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1. Reset usage counter Menu Scan axis usage ae Back Press ENTER to continue or CANCEL to quit a Enter c To check if the relevant usage counter has been reset enter the Printer Information utility gt Page 4 26 HP DesignJets 500 and 800 Series Printers Service Manual 4 19 Service Tests and Utilities NOTE NOTE If you want to Reset the EEROM to the Default Values The EEROM should only be reset if there is a major problem or if the Electronics Module has been replaced by a reused one and you need to reset the EEROM configuration Also reset the EEROM if the Printer does not have the correct Serial Number after powering up a If you want to reset the EEROM to the default values then you should select Reset to defaults and press Enter The following message will appear on the Front Panel Press Enter if you want to proceed with resetting the EEROM or press Cancel if you want to exit without resetting the EEROM Reset to defaults Press ENTER to continue or CANCEL to quit Menu T Back aS Enter After resetting the EEROM to the default values you will need to re enter the Serial Number Model Number and the Font Type without re entering this information the Printer will NOT work DO NOT SWITCH THE PRINTER OFF AND ON AGAIN BEFORE RE ENTERING THESE VALUES Also you will need to perform the Factory Advance Calibration 4 20 HP DesignJets 500 and 800 Series
2. Pinch Arm Mechanism includes the Pinch Arm Lever 7 26 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams LETTI IH MALLETT Ey Figure 13 Pinch Wheel Assemblies HP DesignJets 500 and 800 Series Printers Service Manual 7 27 Parts and Diagrams Scan Axis Motor 1 C7769 60146 1 Scan Axis Motor 2 0515 2282 2 Screw 7 28 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Figure 14 Scan Axis Motor HP DesignJets 500 and 800 Series Printers Service Manual 7 29 Parts and Diagrams Drive Roller Encoder Sensor 1 C7769 60171_ 1 Drive Roller Encoder Sensor Cover Kit 2 0624 0768 1 Screw 3 C7769 60172 1 Drive Roller Encoder Sensor 4 0624 0768 1 Screw 7 30 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Figure 15 Drive Roller Encoder Sensor HP DesignJets 500 and 800 Series Printers Service Manual 7 31 Parts and Diagrams Print Platen Assembly 1 7769 60174 1 1 Print Platen Kit Includes parts for both the 24 and 42 Models 2 0624 0768 31 38 Screws 7 32 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Figure 16 Print Platen Assembly HP DesignJets 500 and 800 Series Printers Service Manual 7 33 Parts and Diagrams Car
3. 8 22 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Spittoon Removal WARNING Switch off the printer and remove the power cord 1 Remove the Left Hand Cover Refer to Page 8 5 2 Release the cables that are attached to the Spittoon 3 Press in the 2 clips to release the Spittoon 4 Lift up the Spittoon and remove from the Printer HP DesignJets 500 and 800 Series Printers Service Manual 8 23 Removal and Installation Electronics Module Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Left Hand Cover Refer to Page 8 5 2 Disconnect ALL the cables from the Electronics Module 3 Remove T 10 screw Type B from the top of the Electronics Module 8 24 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 4 Remove T 10 screw Type B from the back of the Electronics Module 5 Loosen 1 T 10 screw Type B just below the Electronics Module 6 Lift the Electronics Module up and towards the right and remove from Printer HP DesignJets 500 and 800 Series Printers Service Manual 8 25 Removal and Installation Installing the Electronics Module NOTE When installing the Electronics Module make sure that you insert the tab on the Printer into the slot in the Electronics Module 8 26 HP De
4. Figure 20 Paper Axis Motor HP DesignJets 500 and 800 Series Printers Service Manual 7 41 Parts and Diagrams Drive Roller 1 C7769 60157 1 Drive Roller Kit 24 Model Only C7770 60157 1 Drive Roller Kit 42 Model Only 2 C7769 60177 1 Transmission Gear Kit 7 42 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams x a Figure 21 Drive Roller HP DesignJets 500 and 800 Series Printers Service Manual 7 43 Parts and Diagrams Miscellaneous Items E C7769 60185 1 Repackaging Kit 24 Model Only C7770 60007 1 Repackaging Kit 42 Model Only C7769 60178 1 Screw Kit 7 44 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Screw Types 8 4 Left Hand Cover 8 5 Right Hand Cover 8 7 Front Panel 8 9 Window and Top Cover 8 10 Media Deflectors 8 11 Left End Roll Feed 8 13 Right End Roll Feed 8 15 Back Platen 8 17 Media Sensor 8 19 Formatter 8 20 LAN Card 8 21 Spittoon 8 23 Electronics Module 8 24 Power Supply 8 27 Scan Axis Motor Assembly 8 29 Cutter Assembly 8 32 Left Encoder Holder 8 33 Cutter Bushing 8 35 Cutter Guide Bracket 8 36 Drive Roller Encoder Sensor 8 38 Trailing Cable 8 40 Ink Supply Station 8 48 Interconnect PCA 8 50 Service Station and Aerosol Fan 8 52 Cutter Guide 8 55 Print Platen 8 56 Service Station Holder 8 57 Interconnect C
5. 11 1990 2001 Date DDD divided by 30 plus one if there is a remainder gives you the month The remainder gives you the day of the month e g 280 280 30 9 1 10 October 10th 360 360 30 12 December 30th Engine F W The current version of the Firmware being used by the Printer and the date that it was updated Formatter F W The current version of the Firmware being used by the Formatter if it is installed m Hard disk F W The current version of the Firmware being used by the Hard Disk only if the Formatter is installed m Paper usage The amount of media used by the Printer E Ink usage The amount of Ink used by the Printer m Scan axis usage Number of Scan Axis cycles represented as a percentage over the maximum number of Scan Axis cycles that the HP DesignJets 500 and 800 Series Printers Service Manual 4 27 Service Tests and Utilities Printer is designed to support If the percentage is more than 100 and the Printer is experiencing problems then try the following 1 Apply Lubricant to the Drive Roller 2 Replace the Carriage Assembly including the Belt Page 8 78 3 Replace the Scan Axis Motor gt Page 8 29 Paper axis usage Number of Paper Axis movements represented as a percentage over the maximum number of Paper Axis movements that the Printer is designed to support If the percentage is more than 100 and the Printer is experiencing problems then try the followi
6. For HP Internal Use Only Copyright Hewlett Packard Company 2000 This document contains proprietary information that is protected by copyright All rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of Hewlett Packard Company First Edition August 2000 Technical Marketing Barcelona Division Warranty The information contained in this document is subject to change without notice Hewlett Packard makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose Hewlett Packard shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Hewlett Packard Espanola S A Avda Graells 501 08190 Sant Cugat del Valles Spain WARNING The procedures described in this manual are to be performed by HP qualified service personnel only Electrical Shock Hazard 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 Disconnect the Printer from the power source prior to performing any maintenance Prevent water or any other liquids from running onto electrical compon
7. kal Back Press ENTER for Set up menu p amp Enter 2 Press the T or J key until the front panel highlights Log Press the Enter key Set up menu A Menu Expansion cards Back Altitude 0 1000 m Log p ese Enter 3 14 HP DesignJets 500 and 800 Series Printers Service Manual Ink Supplies Troubleshooting 3 Press the T or J key until the front panel highlights Printheads Press the Enter key Log Printheads Errors Menu Back v amp Enter 4 Press the T or J key until the front panel highlights the color that you want to see information on Press the Enter key Printhead history Select color Menu Back v de Enter 5 The front panel displays the history of the last 5 Printheads of the selected color use the arrow keys to scroll through the complete list Press the T or J key until the front panel highlights the item number that you want to see information on Press the Enter key Black P H history Select for more info Printhead currently installed 1 Installed OK 2 Removed OK 3 Removed too early 4 Removed Err 0024 5 Removed Err 0023 Menu Back v a Enter The status displayed for the last 5 Printheads could be any of the following Installed OK A Printhead is currently installed in the Printer and no error is detected Installed Err xxxx A Printhead is currently installed in th
8. 16 25 26 Carriage and Printhead flex circuit replace and 28 Carriage Assembly 18 19 23 Printhead Error Reseat faulty Printhead replace and 24 faulty Printhead clean Carriage and Printhead flex circuit 27 Printhead Error Printhead will die soon 29 Acumen Error Replace faulty Printhead check other Printheads or Cartridges only if all Printheads fail with this Error Code Try the above recommened actions one at a time and check if the problem disappears 3 22 HP DesignJets 500 and 800 Series Printers Service Manual Ink Supplies Troubleshooting Summary of Solving Ink Supplies Problems Most of the problems that you could encounter when working with the Ink Supplies are solved with guidance from the front panel Problems reseating the Printhead If you have inserted the printhead into the Carriage Assembly and the Printer rejects it displays a faulty or missing icon try the following steps NOTE Check that during the priming process the Setup Printheads are installed in the Carriage If the printing Printheads are installed in the carriage during the priming process they will be rejected and the front panel will show the Normal printheads found Open window and replace with SETUP printheads message m Check that you have removed the protective tape from the printhead E Insert the Printhead into the Carriage Assembly but this time close the cover using the latch E C
9. The ISS is the part of the Printer that provides the pressure to pump the ink from the Ink Cartridges to the Printheads It has a mechanism for each one of the four Ink Cartridges Each mechanism consists of a spring that pulls from a rocker that pushes the lifter that pressurizes the bongo There is a camshaft which is driven by an electric motor that moves the four lifters down pressing on the rocker The ISS also has sensors which can detect when the pump chamber is empty and needs to be refilled by pushing down the lifters The following diagram explains the operation of the ISS Reservoir Opto triggers on this edge HP DesignJets 500 and 800 Series Printers Service Manual 10 7 Functional Overview These are the key functions of the ISS E Ink Cartridges support and location m Prevents incorrect insertion of colors and inks E Provides electrical connection to the Ink Cartridges Locates the supply end of the Tubes Assembly Contains ink from leaks E Includes the ISS PCA which contains the backup EEROM Slots for the Ink Cartridges Pump Sensor ISS PCA contains the backup EEROM Lifter Foam to contain ink from leaks Pump Motor 10 8 HP DesignJets 500 and 800 Series Printers Service Manual Functional Overview Tubes Assembly The Tubes Assembly is the part of the Ink Delivery System which physically drives the ink from the Ink Cartridges in the ISS to the Printheads in t
10. 11 Carriage Axis shutdown during the Carriage Movement test Refer to Error Code 86 01 2 18 HP DesignJets 500 and 800 Series Printers Service Manual System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Codes 86 13 Carriage Axis shutdown Firmware Error Try the following E Switch the Printer Off and wait a few minutes Switch the Printer On again and check if the Error Code has disappeared E If the Error Code reappears check for a new Firmware release m If the new Firmware release does not solve the problem or if new Firmware release was not available contact the HP Response Center or directly to the Division supplying the following information Model and Serial Number of the Printer Firmware release of the Printer use the Printer Information utility Page 4 26 The complete Error Code information including the linefeed where the error occurred use the Error Log utility to obtain this information gt Page 2 5 87 13 Unable to read the Carriage Encoder Sensor Try the following m Switch the Printer Off and wait a few minutes Switch the Printer On again and check if the Error Code has disappeared m If the Error Code continues replace the Carriage Assembly gt Page 8 78 or the Encoder Strip gt Page 8 76 93 10 Ink Syste
11. 7 44 HP DesignJets 500 and 800 Series Printers Service Manual 5 Table of Contents Removal and Installation 8 1 Introduction 8 2 Safety Precautions 8 2 Electrostatic Discharge ESD Precautions 8 3 Required Tools 8 3 Screw Types 8 4 Left Hand Cover 8 5 Right Hand Cover 8 7 Front Panel 8 9 Window and Top Cover 8 10 Media Deflectors 8 11 Left End Roll Feed 8 13 Right End Roll Feed 8 15 Back Platen 8 17 Media Sensor 8 19 Formatter 8 20 LAN Card 8 21 Spittoon 8 23 Electronics Module 8 24 Power Supply 8 27 Scan Axis Motor Assembly 8 29 Cutter Assembly 8 32 Left Encoder Holder 8 33 Cutter Bushing 8 35 Cutter Guide Bracket 8 36 Drive Roller Encoder Sensor 8 38 Trailing Cable 8 40 Ink Supply Station 8 48 Interconnect PCA 8 50 Service Station and Aerosol Fan 8 52 Cutter Guide 8 55 Print Platen 8 56 Service Station Holder 8 57 Interconnect Cable 8 59 Ink Supply Tubes 8 60 Vacuum Fan 8 64 Pinch Arm 8 66 Pinch Arm Mechanism 8 67 Pinch Arm Lever 8 69 6 HP DesignJets 500 and 800 Series Printers Service Manual Table of Contents Pinch Arm Sensor 8 71 Fork Idler Tensioner and Idler Pulley 8 74 Encoder Strip 8 76 Carriage Assembly Including Belt 8 78 Paper Axis Motor 8 84 Drive Roller 8 86 Gear Assemblies 8 92 Preventive Maintenance 9 1 Moisture on the Printer 9 2 Noisy Carriage Bushing 9 2 Belt Swelling 9 2 Cleaning the Printer 9 2 General Cleaning 9 2 Cleaning the Dr
12. Axis shutdown occurs which is not caused by a paper jam The Paper Advance test will perform the following tests E Paper Axis Motor test m Drive Roller Encoder Sensor test m Drive Roller test This Service Test can be performed by the End User with the guidance of a HP Support person via the phone IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE REPLACING PAPER AXIS COMPONENTS IF THIS TEST PASSES DO NOT REPLACE ANY PAPER AXTIS COMPONENTS Perform the Paper Advance test as follows In the Service Tests submenu scroll to Paper Advance test and press Enter Service tests Menu Troubleshooting Aerosol Fan test Back Ink Supply Station Paper advance test Carriage movement test p gt Enter The test will first check if the Paper Axis Motor is working by moving it slightly backwards and forwards If this test passes the following message will be displayed press Enter to continue to the next stage of the test Paper Advance test Menu A Back Paper axis motor test passed Press ENTER to continue gt Enter IF THIS TEST PASSES DO NOT REPLACE THE PAPER AXIS MOTOR 4 10 HP DesignJets 500 and 800 Series Printers Service Manual Service Tests and Utilities 3 If the test fails while checking the Paper Axis Motor then the following message will be displayed Paper Advance test System error 41 10 Paper axis motor failed In this case
13. Change Ink Tubes 4 25 Printer Information 4 26 Service Calibrations 5 1 Entering the Service Calibrations Menu 5 3 Printhead Alignment includes PPS Calibration 5 5 Color Calibration 5 7 Advance Calibration 5 9 Factory Advance Calibration 5 11 HP DesignJets 500 and 800 Series Printers Service Manual Table of Contents Print Quality 6 1 Print Quality 6 2 Print Quality Troubleshooting Checklist 6 2 How to Use the Troubleshooting Procedure 6 4 What is the Troubleshooting Procedure 6 4 Considerations for Using the Troubleshooting Procedure 6 4 Performing the Troubleshooting Procedure 6 4 Troubleshooting Procedure Flowchart 6 7 No Printing Defects Found Using the Troubleshooting Procedure 6 8 Solving Color Accuracy problems 6 9 Color Consistency problems 6 9 Long Term Color Bleeding Glossy Papers 6 9 Media 6 10 There are Smears or Scratching on the Printed Media 6 10 Parts and Diagrams 7 1 Printer Support 7 2 Right Hand Cover 7 4 Left Hand Cover 7 6 Top Cover and Deflectors 7 8 Rollfeed Module 7 10 Back Platen Assembly 7 12 Electronics Module 7 14 Power Supply 7 16 Cutter Assemblies 7 18 Ink Delivery System 7 20 Service Station and Spittoon 7 22 Service Station Holder 7 24 Pinch Wheel Assemblies 7 26 Scan Axis Motor 7 28 Drive Roller Encoder Sensor 7 30 Print Platen Assembly 7 32 Carriage Assembly 7 34 Vacuum Fan 7 36 Interconnect Cable 7 38 Paper Axis Motor 7 40 Drive Roller 7 42 Miscellaneous Items
14. Encoder Holder 8 33 Left End Roll Feed 8 13 Left Hand Cover 8 5 Media Deflectors 8 11 Media Sensor 8 19 Paper Axis Motor 8 84 Pinch Arm 8 66 Pinch Arm Lever 8 69 Pinch Arm Mechanism 8 67 Pinch Arm Sensor 8 71 Power Supply 8 27 Print Platen 8 56 Right End Roll Feed 8 15 Right Hand Cover 8 7 Scan Axis Motor Assembly 8 29 Service Station Holder 8 57 Service Station Aerosol Fan 8 52 Spittoon 8 23 Trailing Cable 8 40 Vacuum Fan 8 64 Window and Top Cover 8 10 Required Tools 8 3 Right End Roll Feed 8 15 Right Hand Cover 8 7 S Safety Precautions 8 2 Scan axis Maintenance 9 4 Scan Axis Motor Assembly 8 29 Scheduled Maintenance 9 3 Scratching 6 10 Screw Types 8 4 Service Calibrations 1 2 Advance Calibration 5 9 Color Calibration 5 7 Entering 5 3 Factory Advance Calibration 5 11 Printhead Alignment 5 5 Service ID 4 27 Service Station 10 10 Service Station Holder 8 57 Service Station Aerosol Fan 8 52 Service Tests 1 2 Carriage Movement 4 8 Entering 4 4 Ink Supply Station 4 6 Paper Advance Test 4 10 Service Utilities Change Cutter 4 24 Change Ink Tubes 4 25 EEROM Setup 4 16 Entering 4 14 Prime Tubes 4 23 Printer Information 4 26 Turn Drive Roller 4 21 Unlock Carriage 4 22 Smears 6 10 Solving Print Quality Problems 1 3 Solving Print Quality Problems 1 3 Spittoon 8 23 System Error Codes 0110 2 7 0111 2 7 0112 2 7 0113 2 8 0210 2 8 0213 2 8 0310 2 9 0411 2 9 0509 Error 2 9 0510 Error 2 9 0510 Warning 2 9 0511 2 1
15. Level 3 hard recovery was performed 3 is the maximum recovery level that the Printer can perform before asking the customer to replace the Printhead m The reported Error Code if any m The date the Printhead was removed from the Printer Is the Printer Causing Repetitive Printhead Problems The minimum life expectancy of the Printheads is 530cc for the Black Printhead and 200cc for the Color Printheads If Print Quality is poor before the minimum life expectancy of the Printhead has been reached the Troubleshooting procedure should be performed Refer to Page 6 4 which will determine whether the Printhead needs replacing or not after performing various levels of recovery actions After performing a recovery action the Printhead will be encoded with either 1 2 or 3 depending on the strength of the recovery action performed 3 16 HP DesignJets 500 and 800 Series Printers Service Manual Ink Supplies Troubleshooting Now if a Printhead is removed even after Level 3 recovery has been performed and the minimum life expectancy has not been reached the Printhead will be marked Removed too early If a customer complains about having to replace the Printheads frequently before the minimum life expectancy has been reached using the information obtained with the Printhead History Utility you can determine if the Printer is causing repetitive problems to the Printheads as follows 1 Enter the Printhead History Utility an
16. Measure pattern and press Enter Advance calibration Create pattern Measure pattern Restore factory while the Printer measures the pattern Calibrating Job management menu cy H E F A Menu Back v eS Enter 8 The Printer will measure the alignment marks using the line sensor on the Carriage Assembly The following message will be displayed 9 Once the calibration is completed the following message will be displayed Calibration finished successfully Press ENTER to continue Menu Back es Enter 5 10 HP DesignJets 500 and 800 Series Printers Service Manual Service Calibrations Factory Advance Calibration The purpose of this Service Calibration is to calibrate the nominal advance of the media This calibration is necessary to control the exact movement of the media in order to avoid print quality problems like banding The values from the Calibration will then be stored in the EEROM and the user can restore the Printer to these values by selecting Restore factory in the Advance Calibration menu Perform the Factory Advance Calibration whenever Banding is detected in prints for all HP Media standard paper types and Printheads Diagnostic is OK m Drive Roller is disassembled or replaced E Paper Axis Motor Assembly is disassembled or replaced m Electronics Module AND the Ink Supply Station are replaced Perform the Factory A
17. Printers Service Manual Service Tests and Utilities Turn Drive Roller The purpose of this Service Utility is to rotate the Drive Roller in order to clean it NOTE REMOVE THE MEDIA BEFORE PERFORMING THIS OPERATION Perform the Turn Drive Roller utility as follows 1 In the Service Utilities submenu scroll to Turn Drive Roller and press Enter Service utilities amp Menu Change ink tubes Unlock Carriage Turn Drive Roller Back Prime tubes EEROM Setup y enter 2 Once the utility starts the Drive Roller will begin to turn slowly and the following message will be displayed Everytime the Drive Roller completes a turn the counter will increase by one Turning Drive Roller turns 2 Press CANCEL to stop 3 If you want to stop the Drive Roller from turning press Cancel and the following message will appear on the front panel Press Enter if you want to return to the Service Utility menu or press Back if you want to continue turning the Drive Roller Turning Drive Roller Turning Drive Roller stopped Press ENTER to finish or BACK to resume HP DesignJets 500 and 800 Series Printers Service Manual 4 21 Service Tests and Utilities NOTE Unlock Carriage The purpose of this Service Utility is to unlock the Carriage Assembly which is normally locked by the Service Station in order to cap the Printheads Once unlocked the Carriage Assemb
18. Removed too early Error code 4 Removed too early Removal date 20 Feb 02 5 Removed Err 0025 PH Info Black 3 Ink used 355 cc 67 Usage time 201 days P H cleaning 0 Error code Summary Removal date 20 Sep 01 If consecutive Printheads are being replaced too early and the P H cleaning PH Info Black 4 Ink used 127 cc 24 Usage time 65 days code for all of them is 2 or lower the customer Error code should be advised to use Removal date 24 Nov 00 the Troubleshooting procedure before replacing Printheads As you can see in the above example all the Printheads were removed before the minimum life expectancy was reached Ink used is below 100 and the maximum recovery action was not performed P H cleaning code is 0 1 or 2 Therefore the conclusion is that the Printer is OK and the problem is that the customer is replacing the Printheads too early In this case advise the customer to use the Troubleshooting procedure refer to Page 6 4 to determine if Printheads need replacing or not Emphasize that performing the Troubleshooting procedure could recover the Printhead if it is printing badly therefore the User wouldn t need to buy new Printheads frequently HP DesignJets 500 and 800 Series Printers Service Manual 3 19 Ink Supplies Troubleshooting NOTE Troubleshooting Repetitive Ink Cartridge Messages When you see the mess
19. Setup Menu Press the following key combination to access the special Service Menu Set up menu Printer information T O set up Front panel Altitude 0 1000 m Log For On site Engineers press the Up and Enter keys to access the complete list of Service Tests Menu A Back gt Enter Set up menu Printer information T O set up Front panel Altitude 0 1000 m Log For Call Agents who will request the User to perform certain troubleshooting actions press the Down and Enter keys to access a limited list of Service Tests Menu Back v O Enter 3 Once inside the Service Tools Menu press the T or J key until the front panel displays Service Utilities and then press Enter Service Menu Service tests Service calibrations Service utilities Menu Back Pa Enter 4 14 HP DesignJets 500 and 800 Series Printers Service Manual Service Tests and Utilities 4 Press the Enter key to begin a specific utility when the required Service Utility is highlighted Service utilities Change ink tubes Unlock Carriage Turn Drive Roller Prime tubes EEROM Setup Menu Back v amp Enter HP DesignJets 500 and 800 Series Printers Service Manual 4 15 Service Tests and Utilities WARNING EEROM Setup The purpose of this Service Utility is to modify identification parameters such as serial and model
20. Try the following Switch the Printer Off and wait a few minutes Switch the Printer On again and resend the file that you were trying to print m If the Error Code reappears after resending the file then try generating the file again and try to print again m If the file that is causing this error is PostScript check if it is Binary If the file is Binary use AppleTalk to send the file to the Printer If AppleTalk is not being used to send the Binary file to the Printer then change the PostScript settings to Binary through the Front Panel Set up menu PS settings Encoding Binary m If the Error Code continues to reappear check for a new release of the Driver 64 04 Firmware Error USB Port Try the following m Switch the Printer Off and wait a few minutes Switch the Printer On again and check if the Error Code has disappeared E If the Error Code reappears check for a new Firmware release m If the new Firmware release does not solve the problem or if new Firmware release was not available then contact the HP Response Center or directly to the Division supplying the following information Model and Serial Number of the Printer Firmware release of the Printer use the Printer Information utility Page 4 26 The complete Error Code information including the linefeed where the error occurred use the Error Log utility to obtain this information gt Page 2 5 2 14 HP DesignJets 500 and
