HP Z5200 Owners Manual

							●Spindle on page 223
●
Left Spindle Holder on page 224
●
Right Spindle Holder on page 224
●
Clean Out Assembly on page 225
●
Out Of Paper Sensor on page 226
●
Left Roll Guide on page 229
●
Right Roll Guide on page 230
●
Encoder Strip (with spring and attachment nut) on page 231
●
Encoder Strip on page 236
●
Trailing Cable on page 237
●
Carriage Asse mbly (with or without Trailing Cable) on page 244
●
Carriage Rear Bushing on page 254
●
Belt Assembly on page 256
●
Scan-Axis Motor on page 257
●
Carriage  Rail Oiler on page 260
●
Color Sensor (ESP) on page 262
●
Line Sensor on page 267
●
Carriage Cover (includes Carriage Latch) on page 272
●
Carriage PCA on page 276
●
Right Ink Supply Station on page 280
●
Left Ink Supply Station on page 284
●
Ink Supply Tubes on page 288
●
Formatter on page 296
●
Hard Disk Drive on page 297
●
Electronics Module (Main PCA and PSU) on page 298
●
Starwheel Assembly on page 301
●
Print Zone Overdrive on page 302
●
Left Spittoon on page 306
●
Encoder Disk and Encoder Sensor on page 308
●
Media Advance Drive on page 311
●
Pinchwheel Assembly on page 314
●
Pinch Roller on page 319
●
Left Starwheel Lifter on page 320
●
Right Starwheel Lifter on page 322
ENWW 167 
						

							●Starwheel Motor on page 325
●
Full Bleed Foam on page 326
168 Chapter 6   Removal and Installation ENWW 
						

							Introduction
This chapter is a step-by-step guide to the removal and installation of the key components of the printer.
You may find it useful to check off the steps as they are performed. Use the illustrations for each
procedure to identify the part s referred to in the text.
The procedures appear in order of removal. The whol e machine can be stripped down by starting at the
beginning of this chapter and workin g 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. If the test passes you will not need to replace the component.
Safety Precautions
Review the instructions identified by WARNING and CAUTION symbols before you service the printer.
Follow these warnings and cautions for your protection and to avoid damaging the printer.
NOTE: 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 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.
Electrostatic Discharge (ESD) Precautions
To prevent damage to the Printer circuits fr om high-voltage electrostatic discharge (ESD):
1. Do not wear clothing that is  subject to static build up.
2. Do not handle integrated circui ts (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 disa ssembling 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
All the special tools and equipment required to disa ssemble, service and repair the Printer are provided
in the Toolkit P/N Q6683–67001. Some tools can be ordered separately from the toolkit. Refer to 
Parts
and Diagrams on page 151 .
The Toolkit contains the following tools:
Table 6-1    Toolkit P/N Q6683-67001
Description/CommentsHP Part Number
13 mm Combination SpannerQ6675-67011
Alcohol Q6675-60070
ENWW Introduction 169 
						

							Allen Key #2Q6675-60041
Cleaning Cloth9300-2531
Flex Contacts Cleaning SupportQ1271-40384
Lubricant OilQ6675-60061
Media Driver Adjustment ToolQ6675-67009
Handle for Media Driver Tool SupportQ6675-67010
SpannerQ6675-67011
Oil DispenserQ6675-60062
Pinchwheel Alignment ToolQ5669-20595
Pinchwheel Insertion ToolQ5669-20594
Protective Plastic GlovesQ6675-60035
Screwdriver8710-2456
TweezersQ6675-60037
Cleaning AssemblyC6071-60218
You will also need the following standard hand tools:
Table 6-2  Standard Tool Requirements
Description/CommentsSize
Long Torx Screwdriver1/4 inch drive
Torx Bit (75 mm)8
10
15
20
Phillips Screwdriver1
PliersN/A
SnipsN/A
Pipe Spanner5.5 mm
Flat Bladed Screwdriver N/A
Service Calibration Guide to Removal and Installation
Using the Service Calibration Guide
When you remove most printer components, you will need to perform a part icular set of Service
Calibrations and Diagnostic tests to ensure proper printer performance.
The Service Calibration Matrix sh ows which service calibrations an d diagnostic tests need to be
performed whenever you remove and install part icular printer components (left most column).
The calibrations must be performed in the order they are shown in the row.
Start by locating the component you have removed and installed in the left most column.
Table 6-1    Toolkit P/N Q6683-67001 (continued)
170 Chapter 6   Removal and Installation ENWW 
						

