removing the Access Door
With the access door partially open, pull the access door off of the two hinges.

Note
Even though this procedure requires a significant amount of force to separate the access door
from the top cover, care should be taken to avoid breaking the hinge points on the access door
and top cover.

2. Removing the Top Cover

Tool Required: Flat Blade Screwdriver.
1. First remove the Access Door, removal procedure 1. Then turn the printer on its back and
remove the end caps by pulling them towards you.

2. With the back of the printer facing you, remove the I/O cover by releasing the three
latches.

3. Now turn the printer on its back and release the six top cover latches and slide the cover
off.

3. Removing the Wings

Tool Required: Flat Blade Screwdriver
1. First remove the access door and the top cover, removal procedures 1 and 2.
2. To remove the Wings, press on the three tabs on the wing base and lift the Wing from the
chassis.

4. Removing the Output Tray

Tool Required: Flat Blade Screwdriver
1. First remove the access door and the top cover, removal procedures 1 and 2.
2. Remove the Output Tray by releasing the two latches on each side of the tray frame and
sliding the Output Tray from the chassis.

5. Disassembling the Output Tray

1. To remove the output tray bar, bend the bar to allow the bar pivot pin to clear the frame.
Then remove the bar from the frame.

2. Remove the drawer by pulling up on the back of the drawer while sliding the drawer out
of the tray.

3. To remove the length adjuster, press on the guide pin from the bottom of the drawer.
Then slide the length adjuster forward and out of the drawer.

4. To remove the tray, flex the Frame away from the tray freeing the pivot pins. Then rotate
the tray away from the frame.

Removing Internal Assemblies

6. Removing the Keypad
Tool Required: Small Flat Blade Screwdriver.
1. First remove the Access Door and Top Cover, removal procedures 1 and 2.
2. Turn over the top cover and find the two tabs inside the top cover. Release the tabs and
remove the bezel from the top case.

3. Remove the buttons by releasing the two tabs and removing the buttons.

4. To remove the lightpipe, release the two tabs and remove the lightpipe from the case.

7. Removing the Pressure Plate

Tool Required: Flat Blade Screwdriver.

1. First remove the Access Door and Top Cover, removal procedures 1 and 2.
2. Push back the pressure plate latch and release the pressure plate.

3. Lift the pressure plate from the mechanism.

8. Removing the Mechanism Assembly
Tool Required: Posidrive Screwdriver.

1. First remove the Access Door and Top Cover, removal procedures 1 and 2.

2. Lift the mechanism from the base after removing four screws (green circles indicate
screw locations).

9. Removing the Logic PCA

Tools Required: Pozidriv and flat blade screwdrivers.
1. With the printer on, open the access door to move the carriage to the center of the
mechanism.
2. With the carriage centered, unplug the printer.
3. Remove the Access Door and Top Cover, removal procedures 1 and 2.
4. Disconnect the two flex cables from the flex cable support.
5. Release the four flex cable ZIF (Zero Insertion Force) connectors by pushing out the clip
on the side of each connector with the screwdriver.
6. Remove the two flex cables from the four ZIF connectors.
7. Pull the two motor cables off their connectors on the Logic PCA.

8. Unscrew the Logic PCA mounting screws and remove the Logic PCA from the
mechanism.

Installing the logic PCA

To avoid damage when installing the logic PCA, make sure the cables that connect to the logic
PCA are properly routed.

10. Removing the Ground Plane and Sensor PCA

Tool Required: Pozidriv Screwdriver.
1. First remove the Access Door, Top Cover and Logic PCA, removal procedures I, 2 and 9.
2. Remove the two ground plane screws and lift the ground plane from the mechanism.

Installing the Ground Plane

When installing the ground plane, make sure the motor cables are routed through the notches on
the lower edge of the ground plane, see Installing the Logic PCA in section 9.

11. Removing the Access Door Sensor lever

Tool Required: Pozidriv Screwdriver.
1. With the printer on, open the access door to move the carriage to the center of the
mechanism.
2. With the carriage centered, unplug the printer.
3. Remove the Access Door and Top Cover, removal procedures 1 and 2.
4. With the sensor lever tilted forward, pull up on the lever and remove it from the
mechanism.

Removing Mechanism Carriage Path Components

12. Removing the Tension Bracket, Spring, Idler Pulley, and Idler Shaft
Tool Required: Broad Tweezers.
1. With the printer on, open the access door to move the carriage to the center of the
mechanism.
2. With the carriage centered, unplug the printer.
3. Remove the Access Door and Top Cover, removal procedures 1 and 2.
4. Release the carriage belt tension by pressing inward on the tension bracket and lifting the
carriage belt off of the carriage motor pulley.

5. Slide the idler pulley and idler shaft out of the tension bracket.

6. Push and hold in the belt tension bracket to release tension on the bracket. Use the
broad tweezers to pry up the bottom part of the bracket and unlatch it. Then pry down on
the top part of the bracket and ease it out.
7. Lift the tension bracket and spring from the mechanism.

13. Removing the Encoder Strip

1. With the printer on, open the access door to move the carriage to the center of the
mechanism.
2. With the carriage centered, unplug the printer.
3. Remove the Access Door and Top Cover, removal procedures 1 and 2.

4. Push inward on the encoder spring (located at the left end of the encoder) to release
tension on the encoder strip.

5. Disconnect the right end of the encoder from the right end of the mechanism.
6. Slide the encoder strip out of the carriage assembly and turn the encoder strip 90
degrees to remove it from the encoder spring.
Installing the Encoder Strip
When installing the encoder strip, be sure to route the encoder strip through the slot on the
carriage assembly.

