DJ 652x / 654x Disassembly Procedures

Deskjet 652x , 654x

Exploded Views

DJ 654x

DJ 652x

HP DJ 652x / 654x Disassembly Procedures

Table of Contents
DJ 652x Case Part Disassembly Procedures .......................................................3
Required Tools ..................................................................................................3
DJ 652x Case Parts ..........................................................................................3
Rear Cleanout Assembly and Rear Cover.....................................................3
Top Case, Access Door, and Keypad Assembly ...........................................4
Lower Case Parts and End Caps...................................................................7
DJ 654x Case Part Disassembly Procedures .....................................................11
Required Tools ................................................................................................11
DJ 654x Case Parts ........................................................................................12
Rear Cleanout Assembly and Rear Cover...................................................12
Access Door ................................................................................................13
Top Case and Keypad Assembly.................................................................14
Removing the In Tray. .................................................................................16
DJ 652x and DJ 654x Printer Mechanism Disassembly ..................................19
Absorber Tray and Absorbers......................................................................19
Main Logic PCA and Front USB Pigtail........................................................20
Side Bracket, Carriage Assembly, Carriage Rod, and Carriage Motor ........21
Gear Guard and Pick Assembly...................................................................25
Backbone and Anti-Rotation Assembly........................................................26
Upper Paper Guide, Upper Paper Guide Hanger, and IPA Sensor .............28
Platen Assembly ..........................................................................................30
Paper Encoder Guard..................................................................................31
Feed Roller Assembly..................................................................................32
Output Roller Assembly ...............................................................................33
Paper Motor Bracket Assembly ...................................................................34
Lower Paper Guide Assembly .....................................................................35

HP DJ 652x / 654x Disassembly Procedures

DJ 652x Case Part Disassembly Procedures

Required Tools

Small Screwdriver
Long Screwdriver
Needle Nose Pliers
Torx T-10 Driver (Magnetized Recommended)

DJ 652x Case Parts

Rear Cleanout Assembly and Rear Cover
1. Press the Rear Cleanout Assembly latches inward and pull the Rear
Cleanout Assembly from the printer.
2. Remove the two Rear Cover screws.
3. While lifting the Top Cover, pry out the left and right End Caps and lift the
Rear Cover from the printer.
Note: The Rear Cleanout and Rear Cover are the only case parts to remove in
order to gain access to the Main Logic PCA.

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HP DJ 652x / 654x Disassembly Procedures

Top Case, Access Door, and Keypad Assembly

1. Open the Access Door and lower the In Tray.
2. Remove the front right screw, located in front of the Service Station.
3. Remove the Keypad Assembly by prying the latch fingers, inside the Top
Cover, sliding the Keypad Assembly to the right, then pulling on the
Keypad Assembly.
4. Disconnect the Keypad Assembly from the printer.

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HP DJ 652x / 654x Disassembly Procedures

5. Remove the front left screw, located behind the Keypad Assembly
location.
6. Release the Left End Cap from the Top Cover Assembly by prying at latch
point A .
7. Release the left side of the Top Cover Assembly by releasing the latch
from below the Chassis at latch point B.
8. Release the Right End Cap from the Top Cover Assembly by prying at
latch point C.
9. Release the right side of the top Cover Assembly by releasing the latch
from latch point D.

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10. With the Top Cover Assembly removed from the printer and the Access
Door closed to the Top Cover Assembly, pry at the gear hinges and
release the Access Door Assembly from the Top Cover Assembly.

HP DJ 652x / 654x Disassembly Procedures

HP DJ 652x / 654x Disassembly Procedures

Lower Case Parts and End Caps

1. Release the Lower Right Case latch by prying up between the chassis and
the Lower Right Case.
2. Rotate the Lower Right Case from the chassis.
3. Release the Lower Left Case latch by prying up between the chassis and
the Lower Left Case
4. Rotate the Lower Left Case from the Chassis.

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HP DJ 652x / 654x Disassembly Procedures

5. Remove the friction gears from the End Caps.

6. Release the End Caps from the Lower Case Parts by releasing at the two
latch points.
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HP DJ 652x / 654x Disassembly Procedures

Removing the In Tray.

1. Remove any media in the In Tray. With the Top Cover, Lower Case Parts,
and End Caps removed, remove the two screws holding the Starwheel
Roller Assembly on the printer.
2. Lift the Starwheel Roller Assembly from the printer.
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3. Remove the In Tray screw by reaching through an access hole between

the Output Roller Assembly and the Platen Assembly. Note: a magnetized
Torx T-10 screwdriver is highly recommended.