21. WARNING Switch off the printer and remove the power cable NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove 1 T 20 screw Type F from the back of the Right Hand Cover 2 Open the Ink Cartridge Door and remove T 20 screw Type F from the back of the Right Hand Cover 3 Keep the Ink Cartridge Door open and remove T 20 screw Type F from the top of the Right Hand Cover HP DesignJets 500 and 800 Series Printers Service Manual 8 7 Removal and Installation 4 Remove T 20 screw Type F from the front of the Right Hand Cover 5 Open the Window and remove 1 T 20 screw Type F from the side plate 6 Remove the Right Hand Cover NOTE Always keep the Ink Cartridge door open when removing installing the Right Hand Cover 8 8 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Front Panel Removal WARNING Switch off the printer and remove the power cable 1 Remove the the Right Hand Cover Refer to Page 8 7 2 Remove the Right Hand Trim t 3 Disconnect Front Panel Connector from the ISS PCA 4 Unclip the Front Panel and remove from the Printer HP DesignJets 500 and 800 Series Printers Service Manual 8 9 Removal and Installation Window and Top Cover Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the
22. also performs a spitting action in order to recover or refresh the nozzle performance therefore the Service Station contains a Spittoon to retain the ink thus reducing the risk of ink leakage A secondary Spittoon which performs the same routine is located on the left hand side of the Printer The function of wiping is to remove ink residue and external debris from the Printhead so that good drop ejection and nozzle performance is maintained throughout the life of the Printhead To help dissolve the ink spread on the nozzle plate and also to lubricate the wiper as it scrubs the nozzle plate some dissolvent and lubricant PolyEthileneGlycol 400 is applied to the Printheads nozzle plate also by means of wiping Also the Aerosol Fan is located at the bottom of the Service Station so if the Aerosol Fan fails for any reason the complete Assembly Service Station and Aerosol Fan needs to be replaced Spittoon Capping System Wiping System Service Station Motor 10 10 HP DesignJets 500 and 800 Series Printers Service Manual Glossary ac Alternating current ANSI size An American standard media size e g D E application The software you use to create your drawings APS Air Pressurization System Centronics A standard for the parallel interface between computer and device clipping Losing part of a drawing at the edges CMYK Cyan magenta yellow and black The colors of the printer s four in
23. and Utilities NOTE WARNING g Carriage Movement o The purpose of this test is to verify the movement of the scan axis components at several speeds This test checks for the following problems E Friction problems with worn out slider rod or Carriage Bushings m Blockage due to problems with the Service Station Em Problems with encoder sensing This Service Test can be performed by the End User with the guidance of a HP Support person via the phone IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE REPLACING THE CARRIAGE ASSEMBLY IF THIS TEST PASSES DO NOT REPLACE THE CARRIAGE ASSEMBLY Perform the Carriage Movement test as follows In the Service Tests submenu scroll to Carriage movement and press Enter Service tests Menu Troubleshooting Aerosol Fan test Back Ink Supply Station Paper advance test Carriage movement test C Enter The test will start and the following message will appear on the Front Panel Carriage movement Carriage movement test Moving Carriage Please wait Once the Printer has completed the test it will analyze the data received while performing the test Once the data has been analyzed the following message will appear on the Front Panel Carriage movement Menu Carriage movement test Back Ready to display results Press ENTER enter 4 8 HP DesignJets 500 and 800 Series Printers Service Manual Servi
24. contain false values or because both of them have failed 2 Turn Drive Roller gt Page 4 2 The purpose of this Service Utility is to rotate the Drive Roller in order to clean it 3 Unlock Carriage Page 4 22 The purpose of this Service Utility is to unlock the Carriage Assembly which is normally locked by the Service Station in order to cap the Printheads Once unlocked the Carriage Assembly can then be moved freely along the Printer by hand 4 Prime Tubes Page 4 23 The purpose of this Service Utility is to prime the Ink Supply Tubes after they have been replaced or if a situation arises where you need to force the priming procedure 5 Change Cutter Page 4 24 The purpose of this Service Utility is to move the Cutter Assembly to a position where it can be replaced 6 Change Ink Tubes Page 4 25 The purpose of this Service Utility is to move the Carriage Assembly to a position where it makes the removal of the Ink Supply Tubes much easier 7 Printer Information Page 4 26 The purpose of this Utility is the following E Report basic parameters for call qualification m Identify potential problems HP DesignJets 500 and 800 Series Printers Service Manual 4 13 Service Tests and Utilities Entering the Service Utilities Menu 1 Press the T or J key until the front panel displays the Setup Menu and then press Enter Press ENTER for Set up menu G G a Menu Back D Enter 2 Once inside the
25. expansion needed 16 MB no expansion needed Hard Disk Not available Not available Network Card Option Option Formatter Option Option Power CAD GA HP DesignJet 800 HP DesignJet 800PS Part Number 24 Model C7779B 24 Model C7779C 42 Model C7780B 42 Model C7780C Resolution 2400 x 1200 dpi Super Best 2400 dpi Super best Languages E HPGL 2 E PostScript Level 3 E HPGL 2 Memory 96 MB expandable to 160 MB 160 MB Hard Disk 6 GBytes Queuing 6 Gbytes Asian Fonts included Network Card Standard Standard Formatter Standard Standard 10 2 HP DesignJets 500 and 800 Series Printers Service Manual Functional Overview Electrical System Introduction The Printer s engine electronics Main PCA is controlled by a Kayak ASIC Kayak is the application specific integrated circuit ASIC designed in Hewlett Packard s Vancouver Printer Division forming the heart of the thermal inkjet large format printer digital electronics Electronics Enclosure Cooling Fan Formatter Main PCA LAN Card Hardware Description m The Kayak ASIC is fed with a 15 975MHz crystal quartz which through a phase lock loop PLL is raised to 192MHz and after that divided to the ColdFire frequency of 96MHz and further divided to the external memory bus of 483MHz m The Kayak ASIC incorporates the CF3_g Motorola CF3MRSX processor mega cell As implemented in Kayak the processor with 8KB of unified cache has a maximum operating frequency o
26. prints Glossary raster A method for defining an image in terms of dots rather than lines Raster data typically needs more memory than vector data RGB Red green and blue A standard color model RIP Raster Image Processor RTL Raster Transfer Language One of Hewlett Packard s standard graphics languages for plotters and printers Produces raster data ROM DIMM A physical module containing read only data that can be installed in the back of the printer to provide upgrades Scan axis The horizontal axis as you look at the printer from the front semi gloss photo A semi glossy opaque photographic paper spindle The rod which holds the roll of media G 3 Glossary G 4 Index Index A Advance Calibration 5 9 B Back Platen 8 17 Banding 1 6 Belt 8 78 Belt Swelling 9 2 Boot Up Sequence 1 12 C Carriage Assembly 8 78 Carriage Movement Test 4 8 Change Cutter 4 24 Change Ink Tubes 4 25 Cleaning Drive Roller 9 3 General 9 2 Print Platen 9 3 Printer 9 2 Color Calibration 5 7 Color differences 1 6 Cover Sensors 1 3 Cutter Assembly 8 32 Cutter Bushing 8 35 Cutter Guide 8 55 Cutter Guide Bracket 8 36 D Drive Roller 8 86 Drive Roller Encoder Sensor 8 38 E EEROM Setup 4 16 Change Font Type 4 18 Reset EEROM Values 4 20 Reset Usage Counter 4 19 Select Model Number 4 16 Select Serial Number 4 17 Electrical System 10 3 Electronics Module 8 24 Encoder Strip 8 76 Ent
27. the Carriage Cover 8 40 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation ml 6 Remove all the Printheads 7 Loosen T 8 screw that secures the Tubes to the Carriage 8 Unclip the Tubes from the Carriage and lift up HP DesignJets 500 and 800 Series Printers Service Manual 8 41 Removal and Installation 9 Move the Tubes Assembly clear from the Carriage Assembly 10 Close the Carriage Cover 11 Unclip the Carriage Cover clip located on the left hand side of the Carriage use a screwdriver if necessary 8 42 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 12 Remove the clip securing the Trailing Cable Remove 13 Disconnect the Trailing Cable from the Carriage Assembly 14 Slide the Trailing Cable out of the clip inside the Carriage Assembly and then lift up to free it from the Carriage HP DesignJets 500 and 800 Series Printers Service Manual 8 43 Removal and Installation 15 Move the Carriage Assembly to the right so that the Trailing Cable clips on the beam are visible 16 Release ALL the clips on the beam that secure the Trailing Cable 17 Slide the Plastic Holder that kept the Trailing Cable flat to the right to release it from the retaining clip 8 44 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 18 Remove the Plast
28. the sensor 8 18 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Media Sensor Removal WARNING Switch off the printer and remove the power cord 1 Remove the Right Hand Cover Refer to Page 8 7 2 Remove the Spindle 3 Disconnect the Media Sensor Cable from the ISS PCA 4 Unclip the Media Sensor Cover and remove from the Printer 5 Unclip the Media Sensor from underneath the Back Platen Route the Media Sensor cable out where necessary and remove the Media Sensor HP DesignJets 500 and 800 Series Printers Service Manual 8 19 Removal and Installation Formatter Removal WARNING Switch off the printer and remove the power cord 1 Remove the LAN Card Cover from the back of the Left Hand Cover 2 With a flat end screwdriver unscrew the 2 screws that attach the Formatter to the Electronics 3 Remove the Formatter 8 20 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation LAN Card Removal WARNING Switch off the printer and remove the power cord 1 Remove the LAN Card Cover from the back of the Left Hand Cover 2 Disconnect the LAN Cable from the LAN Card 3 With a flat end screwdriver unscrew the 2 screws that attach the LAN Card to the Electronics HP DesignJets 500 and 800 Series Printers Service Manual 8 21 Removal and Installation 4 Remove the LAN Card from the Printer
29. to resolve the problem replace the Paper Axis Motor gt Page 8 84 4 If the Paper Axis Motor test passes the Printer will try to read the Drive Roller Encoder Sensor while moving the Paper Axis Motor If the Printer can read the signals from the Encoder Sensor then the test has passed and the following message will be displayed press Enter to continue to the next stage of the test Paper Advance test Menu Back Roller encoder sensor test passed Press ENTER to continue amp Enter WARNING IF THIS TEST PASSES DO NOT REPLACE THE DRIVE ROLLER ENCODER SENSOR 5 If the Printer has problems reading the signal from the Drive Roller Encoder Sensor then the test has failed and the following message will be displayed Paper Advance test System error 56 10 Roller encoder sensor failed In this case to resolve the problem replace the Drive Roller Encoder Sensor gt Page 8 38 HP DesignJets 500 and 800 Series Printers Service Manual 4 11 Service Tests and Utilities 6 Itis possible that while performing this test a Paper Axis shutdown occurs in which case the following message will be displayed Paper Advance test System error 81 11 Paper axis shutdown In this case to resolve the problem try the following Open the Window and check for any visible obstacles that could be restricting the movement of the Drive Roller Try cleaning
30. to see information on Press the Enter key Error log Menu Select for more info 1 Error 21 10 2 Error 01 11 pack 3 Error 21 11 4 Error 43 10 p amp Enter 5 The front panel displays information on the selected item Error log NOTE To view information on another Error Code press BACK and the front panel will return to the previous screen 2 6 HP DesignJets 500 and 800 Series Printers Service Manual System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Codes 01 10 Electronics Module failure The possible cause could be 1 The Electronics Module is of the wrong type a 16 MB Electronics Module will not work in a 24 Model 2 Reading writing or initializing the EEROM failed 3 One of the ASIC s was not found within the Serial Bus that connects the Electronics Module to the Carriage Assembly 4 One of the ASIC s did not respond to the Serial Bus that connects the Electronics Module to the Carriage Assembly 5 The Electronics Module is requesting a move to the Service Station while the previous move is still being completed 6 The Electronics Module Cooling Fan has reached its current limit Replace the Electronics Module gt Page 8 24 01 11 The Electronics Module Cooling Fan badly connected Reco
31. use a screwdriver if necessary 18 Remove the clip securing the Trailing Cable Remove the Carriage Assembly HP DesignJets 500 and 800 Series Printers Service Manual 8 81 Removal and Installation 20 Slide the Trailing Cable out of the clip inside the Carriage Assembly and then lift up to free it from the Carriage 21 Slide the carriage including the Belt to the right and out of the Printer 22 The Belt can then be slipped off the Carriage Clips 8 82 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Installing the Carriage Assembly NOTE NOTE When connecting the Trailing Cable to the Carriage make sure that you align the red lines on the Trailing Cable as shown in this drawing When installing the Belt make sure that you insert it into the Carriage as shown in this drawing Tensioner gt gt HP DesignJets 500 and 800 Series Printers Service Manual 8 83 Removal and Installation Paper Axis Motor Removal WARNING Switch off the printer and remove the power cord 1 Remove the Spindle 2 Remove the Left Hand Cover Refer to Page 8 5 3 Remove the Back Platen make sure the Lever is in the UP position Refer to Page 8 17 Disconnect the Paper Axis Motor Cables from the Electronics Module SA A A AT ZA 5 Remove 2 T 15 screws Type J from the Paper Axis Motor NOTE M
32. 0 0811 2 10 Index 4 HP DesignJets 500 and 800 Series Printers Service Manual Index 1111 2 10 1113 2 10 1211 2 10 2110 2 11 2111 2 11 2210 2 11 4110 2 11 4113 2 12 4210 2 12 4310 2 12 4311 2 12 5610 2 12 5613 2 13 6104 2 13 6105 2 14 6404 2 14 7104 2 15 7106 2 15 7204 2 16 System Error Codes 1 2 Troubleshooting Procedure 6 4 Considerations for using 6 4 Flowchart 6 7 How to use it 6 4 No Defects Found 6 8 Tubes Assembly 10 9 Turn Drive Roller 4 21 U Unlock Carriage 4 22 Vv Vacuum Fan 8 64 Vertical Line Straightness Problems 5 5 7304 2 16 7904 2 17 8101 2 17 W 8111 2 17 8510 2 18 Window and Top Cover 8 10 8601 2 18 8611 2 18 8613 2 19 8713 2 19 9310 2 19 Continuable 2 2 Explanation 2 2 Non Continuable 2 2 T Trailing Cable 8 40 Troubleshooting Boot Up Sequence 1 12 Color differences 1 6 Formatter Accessory Card LEDs 1 14 Media Jams 1 4 Paper Axis Shutdowns 1 4 Power Switch LED 1 10 Priming Procedure 1 7 HP DesignJets 500 and 800 Series Printers Service Manual Index 5 Index Index 6 HP DesignJets 500 and 800 Series Printers Service Manual About this Edition This is the Ist edition of this Service Manual lst edition titled HP DesignJet 500 and 800 Series Printers Service Manual LA eackarD What s in this Service Manual This manual contains information necessary to test calibrate and service HP DesignJet 500 models C7769B C7770B HP
33. 4 Dryer Blower 4 Paper Axis Motor 42 Scan Axis Motor 43 Vacuum Fan 44 Aerosol fan 51 Window Sensor 52 Drop Detector 33 Media Sensor 54 Pinch Arm Sensor 55 Line Sensor 56 Drive Roller Encoder Sensor 57 Ink Leak Detector 58 Color Sensor 59 Media Type Sensor 6l Language Interpreting 62 Input Output through Parallel Port 63 Input Output through Network Card 64 Input Output through USB Port 71 Memory Management 72 Generic Firmware 73 Servo HP DesignJets 500 and 800 Series Printers Service Manual 2 3 System Error Codes Code Component System 81 Media Advance 82 Media Cut 83 Single Sheet Feeding 84 Roll Feeding 85 Media Axis Encoder Reading 86 Carriage Movement 87 Scan Axis Encoder Reading 91 Printhead Firing 92 Servicing 93 Ink Pumping The following table explains the last 2 digits of the System Error Code Code Recovery Action Response 0l Replace 02 Reseat Reconnect Clean Adjust manually Possible for 03 Calibrate Adjust using Automatic Process customerto 04 Power OFF perform 05 Upgrade System Firmware action 06 Upgrade Driver 07 Add Accessory 09 Wrong Part Installed 10 Replace 11 Reseat Reconnect Clean Adjust manually 12 Calibrate Adjust using Automatic Process On Site 13 Power OFF visit 14 Upgrade System Firmware required 15 Upgrade Driver 16 Add Accessory 19 Wrong Part Installe
34. 769 60148 3 0624 0769 C7769 60164 p lt ph pb f ph pah 7 20 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Figure 10 Ink Delivery System HP DesignJets 500 and 800 Series Printers Service Manual 7 21 Parts and Diagrams Service Station and Spittoon C7769 60149 Service Station Aerosol Fan 0624 0769 2 Screw Plas 6 19 0 5 in C7769 60165 1 Left Spittoon Assembly 7 22 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Figure 11 Service Station and Spittoon HP DesignJets 500 and 800 Series Printers Service Manual 7 23 Parts and Diagrams Service Station Holder 1 C7769 60156 1 Service Station Holder Right Hand Bracket 2 0515 2282 4 Screw 3 0624 0769 2 Screw 4 C7769 60173 1 Interconnect PCA 5 0624 0769 1 Screw 6 C7769 60176 1 Tensioner Assembly Kit 7 24 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Figure 12 Service Station Holder HP DesignJets 500 and 800 Series Printers Service Manual 7 25 Parts and Diagrams Pinch Wheel Assemblies 1 C7769 60181 1 Pinch Arm Mechanism 24 Model C7770 60015 1 Pinch Arm Mechanism 42 Model 2 C7769 60175 3 5 Pinch Arm 3 0515 2521 2 Screw 4 C7769 60074 1 Pinch Arm Sensor 5 0624 0768 1 Screw
35. 800 Series Printers Service Manual System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Codes 71 04 Problem allocating Memory This Error Code only appears in HP DesignJets 800 Series or in the HP DesignJet 500 Series with an HP GL 2 card installed Try the following E Switch the Printer Off and wait a few minutes Switch the Printer On again and check if the Error Code has disappeared E If the Error Code reappears check for a new Firmware release m If the new Firmware release does not solve the problem or if new Firmware release was not available then contact the HP Response Center or directly to the Division supplying the following information Model and Serial Number of the Printer Firmware release of the Printer use the Printer Information utility Page 4 26 The complete Error Code information including the linefeed where the error occurred use the Error Log utility to obtain this information Page 2 5 71 06 Out of Memory problem This Error Code only appears in HP DesignJets 800 Series or in the HP DesignJet 500 Series with an HP GL 2 card installed when processing either a PostScript or HP GL 2 file Try the following E Check the amount of RAM in the Printer using the Front Panel use the Printer Information utility Page 4 26 If necessary install more memory into the Formatter If the pro
36. A 17 Disconnect the Paper Axis Motor Cables and the Vacuum Fan Cable from the Electronics Module 18 Remove 1 screw T 10 from the Grounding Strip HP DesignJets 500 and 800 Series Printers Service Manual 8 87 Removal and Installation 19 Remove 1 screw T 15 from the Right Back Trim and remove trim 20 Remove screw T 15 from the Left Back Trim and remove trim 21 Remove 4 screws T 25 that secure the Top Part of the Printer to the Bottom Part from the Left Hand Side 8 88 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 22 Remove 4 screws T 25 that secure the Top Part of the Printer to the Bottom Part from the right hand side 23 Make sure the Media Lever is in the UP Position and lift the complete Top Part of the Printer away from the Bottom Part NOTE The Top Part of the Printer is very heavy so 2 people should perform this step 24 Remove 1 screw T 15 from the Axle Spring HP DesignJets 500 and 800 Series Printers Service Manual 8 89 Removal and Installation 25 Remove the Axle Spring NOTE Be very careful when removing the Axle Spring because you could damage the Encoder Disc 26 Remove the Encoder Disc Cover Release the levers on both ends of the Drive Roller 8 90 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 28 Lift Drive Roller out of the
37. A Paper Axis shutdown can happen when the Printer detects that the Drive Roller is not moving but at the same time power is being supplied to the Paper Axis Motor which should be turning the Drive Roller The reasons for the Paper Axis shutdown and their solutions are explained as follows The Paper Axis Motor does not respond to the electrical simulation E It is possible to determine whether the Paper Axis is faulty by performing the Paper Advance Test Refer to Page 4 0 The Printer will move the Motor backwards and forwards and measure directly from the Motor Encoder whether the Paper Axis Motor responded to the force If the Paper Axis Motor did not respond the solution would be to replace the Paper Axis Motor Page 8 84 The Transmission Gears which transmit the movement to the Drive Roller are not turning This problem could be caused either by blockage of the gears caused by an obstacle or by one of the gears being damaged To solve the problem try the following m Remove the Back Platen Page 8 67 and check if there are any obstacles blocking the Gears Remove the obstacles if necessary m Remove the Back Platen Page 8 67 and check if the Transmission Gears are damaged If the Gears are damaged replace the Gear Assemblies Page 8 92 The Drive Roller cannot move because of an obstacle or because it is damaged To solve the problem try the following m Remove the Back Platen Page 8 67 and check if there a
38. Back Platen make sure the Pinch Arm Lever is in the UP Position Refer to Page 8 17 3 Remove 2 T 20 screws Type H from each Pinch Arm NOTE There 5 Pinch Arms in the 42 Model and 3 in the 24 Model 4 Remove the Pinch Arm s 8 66 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Pinch Arm Mechanism Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Back Platen make sure the Pinch Arm Lever is in the UP Position Refer to Page 8 17 2 Remove ALL the Pinch Arms Refer to Page 8 66 3 Remove 1 T 15 screw Type E that attaches the Cam to the Lever 4 Remove 1 T 15 screw from the left hand side of the Cam HP DesignJets 500 and 800 Series Printers Service Manual 8 67 Removal and Installation 5 Open the Media Guide by unclipping it 6 While pulling the Media Clip down move the complete assembly to the left towards you and then to the right and remove completely 8 68 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Pinch Arm Lever Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Right Hand Cover Refer to Page 8 7 2 Make sure the Pinch Arm Lever is in the UP Position 3 Remove 1 T 15 s
39. DesignJet 500PS models C7769C C7770C HP DesignJet 800 models C7779B C7780B HP DesignJet 800PS model C7779C C7780C For information about using these printers refer to the corresponding User and Quick Reference Guides The procedures described in this manual are to be performed by HP qualified Service Personnel only HP DesignJet 500 and 800 Series Large Format Printers
40. Follow these instructions to troubleshoot the message Printhead Error message Replace the Printhead that has failed If the message continues to appear clean the electrical contacts inside the Carriage Assembly power OFF the Printer first and the electrical contacts of the Printhead make sure you use water based solutions only If the message continues to appear after cleaning the Carriage Assembly and the Printhead replace the Printhead again If the message still continues to appear replace the Carriage Assembly Page 8 78 HP DesignJets 500 and 800 Series Printers Service Manual 3 21 Ink Supplies Troubleshooting NOTE Printhead Error Codes Printhead Error Codes consist of 4 digits which explain whether a Printhead is In or Out of Warranty and what problem has caused the Printhead to fail The following table explains the first 2 digits of the Printhead Error Code Code Explanation 00 Black Printhead In Warranty 01 Magenta Printhead In Warranty 02 Cyan Printhead In Warranty 03 Yellow Printhead In Warranty 10 Black Printhead Out of Warranty 11 Magenta Printhead Out of Warranty 12 Cyan Printhead Out of Warranty 13 Yellow Printhead Out of Warranty The following table explains the last 2 digits of the Printhead Error Code Code Explanation 02 to 09 Acumen Error Replace faulty Printhead only 10 12 14 Printhead Error Replace faulty Printhead clean
41. OM Setup 4 16 Turn Drive Roller 4 21 Unlock Carriage 4 22 Prime Tubes 4 23 Change Cutter 4 24 Change Ink Tubes 4 25 Printer Information 4 26 HP DesignJets 500 and 800 Series Printers Service Manual 4 Service Tests and Utilities Introduction This chapter explains how to use the built in Service Tests and Service Utilities and what to do if any of the Service Tests fail If possible always perform a Service Test on the component that you are about to replace just to make sure that is the component that has failed If the test on that component passes there is no need to replace it Phone Support In certain circumstances a Call Agent can try and troubleshoot the Printer by requesting the Customer to perform a Service Test via the phone Using this process it can be determined whether the Printer requires any on site maintenance Diagnostics Self Test Initialization Sequences Whenever the Printer is switched ON it automatically performs a series of internal self tests and mechanical initialization sequences If any of the parts fail a system error will appear and you should consult Chapter 2 System Error Codes Entering Service Menu at Power Up Only for Onsite Repair If the Printer fails to initialize completely because of a System Error and you need to use the Service Menu Service Tests and Utilities the Printer can be powered up in Service Mode by pressing the Up and Enter keys while switching the Prin
42. Printer Make sure you take care when lifting the Drive Roller because the Encoder Disc could get damaged HP DesignJets 500 and 800 Series Printers Service Manual 8 91 Removal and Installation Gear Assemblies Removal WARNING Switch off the printer and remove the power cord 1 Remove the Spindle Remove the Left Hand Cover Refer to Page 8 5 Remove the Right Hand Cover Refer to Page 8 7 4 Remove the Left and Right Trims 5 Remove the Front Panel Refer to 10 11 12 13 14 15 16 Page 8 9 Remove the Top Cover and Window Refer to Page 8 10 Remove all the Media Deflectors Refer to Page 8 11 Remove the Back Platen make sure the Lever is in the UP position Refer to Page 8 17 Remove the Media Sensor Refer to Page 8 19 Remove the Spittoon Refer to Page 8 23 Remove the Cutter Assembly Refer to Page 8 32 Remove the Cutter Guide Bracket Refer to Page 8 36 Remove the Drive Roller Encoder Sensor Refer to Page 8 38 Remove the Ink Supply Station Refer to Page 8 48 Remove the Cutter Guide Refer to Page 8 55 Remove the Paper Axis Motor Refer to Page 8 84 8 92 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 17 Remove the Drive Roller Refer to Page 8 86 18 Remove the 2 locking pins from the Gears 19 Remove the Gears HP DesignJets 500 and 800 Series Printers Ser
