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HP DesignJet Z5200 Service Manual

1. ENWW 242 Chapter 6 Removal and Installation 23 Remove the Trailing Cables from the printer Installation E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 NOTE Make sure you carry out the following actions during the installation of the Trailing Cable 1 Use an alcohol from the Lubrication Kit or Tool Kit dampened cloth to remove all traces of residual adhesive remaining from the double sided pads removed from the printer before applying new pads in the same positions as the original pads 2 Make sure both ribbon cables of the Trailing Cable are routed below the lower attachment clips of the Carriage Assembly ENWW Trailing Cable 243 3 Make sure that the Ferrite Core is correctly positioned so that the small cover of the Carriage PCA closes correctly to avoid possible friction damage to the Trailing Cable during operation of the printer mm N iy ba n 4 k Y Carriage Assembly with or without Trailing Cable Removal E NOTE Switch off the printer and remove the power cable NOTE If you replace the Carriage Assembly with service parts Q6683 60231 24 inch or Q6687 60087 44 inch that include a Trailing Cable remember to remove the Trailing Cable with the Carriage Assembly
2. Error uploading firmware update file Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Make sure the connection between the computer and the printer is functioning properly e _ Try to update the Firmware again 74 1 YZ Cause Solution Error uploading media profile update file Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Make sure the connection between the computer and the printer is functioning properly e Try to upload the media profile update file again 75 1 YZ Cause Solution Preventive Maintenance Kit 1 counter active Scan Axis Try the following Components Ink Supply Tubes Trailing Cable Carriage e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Change the Belt Assembly the Scan Axis Motor the Ink Supply Tubes Carriage Assembly this does not include the Carriage PCA but it does include the Trailing Cable You should change Preventive Maintenance Kit 1 Refer to Preventive Maintenance Kit 1 on page 330 e Once the parts have been changed use the Service Menu to reset the counters that affect PMKit 1 System Error Codes Full Descriptions 67 75 2 YZ Cause Sol
3. 9 Remove the four T 15 screws that secure the Ink Supply Tubes to the Carriage Assembly ENWW Color Sensor ESP 263 11 Close and lock the Carriage Cover 12 13 Unclip and slide off the small cover of the Carriage Assembly Carriage PCA 264 Chapter6 Removal and Installation ENWW 14 Remove one T 15 screws that secures the large cover of the Carriage PCA 15 16 ENWW Color Sensor ESP 265 17 Remove one T 10 screw that secures the Color Sensor ESP to the Carriage Assembly 18 Loosen the T 10 uncapping screw sufficiently so you can manually move the Carriage Assembly in step 26 266 Chapter6 Removal and Installation ENWW 20 Carefully unroute the Color Sensor ESP cable from the Carriage Assembly 21 Remove one T 10 screw that secures the Color Sensor ESP to the Carriage Assembly 22 Remove the Color Sensor ESP from Carriage Assembly E NOTE When you reinstall the Color Sensor ESP be very careful not to overtighten the attachment screw because this will damage cause irreparable damage to it Take care when you route the Color Sensor ESP cable so it lays flat and is not twisted This ensures that when you reconnect it to the connector in the Carriage Assembly it is connected correctly If the cable has been twisted during the routing there is a danger that the connection is inverted Line Sensor Removal ENWW Line Sensor 267 E NOTE Switch off the printer
4. 20 Chapter1 Ink Supplies Troubleshooting amp Print Quality ENWW 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 A full list of front panel messages are supplied in the User s Guide You Cannot Insert the Ink Cartridge Into the Printer 1 Ensure that you have the correct hp Ink Cartridge 2 Ensure that the Ink Cartridge is the correct color for that slot 3 Ensure that the Ink Cartridge is the correct orientation with the color coded label at the top E NOTE Never clean inside the Ink Cartridge slots as this can cause damage to the Printer You Cannot Insert the Printhead Into the Printer 1 Ensure that you have the correct hp Printhead 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 The front panel says to reset or replace a printhead 1 From the front panel turn the power off then ON 2 Check the front panel display message if it shows the ready message the printer is ready to print lf the problem remains continue with the next step 3 Remove the printhead 4 Clean the electrical connections on the backside of the printhead with a lint free cloth You can carefully use a mild rubbing alcohol if moisture is needed to remove residue Do not use water You can use the