HP DJ 652x / 654x Disassembly Procedures

4. Place the printer on it back and release the In Tray Assembly latch.
5. Pull the In Tray Assembly from the printer.

HP DJ 652x / 654x Disassembly Procedures

DJ 654x Case Part Disassembly Procedures

Required Tools

Small Screwdriver
Long Screwdriver
Needle Nose Pliers
Torx T-10 Driver (Magnetized Recommended)

HP DJ 652x / 654x Disassembly Procedures

DJ 654x Case Parts

Rear Cleanout Assembly and Rear Cover
1. Press the Rear Cleanout Assembly latches inward and pull the Rear
Cleanout Assembly from the printer.
2. Remove the two Rear Cover screws.
3. Lift the Rear Cover from the printer.
Note: The Rear Cleanout and Rear Cover are the only case parts to remove in
order to gain access to the Main Logic PCA.

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HP DJ 652x / 654x Disassembly Procedures

Access Door
1. Pull on the bottom of the right and left End Cap Trim and lift them from the
printer.
2. Pull the right and left End Caps from the printer.
3. Open the Access Door.
4. Pull out on the Access Door right gear hinge, freeing the right side of the
Access Door from the printer. Remove the Access Door from the printer.

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HP DJ 652x / 654x Disassembly Procedures

Top Case and Keypad Assembly

4. With the two rear screws and Rear Cover removed, release the right front
latch of the top cover by reaching down in front of the color pen latch with
a long screwdriver. Lift the right side of the Top Cover to release the cover
from the latch.
5. Release the left front latch of the top cover by reaching down below the
inside of the Keypad Assembly area and lifting on the left side of the Top
Cover.

HP DJ 652x / 654x Disassembly Procedures

1. Push on the tab, located on the inside of the Top Cover and Keypad
Assembly.
2. Pry out the Keypad Assembly from the Top Cover Assembly.
3. Disconnect the Keypad Assembly Cable.

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HP DJ 652x / 654x Disassembly Procedures

Removing the In Tray.

1. Remove the Output Tray Assembly from the printer.
2. Remove any media in the In Tray.
1. With the Top Cover removed, remove the two screws holding the
Starwheel Roller Assembly on the printer.
2. Lift the Starwheel Roller Assembly from the printer.
3. Remove the In Tray screw by reaching through an access hole between
the Output Roller Assembly and the Platen Assembly.

HP DJ 652x / 654x Disassembly Procedures

4. Place the printer on it back and release the In Tray Assembly latch.
5. Pull the In Tray Assembly from the printer.

HP DJ 652x / 654x Disassembly Procedures

Lower Case Parts

1. Release the Lower Right Case latch by prying up between the chassis and
the Lower Right Case.
2. Rotate the Lower Right Case from the chassis.
3. Release the Lower Left Case latch by prying up between the chassis and
the Lower Left Case
4. Rotate the Lower Left Case from the Chassis.

HP DJ 652x / 654x Disassembly Procedures

DJ 652x and DJ 654x Printer Mechanism Disassembly

Absorber Tray and Absorbers
1. Release the two latches on the Absorber Tray, located below the Platen
Assembly, and lower the Absorber Tray from the mechanism.
2. Remove the two Absorbers from the Absorber Tray.
Caution: The Absorbers may be saturated with ink.
Note: The Absorber Tray and Absorbers can be removed from the printer without
disassembling the printer.

HP DJ 652x / 654x Disassembly Procedures

Main Logic PCA and Front USB Pigtail

1. Remove the Rear Cover.
2. Remove the two Main Logic PCA screws.
3. Disconnect the Cable Harness Assembly, Carriage Flex Cables, Front
USB cable, and the Service Station Motor cable from the Main Logic PCA.
4. Remove the Main Logic PCA from the printer.
5. Remove the two front USB screws.
6. Remove the front USB connector from the Chassis.
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HP DJ 652x / 654x Disassembly Procedures

Side Bracket, Carriage Assembly, Carriage Rod, and Carriage Motor

1. With the case parts removed, remove the four Side Bracket screws.
2. Rotate the Side Bracket from the printer Chassis.

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3. If the Carriage Assembly is locked onto the Service Station Assembly,

remove the cap on the Chassis below the Service Station. With your
finger, release the Carriage Assembly from the Service Station Assembly.
4. Slide the Carriage Assembly toward the middle of the mechanism.
5. Push in on the Encoder Spring and disconnect the Encoder Strip.
6. Disconnect the Encoder Strip at its right end. Gently draw the Encoder
Strip to the left to remove the Encoder Strip from the Carriage Assembly.
During this process, the Encoder Strip probably will be contaminated by
grease from the Carriage Rod. Discard the Encoder Strip.
7. Remove the Rod Spring from the right end of the Carriage Rod.

HP DJ 652x / 654x Disassembly Procedures

8. Disconnect the Anti-Static Brush from the Encoder Spring

9. Remove the Belt Tensioner Spring from the Belt Tensioner.
10. Remove the Carriage Belt from the Belt Tensioner pulley and the Carriage
Motor pulley.
11. Remove the Trailing Cable Clamp screw.
12. Slide the Trailing Cable Clamp to the right and remove the Trailing Cable
Clamp from the mechanism.
13. Release the Flex Cables from the Mechanism.
14. Remove the three screws holding the Carriage Rod to the mechanism.
15. Lift the Carriage Assembly and Carriage Rod from the mechanism as one
assembly.