43. Printers Service Manual Troubleshooting NOTE NOTE If you need to reseat the Start up Printheads make sure you re insert them in the same color slot in the Carriage m The Printer will request you to reseat the Start up Printheads or in the case of missing Start up Printheads you should install them or order new ones and then retry the priming process if the priming process fails 3 times because of the same problem it will display a System Error In this situation the problem could be the following 1 The Start up Printheads were not installed correctly or they are missing one or all of them 2 The Start up Printheads do not work properly and do not allow air to flow one or all of them 3 The Ink Supply Station fails to pressurize the Ink Cartridges To check this perform the Ink Supply Station test Page 4 6 4 The Ink Supply Tubes are blocked preventing the ink from flowing correctly m If a System Error is displayed try the following 1 The Ink Cartridge valve is broken so the Ink Cartridge should be replaced 2 The Start up Printhead is not working properly and allows ink to flow outside 3 The Ink Supply Tube is leaking The last 2 cases will be more obvious because there will be a lot of ink in the Printer around 20 cc of ink Remove the Ink Cartridges and release the Tubes Bracket from the Ink Supply Station and check if there is ink in this area For more information on this problem refer t
44. Printing a page whose X axis the axis vertical to the printer as you look at it from the front is longer than a standard page size G 2 margin The space around the page added by the printer to separate one page from another and to avoid printing right to the edge of the media matte Not glossy media The material usually paper onto which the printer prints nesting Placing two or more pages side by side on roll media to avoid waste palette A set of logical pens defined by color and width Paper axis The vertical axis as you look at the printer from the front PJL Printer Job Language A programming language that controls jobs going to a printer PML Printer Management Language parallel interface A type of interface between computer and device Generally faster than a serial interface PANTONE The PANTONE MATCHING SYSTEM is an international standard for color communication in the graphics art industry pen Even though the plotter has no physical pens the lines it draws match the attributes of a pen platen The exterior part of the printer on which the media rests before going into the media entry slot printing area Page size minus margins PostScript A standard page markup language commonly used by graphics and desktop publishing software applications PSU Power Supply Unit queueing Placing each print received by the device into memory for processing with other
45. able 8 59 Ink Supply Tubes 8 60 Vacuum Fan 8 64 Pinch Arm 8 66 Pinch Arm Mechanism 8 67 Pinch Arm Lever 8 69 Pinch Arm Sensor 8 71 Fork Idler Tensioner and Idler Pulley 8 74 Encoder Strip 8 76 Carriage Assembly Including Belt 8 78 Paper Axis Motor 8 84 Drive Roller 8 86 Gear Assemblies 8 92 HP DesignJets 500 and 800 Series Printers Service Manual 8 1 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 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 NOTE 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 Safety Precautions Review WARNING and CAUTION symbols and instructions before you service the printer 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 groun
46. ages shown below the normal procedure is to replace the Ink eat that has failed ran out of ink or has expired nk menu nk menu Sq Ink cartridge cartridges will expire rep Agee ji i in day ee A e iTi nk menu nk menu T Ink cartridge NS a But in certain circumstances even after replacing the Ink Cartridge the above messages continue to appear This could mean that one of the components of the Printer is failing and requires cleaning or replacing Follow these instructions to troubleshoot each message Ink Cartridge Error message 1 Replace the Ink Cartridge that has failed If the message continues to appear clean the electrical contacts inside the Ink Supply Station power OFF the Printer first If the message continues to appear after cleaning the Ink Supply Station replace the Ink cartridge again If the message still continues to appear replace the Ink Supply Station Page 8 48 You could also get repetitive Ink Cartridge Error messages if the Ink Cartridge is leaking In this case try the following Reinsert the failing Ink Cartridge and if the status is OK you may continue to print If after reinserting the Ink Cartridge fails again then replace the Ink Cartridge If the message continues to appear after replacing the Ink Cartridge then replace the Ink Supply Tubes Page 8 60 Out of Ink message 1 Replace the Ink Cartridge that has failed If the message continues to appear replac
47. ake sure that you keep hold of the Paper Axis Motor when removing the screws otherwise the Motor could fall and be damaged 8 84 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 6 Remove the Paper Axis Motor including the cables HP DesignJets 500 and 800 Series Printers Service Manual 8 85 Removal and Installation Drive Roller Removal WARNING Switch off the printer and remove the power cord 1 Remove the Spindle Remove the Left Hand Cover Refer to Page 8 5 Remove the Right Hand Cover Refer to Page 8 7 4 Remove the Left and Right Trims 5 Remove the Front Panel Refer to 10 11 12 13 14 15 Page 8 9 Remove the Top Cover and Window Refer to Page 8 10 Remove all the Media Deflectors Refer to Page 8 11 Remove the Back Platen make sure the Lever is in the UP position Refer to Page 8 17 Remove the Media Sensor Refer to Page 8 19 Remove the Spittoon Refer to Page 8 23 Remove the Cutter Assembly Refer to Page 8 32 Remove the Cutter Guide Bracket Refer to Page 8 36 Remove the Drive Roller Encoder Sensor Refer to Page 8 38 Remove the Ink Supply Station Refer to Page 8 48 Remove the Cutter Guide Refer to Page 8 55 8 86 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 16 Disconnect the Pinch Arm Sensor Cable from the Interconnect PC
48. al 3 17 Ink Supplies Troubleshooting used is below 100 and the maximum recovery action was also performed P H cleaning code is 3 Therefore the conclusion is that the Printer is causing the Printheads to fail In this situation to resolve the problem try the following Check the amount of ink used by the Printhead Page 3 10 Obtaining Printhead Information If the amount of ink used by the Printhead is less than 1 Ink Cartridge 69 cc then replace the Ink Cartridge for that color Check if the Ink Supply Station is faulty by performing the Ink Supply Station test Page 4 6 If the test fails replace the Ink Supply Station Page 8 48 Use the printer Information utility to check the usage of the Service Station Page 4 26 If the usage of the Service Station is close to 100 then replace the Service Station gt Page 8 52 Check if the Ink Supply Tubes are faulty by installing new Start up Printheads into the Carriage and see if ink flows to them you will need to perform the Prime Tubes Utility Page 4 23 If the ink DOES NOT flow to the Start up Printheads replace the Ink Supply Tubes Page 8 60 Is the User Replacing the Printheads too Early In the same way that you can determine if the Printer is causing failures in the Printheads you can determine if the customer is replacing the Printheads before the minimum life expectancy has been reached without performing the maximum recovery action Troubleshooting pr
49. art 6 7 No Printing Defects Found Using the Troubleshooting Procedure 6 8 Long Term Color Bleeding Glossy Papers 6 9 Solving Color Accuracy problems 6 9 Color Consistency problems 6 9 Media 6 10 There are Smears or Scratching on the Printed Media 6 10 HP DesignJets 500 and 800 Series Printers Service Manual 6 1 Print Quality Print Quality Print Quality Troubleshooting Checklist When faced with a Print Quality problem use the following checklist as a guide in troubleshooting the problem Problem reproduction E Reproduce the problem that the customer is seeing using their original settings Printer configuration m Print Mode Set to Best in the driver m Dry time Set to Automatic E Select the correct media setting when loading the media Hardware check list Firmware Revision E Check if the latest version of the firmware is installed If not update the Printer with the latest firmware revision Printheads Printhead Troubleshooting Process If you don t have any samples yet reproduce the original problem with the correct printer settings Perform the Troubleshooting procedure using the exact settings and Media that the Customer used when faced with the Print Quality problem Printhead Alignment and Check E Perform the Printhead Alignment using HP High Gloss Photo Paper If not available use Coated media if required Media E Make sure that you use HP or HP approved media E Select the correct m
50. artridge is installed and must be replaced before any further printing can be done Sand Clock the Ink Cartridge will expire in X amount of days The X is displayed at the top of the screen 3 12 HP DesignJets 500 and 800 Series Printers Service Manual Ink Supplies Troubleshooting Printhead Status Messages There are two circumstances under which you may need to replace a Printhead E The Printer has detected that the Printhead is faulty or is of the wrong model type E During the Printhead Alignment or Troubleshooting procedure the Printhead could not be recovered and the customer thinks that the Print Quality is not good enough Also you should remove the Printheads if the Printer needs to be transported to another location If the Printer detects that a Printhead needs replacing you will see the message Error Select Replace printheads with five icons explained below referring from left to right to the Cyan Black Magenta and Yellow Printheads The icons may be any of the following The Printhead is OK Empty box flashing the Printhead is missing and the correct one must be inserted Flashing cross the Printhead is faulty or is of the wrong model type Reseat the Printhead and check if the problem is resolved If not replace the Printhead Exclamation Mark the Printer has determined that one of the Printheads has worn out and should be replaced Replace the Printhead t
51. bes Unlock Carriage Turn Drive Roller Pack Prime tubes EEROM Setup v Enter 2 Once the utility starts the printer will display the following message on the front panel If you want to abort the Prime Tubes utility press Cancel and you will return to the Service Utility menu Prime tubes Press ENTER to force tube priming at next power up CANCEL to abort 3 If you press Enter the following message will be displayed on the Front Panel You should switch the Printer ON and OFF in order to start the priming process Prime tubes Power off on machine to start tube priming 4 When you power On the Printer the Printer will initialize and then display the following message You will need to remove the normal Printheads and replace them with Start up Printheads Open window and remove normal printheads to prepare ink system HP DesignJets 500 and 800 Series Printers Service Manual 4 23 Service Tests and Utilities Change Cutter The purpose of this Service Utility is to move the Cutter Assembly to a position where it can be replaced NOTE In order to actually replace the Cutter Assembly refer to Page 8 32 Perform the Change Cutter utility as follows 1 In the Service Utilities submenu scroll to Change cutter and press Enter Service utilities 3 Menu Change Cutter Change ink tubes Back Unlock Carriage Turn Drive Rolle
52. blem continues contact the HP Response Center or directly to the Division supplying the following information Model and Serial Number of the Printer Firmware release of the Printer use the Printer Information utility Page 4 26 The complete Error Code information including the linefeed where the error occurred use the Error Log utility to obtain this information Page 2 5 2 16 HP DesignJets 500 and 800 Series Printers Service Manual System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Codes 79 04 Firmware Error Try the following E Switch the Printer Off and wait a few minutes Switch the Printer On again and check if the Error Code has disappeared E If the Error Code reappears check for a new Firmware release E If the new Firmware release does not solve the problem or if new Firmware release was not available then contact the HP Response Center or directly to the Division supplying the following information Model and Serial Number of the Printer Firmware release of the Printer use the Printer Information utility Page 4 26 The complete Error Code information including the linefeed where the error occurred use the Error Log utility to obtain this information gt Page 2 5 81 01 Paper Axis shutdown If this err
53. blem continues try processing the file in the PC instead of the Printer select Avoid out of memory in Advanced options in the Driver HP DesignJets 500 and 800 Series Printers Service Manual 2 15 System Error Codes System Error Problem Description Corrective Action System Error Problem Description Corrective Action 72 04 Problem in the Scan Axis Firmware Error Try the following Switch the Printer Off and wait a few minutes Switch the Printer On again and check if the Error Code has disappeared If the Error Code reappears check for a new Firmware release If the new Firmware release does not solve the problem or if new Firmware release was not available then contact the HP Response Center or directly to the Division supplying the following information Model and Serial Number of the Printer Firmware release of the Printer use the Printer Information utility Page 4 26 The complete Error Code information including the linefeed where the error occurred use the Error Log utility to obtain this information gt Page 2 5 73 04 Servo Error Try the following Switch the Printer Off and wait a few minutes Switch the Printer On again and check if the Error Code has disappeared If the Error Code reappears check for a new Firmware release If the new Firmware release does not solve the problem then replace the Electronics Module Page 8 24 If the pro
54. bly 42 Model C7770 60018 NI N Hardware Kit Includes Screw Drivers 7 2 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Figure 1 Printer Support HP DesignJets 500 and 800 Series Printers Service Manual 7 3 Parts and Diagrams Right Hand Cover 1 C7769 60159 1 Right Hand Cover Grey HP DesignJet 500 Series Only C7779 60159 1 Right Hand Cover Black HP DesignJet 800 Series Only 0624 0771 5 Screws 3 C7769 60160 1 Trim Kit Includes the front and back trims for the left and right sides 4 C7769 60161 1 Front Panel 7 4 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Figure 2 Right Hand Cover HP DesignJets 500 and 800 Series Printers Service Manual 7 5 Parts and Diagrams Left Hand Cover Bl C7769 60158 1 Left Hand Cover Grey HP DesignJet 500 Series Only C7779 60158 1 Left Hand Cover Black HP DesignJet 800 Series Only 0624 0771 5 Screws 3 C7769 60160 1 Trim Kit Includes the front and back trims for the left and right sides 7 6 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Figure 3 Left Hand Cover HP DesignJets 500 and 800 Series Printers Service Manual 7 7 Parts and Diagrams Top Cover and Deflectors 1 C7769 60154 1 Top Cove
55. but the Printer does not know which one it is Error Select Replace printheads In order to identify and replace the failing Printhead try the following 1 Select replace Printheads from the front panel 2 Open the Carriage cover and remove ALL the Printheads HP DesignJets 500 and 800 Series Printers Service Manual 3 7 Ink Supplies Troubleshooting NOTE 3 Reinsert the Cyan Printhead only and close the Carriage cover and the Window Check the front panel if the status of the Cyan Printhead is X or then the conclusion is that the Cyan Printhead is faulty and must be replaced If the status of the Cyan Printhead is OK the conclusion is that the Cyan Printhead is working correctly Repeat the process from step 1 for the other Printheads to identify which one is failing m Printhead Warning message When this message appears normally appears when you check the status of the Printheads by selecting the Ink Menu the Printer has determined that one of the Printheads has worn out and should be replaced Ei Printhead warning Foor print quality The Printer normally determines this when The Printhead Alignment fails due to a faulty Printhead and the Printer tries to recover the Printhead upto 3 times but is not successful after the 4th attempt at the Printhead Alignment or if the recovery process or the Printhead Alignments are cancelled The Troubleshooting process is performed but the Printer canno
56. ce Manual 8 77 Removal and Installation Carriage Assembly Including Belt Removal 1 Perform the Service Utility Unlock Carriage Refer to Page 4 22 NOTE Switch off the Printer after performing this Utility 2 Remove the Left Hand Cover Refer to Page 8 5 3 Remove the Right Hand Cover Refer to Page 8 7 4 Remove the Top Cover and Window Refer to Page 8 10 5 Remove the Front Panel Assembly Refer to Page 8 9 6 Remove the Service Station Refer to Page 8 52 7 Remove the Fork Idler Tensioner and Idler Pulley Refer to Page 8 74 8 Remove the Encoder Strip Refer to Page 8 76 9 Remove the Service Station Holder Refer to Page 8 57 Manually move the carriage to the correct position to remove the Tubes Assembly from the Carriage 8 78 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 11 Release the latch and lift up the Carriage cover 13 Loosen 1 T 8 screw that secures the Tubes to the Carriage HP DesignJets 500 and 800 Series Printers Service Manual 8 79 Removal and Installation 14 Unclip the Tubes from the Carriage and lift up 15 Move the Tubes Assembly clear from the Carriage Assembly 16 Close the Carriage Cover 8 80 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 17 Unclip the Carriage Cover clip located on the left hand side of the Carriage
57. ce Tests and Utilities 4 If you press Enter the Front Panel will display a list of the different results you can view You can make your selection using the arrow keys and press Enter to view the selection Test results Select item for more information PWM Speed offset Stabilization distance Menu Back v a Enter 5 If you selected PWM the Front Panel will display the results of the PWM test PWM results Average XXX i Std dev X Average value of the PWM Standard deviation value of the PWM 6 If you selected Speed offset the Front Panel will display the results of the Speed offset Speed offset results Average ips X er Std dev ips X Average value of the speed offset Standard deviation value of the speed offset 7 If you selected Stabilization distance the Front Panel will display the results of the Stabilization distance results Stabilization distance Stabilizat dist mm XX HP DesignJets 500 and 800 Series Printers Service Manual 4 9 Service Tests and Utilities NOTE WARNING WARNING ox Paper Advance Test The purpose of this test is to identify whether there is too much friction in the paper axis drive system which is caused by defects with the Transmission Gears Drive Roller or the Paper Axis Motor This test should be performed when a Paper
58. ched the Troubleshooting procedure should be performed which will determine whether the Printhead needs replacing or not after performing various levels of recovery actions For information on solving Print Quality problems see Chapter 6 Print Quality The Printer does not Power ON 1 Check that the power cord is connected correctly to the Printer and to the Power Socket 2 Check that the Front Panel Cable is correctly connected to the Interconnect PCA Also make sure that the Front Panel cable is not damaged 3 Check that the Interconnect Cable is properly connected at the both ends of the Printer Cover Sensors are not Working 1 Check if the faulty sensor is installed correctly 2 Check if the cable for the faulty sensor is connected correctly 3 Replace the faulty Sensor or the assembly that contains the Sensor The Line Sensor has Problems Detecting Media 1 Check the type of media that is being used since the Line Sensor may have problems detecting transparent media or some types of Non HP media Try loading white HP media in to the Printer and check if the Line Sensor detects it 2 Excessive ink deposits on the Print Platen surface can fool the sensor by reflecting the light Clean the Print Platen 3 The Line Sensor is damaged or faulty Replace the Carriage Assembly Page 8 78 HP DesignJets 500 and 800 Series Printers Service Manual 1 3 Troubleshooting Troubleshooting Paper Axis Shutdowns
59. controls for the user to modify the image in order to obtain the desired colors E Printing with PostScript reduces the problem significantly E Avoid very long exposures to extreme environmental conditions after printing with glossy media more than 12 hours at 80 humidity may result in severe changes in color Banding at variable extreme environmental conditions Since the Accuracy Calibration has been done at normal environmental conditions printing in extreme environmental conditions will cause banding because the advance of the Drive Roller does not correspond to the same conditions that the calibration was done in To solve the problem try the following E Perform the Accuracy Calibration in the new environmental conditions Refer to the User s Guide 1 6 HP DesignJets 500 and 800 Series Printers Service Manual Troubleshooting The Priming Procedure Fails When the customer first receives the Printer it is supplied with a set of four Start up Printheads pre installed in the Printhead Carriage These Start up Printheads are used for the priming of the tubes in the Ink Delivery System When the Printer is powered ON for the first time the Printer will automatically perform the priming process Without the priming process the customer will NOT be able to use the Printer The initial startup assumes that the Start up Printheads are installed but the Printer cannot detect them because the Printer can only dete
60. crew Type I and washer that secures the Lever to the chassis HP DesignJets 500 and 800 Series Printers Service Manual 8 69 Removal and Installation 4 Remove T 15 screw Type E that secures the Lever to the Cam 5 Lower the Pinch Arm Lever and remove from the Printer including the lever bushing 8 70 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Pinch Arm Sensor Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Right Hand Cover Refer to Page 8 7 2 Raise the Media Lever 3 Lift tab up and slide Right Deflector to the left and lift up HP DesignJets 500 and 800 Series Printers Service Manual 8 71 Removal and Installation 4 Remove T 20 screw Type C from the Right Deflector Bracket 6 Remove 1 T 8 screw Type G from the Pinch Arm Sensor 8 72 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 7 Disconnect the Pinch Arm Sensor Cable from the Interconnect PCA 8 Remove the Pinch Arm Sensor including the cable HP DesignJets 500 and 800 Series Printers Service Manual 8 73 Removal and Installation Fork Idler Tensioner and Idler Pulley Removal WARNING Switch off the printer and remove the power cord 1 Remove the Left Hand Cover Refer to Page 8 5 2 Remove th
61. crewdriver HP DesignJets 500 and 800 Series Printers Service Manual 8 3 Removal and Installation Screw Types Type Torx Length Head Type Thread Type Part Number mm A T 20 17 Pan Taptite 0515 1743 B T 10 8 0 Pan Taptite 0515 2200 C T 20 10 Pan Taptite 0515 2282 D T 10 17 5 Pan Washer Plastite 0515 2675 E T 15 12 7 Pan Plastite 0624 0769 F T 15 20 Pan Plastite 0624 0771 G T 8 12 7 Pan Plastite 0624 0768 H T 20 35 Pan Taptite 0515 2521 I T 15 9 5 Pan Plastite 0515 2981 J T 10 8 Pan Machined 0515 2246 8 4 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Left Hand Cover Removal WARNING Switch off the printer and remove the power cable NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Spindle 2 Remove 3 T 20 screws Type F from the Rear of the Left Hand Cover 3 Remove the LAN Card Cover from the back of the Left Hand Cover HP DesignJets 500 and 800 Series Printers Service Manual 8 5 Removal and Installation 4 Remove T 20 screw Type F from the front of Left Hand Cover 5 Open the Window and remove 1 T 20 screw Type F from the side plate NOTE Be careful not to drop the screw into the Printer 6 Remove the Left Hand Cover 8 6 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Right Hand Cover Removal
62. ct Cable is connected correctly to the Electronics Module and to the Interconnect PCA 2 Ifthe Interconnect cable is connected correctly and the LED continues to flash twice then replace the Interconnect Cable gt Page 8 59 LED Flashes 3 times every few seconds The Printer cannot detect the Front Panel Try the following 1 Check that the Front Panel is connected correctly to the Interconnect PCA 2 Check that the Interconnect Cable is properly connected at the both ends of the Printer 3 If the Front Panel is connected correctly and the LED continues to flash 3 times then replace the Front Panel gt Page 8 9 4 Replace the Interconnect Cable gt Page 8 59 5 Replace the Electronics Module Page 8 24 LED Flashes 4 times every few seconds This indicates that the Main PCA has failed Replace the Electronics Module Page 8 24 LED Flashes 5 times every few seconds This indicates that the Main PCA has failed Replace the Electronics Module Page 8 24 HP DesignJets 500 and 800 Series Printers Service Manual 1 11 Troubleshooting Using the Boot Up Sequence to Troubleshoot When you Power On the Printer the Printer performs the Boot Up sequence which initializes the major components of the Printer If for some reason the Boot Up sequence fails because a component has failed to initialize the following explanations will help you to locate the failing component During the first phase of the Boot up sequenc