5. 7 Remove all the Ink Cartridges from the Printer ENWW Left Cover 189 8 Carefully push the edge of the Ink Cartridge Blanking Plate to the left 9 Carefully push the edge of the Ink Cartridge Blanking Plate to the left 10 Lift the right edge of the Ink Cartridge Blanking Plate 190 Chapter6 Removal and Installation ENWW 11 Remove the Ink Cartridge Blanking Plate from the Printer 13 Lift the Formatter Housing out of the printer ENWW Left Cover 191 14 Remove one T 15 screw that secures the Left Cover top rear accessible under the Formatter Housing 15 GA 16 Remove one T 15 screw that secures the Left Cover bottom rear 192 Chapter6 Removal and Installation ENWW 17 Remove one T 15 screw that secures the Left Cover bottom front accessible under Front Cover 18 Remove one T 15 screw that secures the Left Cover top front accessible Ink Cartridge Door ENWW Left Cover 193 20 Remove the Left Cover from the Printer Rear Tray Removal E NOTE Switch off the printer and remove the power cable 1 Open the Rear Tray to approximately 10 degrees less than the fully open position 2 Lift the Rear Tray vertically enough approximately 20 mm to allow the rear attachment lugs to be out of the locked position 194 Chapter6 Removal and Installation ENWW 3 Carefully slide the Rear Tray out of the printer Rear Cover Removal E NOTE Switch off the
6. 108 Chapter 3 Diagnostic Menu ENWW 22 The Front Panel prompts you to shutdown the printer to complete the test Ink Delivery System Press any key to shutdown the system 23 Press any key to shutdown the printer Check Ink Supplies 1 Inthe Diagnostics menu scroll to 7 IDS and press OK Diagnostics menu oil gt Call AXIS Paper Drive Electronics Module Carriage Assembly Sensors SOL 2 The Front Panel will show the7 IDS submenu gt Ink Delivery System gt Check Ink Supplies 3 Inthe IDS submenu scroll to Check Ink Supplies and press OK to start the test 4 The Check Ink Supplies test starts and the front Panel displays the following messages e Starting Horburgh amp Mips e Starting Nvm e Getting Part Number e Starting Supplies e Starting AcumenSupplies e Reading Ink Supplies 5 The Front Panel then displays Check Ink Supplies test results Starting ColorSensor Starting ColorSensing SOL enable disable OK Press any key to continue 6 Press any key to continue ENWW Service Tests Diagnostics 109 7 The Front Panel shows the test complete display for a few seconds Check Ink Supplies 8 The Front Panel prompts you to shutdown the printer to complete the test Check Ink Supplies Press any key to shutdown the system 9 Press any key to shutdown the printer Check Leakage 1 In the Diagnostics menu scroll to 7 IDS and press OK Diagnostics m
7. 50 Chapter2 System Error Codes ENWW 02 1 YZ Cause Solution Encoder seems to be wrong Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Check that the Carriage Assembly stopper is correctly installed e Replace the Carriage Assembly gt See Carriage Assembly with or without Trailing Cable on page 244 e Ifthe System Error continues replace the Encoder Strip gt refer Encoder Strip with spring and attachment nut on page 231 and Encoder Sensor refer Encoder Disk and Encoder Sensor on page 308 02 2 YZ Cause Solution Problem with the Carriage PCA Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Check that the Trailing Cable is not damaged e Check that the Trailing Cable is correctly connected between the Main PCA and Carriage PCA e Replace the Carriage Assembly refer Carriage Assembly with or without Trailing Cable on page 244 e Ifthe System Error continues replace the Formatter refer Formatter on page 296 03 YZ Cause Solution Problem with Power Supply Unit Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Perform the Electronics Module Test Diagno
8. ESP Calibration on page 149 Troubleshooting Media Jams Printhead Crashes The failure modes media jam and head crash are grouped together because in many cases a media jam causes the media to lift up into the Carriage path and cause a Printhead crash thus causing many media jam failures to be reported as head crashes 1 Did the media jam occur when loading media e Ifthe client has had media jams it is common for pieces of media to get stuck in the media path Clear the media path E amp E NOTE When clearing a media jam sometimes media is stuck in the paper path To clear this you must lift the Media Lever and insert thicker media into the paper path to push out the media that is still stuck there 2 Is the customer using non HP media e The use of non HP media can easily be the cause of media jams and head crashes especially head crashes because HP media is specially formulated to avoid cockle one of the primary causes of head crashes If the media is not HP approved advise the customer to use HP media and check to see if the problem is now solved Chapter 1 Ink Supplies Troubleshooting amp Print Quality ENWW 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 Media Advance Roller does not correspond to the same conditions that the calibration