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HP DJ 652x / 654x Disassembly Procedures

16. Slide the Carriage Rod from the Carriage Assembly.

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17. Disconnect the Carriage Motor from the Cable Harness.

18. Remove the two Carriage Motor screws.
19. Remove the Carriage Motor from the mechanism.
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HP DJ 652x / 654x Disassembly Procedures

Service Station
1. With the Carriage Assembly removed, lift the right side of the Service
Station Assembly to release the Service Station Assembly from the
Chassis.
2. Lift the Service Station Assembly from the Chassis.

HP DJ 652x / 654x Disassembly Procedures

Gear Guard and Pick Assembly

1. Use a Torx or blunt screwdriver to loosen the lower snap from the front of
the printer. It is difficult to see during this maneuver, and the operator will
need to fit the screwdriver past the Lifter Spring and the Carriage and
Paper path motors.
2. With the bottom snap loose, release the top snap on the Gear Guard.
3. From the rear of the printer, find the two polar bearings attaching the Pick
Assembly to the Chassis. Release them and rotate them toward the rear
of the printer.
4. Gently lift the Pick Assembly out of the printer.
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HP DJ 652x / 654x Disassembly Procedures

Backbone and Anti-Rotation Assembly

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2.
3.
4.
5.

Rotate and Remove the two Carriage Rod clips.

Disconnect the Wiring Harness from the Encoder PCA.
Remove the two screws holding the Backbone Assembly to the Chassis.
Lift and bring forward to remove the Backbone Assembly from the printer.
Remove the two screws securing the Anti-Rotation Assembly to the
Chassis.
6. Lift the Anit-Rotation Assembly from the Chassis.
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HP DJ 652x / 654x Disassembly Procedures

Wiring Harness
1. Remove the screw holding the Duplexer Interconnect PCA to the Chassis.
2. Remove the thru-hole cable ties by compressing with needle-nosed pliers.
3. Disconnect the Wiring Harness from the Paper path Motor.
4. Disconnect the Wiring Harness from the Paper path encoder PCA.
5. Remove the Wiring Harness from the Chassis.
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HP DJ 652x / 654x Disassembly Procedures

Upper Paper Guide, Upper Paper Guide Hanger, and IPA Sensor
Caution: The Upper Paper Guide Assembly is fragile and easily damaged.
1. From the rear, push the Upper Paper Guide Springs forward to release the
Upper Paper Guide from the Upper Paper Guide Hanger.
2. Move the Upper Paper Guide Spring back off the Upper Paper Guide and
remove it from the printer.

HP DJ 652x / 654x Disassembly Procedures

3. Remove the two screws securing the Upper Paper Guide Hanger to the
Chassis.
4. Pry and lift the Upper Paper Guide Hanger from the Chassis.
5. Lift and remove the IPA sensor from the Chassis.

HP DJ 652x / 654x Disassembly Procedures

Platen Assembly
1. Release the two Platen Assembly latches.
2. Disconnect the Platen Assembly from the Feedroller Assembly.
3. Lift the Platen Assembly from the Chassis.

HP DJ 652x / 654x Disassembly Procedures

Paper Encoder Guard

1. Pry the finger on the Guard.
2. And remove it from the Chassis.

HP DJ 652x / 654x Disassembly Procedures

Feed Roller Assembly

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7.

Using needle nose pliers, remove the Caber Pin.

Remove the Shifter Spring.
Release and rotate the Paper Motor Bracket Bearing.
Release and rotate the two other Polar Bearings.
Lift and remove the Feed Roller Assembly from the Chassis.
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HP DJ 652x / 654x Disassembly Procedures

Output Roller Assembly

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2.
3.
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5.

Rotate the right tab until it is pointing down.

Pull the right tab off of the Output Roller Assembly by pulling to the right.
Rotate the left tab until it is pointing down.
Push the left tab to the right to disengage it from the chassis.
Lift the Output Roller Assembly from the Chassis.

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HP DJ 652x / 654x Disassembly Procedures

Paper Motor Bracket Assembly

1. Remove the screw, near the front of the assembly.
2. Lift and remove the Paper Motor Bracket Assembly.

HP DJ 652x / 654x Disassembly Procedures

Lower Paper Guide Assembly

1. From the rear of the printer, use a flat-bladed screwdriver to release the
two tabs anchoring the lower Paper Guide.
2. Rotate the Lower Paper Guide Assembly toward the front of the printer to
release its forward tabs.
3. Lift and remove the Lower Paper Guide Assembly.
4. Lift and remove the Kicker.

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HP DJ 652x / 654x Disassembly Procedures