63. ct normal Printheads If normal Printheads are installed during the initial startup the Printer will request the User to remove them and check if they really have been removed It will then request the User to install the Start up Printheads Also the Printer will request the User to install the Ink Cartridges if they have not been installed already If the Ink Cartridges contain less than 20cc of ink the Ink Cartridges are encoded with the quantity of ink remaining they will be rejected Normally with a new Printer this should not be a problem since the Printer comes with Ink Cartridges that are full but there maybe cases when the Ink Supply Tubes need to be replaced in which case half empty Ink Cartridges may be used Once the Printer assumes that the Start up Printheads and Ink Cartridges with enough ink are installed the priming process will begin If the priming process is completed successfully the Printer will directly proceed to the Printhead replacement procedure in order to replace the used Start up Printheads with normal Printheads Once the priming process has started it can fail due to 2 different problems m The Ink Supply Tubes were not completely empty This is the most common cause especially if the Printer has been powered ON and OFF several times with the Ink Cartridges installed since the initialization process performs at least one pumping cycle m The Printer detects that one or more of the tubes cannot be det
64. cumulation of ink particles and dust from the media or the atmosphere in the vicinity of the slider rods Scan Axis maintenance requires the cleaning of the slider rods properly and a lubricant to apply onto the rods It also requires the replacement of the Ink Tubes System The most important parts to keep clean are the upper and internal sides of the rods 9 4 HP DesignJets 500 and 800 Series Printers Service Manual Functional Overview Introduction 10 2 SKU Overview 10 2 Electrical System 10 3 Power Supply Unit PSU 10 5 Front Panel 10 6 Ink Delivery System IDS 10 7 Ink Supply Station ISS 10 7 Tubes Assembly 10 9 Service Station 10 10 HP DesignJets 500 and 800 Series Printers Service Manual 10 1 Functional Overview Introduction This Chapter contains a simplified description of the HP DesignJet 500 800 Printer circuits and mechanical functions Mechanical and Printed Circuit Assembly PCA overviews present a functional description of how the Printer operates SKU Overview In total there are 8 SKU s which are detailed as follows Windows Windows HP DesignJet 500 HP DesignJet 500PS Part Number 24 Model C7769B 24 Model C7769C 42 Model C7770B 42 Model C7770C Resolution 1200 x 600 dpi 1200 x 600 dpi Languages E Raster Data Only E MAC WIN PostScript RIP E HPGL 2 Upgrade still 600 dpi Memory 16 MB no
65. d 2 4 HP DesignJets 500 and 800 Series Printers Service Manual System Error Codes Error Log Utility The Error Log utility contains a record of the last 10 system error codes the Printer has experienced The purpose of this information is to m Determine whether the Printer is experiencing repetitive failures m Determine whether the previous problems are causing the current failure in the printer E Determine whether there are additional symptoms to the current system error code The information that is stored for each error code is m The reported System error code m The code line in the Firmware where the error was triggered m The date when the error code was triggered Accessing the Error Log Utility 1 Press the T or J key until the front panel displays the Setup Menu and then press Enter Q A vem N a Back Press ENTER for Set up menu p Enter 2 Press the T or J key until the front panel highlights Log Press the Enter key Set up menu Menu Expansion cards T O set up Back front panel Altitude 0 1000 m Log amp Enter HP DesignJets 500 and 800 Series Printers Service Manual 2 5 System Error Codes 3 Press the T or J key until the front panel highlights Errors Press the Enter key Log Menu Back Printheads v Errors amp Enter 4 Press the or J key until the front panel highlights the error code that you want
66. d 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 8 2 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 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 Ground earth your body while disassembling 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 The following tools are required to disassemble and repair the Printer D ja Long Torx Screwdriver with the indicated attachments T8 T9 T10 T15 T20 TI5L OO O i Nut driver with the indicated attachments mg ad D 3 16 55 inch mm eo Small flat blade s
67. d Select the color of the Printhead that is experiencing the replacement problem In the following example Printheads 2 3 and 4 were removed too early Black P H history Select for more info 1 Installed OK These 3 Printheads were 2 Removed too early removed from the Printer 3 Removed too early aR Menoe OE before the minimum life 5 Removed Err 0025 expectancy was reached 2 In order to check if the recovery process Troubleshooting procedure was performed on each Printhead select the Printhead and press the Enter key Black P H history PH Info Black 2 Select for more info Ink used 260 cc 49 1 Installed OK Usage time 135 days 2 Removed too early P H cleaning 3 3 Removed too early Error code 4 Removed too early Removal date 20 Feb 02 5 Removed Err 0256 PH Info Black 3 Ink used 355 cc 67 Usage time 201 days P H cleaning 3 Error code Summary Removal date 20 Sep 01 If 3 or more Printheads have been removed too early and the P H cleaning Ink used L27 ec 24 code for all of them is 3 then try the troubleshooting Error code steps on the following page Removal date 24 Nov 00 PH Info Black 4 As you can see in the above example all the Printheads were removed before the minimum life expectancy was reached Ink HP DesignJets 500 and 800 Series Printers Service Manu
68. dvance Calibration as follows NOTE Make sure you load HP High Gloss Photo Paper or HP Bright White Inkjet Paper in to the Printer before performing this calibration Do NOT use any other type of media apart from HP High Gloss Photo Paper or HP Bright White Inkjet Paper otherwise the Printer will display Calibration Error on the Front Panel and the calibration will be cancelled 1 In the Service Calibrations submenu scroll to Factory advance cal and press Enter Service calibrations Menu Align printheads Back Color calibration Advance calibration v Factory advance cal Enter 2 When the following message appears on the front panel select Create pattern and press Enter Factory advance cal Menu Back Create pattern Measure pattern Enter HP DesignJets 500 and 800 Series Printers Service Manual 5 11 Service Calibrations 3 If media is not loaded the following message appears on the front panel and you must load media into the Printer NOTE Do NOT use any other type of media apart from HP High Gloss Photo Paper or HP Bright White Inkjet Paper Paper not present Load paper to print calibration pattern Press ENTER to continue 4 The Printer will start to print the Accuracy Calibration Pattern and the following message will be displayed on the front panel Job management G G EJ Calibrating 5 The following drawing sh
69. e 2 0515 2200 3 Screw Tap M3 x 10 mm 3 J3113A 1 EIO Card 4 C7769 60143 1 Formatter HP DesignJet SOOPS 800 and 800PS Only C7772A 1 Formatter HP DesignJet 500 Only 7 14 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Figure 7 Electronics Module HP DesignJets 500 and 800 Series Printers Service Manual 7 15 Parts and Diagrams Power Supply 1 C7769 60145 1 2 0515 2200 3 Screw Tap M3 x 10 mm 7 16 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Figure 8 Power Supply HP DesignJets 500 and 800 Series Printers Service Manual 7 17 Parts and Diagrams Cutter Assemblies C7769 60163 1 C7769 60169 1 Cutter Bushing 3 C7769 60179 1 Cutter Guide 24 Model Only C7769 60017 1 Cutter Guide 42 Model Only 4 C7769 60170 1 Cutter Guide Bracket and Left Encoder Holder Kit 5 0515 2200 1 Screw Cutter Guide Bracket 0515 1743 2 Screw Left Encoder Holder 7 18 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Figure 9 Cutter Assemblies HP DesignJets 500 and 800 Series Printers Service Manual 7 19 Parts and Diagrams Ink Delivery System Tubes Assembly 24 Model Only Tubes Assembly 42 Model Only Ink Supply Station Screw Plas 6 19 0 5 in Start up Printheads 1 C7769 60153 C7770 60153 C7
70. e Printer and an error has been detected For Printhead error codes refer to Page 3 22 E Installed Unknown The status of the installed Printhead is unknown m Removed OK The Printhead was replaced correctly after the minimum life expectancy of the Printhead was reached without any error being reported Removed too early The Printhead was replaced before the HP DesignJets 500 and 800 Series Printers Service Manual 3 15 Ink Supplies Troubleshooting minimum life expectancy of the Printhead was reached and without any error being reported Removed Unknown The status of the replaced Printhead was unknown Removed Err xxxx The printhead was replaced after being marked with an error code For Printhead Error Codes refer to Page 3 22 The front panel displays information on the selected item PH Info Black 4 Ink used 260 cc 49 Usage time 135 days P H cleaning 0 Error code 0025 Removal date 20 Sep 01 The information displayed is m The amount of ink the Printhead has consumed m The number of days the Printhead has been installed in the Printer E A code indicating whether Printhead recovery Troubleshooting procedure has been performed or not 0 indicates that the Printhead recovery was never performed 1 indicates that a Level 1 soft recovery was performed 2 indicates that a Level 2 medium recovery was performed 3 indicates that a
71. e all the squares turn grey the Printer is initializing the Operating System If for some reason this sequence fails try the following 1 Switch the Printer Off and wait a few minutes Switch the Printer On again and check if the initialization sequence is successful 2 If the initialization sequence fails again replace the Electronics Module Page 8 24 PLOT During the second phase of the Boot up sequence all the squares turn black the Printer is initializing various components too numerous to mention In normal circumstances if a component fails during this sequence a System Error will appear and you should refer to Chapter 2 System Error Codes The following information explains what is being initialized as each square turns black EO Initializing various components of the Main PCA SERRE Initializing various components of the Main PCA Initializing a portion of the Firmware a Initializing various components of the Main PCA 1 12 HP DesignJets 500 and 800 Series Printers Service Manual Troubleshooting P Initializing various components of the Main PCA me Initializing a portion of the Firmware ae Initializing the I O es Initializing the User Interface Front Panel menus Pe Initializing a portion of the Firmware a Initializing the Formatter a Initializing the communication between Main PCA and Formatter a aa End of initialization sequence Entering Service Menu at Powe
72. e Right Hand Cover Refer to Page 8 7 3 Release the tension from the right hand side of the Belt by pulling the Tensioner down and pushing it towards you to lock it into position 4 Release the Belt from the Scan Axis Motor on the left hand side 8 74 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation NOTE 5 Pull out the Belt from the right hand side of the Printer and remove the Idler Pulley 6 Unlock the Tensioner and remove from the Printer If it is too difficult to unlock the tensioner by hand try using a Screwdriver as a lever instead HP DesignJets 500 and 800 Series Printers Service Manual 8 75 Removal and Installation Encoder Strip Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Left Hand Cover Refer to Page 8 5 2 Remove the Right Hand Cover Refer to Page 8 7 3 Remove 1 T 15 screw Type E that secures the Encoder Strip to the Left Encoder Holder 4 Release the Encoder Strip from the left hand side NOTE The Encoder Strip is sharp so be careful when touching it 8 76 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 5 Release the Encoder Strip from the Service Station Holder 6 Remove the Encoder Strip from the Printer HP DesignJets 500 and 800 Series Printers Servi
73. e Service Station out of the Printer 7 Slide the Assembly towards you to the right and remove HP DesignJets 500 and 800 Series Printers Service Manual 8 53 Removal and Installation Installing the Service Station Aerosol Fan NOTE When installing the Service Station make sure that you line up the tabs on the Service Station with the structure of the Service Station Holder 8 54 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Cutter Guide Removal WARNING Switch off the printer and remove the power cord 1 Remove the Cutter Assembly Refer to Page 8 32 2 Place your hands on the Cutter Guide as shown in the drawing and lift up This is a cross sectional view of the Printer showing how the Cutter Guide is seated 3 Pull the Cutter Guide out to the right and remove from the Printer HP DesignJets 500 and 800 Series Printers Service Manual 8 55 Removal and Installation Print Platen Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Cutter Assembly Refer to Page 8 32 2 Remove the Cutter Guide Refer to Page 8 55 3 Remove the following screws Type G from the Print Platen m 24 Screws T 8 for the 24 model m 36 Screws T 8 for the 42 model 4 Pull the tabs out slightly and lift each piece of the Print Platen from the Pr
74. e the Ink Cartridge again If the new Ink Cartridge is consumed too quickly then the Ink Supply Tubes could be broken in which case replace the Ink Supply Tubes gt Page 8 60 If the message still continues to appear perform the Ink Supply Station test gt Page 4 6 If the test fails replace the Ink Supply Station gt Page 8 48 3 20 HP DesignJets 500 and 800 Series Printers Service Manual Ink Supplies Troubleshooting NOTE Expiration message In order to determine the correct date the Printer reads the information sent with a print file which includes the current date The printer will then compare this date to the expiration date on the Ink Cartridge Replace the Ink Cartridge that has reached the expiration date Check the expiration date of the Ink Cartridge see page Page 3 9 Obtaining Ink Cartridge Information If for example todays date is 02 Nov 00 and the expiration date of the Ink Cartridge is 07 Jun 01 then the customers computer should be checked to see if the correct date is configured Troubleshooting Repetitive Printhead Error Messages When you see the message shown below the normal procedure is to replace the Printhead that has failed Ei E Error Select Replace printheads But in certain circumstances even after replacing the Printhead the above message continues to appear This could mean that one of the components of the Printer is failing and requires cleaning or replacing
75. ected as filled with ink The most likely cause for this problem is Ink Cartridges with a faulty valve Even if the priming process fails the Printer will try to verify whether the priming process has been completed by moving the Carriage to the access position and you will see the following HP DesignJets 500 and 800 Series Printers Service Manual 1 7 Troubleshooting message on the Front Panel Unable to prepare ink system Open window to check SETUP printheads Open the Window and you will see the following message on the Front Panel A Menu 1 Lift printhead cover 2 Check if there is ink inside printhead windows Back 3 Press ENTER to continue Y Enter Check for ink Open the Carriage Cover and check if there is ink inside the Start up Printheads On the Front Panel you will see the following question and you will need to select the answer depending on whether the Start up Printheads were filled with ink or not 2 Menu Are all printhead windows filled with ink amp Back ALL with some ink NOT all with ink p Enter If there is ink in all of the Start up printheads the Printer considers that the priming procedure has been completed successfully and will proceed to the Printhead replacement process If you select NOT all with ink the Printer will react differently depending on the source of the problem 1 8 HP DesignJets 500 and 800 Series
76. edia type through the front panel when loading it Driver print quality configuration To clarify if the reason of the problem is related with the print mode defined with the Non HP Driver try the following E Print the same sample using the Non HP driver and their normal media E Print one of the internal demos using HP Media and configuring 6 2 HP DesignJets 500 and 800 Series Printers Service Manual Print Quality the Printer as indicated previously If the output obtained using the HP Solution is good and the one obtained through the 3rd party solution is bad HP support organization should communicate to the customer that the problem is not in the Printer and that he should address it through the 3rd party vendor support structure 7 Service Accuracy Calibration E Perform Service Accuracy calibration using HP High Gloss Photo Paper WARNING Do NOT use any other type of media apart from HP High Gloss Photo Paper or Bright White InkJet Paper when performing the Accuracy Calibration HP DesignJets 500 and 800 Series Printers Service Manual 6 3 Print Quality How to Use the Troubleshooting Procedure What is the Troubleshooting Procedure The Printer contains an internal Troubleshooting procedure which helps you to diagnose and resolve the possible source of any Image Quality or Line Quality defects If Print Quality is poor at anytime the Troubleshooting procedure should be performed which will dete
77. elevant steps to take when troubleshooting the printer Troubleshooting System Error Codes Chapter 2 System Error Codes contains a list of system error codes and their respective descriptions and recommended corrective actions Only try one recommended action at a time and check if the error code has disappeared Performing a Service Test on a Failed Assembly If possible always perform a Service Test on the component assembly that you are about to replace just to make sure that is the component assembly that has failed NOTE If the test on that component assembly passes you should NOT replace it For information on the Service Tests and how to use them see Chapter 4 Service Tests and Utilities Performing the Necessary Service Calibrations Is the printer calibrated correctly after replacing a component NOTE Remember that certain Calibrations are required even if an Assembly has been disassembled to gain access to another Assembly or Component For information on the Service Calibrations and how to use them see Chapter 5 Service Calibrations 1 2 HP DesignJets 500 and 800 Series Printers Service Manual Troubleshooting Solving Print Quality Problems The Printer contains an internal Troubleshooting procedure which helps you to diagnose and resolve the possible source of any Image Quality or Line Quality defects If Print Quality is poor before the minimum life expectancy of the Printhead has been rea
78. ents or circuits or through openings in the enclosure Electrostatic Discharge Refer to the beginning of Chapter 8 of this manual for precautions you should take to prevent damage to the Printer circuits from electrostatic discharge Safety Symbols General definitions of safety symbols are given immediately after the table of contents WARNING The Warning symbol calls attention to a procedure practice or the like which if not correctly performed or adhered to could result in personal injury Do not proceed beyond a Warning symbol until the indicated conditions are fully understood and met CAUTION The Caution symbol calls attention to an operating procedure practice or the like which if not correctly performed or adhered to could result in damage to or destruction of part or all of the product Do not proceed beyond a Caution symbol until the indicated conditions are fully understood and met HP BS SPR UNyoe Co Large Format Printers Service Manual Using this Manual Purpose This Service Manual contains information necessary to test calibrate and service HP DesignJet 500 Printer 24 Model P N C7769B HP DesignJet 500 Printer 42 Model P N C7770B HP DesignJet 500PS Printer 24 Model P N C7769C HP DesignJet 500PS Printer 42 Model P N C7770C HP DesignJet 800 Printer 24 Model P N C7779B HP DesignJet 800 Printer 42 Model P N C7780B HP DesignJet 800PS P
79. er 8 6 Trailing Cable 8 40 Interface Specifications 10 17 ISS Assembly 7 14 L LAN Card 8 21 Left Encoder Holder 8 33 Left End Roll Feed 8 13 Left Hand Cover 8 5 Level of Printer Usage 9 3 Line Sensor 1 3 M Media 6 10 Media Deflectors 8 11 Media Jams 1 4 Media Sensor 8 19 Moisture on the Printer 9 2 N Noisy Carriage Bushing 9 2 O Out of Ink Message 3 6 P Paper Advance Test 4 10 Paper Axis Motor 8 84 Index 2 HP DesignJets 500 and 800 Series Printers Service Manual Index Paper Axis Shutdowns 1 4 Parts List Back Platen Assembly 7 12 Carriage Assembly 7 34 Cutter Assemblies 7 18 Drive Roller 7 42 Drive Roller Encoder Sensor 7 30 Electronics Module 7 14 Ink Delivery System 7 20 Interconnect Cable 7 38 Left Hand Cover 7 6 Miscellaneous Items 7 44 Paper Axis Motor 7 40 Pinch Wheel Assemblies 7 26 Power Supply 7 16 Print Platen Assembly 7 32 Printer Support 7 2 Right Hand Cover 7 4 Rollfeed Module 7 10 Scan Axis Motor 7 28 Service Station and Spittoon 7 22 Service Station Holder 7 24 Top Cover and Deflectors 7 8 Vacuum Fan 7 36 Pen to Paper Spacing Calibration 5 5 Phone Support 4 2 Pinch Arm 8 66 Pinch Arm Lever 8 69 Pinch Arm Mechanism 8 67 Pinch Arm Sensor 8 71 Power Supply 8 27 Power Supply Unit 10 5 Power Switch LED to Troubleshoot 1 10 Preventive Maintenance Kit 9 4 Prime Tubes 4 23 Priming Procedure 1 7 Priming Procedure Fails 1 7 Print Platen 8 56 Print Quality Troubleshooti
80. er contains an internal Troubleshooting procedure which helps you to diagnose and resolve the possible source of any Image Quality or Line Quality defects If Print Quality is poor at anytime the Troubleshooting procedure should be performed which will determine whether the Printhead needs replacing by marking it with an exclamation mark or not after performing various levels of recovery actions HP DesignJets 500 and 800 Series Printers Service Manual 4 3 Service Tests and Utilities Entering the Service Tests Menu NOTE In order to enter the Service Utility Menu please refer to the instructions on Page 4 14 1 Press the T or J key until the front panel displays the Setup Menu and then press Enter A Menu O kal Back Press ENTER for Set up menu p oe Enter 2 Once inside the Setup Menu Press the following key combination to access the special Service Menu Set up menu A Menu pst Printer information j T O set up Back s Front panel o Altitude 0 1000 m Log Enter For On site Engineers press the Up and Enter keys to access the complete list of Service Tests s Set up menu Menu sF Printer information o R T O set up Back ys Front panel Altitude 0 1000 m Log p OO Enter For Call Agents who will request the User to perform certain troubleshooting actions press the Down and Enter keys to access a limited list of Service Tests 3 Once inside the Se
81. ering Error Log Utility 2 5 Printhead History Utility 3 14 Service Calibrations 5 3 Service Tests 4 4 Service Utilities 4 14 Entering Service Menu at Power Up 1 13 Error Log Utility 2 5 ESD Precautions 8 3 Expiration Message 3 6 F Factory Advance Calibration 5 11 Fork Idler Tensioner and Idler Pulley 8 74 Formatter 8 20 HP DesignJets 500 and 800 Series Printers Service Manual Index 1 Index Formatter Accessory Card 1 14 Front Panel 8 9 10 6 Functional Overview Electrical System 10 3 Front Panel 10 6 Ink Delivery System 10 7 Ink Supply Station 10 7 Power Supply Unit 10 5 Service Station 10 10 SKU Overview 10 2 Tubes Assembly 10 9 G Gear Assemblies 8 92 I Ink Cartridge Error Message 3 6 Ink Cartridges 3 2 Obtaining Information 3 9 Status Messages 3 12 Troubleshooting Repetitive Messages 3 20 When should they be replaced 3 6 Ink Delivery System 10 7 Ink Supplies General Information 3 4 General Precautions 3 5 Identifying the Components 3 3 Ink Cartridges 3 2 Printheads 3 3 Summary of Solving Problems 3 23 Ink Supply Station 8 48 10 7 Ink Supply Station Test 4 6 Ink Supply Tubes 8 60 Installing Carriage Assembly 8 83 Electronics Module 8 26 Scan Axis Motor Assembly 8 31 Service Station Aerosol Fan 8 54 Trailing Cable 8 47 Interconnect Cable 8 59 Interconnect PCA 8 50 Installing Air Pressurization System 8 20 Carriage Assembly 8 51 Electronics Module 8 27 Platen Assembly 8 63 Right Hand Cov
82. es Some of the Error Codes are continuable which means you can press Enter on the front panel and continue working with the Printer Non Continuable Error Codes do not allow you to continue working with the Printer in this case power the Printer OFF and ON again and see if the System Error disappears If the Error Code reappears then the Printer requires an on site visit in order to resolve the problem NOTE Even though the customer can continue working with a Continuable Error Code an on site visit should still be planned to troubleshoot the problem System Error Codes Explanation System Error Codes consist of 4 digits which explain which component system is failing and what action should be taken to resolve the problem The following table explains the first 2 digits of the System Error Code Code Component System 0l Main PCA Electronics Module 02 Carriage Carriage PCA 03 Power Supply Unit 04 Network Card 05 Formatter 06 Hard Disk Drive 07 Interconnect PCA 08 Front Panel it Trailing Cable 2 2 HP DesignJets 500 and 800 Series Printers Service Manual System Error Codes Code Component System 12 Carriage Flex Circuit 17 Interconnect Cable 21 Service Station 22 Ink Supply Station 23 Pressure System APS 24 Ink Delivery System 25 Spittoon sl Cutter 32 Take up Reel 33 Sheet Feeder 3
83. etected in prints E Printheads Diagnostic is OK Perform the Advance Calibration as follows 1 In the Service Calibrations submenu scroll to Advance calibration and press Enter Service calibrations Menu Align printheads Back Color calibration Advance calibration Factory advance cal Y Enter 2 When the following message appears on the front panel select Create pattern and press Enter Advance calibration Menu Create pattern Back Measure pattern Restore factory v Enter 3 If media is not loaded the following message appears on the front panel and you must load media into the Printer Paper not present Load paper to print calibration pattern Press ENTER to continue 4 The Printer will start to print the Accuracy Calibration Pattern and the following message will be displayed on the front panel Job management menu fife a Calibrating Ti HP DesignJets 500 and 800 Series Printers Service Manual 5 9 Service Calibrations 5 The following drawing shows you the pattern that will be printed Direction of paper while printing creating pattern y Direction of paper when loading measuring pattern 6 In order to measure the pattern that has been printed load the pattern into the Printer with the printed side up and with the dotted line at the top that is rotated 90 7 Re enter the Advance Calibration and select