9. Ink Cartridge Levels Information and Replacement Ink Cartridge Levels The front panel displays Ink Levels shown as level bars These bars represent how much ink is remaining in the Ink Cartridges as ink is used up the bars get shorter in length There are two methods for checking the ink levels of your Ink Cartridges View Ink Levels Direct Access Key ENWW Pressing the View ink levels direct access key on the Front Panel will immediately show you the ink levels For more information about direct access keys refer Using the Front Panel on page 3 Im lc pK 1g mk R Ink levels Ink Cartridge Levels Information and Replacement 11 View Ink Levels from the ink menu e Choosing the View ink levels options from the Ink menu will immediately show you the ink levels Ink levels SEEEGE Im lc pK lg mK Obtaining Ink Cartridge Information 1 Scroll to the Ink Menu icon and press OK gt View ink levels Replace ink cartridges Replace printheads Ink cartridge information Printhead information 3 Inthe Ink cartridge information submenu scroll to the Ink Cartridge that you want information on and press OK Ink cartridge information iew M ink cartridge View Y ink cartridge View LM ink cartridge View LC ink cartridge View PEK ink cartridge View LG ink cartridge k View Me ink ecartridae bal 12 Chapter1 Ink Supplies Troubleshooting amp P
10. Spindle Removal E NOTE Switch off the printer and remove the power cable 1 Pull the left end of the Spindle viewed from the front of the printer out of the Left Spindle Holder 2 Lift the Spindle out of the printer towards the left viewed from the front of the printer ENWW Spindle 223 Left Spindle Holder Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Spindle refer to Spindle on page 223 2 Remove two I 15 screws that secure the Left Spindle Holder to the printer 3 Rotate the Left Spindle Holder towards the left 4 Remove the Left Spindle Holder from the printer Right Spindle Holder Removal 224 Chapter6 Removal and Installation ENWW E NOTE Switch off the printer and remove the power cable 1 Remove the Spindle refer to Spindle on page 223 2 Remove two T 15 screws that secure the Right Spindle Holder to the printer a 3 Rotate the Right Spindle Holder towards the right Se ___ 4 Remove the Right Spindle Holder from the printer Clean Out Assembly Removal EY NOTE Switch off the printer and remove the power cable 1 Remove the Spindle refer to Spindle on page 223 ENWW Clean Out Assembly 225 2 Disconnect the Out Of Paper Sensor in line connector and unroute its cable 3 Remove the four T 15 screws that secure Clean Out Assembly to the printer 4 Beginning with the left side slide the Clean Out As
11. The Main Board Revision Voltage test starts and the Front Panel displays the following messages e Starting DelSol1 e Getting PCA Revision e Checking Memory Size e Getting HDA Info e Getting File System Info e Getting MainBoard Rev The Front Panel then displays Main Board Voltage test results the value should always be between 0 and 3 3 and prompts you to press any key to continue Electronics Module MainBoard Revision voltage 0 696 Press any key to continue Press any key to continue The Main Memory Size test starts and the Front Panel displays the following messages e Starting DelSol1 e Getting PCA Revision e Checking Memory Size e Getting HDA Info e Getting File System Info e Getting MainBoard Rev e Getting Main Memory Size Service Tests Diagnostics 93 28 The Front Panel then displays Main Memory size test results and prompts you to press any key to continue Electronics Module Main memory size 128MB Press any key to continue 29 Press any key to continue 30 The Front Panel then prompts you to test the Formatter Communications Electronics Module Do you want to check the Formatter communications YES Press UP DOWN to chang and ENTER to select F 31 Press OK to the test the Formatter If you do not wish to test the Formatter use the Arrow keys to select NO and press OK 32 The Formatter Communications test starts and the front Panel displays
12. Reset life counters Diagnostic Print 2 The Printer will display the current time and the new time Use the UP and Down keys to go through the digits and press the OK key to go to the next digit You can press the Cancel key at any time to exit the utility without making any changes Set Date and Time Current Date Thu JUL 6 02 38 38 2006 New Date and Time settings 02 38 38 07 06 2006 Use UP DOWN to scroll BACK to move cursor ENTER to confirm or CANCEL to exit 3 Once the new time has been entered the Front Panel prompts you to confirm the new date and time Set Date and Time New Date and Time 13 06 27 01 17 2007 Press OK to confirm BACK to modify or CANCEL to exit 4 Press OK to confirm the new date and time PressBack to modify the new date and time Press Cancel to exit without changing the date and time 5 Once the new time has been entered the Front Panel will prompt you to shut down the printer If the current RTC Clock cannot be set it could be a possible Firmware error Make sure you have the latest version of the Firmware Set Date and Time Now the printer must be completely switched off Use the front power button Use the back switch if the printer does not shutdown automatically Please do it after exiting this utility 6 Restart the printer 7 Enable Disable Firewall The purpose of this Service Utility is to enable or disable the system firewall ENWW Entering