14. Removing the Carriage Rod and Retainer

Tool Required: Flat Blade Screwdriver.
1. With the printer on, open the access door to move the carriage to the center of the
mechanism.
2. With the carriage centered, unplug the printer.
3. Remove the Access Door, Top Cover and Encoder Strip, removal procedures 1,2 and 13.
4. Release the carriage belt tension by pressing inward on the tension bracket and lifting the
carriage belt off of the carriage motor pulley (see procedure 12).
5. Using a flat blade screwdriver release the clip of the Carriage Rod Retainer, located on
the left end of the Carriage Rod.
6. Lift the Carriage Rod Retainer from the mechanism.

7. Lift the left end of the carriage rod from the metal hanger on the left side of the
mechanism. Do not remove the metal hanger (see note below).
8. Pull the carriage rod out of the carriage assembly.

Note
Do not remove the metal hangers from the mechanism. Removing them will severely impact the
pen to paper spacing adjustment.

15. Removing the Carriage Assembly and Carriage Belt

Tool Required: Flat Blade Screwdriver
1. With the printer on, open the access door to move the carriage to the center of the
mechanism.
2. With the carriage centered, unplug the printer.
3. Remove the Access Door, Top Cover, Encoder Strip and Carriage Rod, removal
procedures 1,2,13 and 14.
4. Disconnect the two flex cables from the flex cable support.
5. Release the four flex cable ZIF (Zero Insertion Force) connectors by pushing out the clip
on the side of each connector with the flat blade screwdriver.
6. Remove the two flex cables from the four ZIF connectors.
7. Remove the tension bracket, spring, idler pulley, and idler shaft (Procedure 12)
8. Lift the carriage assembly from the mechanism.

16. Removing the Rear Rail

Tool Required: Pozidriv Screwdriver.
1. With the printer on, open the access door to move the carriage to the center of the
mechanism.
2. With the carriage centered, unplug the printer.
3. Remove the Access Door and Top Cover, removal procedures 1 and 2.
4. Remove the two rear rail screws and lift the rear rail from the mechanism.

17. Removing the Carriage Motor

Tool Required: Pozidriv Screwdriver.

1. With the printer on, open the access door to move the carriage to the center of the
mechanism.
2. With the carriage centered, unplug the printer.
3. Remove the Access Door, Top Cover, and Mechanism Assembly, removal procedures 1,
2, and 8.
4. Disconnect the carriage motor cable from the logic PCA.
5. Release the carriage belt tension by pressing inward on the tension bracket and lifting the
carriage belt off of the carriage motor pulley (Procedure 12).
6. Remove the two carriage motor screws, at the left and right of the carriage motor pulley,
and lower the carriage motor from the mechanism.

Removing Mechanism Paper Feed Components

18. Removing the Paper Motor and Cluster Gear
Tool Required: Pozidriv Screwdriver.
1. First remove the Access Door and Top Cover, removal procedures 1 and 2.
2. Disconnect the paper motor cable from the logic PCA.
3. Remove the two paper motor screws and then remove the paper motor and cluster gear
from the mechanism.

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19. Removing the Paper Guide Assembly, Upper and lower Pinch Rollers,
Spittoon, Clutch Actuator, Preloader, Pivot Assembly, Pivot Adjuster, and
Paper Separator
Tool Required: Pozidriv Screwdriver.

1. With the printer on, open the access door to move the carriage to the center of the
mechanism.
2. With the carriage centered, unplug the printer.
3. Remove the Access Door, Top Cover, Encoder Strip, Carriage Rod and Carriage
Assembly, removal procedures 1,2,13,14 and 15.
4. Remove the two paper guide screws and lift the paper guide assembly from the
mechanism.

5. Remove the upper pinch rollers by pushing them down and out of the paper guide.

6. Remove the spittoon (containing the paper guide spring and the ink absorber) by lifting it
straight up.

7. Remove the clutch actuator by lifting it up. Remove the preloader by pulling it to the left
and up.

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8. Unscrew and remove the pivot adjuster.

Note: Moving the pivot adjuster requires the Pen to Pivot Adjustment to be performed.

9. When you lift the pivot assembly from the mechanism, disconnect the spring holding it to
the IN tray.

10. Lift the three lower pinch rollers and the paper separator from the mechanism.

20. Removing the Service Station Assembly

Tool Required: Pozidriv Screwdriver.

1. With the printer on, open the access door to move the carriage to the center of the
mechanism.
2. With the carriage centered, unplug the printer.
3. Remove the Access Door and Top Cover, removal procedures 1 and 2.
4. Remove the two service station assembly screws.

5. Lift the service station assembly from the mechanism.

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Removing Service Station Components

21. Removing the Wipers and Pen Caps
Tool Required: Flat Blade Screwdriver.

1. With the printer on, open the access door to move the carriage to the center of the
mechanism.
2. With the carriage centered, unplug the printer.
3. Remove the Access Door and Top Cover, removal procedures 1 and 2.
4. Remove Service Station (Procedure 20).
5. Remove black cap, color cap, foam-color cap, and wipers.

22. Removing the Absorber

1. With the printer on, open the access door to move the carriage to the center of the
mechanism.
2. With the carriage centered, unplug the printer.
3. Remove the Access Door and Top Cover, removal procedures 1 and 2.
4. Remove the Service Station (Procedure 20)
5. Remove the absorber from the bottom of the spittoon.

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