84. ets 500 and 800 Series Printers Service Manual Removal and Installation 11 12 13 Unclip the tubes from the Tubes Guide Release the Tubes Bracket from the Ink Supply Station by pushing the clips inwards and lifting up the Bracket Remove the complete Ink Supply Tubes Assembly from the Printer HP DesignJets 500 and 800 Series Printers Service Manual 8 63 Removal and Installation Vacuum Fan Removal WARNING Switch off the printer and remove the power cord 1 Remove the Left Hand Cover Refer to Page 8 5 2 Remove ALL the Media Deflectors Refer to Page 8 11 3 Disconnect the Vacuum Fan Cable from the Electronics Module 4 Remove the Vacuum Fan Cable from the Cutter Guide Bracket 8 64 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation NOTE NOTE 5 Unclip the Vacuum Fan Assembly from underneath the Printer Push in the clips of the Vacuum Fan starting from the right hand side 6 Remove the Vacuum Fan Assembly from the Printer When removing the Vacuum Fan Assembly make sure you pull the Vacuum Fan cable through the hole in the Chassis HP DesignJets 500 and 800 Series Printers Service Manual 8 65 Removal and Installation Pinch Arm Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Spindle 2 Remove the
85. f 98MHz and at this frequency it is capable of approx 70 MIPS m Two physical EIO slots are supported from which the optional formatters and EIO cards will be plugged Three expansion options are currently supported m The Main PCA will come with an on board 2MB x16 flash memory that will allow both the end user and service engineers to upgrade with the latest firmware code available E A total of 16MB SDRAM x32 or 32MB SDRAM depending on the Printer Model will be loaded in the engine PCA not allowing further user self memory upgrades HP DesignJets 500 and 800 Series Printers Service Manual 10 3 Functional Overview The memory bus is also used to control Navata gate array Navata is a customized ASIC to control most of the Printer s sensors ISS optical sensors pinch wheels digital encoder etc Power Supply Scan Axis Motor driver Vacuum Fan Front Panel Carriage etc A 16k serial EEPROM is used to store different line calibration parameters and the Printer s life history number of plots etc The ISS PCA also contains an EEROM that contains a backup of all critical parameters from the Main EEROM The Main PCA has an analogue IC which controls two DC motors IDS and paper and one stepper motor Service Station This IC as well as the IC in the Carriage PCA is controlled through the VPR serial interface from the Kayak ASIC at a bus clock frequency of 1 6MHz From the Main PCA the Interconnect Cable connect
86. following screws Type A from the rear that attach the Top Cover to the Printer m 2 T 20 screws for the 24 model m 3 T 20 screws for the 42 model 2 Raise Window and unclip at both ends 3 Lift up complete assembly Window and Top Cover and remove from Printer 8 10 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Media Deflectors Removal WARNING Switch off the printer and remove the power cord 1 Make sure the Media Lever is in the UP Position 2 Lift tab up and slide Right Deflector to the left and lift up HP DesignJets 500 and 800 Series Printers Service Manual 8 11 Removal and Installation 3 Lift tab up and slide Middle Deflector to the right and lift up 4 Lift tab up and slide Left Deflector to the right and lift up 8 12 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Left End Roll Feed Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Left Hand Cover Refer to Page 8 5 2 Remove the Spindle 3 Remove T 20 screw Type F from the Left Hand Roll Feed located on the inside next to the Electronics Module 4 Remove 2 T 20 screws Type F from the Left End Roll Feed HP DesignJets 500 and 800 Series Printers Service Manual 8 13 Removal and Installation 5 Move Left E
87. h ends m Replace the Trailing Cable gt Page 8 40 E Replace the Carriage Assembly Page 8 78 12 11 A short detected in the Carriage Assembly Try the following E Remove ALL the Printheads and clean the flex contacts on the Printheads and in the Carriage Assembly E Replace ALL the Printheads Em Replace the Carriage Assembly Page 8 78 2 10 HP DesignJets 500 and 800 Series Printers Service Manual System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Codes 21 10 Service Station failure The possible cause could be 1 The steps counted by the Service Station motor are not consistent with the expected length of the current movement 2 The Aerosol Fan has reached its maximum current limit 3 The Service Station motor has shutdown because of blockage Replace the Service Station Aerosol Fan Assembly gt Page 8 52 21 11 Service Station Aerosol Fan cannot be detected or the Service Station is badly adjusted Try the following E Reconnect the Service Station Aerosol Fan Assembly E Reposition the Service Station trip lever 22 10 Ink Supply Station failure The possible cause could be 1 Reading writing or initializing the backup EEROM failed 2 One of the out of ink sensors l
88. h parameter of the Printer Information is explained as follows Model Number This identifies the model type of the Printer and should be the same number as printed on the Serial Number label located at the back of the Printer If the Model Number on the front panel does NOT match the number on the label then use the EEROM setup Page 4 6 utility to set the correct model number E Serial Number The Serial Number should be the same number as printed on the Serial Number label located at the back of the Printer If the Model Number on the front panel does NOT match the number on the label then use the EEROM setup utility Page 4 16 to set the correct model number m Service ID This number identifies the date when the Printer was bought since it encodes the date when the first print was sent to the Printer This way the end of warranty period can easily be determined without needing a proof of purchase from the customer The Service ID format is YYDDD where YY is the actual year since 1990 and DDD is the number of actual days since January Ist How to calculate the Service ID from a calendar date YY calendar year 1990 e g 1998 1998 1990 08 2001 2001 1990 11 DDD Calendar month 1 x 30 Calendar day or 30 if the day is 31 e g Oct 10th 9 x 30 10 280 Dec 31st 11 x 30 30 360 How to convert the Service ID into a calendar date Year YY 1990 e g 08 08 1990 1998 11
89. he Carriage Assembly The ink flows through a flexible tube from the ISS to the Carriage by means of the pressure applied by the pumping device in the ISS Tubes System ISS Crane In both ends of the tubes there are fluidic interconnections which are designed to prevent any kind of ink leakage and minimize the ink on customers as they interact with the system i e when they must replace Ink Cartridges or Printheads While the Ink Cartridges remain static in the ISS the Carriage goes back and forth along the scan axis of the Printer That is why the tubes have to be flexible in order to follow this movement Since the condition of the ink determines its performance on the printing media and therefore the print quality output the Tubes Assembly must guarantee the properties of the ink coming from the Ink Cartridges until it is delivered to the Printheads This healthy condition is defined by means of maximum water vapor losses and air ingestion that the ink can get along time HP DesignJets 500 and 800 Series Printers Service Manual 10 9 Functional Overview Service Station The purpose of the Service Station is to service the Printheads in order to guarantee their performance along their specified functional life in the following ways m Wiping of Printheads nozzle plate surface m Applying dissolvent on the Printheads nozzle plate surface E Capping the Printheads when they are not printing The Printhead
90. he user can still decide if the Print Quality is good enough for them Question Mark one of the Printheads has experienced a problem but the Printer does not know which one it is Refer to Page 3 7 to determine which Printhead has failed So p a ac HP DesignJets 500 and 800 Series Printers Service Manual 3 13 Ink Supplies Troubleshooting Printhead History Utility The Printhead History utility contains information on the last 5 set of Printheads installed in the Printer The purpose of this information is to E Determine whether the Printer is causing repetitive problems to the Printheads Refer to Page 3 6 E Determine whether the Customer is replacing the Printheads too early without trying to perform any recovery actions gt Refer to Page 3 18 The information that is stored for each Printhead is m How much ink was consumed when the Printhead was replaced m How long the Printhead was installed in the Printer Whether the Printhead was in or out of warranty when it was removed m Whether the Printhead experienced a paper crash m Whether the Customer performed the right level of Printhead recovery Troubleshooting procedure before replacing a Printhead m The date when the Printhead was removed from the printer m The reported Error Code if any Accessing the Printhead History Utility 1 Press the T or J key until the front panel displays the Setup Menu Press the Enter key amp A Menu N
91. ic Holder from the Printer 19 Release the Trailing Cable clips 20 Disconnect the Trailing Cable from the Electronics Module HP DesignJets 500 and 800 Series Printers Service Manual 8 45 Removal and Installation 21 Unclip the Ferrite and remove 22 Slide the Trailing Cable through the Carriage Assembly and remove 8 46 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Installing the Trailing Cable When installing the Trailing Cable make sure that you align the red lines on the Trailing Cable as shown in these drawings HP DesignJets 500 and 800 Series Printers Service Manual 8 47 Removal and Installation Ink Supply Station Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Ink Cartridges 2 Remove the Right Hand Cover Refer to Page 8 7 3 Disconnect the Ink Supply Station Cables Connectors P2 and P4 from the Interconnect PCA 4 Release the Tubes Bracket from the Ink Supply Station by pushing the clips inwards and lifting up the Bracket 8 48 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation NOTE 5 Remove 1 T 15 screw Type E from the top of the Assembly 6 Remove the Ink Supply Station from the Printer The ISS is a complete Assembly that includes the Cartridge Holder t
92. ide of the Belt from the Scan Axis Motor 7 Remove 2 T 20 screws Type C from the Scan Axis Motor NOTE Make sure that you keep hold of the Scan Axis Motor when removing the screws otherwise the Motor could fall and be damaged 8 Remove the Scan Axis Motor 8 30 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Installing the Scan Axis Motor When installing the Scan Axis Motor make sure that you insert the notch in the Printer into the slot in the Scan Axis Motor HP DesignJets 500 and 800 Series Printers Service Manual 8 31 Removal and Installation Cutter Assembly Removal WARNING Switch off the printer and remove the power cord 1 Select the Change Cutter option from the Front Panel Menu 2 Open the Window 3 Lift Tab UP and pull out the Cutter Assembly 8 32 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Left Encoder Holder Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Left Hand Cover Refer to Page 8 5 2 Remove T 15 screw Type E from the Left Encoder Holder attaches the Encoder Strip to the Holder 3 Release the Encoder Strip from the left hand side NOTE The Encoder Strip is sharp so be careful when touching it HP DesignJets 500 and 800 Series Printers Service Man
93. inter NOTE The Print Platen is split into 2 pieces on the 24 model and into 3 pieces on the 42 model 8 56 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Service Station Holder Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Left Hand Cover Refer to Page 8 5 2 Remove the Right Hand Cover Refer to Page 8 7 3 Remove the Right Hand Trim 4 Remove the Front Panel Assembly Refer to Page 8 9 Remove the Interconnect PCA Refer to Page 8 50 Remove the Service Station Refer to Page 8 52 Remove the Fork Idler Tensioner and Idler Pulley Refer to Page 8 74 Remove the Encoder Strip Refer to Page 8 76 Remove 1 T 15 screw Type E that secures the Service Station Holder to the sideplate HP DesignJets 500 and 800 Series Printers Service Manual 8 57 Removal and Installation 10 Remove 1 T 15 screw Type E that secures the Service Station Holder to the sideplate located underneath the Service Station Holder 11 Remove 4 T 20 screws Type C that secure the Service Station Holder to the Printer Chassis 12 Remove the Service Station Holder 8 58 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Interconnect Cable Removal WARNING Switch off the printer and remove the power cord 1 Rem
94. ist of Service Tests 3 Once inside the Service Tools Menu press the T or J key until the front panel displays Service calibrations and then press Enter Service tools 2 Menu Back Service tests Service calibrations Service utilities g Enter HP DesignJets 500 and 800 Series Printers Service Manual 5 3 Service Calibrations 4 Press the Enter key to begin a specific calibration when the required Service Calibration is highlighted Service calibrations Align printheads Color calibration Advance calibration Factory advance cal amp Menu Back 7 Ge Enter 5 4 HP DesignJets 500 and 800 Series Printers Service Manual Service Calibrations Printhead Alignment includes PPS Calibration The purpose of the Printhead Alignment is to correct the alignment between the Printheads in order to prevent color misalignment and print quality defects like banding Normally the Printhead Alignment is performed automatically whenever the printheads are replaced The Printhead Alignment also contains the Pen to Paper Spacing PPS Calibration which is used to solve Vertical Line Straightness VLS problems During normal operation the PPS calibration will not be performed automatically whenever the Printheads are replaced even though the Printhead Alignment will be performed automatically There are two options available when performing the Printhead Alignme
95. istency problems If color consistency is important for the customer it is recommended that they do not use HP GL 2 to print with E Some media may discolor or change with age Check that the media is fresh and has been stored correctly E If the environmental conditions that the customer is printing in change rapidly you may see changes in the color consistency By reducing the time the print stays in extreme environmental conditions after being printed especially very high humidity you can reduce the color consistency problems If you notice that there are color changes between different printers i e between the 750C and this printer it is normal There will be color differences between HP DesignJet Printers because the other Printers use a different type of ink Long Term Color Bleeding Glossy Papers If you see the colors are bleeding into the paper 1 e the color is soaking into the paper making the lines fuzzy and bleary This will be because of the humidity conditions that the printer is working under E Ask the customer to change the paper that they are printing with or Em Remove the printer from the high humidity conditions HP DesignJets 500 and 800 Series Printers Service Manual 6 9 Print Quality NOTE Media Always make sure that the customer is using the appropriate media for the required image and that it is consistent with the software application being used To ensure color accuracy and print q
96. ity 2 Press the T or J key until the front panel highlights Troubleshooting and then press the Enter key amp Menu Back Color calibration Troubleshooting Align printheads Replace printheads p Enter 3 The Printer first checks to see whether the Printheads have been aligned recently Misalignment of the Printheads is a common cause of Print Quality problems so if the Printheads haven t been aligned recently you are prompted to accept the alignment now NOTE The Printhead Alignment requires a few centimeters of Paper loaded and takes several minutes to perform 4 Ifthe Printheads do not seem to require alignment the Printer prints the Diagnostic Print A which contains several blocks of color and a block of thin black broken lines Ignore this aes black bar x 5 Examine the broken lines carefully and when prompted by the front panel indicate whether there are problems with them The sorts of problems to look for are m Jaggedness or serrations in the thin lines like this anana ee The lines should be straight though not necessarily perfectly aligned The irregularities that are significant extend along the whole of the length of the lines Shorter irregularities arranged in columns can be ignored at this stage 6 If you indicate that there is a problem with the dashed lines you are prompted to perform the Advance Calibration procedure 7 If you indicate that the broken line
97. ive Roller Print Platen 9 3 Scheduled Maintenance 9 3 Level of Printer Usage 9 3 Scan Axis Maintenance 9 4 Functional Overview 10 1 Introduction 10 2 SKU Overview 10 2 Electrical System 10 3 Introduction 10 3 Hardware Description 10 3 Power Supply Unit PSU 10 5 Front Panel 10 6 Ink Delivery System IDS 10 7 Ink Supply Station ISS 10 7 Tubes Assembly 10 9 Service Station 10 10 Glossary Index HP DesignJets 500 and 800 Series Printers Service Manual 7 Table of Contents 8 HP DesignJets 500 and 800 Series Printers Service Manual Troubleshooting Introduction 1 2 Troubleshooting System Error Codes 1 2 Performing a Service Test on a Failed Assembly 1 2 Performing the Necessary Service Calibrations 1 2 Solving Print Quality Problems 1 3 The Printer does not Power ON 1 3 Cover Sensors are not Working 1 3 The Line Sensor has Problems Detecting Media 1 3 Troubleshooting Paper Axis Shutdowns 1 4 Problems with the Vacuum Fan 1 5 Vacuum suction much lower at high altitudes 1 5 HP GL 2 color differences in different HP DesignJet Printers 1 6 Banding at variable extreme environmental conditions 1 6 The Priming Procedure Fails 1 7 Using the Power Switch LED to Troubleshoot 1 10 Using the Boot Up Sequence to Troubleshoot 1 12 HP DesignJets 500 and 800 Series Printers Service Manual Troubleshooting Guide to Troubleshooting the Printer Introduction This chapter will guide you through the r
98. ks and also a standard color model coated paper Paper coated on one side for inkjet printing default A value or condition that is assumed if no other value or condition is specified Glossary device An external item connected to the computer printer plotter tape drive etc Your HP DesignJet is a device dpi Dots per inch a measure of print resolution driver The software that controls the communication between a computer and a device front panel The control panel on the right of the printer front panel menus The structure of options in the front panel display graphics language A programming language telling a print device how to output graphic data grayscale Shades of gray to represent colors high gloss film A glossy opaque polyester media type high gloss photo A glossy opaque photographic paper Glossary HP GL 2 One of Hewlett Packard s standard graphics languages for plotters and printers Produces vector data Newer than HP GL IDS Ink Delivery System T O Input output The transmission of data between a computer and a device inked area The smallest rectangle that contains all the content of the drawing while maintaining its relative dimensions ISO size An international standard media size e g Al A2 etc ISS Ink Supply Station JIS size A Japanese standard media size LAN Local area network LDS Leak Detect System long axis printing
99. lean the electrical contacts on both the Printheads and the Carriage Assembly using a damp cloth E Replace the Printhead with a new one You Cannot Insert the Ink Cartridge Into the Printer 1 Ensure that you have the correct HP Ink Cartridge that is suitable for the HP DesignJet 500 800 Series Printer 2 Ensure that the Ink Cartridge is the correct color for that slot 3 Ensure that the Ink Cartridge is in the correct orientation with the color coded label at the top CAUTION Never clean inside the Ink Cartridge slots You Cannot Insert the Printhead Into the Printer 1 Ensure that you have the correct HP Printhead that is suitable for the HP DesignJet 500 800 Series Printer 2 Ensure that the printhead is the correct color for that slot 3 Ensure that the printhead is in the correct orientation 4 Ensure that the protective cap is removed from the Printhead NOTE Do not touch wipe or attempt to clean the Printhead nozzles This can damage the Printhead and reduce print quality HP DesignJets 500 and 800 Series Printers Service Manual 3 23 Ink Supplies Troubleshooting 3 24 HP DesignJets 500 and 800 Series Printers Service Manual Service Tests and Utilities Introduction 4 2 Diagnostics Self Test 4 2 Service Tests Diagnostics 4 3 Entering the Service Tests Menu 4 4 Ink Supply Station 4 6 Carriage Movement 4 8 Paper Advance Test 4 10 Service Utilities 4 13 Entering the Service Utilities Menu 4 14 EER
100. lections Non HP driver m The RIP if it is being used m The software application the client is using Use the following table to configure the system correctly What to Configure Configuration Setting Optimal Setting Printer Front Panel Menu Media Make sure you have selected the correct media type in the front panel Dry time Set to Automatic HP driver Windows Print mode setting set to Best AutoCAD or Mac Non HP drivers The settings available In the software application Software RIPs depend on the driver The wy set Print Quality to Best t typical setti ce a A A E Use no Half Tone or printer default m Half Tone E Make sure that the E Media selection media setting matches the media loaded in the E Print Quality Settings See the user s guide for your application for more printer information about its print quality settings 6 8 HP DesignJets 500 and 800 Series Printers Service Manual Print Quality Solving Color Accuracy problems These are two areas you should review when troubleshooting a color accuracy problem Configuration PostScript option only Check that you are using the correct driver setting and CRD information for the software Check which ink emulation mode has been selected in the front panel Media Make sure that the media loaded is genuine HP media and that the correct media type has been selected on the front panel and in the driver Color Cons
101. ll through the selections and press Enter to make the selection Once the selection is made the 4 16 HP DesignJets 500 and 800 Series Printers Service Manual Service Tests and Utilities symbol y will appear next to the selected model number To return to the EEROM setup options menu press Back Select model number Menu C7769B C7770B C7779B V Breck C7780B C7779C y enter If you want to select the Serial Number a If you want to select the Serial number then you should select Serial number and press Enter The following information will be displayed on the front panel You will need to use the arrow keys to scroll through the complete list because the front panel only allows 6 lines to be displayed at one time Enter serial number Current ESA80035674 j Current Serial Number New encoded into the EEROM 0 Digits of the serial number 1 that you will be selecting 3 will appear here 4 5 6 7 8 Use the arrow keys to scroll 9 through the list of digits and A press ENTER to select the B ones that you require in order C to make the new serial D number E F ES SG Selecting this will delete the Backspace last digit selected b Use the arrow keys to scroll through the list of digits Once the digit that you require is highlighted press Enter to select it and it will appear in the New line Select serial number Menu Curre
102. ly can then be moved freely along the Printer by hand Perform the Unlock Carriage utility as follows In the Service Utilities submenu scroll to Unlock Carriage and press Enter Service utilities Menu Change ink tubes Unlock Carriage k Turn Drive Roller Bac Prime tubes EEROM Setup p e Enter Once the utility starts the printer will begin to unlock the Carriage Assembly and the following message will be displayed on the front panel Unlock Carriage Unlocking Carriage Please wait Once the Carriage is unlocked Printheads have been uncapped the following message will appear on the front panel Unlock Carriage Carriage unlocked Power off the printer to start the repair The Carriage will remain uncapped until another action e g loading paper or replacing Printheads is selected which returns the Printer to normal operation Make sure you leave the Carriage in a locked position once the repair is completed 4 22 HP DesignJets 500 and 800 Series Printers Service Manual Service Tests and Utilities Prime Tubes This purpose of this Service Utility is to prime the Ink Supply Tubes after they have been replaced or if a situation arises where you need to force the priming procedure Prime the tubes as follows 1 In the Service Utilities submenu scroll to Prime tubes and press Enter Service utilities A Menu Change ink tu
103. m startup failed also see Page 7 for more information Try the following m Check for a leak in the Printer If a leak is evident there is ink on Printer components replace the Ink Supply Tubes Page 8 60 E Perform the Prime Tubes utility Refer to Page 4 23 and check how long it takes to complete the procedure If it takes too long to complete the procedure and there is no leak in the Printer then replace the Ink Cartridges If it takes a short time to complete the procedure then replace the Ink Supply Tubes Page 8 60 HP DesignJets 500 and 800 Series Printers Service Manual 2 19 System Error Codes 2 20 HP DesignJets 500 and 800 Series Printers Service Manual Ink Supplies Troubleshooting What are the Ink Supplies 3 2 Ink Cartridges 3 2 Printheads 3 3 Identifying the Components 3 3 General Information About the Ink Supplies 3 4 Some General Precautions When Handling the Ink Supplies 3 5 When Should You Replace the Ink Cartridges 3 6 When Should You Replace the Printheads 3 7 Obtaining Ink Cartridge Information 3 9 Obtaining Printhead Information 3 10 Ink Cartridge Status Messages 3 12 Ink Cartridge Status While Replacing 3 12 Printhead Status Messages 3 13 Printhead History Utility 3 14 Accessing the Printhead History Utility 3 14 Is the Printer Causing Repetitive Printhead Problems 3 16 Is the User Replacing the Printheads too Early 3 18 Troubleshooting Repetitive Ink Cartridge Messages 3 20 Tr