							NOTE:Even if you do not replace the removed component with a new component, you still need to
perform the calibrations indicated by the matrix.
The Service Calibration Matrix
 Service Calibration or Test (P erform in the order shown)
Service Station8. Service Station test, Drop Detector Calibration
Aerosol Fan
Assembly8. Service Station test, Drop Detector Calibration
Drop Detector8. Service Station test, Drop Detector Calibration
Service Station
Spittoon8. Service Station test, Drop Detector Calibration
Primer Assembly8. Service Station test, Drop Detector Calibration
Left Ink Supply
Station7. Ink Delivery System Test (IDS)
Right Ink Supply
Station7. Ink Delivery System Test (IDS)
Carriage Cover4. Carriage Assembly, Line Sensor  Calibration, 3. Electronics Module
Carriage Latch4. Carriage Assembly, Line Sensor Calibration, 3. Electronics Module
Carriage PCA4. Carriage Assembly, Line Sensor Calibration, 3. Electronics Module
PrintMech PCA3. Electronics Module
Front Panel3. Electronics Module
Power Supply Unit
(PSU)3. Electronics Module
Main PCA3. Electronics Module
Ink Supply TubesScan Axis Test, 3. Electronics Module
Media Advance
Drive2. Paper Drive, Paper Advance Calibration, Electronics Module
Encoder Disk2. Paper Drive, Paper Advance Calibration, Electronics Module
Encoder Sensor2. Paper Drive, Paper Advance Calibration, Electronics Module
Media Advance
Roller2. Paper Drive, Paper Advance Calibr ation, Electronics Module, Sensors
Carriage Assembly4. Carriage Assembly, Scan Axis Test, Line  Sensor Calibration, 5. Sensors, Cutter Test
Belt Tensioner4. Carriage Assembly, Scan Axis Test, Line Sensor Calibration, 5. Sensors
Belt Assembly4. Carriage Assembly, Scan Axis Test, Line Sensor Calibration, 5. Sensors
Scan-Axis Motor4. Carriage Assembly, Scan Axis Test, Line Sensor Calibration, 5. Sensors
Trailing Cable4. Carriage Assembly, Scan Axis Test, Line Sensor Calibration, 5. Sensors
Carriage Rear
Bushing4. Carriage Assembly, Scan Axis Test, Line Sensor Calibration, 5. Sensors, Cutter Test
Line SensorLine Sensor Calibration, 5. Sensors, Electronics module
Window Position
Sensor5. Sensors, Electronics module
Out of Paper
Sensor5. Sensors
ENWW
Service Calibration Guide to Removal and Installation 171 
						

							Right Roll Guide5. Sensors
Left Roll Guide5. Sensors
Clean Out
Assembly5. Sensors
Pen to Paper Space
(PPS) SolenoidPRS Test
Encoder StripScan axis
Starwheel
AssemblyStarwheel Lifter Test
Starwheel MotorStarwheel Lifter Test, Electronics Module
Left Starwheel
LifterStarwheel Lifter Test, Electronics Module
Right Starwheel
LifterNone
Print Zone
OverdriveStarwheel Lifter Test
Media Lever
Position Sensor5. Sensors
Pinchwheel
Assembly2. Paper Drive 5. Sensors
Pinch Roller2. Paper Drive 5. Sensors
Preventive
Maintenance Kit #14. Carriage Assembly, Scan Axis Test, Line Sensor Calibration, 5. Sensors
Preventive
Maintenance Kit #28. Service Station Calibration, Drop Detector Calibration
Cutter AssemblyCutter Test
Color Sensor (ESP)Color Sensor (ESP) Calibration, 5. Sensors, Electronics Module
Top CoverElectronics Module
Ink Supply Tubes
Support RailElectronics Module, 5. Sensors
Performing the Service Calib
rations and Diagnostic Tests
When you are ready to perform the service calibration s and diagnostic tests that correspond to the
component you have installed or replaced, cons ult the following page numbers for procedures:
● PRS Test - Refer to 
PRS Test on page 78.
● Scan Axis Test - Refer to 
1. Scan Axis on page 76
.
● Cutter test - Refer to 
Cutter test on page 84
.
● Star Wheel Lifter test - Refer to 
Star Wheel Lifter test on page 76
.
● 2. Paper Drive - Refer to 
2. Paper Drive on page 87
.
● 3. Electronics Module - Refer to 
3. Electronics Module on page 90
.
● 4. Carriage Assembly - Refer to 
4. Carriage Assembly on page 95
.
● 5. Sensors - Refer to 
5. Sensors on page 101
.
172 Chapter 6   Removal and Installation ENWW 
						

							●6. Color Sensor (ESP) - Refer to 6. Color Sensor (ESP) on page 104
.
● 7. Ink Delivery System (IDS) - Refer to 
7. Ink Delivery System (IDS) on page 106
.
● 8. Service Station - Refer to 
8. Service Station on page 110
.
● Paper Advance Calibration - Refer to 
Paper Advance Calibration on page 140
.
● Drop Detector Calibration - Refer to 
Drop Detector Calibration on page 145.
● Line Sensor Calibration - Refer to 
Line Sensor Calibration on page 146
.
ENWW Service Calibration Guide to Removal and Installation 173 
						

							Window
Removal
NOTE:Switch off the printer and remove the power cable.
NOTE:The Window can also be removed with the Top Cover to avoid scratching the Window. To
remove the Window with the Top Cover, refer to
Top Cover on page 205 .
1. Open the Window.
2.Remove the two T-15 screws that secure the left Window hinge locking plate to the Top Cover.
3.Remove the left Window hinge locking plate from the Top Cover.
174 Chapter 6   Removal and Installation ENWW 
						

							4.Remove the Damper Rotary from the Top Cover.
5.Remove the T-15 screws that secure each of the remaining three Window hinge locking plates to
the Top Cover.
6.Remove the remaining three Window hinge locking plates from the Top Cover.
ENWW Window 175 
						

							7.Remove the remaining three Damper Rotary pieces from the Top Cover.
8.Grip the Window at the left and right edges and move  it horizontally towards the right as far as it
will go.
9. Pull the Window towards the front to disengage the hinges.
176 Chapter 6   Removal and Installation ENWW