104. matter the Printer will not allow you to enter this utility and will display the following message on the front panel Font type setting is not available for this type of printer Press BACK or ENTER to return to menu 4 18 HP DesignJets 500 and 800 Series Printers Service Manual Service Tests and Utilities If you want to Reset the Usage Counter NOTE You should only reset the usage counter for a certain component when it has been replaced by a new one Never reset the usage counter for a component when it has not been replaced a If you want to reset some of the parameters of the usage counter to consult the usage counters gt Page 4 26 then you should select Reset usage counter and press ENTER The following information will be displayed on the front panel You will need to use the arrow keys to scroll through the complete list because the front panel only allows 6 lines to be displayed at one time Select the usage counter that you want to reset and then press Enter Reset usage counter Menu Scan axis usage Paper axis usage Serv Station usage Back Spittoon usage Pinch lift usage Cei Enter Cutter usage Carriage usage Ink usage b Once you make a selection for example Scan axis usage the following message will appear on the Front Panel Press Enter if you want to proceed with resetting the counter or press Cancel if you want to exit without resetting the counter
105. mum number of Printhead insertions that the Printer is designed to support If the percentage is more than 100 and the Printer is experiencing problems then try the following 1 Replace the Carriage Assembly gt Page 8 78 4 28 HP DesignJets 500 and 800 Series Printers Service Manual Service Calibrations Service Calibrations 5 2 Entering the Service Calibrations Menu 5 3 Printhead Alignment includes PPS Calibration 5 5 Color Calibration 5 7 Advance Calibration 5 9 Factory Advance Calibration 5 11 HP DesignJets 500 and 800 Series Printers Service Manual 5 1 Service Calibrations Service Calibrations The following is a list of all internal service calibrations available in the Printers Instructions for entering the service calibrations menu are given on Page 5 3 Printhead Alignment Page 5 5 The purpose of this Service Calibration is to correct the alignment between the Printheads This calibration is necessary in order to prevent color misalignment and print quality defects like banding Color Calibration Page 5 7 The purpose of this Calibration is to calibrate the ink system for the specific media loaded into the Printer The Printer stores the calibration data for each type of media that has been calibrated since the Printer was switched ON If the Printer is switched OFF it will only store the last calibration done Advance Calibration Page 5 9 The purpose of this Service Calibration is t
106. n to change the Ink Cartridges is mostly determined by you with guidance from the front panel In conjunction with the messages displayed in the front panel and the message explanations in this chapter you will be able to choose for yourself when is the right time to change the Ink Cartridges The printer will also display the ink level and will tell you when the Ink Cartridge is almost empty This means you have constantly updated information about the Ink Cartridges There are 3 circumstances when you need to replace the Ink Cartridges which are explained as follows Ink Cartridge Error message When this message appears the Ink Cartridge has experienced a problem and should be replaced If this message appears repetitively refer to Page 3 20 Troubleshooting Repetitive Ink Cartridge Messages Ink menu ey Ink cartridge replacement required ABDO i Out of Ink message When this message appears the Ink Cartridge is out of ink and should be replaced If this message appears repetitively refer to Page 3 20 Troubleshooting Repetitive Ink Cartridge Messages Ink cartridge a replacement required ANGI ir Expiration message When this message appears the Printer is warning you that the Ink Cartridge is close to the expiration date Once the expiration date has been reached the Printer will stop working and you will need to install a new Ink Cartridge in order to proceed If this message appears repetitively refer
107. nd Roll Feed down and remove from Printer 8 14 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Right End Roll Feed Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Right Hand Cover Refer to Page 8 7 2 Remove the Spindle 3 Remove 1 T 20 screw Type F from the Right Hand Roll Feed 4 Remove 2 T 20 screws Type F from the Right Hand Roll Feed located on the inside HP DesignJets 500 and 800 Series Printers Service Manual 8 15 Removal and Installation 5 Remove Right Hand Roll Feed 8 16 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Back Platen Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Spindle 2 Make sure the Media Lever is in the UP Position 3 Unclip the Media Sensor Cover and remove from the Printer HP DesignJets 500 and 800 Series Printers Service Manual 8 17 Removal and Installation 4 Unclip the Media Sensor from underneath the Back Platen 5 Remove 2 T 15 screws Type E from the Back Platen 6 Remove the Back Platen by pulling it evenly towards you NOTE Make sure that the Media Sensor is not attached to the Back Platen to prevent pulling the cable and breaking
108. ng 1 Replace the Paper Axis Motor gt Page 8 84 Service Station usage Number of Service Station cycles represented as a percentage over the maximum number of Service Station cycles that the Printer is designed to support If the percentage is more than 100 and the Printer is experiencing problems then try the following 1 Replace the Service Station Page 8 52 Spittoon usage Number of drops spitted into the Spittoon on the left hand side of the Printer represented as a percentage over the maximum number of drops allowed by the Spittoon If the percentage is more than 100 and the Printer is experiencing problems then try the following 1 Replace the Spittoon Page 8 23 Pinch lift usage Number of Pinch lift cycles represented as a percentage over the maximum number of cycles that the Printer is designed to support If the percentage is more than 100 and the Printer is experiencing problems then try the following 1 Replace the Pinch Lift Mechanism gt Page 8 67 Cutter usage Number of times the Cutter has been used represented as a percentage over the maximum number of times that the Printer is designed to support If the percentage is more than 100 and the Printer is experiencing problems then try the following 1 Replace the Cutter Assembly Page 8 32 Carriage usage Number of Printhead insertions in the Carriage stall where the most Printheads have been inserted represented as a percentage over the maxi
109. ng Aerosol Fan test Back Ink Supply Station Paper advance test Carriage movement test v amp Enter Once the test starts the following message will appear on the Front Panel Open the Ink Cartridge door and remove ALL the Ink Cartridges ISS Test Remove all the ink cartridges 4 6 HP DesignJets 500 and 800 Series Printers Service Manual Service Tests and Utilities 3 Once all the Ink Cartridges are removed the Printer will check the Ink Supply Station During this short period the following message will be displayed ISS Test Please wait Checking 4 If the Printer detects all the out of ink signals the Ink Supply Station has passed the test and the following message will appear on the Front Panel ISS Test Menu Test result OK Hack INK SUPPLY STATION OK Press ENTER to return to menu Enter WARNING IF THIS TEST PASSES DO NOT REPLACE THE INK SUPPLY STATION 5 If the Printer does not detect all the out of ink signals then the Ink Supply Station must be faulty and the following message will appear on the Front Panel ISS Test Test result 22 10 Faulty INK SUPPLY STATION Call HP representative In this case to resolve the problem try the following 1 Replace the Ink Supply Station Assembly gt Page 8 48 HP DesignJets 500 and 800 Series Printers Service Manual 4 7 Service Tests
110. ng Checklist 6 2 Printer doesn t power ON 1 3 Printer Information 4 26 Carriage Usage 4 28 Cutter Usage 4 28 Engine Firmware 4 27 Formatter Firmware 4 27 Hard Disk Firmware 4 27 Ink Usage 4 27 Model Number 4 27 Paper Axis Usage 4 28 Paper Usage 4 27 Pinch Lift Usage 4 28 Scan Axis Usage 4 27 Serial Number 4 27 Service Station Usage 4 28 Spittoon Usage 4 28 Printhead Alignment 5 5 Printhead Error unknown Message 3 7 Printhead Error Message 3 7 Printhead History Utility 3 14 Printhead Warning Message 3 8 Printheads 3 3 Error Codes 3 22 Obtaining Information 3 10 Repetitive Problems 3 16 Replacing too Early 3 18 Status Messages 3 13 Troubleshooting Repetitive Error Messages 3 21 When should they be replaced 3 7 Problems Color Accuracy 6 9 Color Consistency 6 9 Cover Sensors 1 3 Line Sensor 1 3 Long Term Color Bleeding 6 9 Vacuum Fan 1 5 Vacuum suction 1 5 R Removing Back Platen 8 17 Carriage Assembly including Belt 8 78 Cutter Assembly 8 32 Cutter Bushing 8 35 Cutter Guide 8 55 Cutter Guide Bracket 8 36 Drive Roller 8 86 HP DesignJets 500 and 800 Series Printers Service Manual Index 3 Index Drive Roller Encoder Sensor 8 38 Electronics Module 8 24 Encoder Strip 8 76 Fork Idler Tensioner and Idler Pulley 8 74 Formatter 8 20 Front Panel 8 9 Gear Assemblies 8 92 Ink Supply Station 8 48 Ink Supply Tubes 8 60 Interconnect Cable 8 59 Interconnect PCA 8 50 LAN Card 8 21 Left
111. nnect the Cooling Fan located on top of the Electronics Module If the Cooling Fan continues to fail check that the connector pins in the Electronics Module are NOT bent 01 12 The EEROM is not configured correctly the product number may be missing Configure the EEROM correctly using the EEROM setup utility Page 4 16 HP DesignJets 500 and 800 Series Printers Service Manual 2 7 System Error Codes System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action 01 13 Electronics Module failure The possible cause could be 1 One of the ASIC s in the Electronics Module is reporting that it is too hot 2 The interruptions from the Scan Axis servo or from the Paper Axis servo are not coming as regularly as they are expected or are coming too late Try the following m Switch the Printer Off and wait a few minutes Switch the Printer On again and check if the Error Code has disappeared m If the Error Code continues replace the Electronics Module Page 8 24 02 10 Carriage failure The possible cause could be 1 The Carriage PCA is not compatible with the rest of the Printer 2 The Carriage ASIC has problems initializing 3 The 2 5V reference voltage generated in the Carriage PCA is out of range 4 One of the Carriage ASIC s cannot be found within the Serial Bus that co
112. nnects the Electronics Module to the Carriage 5 One of the Carriage ASIC s did not respond to the Serial Bus that connects the Electronics Module to the Carriage Assembly Replace the Carriage Assembly Page 8 78 02 13 Carriage failure The possible cause could be 1 One of the ASIC s in the Carriage is reporting that it is too hot Try the following E Switch the Printer Off and wait a few minutes Switch the Printer On again and check if the Error Code has disappeared m If the Error Code continues replace the Carriage Assembly gt Page 8 78 2 8 HP DesignJets 500 and 800 Series Printers Service Manual System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Codes 03 10 Power Supply failure Replace the Power Supply Unit Page 8 27 04 11 LAN Card not detected Power OFF the Printer and reconnect the LAN Card 05 09 Error Only applicable to HP DesignJet 500 Series Formatter installed instead of HP GL 2 Accessory Card Power OFF the Printer and remove the Formatter and install the HP GL 2 Accessory Card gt Page 8 20 NOTE If this Error Code appears on a De
113. nt m Standard Use this when only the Printheads need to be aligned This Alignment normally takes about 4 minutes to be completed and requires media of at least A4 Letter size loaded in landscape E Special Use this when VLS problems have been detected when printing line drawings on wide media 36 to 42 in Fast Mode Using this option the Printer will perform both the regular Printhead Alignment and the PPS Calibration This Alignment normally takes about 11 minutes and requires media of at least A3 B size loaded in landscape Perform the Printhead Alignment as follows WARNING Make sure you use HP Bright White InkJet Paper Bond HP Coated Paper HP Heavy Coated Paper HP High Gloss Paper HP Satin Paper or Plain Paper If you try to use any other type of Paper the Printer will not allow you to perform the Alignment 1 In the Service Calibrations submenu scroll to Align printheads and press Enter Service calibrations Menu Align printheads Back Color calibration Advance calibration v Factory advance cal a Enter 2 The following message will appear asking you if you want to perform the Standard alignment or the Special alignment Select HP DesignJets 500 and 800 Series Printers Service Manual 5 5 Service Calibrations the alignment you want to perform and then press Enter Align printheads Menu Back Standard 4 5 min Special 11 min y Enter 3 The Printer will start t
114. nt ESA80035674 Sew ESB75_ Back 6 7 v d Enter HP DesignJets 500 and 800 Series Printers Service Manual 4 17 Service Tests and Utilities c Once you have entered the last digit of the new serial number the front panel will display the following message Serial number Menu Serial number entered is ESB7531008 Bick Press ENTER to confirm or BACK to correct amp Enter d If you press Enter the new serial number will be stored in the EEROM and the Printer will return to the EEROM setup options menu If you press Back the previous screen will be displayed and the last digit of the new serial number will be deleted You now have the opportunity to modify the new serial number Enter serial number 2 Menu Current ESA80035674 pem ESB753100_ Back 1 2 v de Enter If you want to change the Font Type a Ifyou want to change the Font Type to Japanese then you should select Font type and press Enter The following message will be displayed on the front panel asking you to confirm whether you want to change the font to Japanese Select YES and press Enter if you want to change to Japanese Select NO and press Enter if you don t want to change the font type to Japanese Do you want to set font Menu type to Japanese A Back YES N NO v amp Enter NOTE If the Printer is not a DesignJet 800PS or if the Printer does not detect a for
115. numbers as well as the Font Type This only needs to be performed when EEROM failures cannot be recovered where both the current EEROM located in the Main PCA and the backup EEROM located in the Ink Supply Station contain false values or because both of them have failed Also you can use this utility to reset the usage counters for parts that have been replaced in order to correctly reflect the true usage of the relevant parts After any change in the EEROM switch the Printer OFF and ON again in order to ensure that the change takes effect in all the subsystems of the Printer Perform the EEROM Setup as follows In the Service Utilities submenu scroll to EEROM Setup and press Enter Service utilities Menu Change ink tubes Unlock Carriage Turn Drive Roller Back Prime tubes EEROM Setup p go gt Enter The Printer will display a list of EEROM Setup options You can make your selection using the arrow keys and press Enter to view the selection Model number Serial number EEROM Setup options Menu Back Font type Reset usage counter Reset to default v Ge Enter If you want to select the Model Number a If you want to select the Model number then you should select Model number and press Enter A list of all the printer model numbers available will appear on the front panel The current model selected will have the symbol y next to the model number Use the arrow keys to scro
116. o System Error 93 10 on Page 2 19 HP DesignJets 500 and 800 Series Printers Service Manual 1 9 Troubleshooting NOTE Using the Power Switch LED to Troubleshoot In certain circumstances the LED located in the power switch located on the left hand side of the Printer can help to troubleshoot the Printer The LED can be OFF ON or flashing and using different combinations can indicate different problems You should only use the LED to troubleshoot when the Printer does not Power up completely The LED may flash in other circumstances which are completely normal and this does not mean that there is a problem with the Printer LED OFF LED ON LED is OFF This indicates that the Power Supply Unit is completely dead Try the following Check that power cord is connected correctly to the Printer and to the Power Socket Also make sure that you firmly press the Power Switch to the ON position Replace the Power Supply Unit Page 8 27 LED is ON all the time This indicates that the Main PCA is completely dead Replace the Electronics Module Page 8 24 LED is Flashing continuously A problem has been detected with the previous firmware upgrade Try resending the firmware upgrade file LED Flashes twice every few seconds The Printer cannot detect HP DesignJets 500 and 800 Series Printers Service Manual Troubleshooting the Interconnect Cable Try the following 1 Check that the Interconne
117. o calibrate the nominal advance of the media This calibration is necessary to control the exact movement on the media type that will be used upto 2 in order to avoid print quality problems like banding Factory Advance Calibration Page 5 11 The purpose of this Service Calibration is to calibrate the nominal advance of the media This calibration is necessary to control the exact movement of the media in order to avoid print quality problems like banding The values from the Calibration will then be stored in the EEROM and the user can restore the Printer to these values by selecting Restore factory in the Advance Calibration menu 5 2 HP DesignJets 500 and 800 Series Printers Service Manual Service Calibrations Entering the Service Calibrations Menu 1 Press the T or 4 key until the front panel displays the Set up Menu and then press Enter Set up menu A mnu Press ENTER for Set up menu v d Enter 2 Once inside the Setup Menu Press the following key combination to access the special Service Menu Set up menu 4 Menu Printer information Back Altitude 0 1000 m Log a Enter For On site Engineers press the Up and Enter keys to access the complete list of Service Tests Menu Back Altitude 0 1000 m Log 7 a Enter For Call Agents who will request the User to perform certain troubleshooting actions press the Down and Enter keys to access a limited l
118. o print the alignment pattern and the following message will be displayed on the front panel Aligning printheads Please wait 4 Once the Printhead Alignment is completed the following message will be displayed on the front panel Menu Printheads successfully aligned Back SS Enter Press ENTER to continue 5 If the calibration fails due to poor Print Quality it will try and recover the Printheads and retry the Printhead Alignment f the Calibration continues to fail due to Printhead problems the Printer will mark the failing Printheads but they will still be usable 5 6 HP DesignJets 500 and 800 Series Printers Service Manual Service Calibrations Color Calibration The purpose of this Calibration is to calibrate the ink system for the specific media loaded into the Printer The Printer stores the calibration data for each type of media that has been calibrated since the Printer was switched ON If the Printer is switched OFF it will only store the last calibration done Perform the Color Calibration as follows NOTE Make sure you load media before performing this calibration 1 Inthe Service Calibrations submenu scroll to Color calibration and press Enter Service calibrations Menu Align printheads Back Color calibration Advance calibration v Factory advance cal SS Enter 1 In the Color Calibration submenu scroll to Calibrate paper and pre
119. ocated in the Ink Supply Station is not reporting what it should during the initializing process while depressurizing Replace the Ink Supply Station Page 8 48 41 10 Paper Axis Motor failure Replace the Paper Axis Motor Page 8 84 HP DesignJets 500 and 800 Series Printers Service Manual System Error Codes System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action 41 13 Error in the Paper Axis Motor Encoder quadrature Try the following E Switch the Printer Off and wait a few minutes Switch the Printer On again and check if the Error Code has disappeared m If the Error Code continues replace the Paper Axis Motor Page 8 84 42 10 Scan Axis Motor failure Replace the Scan Axis Motor Page 8 29 43 10 Vacuum Fan failure Replace the Vacuum Fan Page 8 64 43 11 Vacuum Fan not detected Reconnect the Vacuum Fan 56 10 Drive Roller Encoder Sensor error Replace the Drive Roller Encoder Sensor gt Page 8 38 2 12 HP DesignJets 500 and 800 Series Printers Service Manual System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Erro
120. ocedure If the user replaces the Printhead without performing a recovery action the Printhead will be marked 0 If the user replaces the Printhead after only performing Levels 1 or Level 2 recovery action the Printhead will be marked 1 or 2 If a customer complains about having to replace the Printheads frequently before the minimum life expectancy has been reached due to poor print quality using the information obtained with the Printhead History Utility you can determine if the Customer is replacing the Printheads too early as follows Enter the Printhead History Utility and Select the color of the Printhead that is experiencing the replacement problem In the 3 18 HP DesignJets 500 and 800 Series Printers Service Manual Ink Supplies Troubleshooting following example Printheads 2 3 and 4 were removed too early Black P H history Select for more info 1 Installed OK These 3 Printheads were 2 Removed too carly removed from the Printer 3 Removed too early ae 4 Removed too early before the minimum life 5 Removed Err 0025 expectancy was reached 2 In order to check if the maximum recovery process Troubleshooting procedure was performed on each Printhead select the Printhead and press the Enter key Black P H history PH Info Black 2 Select for more info Ink used 260 cc 49 1 Installed OK Usage time 135 days 2 Removed too early P H cleaning 0 3
121. op and Tray bottom The complete Assembly must be removed installed together HP DesignJets 500 and 800 Series Printers Service Manual 8 49 Removal and Installation Interconnect PCA Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Right Hand Cover Refer to Page 8 7 2 Disconnect all the cables connected to the Interconnect PCA 3 Remove T 15 screw Type E from the Interconnect PCA 8 50 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 4 Lift the Interconnect PCA and remove HP DesignJets 500 and 800 Series Printers Service Manual 8 51 Removal and Installation Service Station and Aerosol Fan Removal NOTE Refer to the table on Page 8 4 for information on screw types 1 Perform the Service Utility Unlock Carriage Refer to Page 4 22 NOTE Switch off the Printer after performing this Utility 2 Remove the Right Hand Cover Refer to Page 8 7 3 Manually move the Carriage out of the Service Station 4 Disconnect the Service Station and Aerosol Fan Cables connectors P5 and P9 from the Interconnect PCA 8 52 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 5 Remove 2 T 15 screws Type E from inside the Service Station 6 Make sure you lift the Carriage Lock before sliding out th
122. or code appeared but was NOT caused by a paper jam then try the following E Perform the Paper Advance Test gt Page 4 10 81 11 Paper Axis shutdown during the Paper Advance test Refer to Error Code 81 01 HP DesignJets 500 and 800 Series Printers Service Manual 2 17 System Error Codes System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action 85 10 Paper Axis Encoder error The Drive Roller Encoder Sensor cannot find the zero position of the Encoder Disk Try the following m Replace the Drive Roller Encoder Sensor gt Page 8 38 E If the Error Code continues replace the Drive Roller Page 8 86 86 01 Carriage Axis shutdown If this error code appeared but was NOT caused by a paper jam then try the following m Too much friction in the Slider Rod Enter the Printer Information utility Page 4 26 and check the Scan Axis usage If the percentage is close to 100 then lubricate the Slider Rod m The Carriage is bumping into the Service Station If the carriage is stuck at the right hand side of the Printer and cannot be moved out to the center of the Print Platen it is because the Service Station cannot uncap the Printheads In this case replace the Service Station Aerosol Fan Assembly Page 8 52 E Perform the Carriage Movement test gt Page 4 8 86
123. or that you want to see information on Press the Enter key Select printhead Menu Cyan printhead Magenta printhead Back F Enter Yellow printhead Black printhead 5 The front panel displays information on the selected Printhead Black P H info Model HP Black No 11 Menu Back p Enter End of warranty 21 Nov 02 Serial number 01 01 0415293 Ink used 260 cc 49 Paper jams None The information displayed is The Model of the Printhead HP No 11 is recommended Whether the Printhead is In Warranty or Out of Warranty Status of the Printhead whether it is inserted faulty worn out or unknown Printhead Error Code if Printhead is faulty Refer to Page 3 22 The action required depending on the status of the Printhead The end of warranty date of the Printhead The Serial Number of the Printhead How much ink has been consumed by the printhead Note It is possible for a Printhead to consume more than one Ink Cartridge Also the indicates the percentage over the expected life of the Printhead BUT a Printhead may last more than 100 Whether the Printhead Alignment has been performed since the last Printhead replacement Whether Color Calibration has been performed since the last Printhead replacement Whether a Paper Jam was ever detected while this particular Printhead was installed HP DesignJets 500 and 800 Series Printers Service Manual Ink Supplies Tr
124. oubleshooting Status Bars OD CO b c El ie Ink Cartridge Status Messages The front panel displays four vertical bars These bars represent how much ink is remaining in the Ink Cartridges as ink is used up the bars get shorter in length To see how much ink you have remaining see page Page 3 9 Obtaining Ink Cartridge Information Ink Cartridge Status While Replacing There are two circumstances under which you may need to replace an Ink Cartridge m The Printer has detected that the Ink Cartridge is empty or faulty m You decide to replace the Ink Cartridge If the printer detects that an Ink Cartridge needs replacing you will see the message Ink menu E Ink cartridge replacement required ANGI ir with six icons explained below referring from left to right to the Cyan Black Magenta and Yellow Ink Cartridges The icons may be any of the following The Ink Cartridge is OK the approximate level of the ink is indicated a full cartridge has the whole interior black Flashing the Ink Cartridge is missing and the correct one must be inserted Flashing exclamation mark the Ink Cartridge is low on ink and needs replacing at the earliest opportunity For some types of Prints like line drawings the Ink Cartridge may still last much longer Flashing pump the Ink Cartridge is out of ink and must be replaced before any further printing can be done Flashing cross the wrong Ink C
125. oubleshooting Repetitive Printhead Error Messages 3 21 Printhead Error Codes 3 22 Summary of Solving Ink Supplies Problems 3 23 HP DesignJets 500 and 800 Series Printers Service Manual Ink Supplies Troubleshooting NOTE What are the Ink Supplies For each of the four ink colors used in the Printer there are two separate components the Printhead and the Ink Cartridge Both components are coded with an HP selection number to identify the correct replacement supplies x CA S N Printhead Ink Cartridge 69cc Ink Cartridges The Ink Cartridges for the HP DesignJet 500 and 800 Series Printers require no maintenance or cleaning As long as each Ink Cartridge is inserted correctly into its slot the ink will flow to the Printheads The Ink Cartridges are number coded as follows m HP No 10 for the Black Ink Cartridge m HP No 82 for the Cyan Magenta and Yellow Ink Cartridges It is also possible to use HP No 11 Ink Cartridges for the Cyan Magenta and Yellow colors The HP No 11 Ink Cartridges contain 33cc of ink The front panel displays the status of the Ink Cartridge With the front panel detailed information can be checked on the Ink Cartridges see page Page 3 9 Obtaining Ink Cartridge Information 3 2 HP DesignJets 500 and 800 Series Printers Service Manual Ink Supplies Troubleshooting Printheads The Printheads are extremely durable and do not need to be replaced every time an Ink Ca
126. ove the Left Hand Cover Refer to Page 8 5 2 Remove the Right Hand Cover Refer to Page 8 7 3 Remove the Electronics Module Refer to Page 8 24 4 Remove the Left Encoder Holder Refer to Page 8 33 5 Remove the Service Station Refer to Page 8 52 6 Remove the Service Station Holder Refer to Page 8 57 7 Slide the Cable out of the Printer from the right hand side NOTE Make sure when removing the cable that it does NOT scratch against the edge of the beam NOTE Make sure that the Plastic Protector is NOT removed while removing the Cable HP DesignJets 500 and 800 Series Printers Service Manual 8 59 Removal and Installation Ink Supply Tubes Removal 1 Perform the Service Utility Change Ink Tubes Refer to Page 4 25 2 Open the Window and locate the Carriage Assembly 3 Release the latch and lift up the Carriage Cover 4 Remove all the Printheads 8 60 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 5 Open the Ink Cartridge Access Cover 6 Remove all the Ink Cartridges 7 Switch OFF the Printer and remove the power cord HP DesignJets 500 and 800 Series Printers Service Manual 8 61 Removal and Installation 8 Remove the Top Cover and Window Refer to Page 8 10 9 Loosen T 8 screw that secures the Tubes to the Carriage 10 Unclip the Tubes from the Carriage and lift up 8 62 HP DesignJ
127. ow away dust accumulation with compressed air if available 2 Clean the outer surface of the Printer with a damp sponge or cloth Use a mild soap and water solution if necessary Do not use abrasive cleaners 3 Wipe the Printer dry with a soft lint free cloth 9 2 HP DesignJets 500 and 800 Series Printers Service Manual Preventive Maintenance NOTE WARNING Cleaning the Drive Roller Print Platen If ink is spilled on the Drive Roller or the Print Platen remove the ink Due to the ink s reflectance ink on the Drive Roller or the Print Platen can disrupt the Printer s edge sensing function To remove any ink from the Drive Roller perform the following procedure Prevent water or other liquids from running onto electrical components or circuits or through openings in the module Perform the Turn Drive Roller Utility gt Page 4 21 Open the Top Cover and apply any common household cleaning solution water based only to a soft lint free rag and apply it to the Drive Roller surface while it is rotating Thoroughly clean the Drive Roller surface 3 Press Enter when you have completed the cleaning procedure 4 Allow the Drive Roller to dry before loading media in the Printer Scheduled Maintenance In some segments of the printer market the customer tends to print more than the maximum number of prints that the throughput allows exceeding by far the limit of the design When this happens the customer runs into p
128. ows you the pattern that will be printed Direction of paper while printing creating pattern Y Direction of paper when loading measuring pattern 6 In order to measure the pattern that has been printed load the pattern into the Printer with the printed side up and with the dotted line at the top that is rotated 90 5 12 HP DesignJets 500 and 800 Series Printers Service Manual Service Calibrations 7 Re enter the Advance Calibration and select Measure pattern and press Enter Factory advance cal Create pattern Measure pattern Menu Back v amp Enter 8 The Printer will measure the alignment marks using the line sensor on the Carriage Assembly The following message will be displayed while the Printer measures the pattern Calibrating Job management menu cy Gb S ri 9 Once the calibration is completed the following message will be displayed Calibration finished successfully Press ENTER to continue Menu Back Ie Enter HP DesignJets 500 and 800 Series Printers Service Manual 5 13 Service Calibrations 5 14 HP DesignJets 500 and 800 Series Printers Service Manual Print Quality Print Quality 6 2 Print Quality Troubleshooting Checklist 6 2 How to Use the Troubleshooting Procedure 6 4 What is the Troubleshooting Procedure 6 4 Performing the Troubleshooting Procedure 6 4 Troubleshooting Procedure Flowch
129. place the Vacuum Fan Page 8 64 2 Ifthe Vacuum Fan held the sheet in place but couldn t correctly load it then there could be a problem with the Drive Roller In this case replace the Drive Roller gt Page 8 86 Vacuum suction much lower at high altitudes Sometimes at high altitudes the vacuum force holding down the media will be lower therefore the media will not be held in place properly causing E Ink Smearing on the Media m Printhead crashes against the Media Cut Sheet loading problems high probability m Roll Media loading problems low probability The solution to this would be to change the Vacuum force by changing the Altitude setting This can be done via the front panel gt Set up Menu Altitude HP DesignJets 500 and 800 Series Printers Service Manual 1 5 Troubleshooting HP GL 2 color differences in different HP DesignJet Printers Color differences between one image printed on the HP DesignJet 500 800 Series and the rest of the DesignJet platforms are due to the different chemistry of the 500 800 series inks compared with the rest of the inks for other printers This color variability among different HP DesignJet Series Printers has always been present To solve the problem try the following E Perform the color calibration from the driver at the time of printing However that calibration is not very accurate but it may help in the most severe cases Some applications have color
130. printed with Print Quality set to Best instead of Normal or Draft 6 6 HP DesignJets 500 and 800 Series Printers Service Manual Print Quality Troubleshooting Procedure Flowchart START HERE Printer checks whether Printhead Alignment has recently been done Printhead Alignment hasn t gt been done recently 9 gt Printhead Alignment has been done recently gt ihn Craton v Printer prints Are all black lines in fo A Diagnostic Print A Diagnostic Print A 8 straight Yes _ Are the colored blocks in Diagnostic Print A OK If possible Printer No lt q fe to Clean Lae Yes all OK Printer checks Printer prints m Diagnostic Print B lt 4 No4 whether the Printheads have been cleaned recently v Are the colored patterns in xe Diagnostic Print B S OK Ye all OK C No v If possible Printer tries to Clean Printheads v HP DesignJets 500 and 800 Series Printers Service Manual 6 7 Print Quality No Printing Defects Found Using the Troubleshooting Procedure If all the test patterns from the Troubleshooting procedure are correct and you still experience print quality problems here are some of the more likely causes to check E The print mode used in the Printer is not right for the image that is being printed this is defined by the printer s front panel menu se
131. r Grey HP DesignJet 500 Series Only C7770 60154 1 Top Cover Grey HP DesignJet 500 Series Only C7779 60154 1 Top Cover Black HP DesignJet 800 Series Only C7780 60154 1 Top Cover Black HP DesignJet 800 Series Only 0515 1743 2 3 Screws 3 C7769 60167 2 3 Media Deflectors comes as a kit 7 8 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Figure 4 Top Cover and Deflectors HP DesignJets 500 and 800 Series Printers Service Manual 7 9 Parts and Diagrams Rollfeed Module C7769 60162 1 Rollfeed Module Kit 0624 0771 6 Screw Plas M4 lin 3 C7769 60184 1 Spindle 24 Model Only 1 C7770 60008 Spindle 42 Model Only 7 10 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams cn t 4 ErP s2 Figure 5 Rollfeed Module HP DesignJets 500 and 800 Series Printers Service Manual 7 11 Parts and Diagrams Back Platen Assembly 1 C7769 60155 1 Back Platen 24 Model Only C7770 60155 1 Back Platen 42 Model Only 0624 0769 2 Screw 3 C7769 60168 1 Media Sensor 7 12 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Figure 6 Back Platen Assembly HP DesignJets 500 and 800 Series Printers Service Manual 7 13 Parts and Diagrams Electronics Module 1 C7779 60144 1 Electronics Modul
132. r Prime tubes z ae Enter 2 The Carriage will move to the left hand side of the Printer pick up the Cutter and move it to a position where the Cutter can be replaced 4 24 HP DesignJets 500 and 800 Series Printers Service Manual Service Tests and Utilities Change Ink Tubes The purpose of this Service Utility is to move the Carriage Assembly to a position where it makes the removal of the Ink Supply Tubes much easier NOTE In order to actually replace the Ink Supply Tubes refer to Page 8 60 Perform the Change Ink Tubes utility as follows 1 In the Service Utilities submenu scroll to Change Ink Tubes and press Enter Service utilities A Menu Change ink tubes Unlock Carriage Turn Drive Roller Bacy Prime tubes EEROM Setup F Enter 2 Once the utility starts the printer will display the following message on the front panel If you want to abort the Change Ink Tubes utility press Cancel and you will return to the Set up menu Change ink tubes Press ENTER to continue or CANCEL to quit 3 If you press Enter the Carriage will move to a position where you change the Ink Supply Tubes and the following message will be displayed on the Front Panel You should switch the Printer OFF before starting to change the Ink Supply Tubes 1 Switch off the machine 2 Refer to the Service Manual to replace tubes NOTE The next time the Printer is switched ON i
133. r Codes 56 13 Error in the Drive Roller Encoder Sensor quadrature Try the following m Switch the Printer Off and wait a few minutes Switch the Printer On again and check if the Error Code has disappeared E If the Error Code continues replace the Drive Roller Encoder Sensor gt Page 8 38 61 04 Firmware Error Try the following E Switch the Printer Off and wait a few minutes Switch the Printer On again and check if the Error Code has disappeared E If the Error Code reappears check for a new Firmware release m If the new Firmware release does not solve the problem or if new Firmware release was not available then contact the HP Response Center or directly to the Division supplying the following information Model and Serial Number of the Printer Firmware release of the Printer use the Printer Information utility Page 4 26 The complete Error Code information including the linefeed where the error occurred use the Error Log utility to obtain this information Page 2 5 HP DesignJets 500 and 800 Series Printers Service Manual 2 13 System Error Codes System Error Problem Description Corrective Action System Error Problem Description Corrective Action 61 05 Error Processing Job This Error Code only appears in HP DesignJets 800 Series or in the HP DesignJet 500 Series with an HP GL 2 card installed when processing either a PostScript or HP GL 2 file
134. r Up Only for Onsite Repair If the Printer fails to initialize completely because of a System Error and you need to use the Service Menu Service Tests and Utilities the Printer can be powered up in Service Mode by pressing the Up and Enter keys while switching the Printer ON This will give you access to some of the Service Tests and Utilities without having to complete the System Initialization if you perform some of the tests they will need to initialize the relevant part of the System HP DesignJets 500 and 800 Series Printers Service Manual 1 13 Troubleshooting Using the Formatter Accessory Card LEDs to Troubleshoot In certain circumstances the LEDs located in the Formatter or HP GL 2 Accessory Card can help to highlight certain failures There are 3 LEDs Red Yellow and Green and using different combinations can indicate different problems p gt R LED s on the HP GL 2 Accessory Card BOLT TTT 49323 eEELLLLLTL ITI TT TTT The LED s on the Formatter can be seen without having to remove the Left Hand Cover LED s on the Formatter m The yellow LED normally flashing indicates that the Formatter Accessory Card is alive If it stops flashing it means that the Formatter Accessory Card has failed and should be replaced Em The green LED indicates that there is power being supplied to the HP DesignJets 500 and 800 Series Printers Service Manual Troubleshooting Formatter Acces
135. re any obstacles blocking the Drive Roller Remove the obstacles if necessary m Remove the Back Platen Page 8 67 and check if the Drive Roller is damaged If the Drive Roller is damaged replace the Drive Roller Page 8 86 The Drive Roller Encoder Sensor is faulty E It is possible to determine whether the Encoder Sensor is faulty by loading a sheet of paper from the front of the Printer If the Drive Roller is working the sheet will be loaded correctly and the Printer will detect that media has been loaded using the Media Sensor Therefore the problem must be the Encoder Sensor and the solution would be to replace the Encoder Sensor Page 8 38 1 4 HP DesignJets 500 and 800 Series Printers Service Manual Troubleshooting Problems with the Vacuum Fan If you have problems loading either Roll or Sheet Media then there could be a problem with the Vacuum Fan To verify if there really is a problem with the Vacuum Fan try the following 1 With the Printer ON open the Window of the Printer and place a sheet of HP High Gloss Photo Paper must be D Size aligned with the blue lines on the Center Platen If the Vacuum Fan holds the sheet in place and then loads it correctly then the Vacuum Fan functions correctly If the Vacuum Fan does not hold the sheet in place no suction then try the following Check that the holes in the Center Platen are NOT blocked m Check that the Vacuum Fan is installed correctly E Re
136. riage Assembly C7769 60151 Carriage Assembly C7769 60147 Trailing Cable 24 Model Only C7770 60147 Trailing Cable 42 Model Only C7769 60182 Belt 24 Model Only C7770 60014 Belt 42 Model Only C7769 60183 Encoder Strip 24 Model Only C7770 60013 Encoder Strip 42 Model Only 0624 0769 pee eee e ph e Screw 7 34 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Lv a Figure 17 Carriage Assembly HP DesignJets 500 and 800 Series Printers Service Manual 7 35 Parts and Diagrams Vacuum Fan 1 C7769 60150 1 Vacuum Fan 7 36 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Figure 18 Vacuum Fan HP DesignJets 500 and 800 Series Printers Service Manual 7 37 Parts and Diagrams Interconnect Cable 1 C7769 60180 1 Interconnect Cable 24 Model Only C7770 60016 1 Interconnect Cable 42 Model Only 7 38 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Figure 19 Interconnect Cable HP DesignJets 500 and 800 Series Printers Service Manual 7 39 Parts and Diagrams Paper Axis Motor 1 7769 60152 1 Motor Assembly 2 0515 2246 2 Screw 7 40 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams
137. rint quality problems and continuous Printer failures The purpose of scheduled preventive maintenance is to avoid these failures ensuring a good performance during all the product life Level of Printer Usage Normal printer use means 6 000 000 printing carriage cycles Under normal usage conditions it will be approximately 5 years before the printer needs maintenance If the printer is used more than the normal usage conditions then it will need maintenance service much more frequently One of the EEROM counters is assigned to counting the number of carriage cycles as well as the usage cycles of other major components When the printer exceeds this amount the front panel HP DesignJets 500 and 800 Series Printers Service Manual 9 3 Preventive Maintenance NOTE NOTE displays the following message Maintenance Advised The Maintenance Advised message could also appear when the Spittoon in the Service Station is full The Printer Information utility also conveys the usage information and it is accessible by the user Once the maintenance advised message is displayed the preventive maintenance kit must be used to replace the most worn parts of the printer Use the Removal and Installation Chapter of this Service Manual as a guide to replace the necessary parts Scan Axis Maintenance In addition to the wearing of the Scan Axis Motor and the Ink Tubes System the friction in this area can increase due to the ac
138. rinter 24 Model P N C7779C HP DesignJet 800PS Printer 42 Model P N C7780C For information about using these printers refer to the corresponding User and Quick Reference Guides Readership The procedures described in this Service Manual are to be performed by HP Certified Service Personnel only Part Numbers Part Numbers for Printer options accessories and service parts are located in Chapter 7 Conventions A small arrow is used to indicate other parts of the Service Manual where you can find information related to the topic you are consulting 2 HP DesignJets 500 and 800 Series Printers Service Manual Table of Contents Table of Contents Troubleshooting 1 1 Introduction 1 2 Troubleshooting System Error Codes 1 2 Solving Print Quality Problems 1 3 Cover Sensors are not Working 1 3 The Line Sensor has Problems Detecting Media 1 3 Troubleshooting Paper Axis Shutdowns 1 4 Problems with the Vacuum Fan 1 5 Vacuum suction much lower at high altitudes 1 5 HP GL 2 color differences in different HP DesignJet Printers 1 6 Banding at variable extreme environmental conditions 1 6 The Priming Procedure Fails 1 7 Using the Power Switch LED to Troubleshoot 1 10 Using the Boot Up Sequence to Troubleshoot 1 12 Using the Formatter Accessory Card LEDs to Troubleshoot 1 14 System Error Codes 2 1 Introduction 2 2 Continuable and Non Continuable Error Codes 2 2 System Error Codes Explanation 2 2 Er
139. rinter does not even start to power up i e nothing seen on the Front Panel and the LED in the Power Switch is NOT flashing without the LAN Card nor the Formatter Accessory Card but the power switch LED is ON all the time the problem could be with the Electronics Module or the Power Supply Unit Em The red LED will flash a few times when the Printer is started up but if it stays lit all the time or flashes continuously then this indicates that the Formatter Accessory Card is faulty and should be replaced HP DesignJets 500 and 800 Series Printers Service Manual 1 15 Troubleshooting 1 16 HP DesignJets 500 and 800 Series Printers Service Manual System Error Codes Introduction 2 2 Continuable and Non Continuable Error Codes 2 2 System Error Codes Explanation 2 2 Accessing the Error Log Utility 2 5 01 10 2 7 01 11 2 7 01 12 2 7 01 13 2 8 02 10 2 8 02 13 2 8 03 10 2 9 04 11 2 9 05 10 Warning Only applicable to HP DesignJet 800 Series 2 9 05 11 2 10 HP DesignJets 500 and 800 Series Printers Service Manual 2 1 System Error Codes Introduction System error codes are hexa decimal based numbers generally caused by internal system errors The following pages contain a list of system error codes and their respective descriptions and recommended corrective actions Only try one recommended action at a time and check if the error code has disappeared Continuable and Non Continuable Error Cod
140. rmine whether the Printhead needs replacing by marking it with an exclamation mark or not after performing various levels of recovery actions Considerations for Using the Troubleshooting Procedure 1 It is important that the media that you use for the Troubleshooting procedure is exactly the same as the one that the customer used when they experienced the print quality problem If the customer used HP Glossy Paper size AO then you must use HP Glossy Paper size AO If you use a different type of media or a different size then there is a possibility that the print quality problem will not be resolved 2 If the customer is using non HP media and after the Troubleshooting procedure you still have the same print quality problems change to genuine HP media and repeat the Troubleshooting procedure Using this process you can determine if the problem is with the Printer or with the non HP media 3 If you do not see any problems with the Troubleshooting procedure but still experience print quality problems then the problem may not be with the Printer itself The problem may be with the RIP or the driver for example Performing the Troubleshooting Procedure 1 To perform the Troubleshooting procedure press the T or J key until the front panel displays the Ink Menu and then press Enter 3 A vem Ink cartridges Back v T Enter vvo int 6 4 HP DesignJets 500 and 800 Series Printers Service Manual Print Qual
141. ror Log Utility 2 5 Accessing the Error Log Utility 2 5 Ink Supplies Troubleshooting 3 1 What are the Ink Supplies 3 2 Ink Cartridges 3 2 Printheads 3 3 Identifying the Components 3 3 General Information About the Ink Supplies 3 4 Some General Precautions When Handling the Ink Supplies 3 5 When Should You Replace the Ink Cartridges 3 6 When Should You Replace the Printheads 3 7 Obtaining Ink Cartridge Information 3 9 HP DesignJets 500 and 800 Series Printers Service Manual 3 Table of Contents Obtaining Printhead Information 3 10 Ink Cartridge Status Messages 3 12 Ink Cartridge Status While Replacing 3 12 Printhead Status Messages 3 13 Printhead History Utility 3 14 Accessing the Printhead History Utility 3 14 Is the Printer Causing Repetitive Printhead Problems 3 16 Is the User Replacing the Printheads too Early 3 18 Troubleshooting Repetitive Ink Cartridge Messages 3 20 Troubleshooting Repetitive Printhead Error Messages 3 21 Printhead Error Codes 3 22 Summary of Solving Ink Supplies Problems 3 23 Service Tests and Utilities 4 1 Introduction 4 2 Phone Support 4 2 Diagnostics Self Test 4 2 Service Tests Diagnostics 4 3 Entering the Service Tests Menu 4 4 Ink Supply Station 4 6 Carriage Movement 4 8 Paper Advance Test 4 10 Service Utilities 4 13 Entering the Service Utilities Menu 4 14 EEROM Setup 4 16 Turn Drive Roller 4 21 Unlock Carriage 4 22 Prime Tubes 4 23 Change Cutter 4 24
142. rtridge is replaced They are independent of the Ink Cartridges and will continue giving excellent image quality results even if the Ink Cartridges are low on ink In order to know when to replace a Printhead see page Page 3 7 When Should You Replace the Printheads The Printheads are number coded HP No 11 for ALL colors If you notice a decline in print quality such as lines or dots missing from text graphics go to page Page 6 4 Performing the Troubleshooting Procedure Identifying the Components The following illustration will help you identify the components of the ink supplies HP DesignJets 500 and 800 Series Printers Service Manual 3 3 Ink Supplies Troubleshooting General Information About the Ink Supplies For optimum results from the printer and modular ink delivery system always follow these guidelines when handling the ink supplies Always install the Ink Cartridges and Printheads before the expiration date which is on the packaging Install Ink Cartridges and Printheads in their color coded slots Follow the instructions on the front panel of the Printer during installation Avoid unnecessary removal of the Ink Cartridges and Printheads When turning off the Printer always use the power Off button located on the left hand side of the Printer The Printheads are then stored correctly which prevents them from drying out The Ink Cartridges should never be removed while the Printer is printing The
143. rvice Tools Menu press the T or J key until the front panel displays Service Tests and then press Enter Service tools Menu Back Service tests Service calibrations Service utilities Enter 4 4 HP DesignJets 500 and 800 Series Printers Service Manual Service Tests and Utilities 4 Press the Enter key to begin a specific test when the required Service Test is highlighted Service tests Troubleshooting Aerosol Fan test Ink Supply Station Paper advance test Carriage movement test amp Menu Back v a gt Enter HP DesignJets 500 and 800 Series Printers Service Manual 4 5 Service Tests and Utilities NOTE WARNING oe Ink Supply Station The purpose of this test is to verify the operation of the Ink Supply Station A failure of the out of ink sensors or the springs in the Ink Supply Station will eventually damage the Printheads because the Printer will try to pump ink from an empty Ink Cartridge stall which will cause the Printhead to dry fire This Service Test can be performed by the End User with the guidance of a HP Support person via the phone IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE REPLACING THE INK SUPPLY STATION IF THIS TEST PASSES DO NOT REPLACE THE INK SUPPLY STATION Perform the Ink Supply Station test as follows In the Service Tests submenu scroll to Ink Supply Station and press Enter Service tests A Menu Troubleshooti
144. s inserted Back Expiration date 15 Aug 2002 Serial number v gt Enter 06 02 1232651 Ink level 63cc 91 HP DesignJets 500 and 800 Series Printers Service Manual 3 9 Ink Supplies Troubleshooting The information displayed 1s m The model of the Ink Cartridge No 10 for Black and No 82 for the Colors is recommended Status of the Ink Cartridge The warranty expiration date of the Ink Cartridge The Serial Number of the Ink Cartridge The amount of ink remaining in the Ink cartridge the error of the ink level can be as much as or 25 according to the specifications of the Printer Obtaining Printhead Information 1 To get information on the Printheads press the T or 4 key until the front panel displays the Ink Menu Press the Enter key Ink menu Ink cartridges suvo fe Menu Back v amp Enter 2 Press the T or J key until the front panel highlights Information Press the Enter key Ink Menu Information Color calibration Troubleshooting Align printheads Replace printheads Menu Back v Enter 3 Press the T or J key until the front panel highlights Printheads Press the Enter key Information Ink cartridges Printheads Menu Back v O Enter 3 10 HP DesignJets 500 and 800 Series Printers Service Manual Ink Supplies Troubleshooting 4 Press the T or J key until the front panel highlights the col
145. s in Diagnostic Print A are OK then examine the blocks of color carefully and when prompted by HP DesignJets 500 and 800 Series Printers Service Manual 6 5 Print Quality 8 10 Ignore these f solid bars gt i 11 12 13 the front panel indicate whether there are problems with them The sorts of problems to look for are m White streaks or bands in the solid blocks If you indicate that there are problems in the blocks of color the Printer will try and clean the Printheads that have the problem A Printhead can be cleaned up to 3 times in this way after which it will need to be replaced you will be informed via the front panel After cleaning the Printheads the Printer reprints the Diagnostic Print A and you need to repeat the previous steps If you indicate that the blocks of color in Diagnostic Print A are OK the Printer will print Diagnostic Print B For each color in the pattern in Diagnostic Print B you are asked about the quality look especially for missing lines If you indicate that a color is defective the Printer tries to clean that printhead After cleaning the Printheads the Printer reprints the Diagnostic Print B and you need to repeat the previous steps If none of the patterns or blocks in the 2 Diagnostic Prints show any problems it could be that the Print Quality problem is caused by a wrong setting in the software or maybe the print job should have been
146. s to the Interconnect PCA located on the right hand side of the Printer which then splits into different subsystems Front Panel IDS PCA Aerosol Fan Service Station and media loading sensors pinch media sensor and media button Two discrete drivers are implemented for the Carriage Motor driver and the Vacuum Fan The Main PCA comes with fully protected motor drivers for Carriage Paper Axis Service Station and IDS motors Any short circuit will be detected and protected Trailing Cables come with an interlock loop that will prevent from turning on voltages in the Carriage while the Trailing Cable is not properly connected A similar approach of using an interlock pair is used in the Interconnect Cable to ensure it is properly connected The EIO slots do not allow for hot insertions while the machine is powered That is why it is very important to always power off the Printer before inserting the EIO Card or the Formatter or else the Main PCA could be burned Serial channel to be used for line production and service purposes only will be isolated from Kayak pins with a GPIO in the Navata ASIC 10 4 HP DesignJets 500 and 800 Series Printers Service Manual Functional Overview Power Supply Unit PSU The PSU is used to supply the power required by the printer in any condition and has the following features m 130W maximum continuous average power 171 W at peak with power factor correction E 4 outputs with
147. signJet 800 Series Printer then the model number configured in the Printer is incorrect the Printer thinks it s a DesignJet 500 Series Printer In this case reconfigure the model number gt Page 4 16 05 10 Warning Only applicable to HP DesignJet 800 Series Formatter not detected Power OFF the Printer and reseat the Formatter 05 10 Error Only applicable to HP DesignJet 800 Series Formatter failure Power OFF the Printer and replace the Formatter gt Page 8 20 05 10 Error Only applicable to HP DesignJet 500 Series HP GL 2 Accessory Card failure Power OFF the Printer and replace the HP GL 2 Accessory Card gt Page 8 20 HP DesignJets 500 and 800 Series Printers Service Manual 2 9 System Error Codes System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action 05 11 Formatter not detected Power OFF the Printer and reconnect the Formatter 08 11 Front Panel cannot be detected Reconnect the Front Panel 11 11 Trailing Cable badly connected Reconnect the Trailing Cable correctly 11 13 Problem with setting the voltage of the Printheads Try the following Check that the Trailing Cable is connected correctly at bot
148. signJets 500 and 800 Series Printers Service Manual Removal and Installation Power Supply Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Left Hand Cover Refer to Page 8 5 2 Remove T 10 Type B screw from the Power Switch on the front of the Printer 3 Disconnect the Power Supply Cable from the Electronics Module HP DesignJets 500 and 800 Series Printers Service Manual 8 27 Removal and Installation 4 Remove 2 T 10 screws Type B that secure Power Supply to the Bracket 5 Remove the Power Supply as one assembly Power Switch and Power Supply Unit 8 28 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Scan Axis Motor Assembly Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Left Hand Cover Refer to Page 8 5 Remove the Right Hand Cover Refer to Page 8 7 Remove the Power Supply Refer to Page 8 27 Disconnect the Scan Axis Motor Cable from the Electronics Module Release the tension from the right hand side of the Belt by pulling the Tensioner down and pushing it towards you to lock it into position HP DesignJets 500 and 800 Series Printers Service Manual 8 29 Removal and Installation 6 Remove the left hand s
149. sory Card If the green LED is NOT lit and the LED in the Power Switch is ON then it could mean that the Formatter Accessory Card is badly connected or that the Printer if switched OFF If after reseating the Formatter Accessory Card the problem persists try the following 1 Switch the Printer OFF and remove the Formatter Accessory Card BUT leaving the LAN Card installed if available Switch the Printer ON If the Printer powers up correctly and the LAN Card works properly then try step 2 If the LAN Card doesn t work then try step 3 2 Switch the Printer OFF and remove the LAN Card from the current slot and install the Formatter Accessory Card in the same slot that was previously used by the LAN Card Switch the Printer ON and check if the green LED in the Formatter Accessory Card is lit If the green LED is NOT lit it means that the Formatter Accessory Card is faulty and should be replaced If the green LED is lit then switch the Printer OFF and install the LAN Card in the vacant slot Switch ON the Printer and check if the LAN Card works properly If the LAN Card does NOT work then there is a problem with the Electronics Module and should be replaced Page 8 24 3 Switch the Printer OFF and remove the LAN Card Switch ON the Printer and check if it initializes completely If it initializes correctly without any problems then the problem could be with the Electronics Module and should be replaced gt Page 8 24 4 If the P
150. ss Enter Color calibration Menu Back Status Calibrate paper Reset y Enter 2 The Printer will start to print the calibration pattern and the following message will be displayed on the front panel Calibrating color Please wait 3 Once the Color Calibration is completed the following message will be displayed on the front panel Menu Calibration finished successfully Back Press ENTER to continue Enter HP DesignJets 500 and 800 Series Printers Service Manual 5 7 Service Calibrations If the calibration fails then the following message will appear on the front panel Menu Calibration error Back gt Enter Press ENTER to continue In this case to resolve the problem try the following m Make sure that you DO NOT use transparent media when performing the Color Calibration m Clean the Line Sensor and try the Calibration again Em Make sure that the Window is closed when you perform the Color Calibration 5 8 HP DesignJets 500 and 800 Series Printers Service Manual Service Calibrations Advance Calibration The purpose of this Service Calibration is to calibrate the nominal advance of the media This calibration is necessary to control the exact movement on the media type that will be used upto 2 in order to avoid print quality problems like banding Perform the Advance Calibration whenever m Banding is d
151. t recover the failing Printhead even after performing the maximum recovery action The user can continue using the Printer even with the Printhead Warning message but will not get the maximum Print Quality that the Printer is designed to provide unless he replaces the worn out Printhead 3 8 HP DesignJets 500 and 800 Series Printers Service Manual Ink Supplies Troubleshooting Obtaining Ink Cartridge Information 1 To get information on the Ink Cartridges press the T or 4 key until the front panel displays the Ink Menu Press the Enter key A Pom Ink cartridges Back sees Vv o 2 Press the T or J key until the front panel highlights Information Press the Enter key Ink Menu Menu Information Color calibration Back Troubleshooting ac Align printheads Replace printheads p amp B Enter 3 Press the T or J key until the front panel highlights Ink cartridges Press the Enter key Information 2 Menu Back Ink cartridges Printheads gt Enter 4 Press the T or J key until the front panel highlights the color that you want to see information on Press the Enter key Select ink cartridge Menu Ink levels Cyan ink cartridge Back Magenta ink cartridge i Yellow ink cartridge Black ink cartridge F amp Enter 5 The front panel displays information on the selected Ink Cartridge Black cartridge info fs Menu Model HP Black No 10 Statu
152. t will automatically start the Priming process HP DesignJets 500 and 800 Series Printers Service Manual 4 25 Service Tests and Utilities NOTE Printer Information The purpose of this Utility is the following E Report basic parameters for call qualification m Identify potential problems Some of the parameters can be reset to zero by using the EEROM Setup utility gt Page 4 16 Check the Printer Information as follows In the Service Utilities submenu scroll to Printer Information and press Enter Service utilities 2 Menu Printer information Printhead information Back Error log Printheads Altitude 0 1000 m y Enter The Printer will display the following information on the front panel You will need to use the arrow keys to scroll through the complete list because the front panel only allows 6 lines to be displayed at one time Printer Information ie Menu Model Number C7779C Serial No ESA0B001023 Service ID 11280 Engine F W v Enter X XX XX Formatter F W X XX XX Hard disk F W X XX XX Paper usage 315 in 8 m Ink used Black 6 cc Cyan 4 ce Magenta 4 cc Yellow 3 cc Scan axis usage 21 Paper axis usage 23 Serv Station usage 19 Spittoon usage 12 Pinch Lift usage 10 Cutter usage 26 Carriage usage 12 Ink usage 2 Back 4 26 HP DesignJets 500 and 800 Series Printers Service Manual Service Tests and Utilities Eac
153. ter ON This will give you access to some of the Service Tests and Utilities without having to complete the System Initialization if you perform some of the tests they will need to initialize the relevant part of the System 4 2 HP DesignJets 500 and 800 Series Printers Service Manual Service Tests and Utilities Service Tests Diagnostics The following is a list of all internal Service Tests available in the Printer Instructions for entering the Service Tests menu are given on Page 4 4 1 Ink Supply Station Page 4 6 The purpose of this test is to verify the operation of the Ink Supply Station A failure of the out of ink sensors or the springs in the Ink Supply Station will eventually damage the Printheads because the Printer will try to pump ink from an empty Ink Cartridge stall which will cause the Printhead to dry fire 2 Carriage Movement Page 4 8 The purpose of this test is to verify the movement of the scan axis components at several speeds This test checks for the following problems E Friction problems with worn out slider rod or Carriage Bushings m Blockage due to problems with the Service Station E Problems with encoder sensing 3 Paper Advance Page 4 10 The purpose of this test is to identify whether there is too much friction in the paper axis drive system which is caused by defects with the Transmission Gears Drive Roller or the Paper Axis Motor 4 Troubleshooting gt Page 6 4 The Print
154. the Drive Roller using the Turn Drive Roller service utility Page 4 21 Also try cleaning the Drive Roller Gears Replace the Drive Roller Page 8 86 Replace the Gear Assemblies Page 8 92 WARNING Only replace one component at a time and try the Service Test again before replacing another component Using this procedure you will be able to determine exactly which component failed If the Drive Roller Encoder Sensor test passes the Printer will try turning the Drive Roller and the following message will appear on the Front Panel Paper Advance test Moving Drive Roller Please wait Once the test is completed the results will be displayed on the front panel Test results wet Average value of the PWM Average PWM XX Standard deviation value of Std dev PWM X the PWM 4 12 HP DesignJets 500 and 800 Series Printers Service Manual Service Tests and Utilities Service Utilities The following is a list of all internal Service Utilities available in the Printers Instructions for entering the Service Utilities menu are given on Page 4 4 1 EEROM Setup Page 4 16 The purpose of this Service Utility is to modify identification parameters such as serial and model numbers as well as the Font Type This only needs to be performed when EEROM failures cannot be recovered where both the current EEROM located in the Main PCA and the backup EEROM located in the Ink Supply Station
155. the I O channels or directly via the front panel The Front Panel is used to display messages like the status of the machine or warnings to configure the printer and to send commands to it cancel the job or print a demo for example The Front Panel has an LCD display 7 keys no LEDs and a buzzer to provide audible feedback to the user The front panel display is a 128 x 64 pixel graphic LCD Every pixel can be activated individually and the controller present on the Front Panel board allows it to display both text and graphics at the same time The Front Panel has a positive reflective type display to improve its viewing characteristics and does NOT have an LED backlight The Front Panel is connected to the Interconnect PCA and NOT directly to the Main PCA Cancel ee Form Feed E and Cut 10 6 HP DesignJets 500 and 800 Series Printers Service Manual Functional Overview Ink Delivery System IDS The Ink Delivery System IDS delivers ink from the off axis Ink Cartridges via permanently connected tubes to the high throughput Printheads for the HP DesignJet 500 800 Series Printers The IDS consists of two major subsystems m The Ink Supply Station ISS m The Tubes Assembly Ink Supply Station ISS In the Printer the Ink Cartridges reside inside the Ink Supply Station ISS The ISS is situated on the right hand side of the Printer and will be able to handle 69cc capacity Ink Cartridges for all colors
156. the Printer HP DesignJets 500 and 800 Series Printers Service Manual 8 37 Removal and Installation Drive Roller Encoder Sensor Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Left Hand Cover Refer to Page 8 5 2 Remove the Spittoon Refer to Page 8 23 3 Remove the Cutter Guide Bracket Refer to Page 8 36 4 Disconnect the Encoder Sensor Cable from the Electronics Module 5 Remove 1 T 8 screw Type G from the Encoder Sensor Cover 8 38 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 6 Depress the clip and remove the Encoder Sensor Cover 7 Remove 1 T 8 screw Type G from the Encoder Sensor 8 Move the Encoder Sensor to the left and remove including the Encoder Sensor Cable HP DesignJets 500 and 800 Series Printers Service Manual 8 39 Removal and Installation Trailing Cable Removal NOTE Refer to the table on Page 8 4 for information on screw types 1 Perform the Service Utility Unlock Carriage Refer to Page 4 22 NOTE Switch off the Printer after performing this Utility 2 Remove the Left Hand Cover Refer to Page 8 5 3 Remove the Top Cover and Window Refer to Page 8 10 4 Manually move the carriage to the correct position to remove the Tubes Assembly from the Carriage 5 Release the latch and lift up
157. tions from the advanced section of the HP GL 2 Driver try disabling one or both of the options auto rotate and inked area If the above fails to solve the problem of smears and scratching change the media that the customer is using to a non paper based media such as HP High Gloss Photo Paper 6 10 HP DesignJets 500 and 800 Series Printers Service Manual Parts and Diagrams Printer Support 7 2 Right Hand Cover 7 4 Left Hand Cover 7 6 Top Cover and Deflectors 7 8 Rollfeed Module 7 10 Back Platen Assembly 7 12 Electronics Module 7 14 Power Supply 7 16 Cutter Assemblies 7 18 Ink Delivery System 7 20 Service Station and Spittoon 7 22 Service Station Holder 7 24 Pinch Wheel Assemblies 7 26 Scan Axis Motor 7 28 Drive Roller Encoder Sensor 7 30 Print Platen Assembly 7 32 Carriage Assembly 7 34 Vacuum Fan 7 36 Interconnect Cable 7 38 Paper Axis Motor 7 40 Drive Roller 7 42 Miscellaneous Items 7 44 HP DesignJets 500 and 800 Series Printers Service Manual 7 1 Parts and Diagrams Printer Support C7782 60001 Bin Assembly 24 Model Flint Grey C778 1 60005 Bin Assembly 24 Model Graphite Grey C7770 60023 Bin Assembly 42 Model Flint Grey C7780 60001 Bin Assembly 42 Model Graphite Grey C7770 60082 Foot Assembly C7770 60021 Legs Assembly C778 1 60004 X Brace Assembly 24 Model C7770 60020 X Brace Assem
158. to Page 3 20 Troubleshooting Repetitive Ink Cartridge Messages Cartridges will expire a in dave 7 3 6 HP DesignJets 500 and 800 Series Printers Service Manual Ink Supplies Troubleshooting When Should You Replace the Printheads In a normal situation the Printhead should ONLY ever be replaced when advised by the Printer If Print Quality is poor the first step should ALWAYS be to perform the Troubleshooting procedure Refer to Page 6 4 which will determine whether the Printhead needs replacing or not after performing various levels of recovery actions The minimum life expectancy of the Printhead is anticipated to be 530cc for the Black Printhead and 200cc for the Color Printheads provided that the Printhead is used under normal operating conditions using HP Ink Cartridges only and its install before date has not lapsed However results vary depending on the print quality setting being used There are 3 circumstances when you need to replace the Printheads which are explained as follows Printhead Error message When this message appears the Printer has determined that one of the Printheads has experienced a problem and should be replaced If this message appears repetitively refer to Page 3 21 Troubleshooting Repetitive Printhead Error Messages Ei Error Select Replace printheads m Printhead Error unknown message When this message appears one of the Printheads has experienced a problem
159. ual 8 33 Removal and Installation 4 Disconnect the Trailing Cable and unclip the Ferrite and remove 5 Remove the Electronics Module Refer to Page 8 24 6 Remove 2 T 20 screws Type A from the Left Encoder Holder 7 Remove the Left Encoder Holder making sure that you first unclip both the Trailing Cable and the Interconnect Cable 8 34 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation Cutter Bushing Removal WARNING Switch off the printer and remove the power cord 1 Remove the Left Hand Cover Refer to Page 8 5 2 Remove the Electronics Module Refer to Page 8 24 3 Remove the Cutter Assembly Refer to Page 8 32 4 Remove the Left Encoder Holder Refer to Page 8 33 5 Slide the Cutter Bushing to the Left and remove from the Printer HP DesignJets 500 and 800 Series Printers Service Manual 8 35 Removal and Installation Cutter Guide Bracket Removal WARNING Switch off the printer and remove the power cord NOTE Refer to the table on Page 8 4 for information on screw types 1 Remove the Left Hand Cover Refer to Page 8 5 2 Remove the Cutter from its position 3 Remove the Vacuum Fan Cable from the Cutter Guide Bracket 8 36 HP DesignJets 500 and 800 Series Printers Service Manual Removal and Installation 4 Remove T 10 screw Type B from the Cutter Guide Bracket 5 Slide the Cutter Guide Bracket out of
160. uality performance of the Printer only media types that have been certified for the Printer should be used Use of non HP media or HP media not certified for the printer may significantly reduce the color and print quality of the required images For details of HP media refer to the User s Guide or the Media Guide for the HP Designjet Printers To have accurate colors the media settings must match the type of media loaded in the printer If the customer is using non HP media with HP drivers the colors in the required print may not be accurate Advise the customer to use HP media if they want to improve the accuracy of the colors There are Smears or Scratching on the Printed Media This problem can appear on paper based coated media if a lot of ink is printed quickly The media cannot absorb the ink quickly enough and becomes distorted As the printheads move over the media the Printheads and the media come into contact with each other and the printed image is smeared Press the Cancel key on the front panel if you continue to print the paper may damage the printheads Cancel the print job from your computer application In order to obtain better results perform the following m Use HP recommended media If the image you are printing has intense color use HP Heavy Coated Paper m Try to increase the print margins by relocating the image on the page from the software application If the customer is using Media Saving Op
161. vice Manual 8 93 Removal and Installation 8 94 HP DesignJets 500 and 800 Series Printers Service Manual Preventive Maintenance Moisture on the Printer 9 2 Noisy Carriage Bushing 9 2 Belt Swelling 9 2 Cleaning the Printer 9 2 General Cleaning 9 2 Cleaning the Drive Roller Print Platen 9 3 Scheduled Maintenance 9 3 Level of Printer Usage 9 3 Scan Axis Maintenance 9 4 HP DesignJets 500 and 800 Series Printers Service Manual 9 1 Preventive Maintenance Preventive Maintenance Moisture on the Printer Users should use the Printer in an environment between 20 and 80 relative humidity To recover from moisture condensation turn the Printer Off and using the main roller as a reference wait until the Printer is completely dry before using it again Noisy Carriage Bushing To prevent noisy movement of the carriage remove aluminum or dust particles from the bushing at the back of the carriage and from the slider path along which the bushing moves Belt Swelling To prevent new belts from swelling incorrectly keep them in their bags with dissicant until you need to install them Cleaning the Printer To maintain the Printer in good operating condition keep it free of dust accumulation ink and other contamination Cleaning intervals are determined by the Printer environment and by the types of Printer supplies used General Cleaning Proper general cleaning should include the following 1 Bl
162. voltages of 5 0V 3 3V 12V and 32V m Operates with convection cooling when 32V output is at minimum load but the Power Supply is cooled by forced air provided by a fan in the Power Supply enclosure when the 32V output is loaded m The Power Supply is connected directly to the Power Switch and a green LED located at the front of the Printer on the bottom left hand side a Power Supply ga TTT Y TULL RH BLL gi I mg figs NUE lt lt lt LLL Y pijl Connector to Main PCA Power Switch Housing Power Switch The Power Supply operates over a voltage range as described in the following table Rated Voltage 100 240 VAC Normal Operating Range 88 264 VAC Functional Operating Range 80 264 VAC Rated Frequency 50 60 Hz Frequency Test Limits 47 63 Hz HP DesignJets 500 and 800 Series Printers Service Manual 10 5 Functional Overview Front Panel As explained earlier the Power Supply provides 5 0V 3 3V 12V and 32V to the Main PCA with the following maximum output currents Voltage Maximum Output Systems Current A 3 3V 8 0 Digital Logic amp EIO cards 5 0V L7 Sensors Front Panel Bitronics and some analog logic in Main PCA Aerosol amp Cooling fans and to generate 12 0V 0 45 the 5 0V going to the carriage 32 0V 3 7 Motors Vacuum Fan and carriage The user can interact with the printer in two ways from the host via
163. y should only be removed when the Printer is ready for you to replace them The front panel will guide you through the removal and installation procedure See page Page 3 6 When Should You Replace the Ink Cartridges 3 4 HP DesignJets 500 and 800 Series Printers Service Manual Ink Supplies Troubleshooting Some General Precautions When Handling the Ink Supplies CAUTION Do not touch wipe or attempt to clean the Printhead nozzles This can damage the Printhead x lt Do not touch the Electrical Contacts Y Do not touch wipe or attempt to clean the printhead nozzles This can damage the printhead C6074297a Handle the Ink Supplies with care In particular the Printhead which is a high precision device must be handled very carefully E Do not touch the Printhead nozzles E Do not touch the Electrical contacts on the Printhead Do not put the Printhead down on the nozzles E Do not be rough when handling the Printheads Always set them down gently Do not drop the Printheads E Proper handling will assure optimum performance throughout the Printhead life E Do not touch the end of the Ink Cartridge which is inserted into the Printer as there may be a small amount of ink on the connection E Avoid storing partially used Ink Cartridges on their ends HP DesignJets 500 and 800 Series Printers Service Manual 3 5 Ink Supplies Troubleshooting When Should You Replace the Ink Cartridges Whe

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