13. SO E E EE E EA 101 Ge COren O ESP ee R AE R 104 7 Ink Delivery System IDS cccccceeccceceeeeceeeeeeeeeeseeeeeeeeaeeeeeeseeeeeeesaaeeseeeas 106 OO IV ICS AMON eaa E E 110 D1 TIMOR ATION eain R REE 117 10 Umt NATO ATO sssi E Ea 117 11 EEROM CSC caeacecigas canny se cece scatetspneiatecissavcned spmcnegeaesecanchseeeueaimetes eet aaia 119 12 Set Unit Configuration Hc scccsosesisisivsasnevaceauvesaebes sane stsssennebendev ee onseasvecdexrerenees 120 TS Enor 7119 THROCOV CY sistant nrnnenstadsandentoaiaxanmnniionsiuaakebesnntondsnatacncdicchtuantannen 120 Se eeepc eine nen ieaie E 123 4 Service Menu Entering the Service Utilities Menu ccccceeccccceeeeeceeeseeeeeeeeaeeeceeeeeeeeceeeseeeeeeeeseeeeeeesaaaeseessaaaeeees 124 POGGIO aeiae a TEE E ss ormes tae set sanhotacmevbeace chicane E EEA E E 125 EE EE EEE TEE A E E EE E E E EE EE E EET 126 1 Turn Drive ROGI aecsssssisnn iE EEEE EEA E EEE 126 2 Purge VIO C Sic csteerecteassnensteeniac tecas naa ea eaS EEan EE era EE EESE O Neun EEEa esaii 128 F N E E E E E E 130 A RESELLERS prerie A E EEE A EOE 131 9 Diagnostic PIMI died Coreg cnesd apa cnecheatun ote denacaberunansu dears tance E aa ai E aei 132 6 SOLAS ING TIME cca tetemaiedictsosicaneiieisansnnsncnetlesguaninesisasieaninneisaticeusiceueysaticndeidadenetnepasnnenteodeedsanesaes 132 7 Enable Disable Firewall cciccsccscncvdaadencasaentwaaesenmastenensaleteeuiondaatonapteedesmoncwssineeddeteetdondsesve
14. Service Manual HP Designjet Z5200ps Photo Printer Version 1 May 2010 jp r HP Designjet Z5200ps GP Photo Printer Service Manual For HP Internal Use Only Copyright Hewlett Packard Company 2010 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 May 2010 Notices ENWW 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 Content Management Department Barcelona Division 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 e Ensure that the ac power outlet mains has a protective earth ground
15. You are recommended to remove the Ink Cartridge and then reinsert it You are recommended to replace the Ink Cartridge with a new Ink Cartridge There is something unexpected about the Ink Cartridge s status The Ink Cartridge has passed the expiration date Printhead status messages OK Missing Test printhead separately Reseat Replace Replacement incomplete Remove The Printhead is operating correctly and no action is required There is no Printhead present or it is not properly connected to the printer You are recommended to test the printheads individually to find the failing printhead Remove all the printheads and insert them alone one by one Closing the latch and the carriage cover after every insertion The front panel display will indicate the failing one showing the reseat or replace message You are recommended to start the printhead removal process from the front panel but instead of removing the printhead simply press the OK key on the front panel You are recommended to remove the printhead and then reinsert it if that fails clean the electrical connections if that fails replace the printhead with a new printhead A printhead replacement process has not completed successfully relaunch the replacement process and let it finish completely it is not needed to change the printheads The printhead is not a suitable type for use in printing for instance a setup printhead
16. and y to change the value Press m to confirm or to exit SNMP Language Write Access Printer localization CANNOT be changed remotely by SNMP Press and to change the value Press m to confirm or to exit 3 Use the Up and Down keys to choose the desired behavior and press OK to confirm your selection The system updates the internal memory to reflect the chosen selection SNMP Language Write Access Changing configuration 4 The Front Panel shows the test complete display until you press OK SNMP Language Write Access Diagnostic result OK Press w to continue 136 Chapter4 Service Menu ENWW 10 Borderless Cut Distance How borderless cutting functions The printer will always cut the roll of media twice once at the end of the last job and then again before the next job starts If the complete space of the media has been printed on full bleed a very small section will be cut in the 1st cut The second cut can be changed by using the setting Borderless Cut Distance The second cut can be set from 15mm to a maximum of 100mm default is 75mm 100 2nd Cut 75mm Tamm 1st Cur 1 Inthe Service Utilities submenu scroll to Borderless cut Distance and press OK Service utilities ST Uate an NS Enable Disable Firewall Enable Disable sleep mode e SNMP New Left Spittoon gt New PinchWheel Setting gt Borderless cut distance 2 Select the value in mm of the distance bef
17. 3 Unroute the two cables disconnected in step 2 from the two cable clamps below the PrintMech PCA 214 Chapter6 Removal and Installation ENWW 5 Disconnect connector from the Drop Detector Motor and Drop Detector Sensor 6 Unroute the cables disconnected in steps 4 and 5 from the two cable clamps a 4 i g3 pe we ee FR Va SSS T ENWW Service Station 215 8 Loosen the T 10 uncapping screw sufficiently so you can manually move the Carriage Assembly in step 9 n 9 Push the Carriage Assembly into the print path to gain access to two T 15 screws that secure the Service Station to the Carriage Rail 10 Use a allen key provided in the tool kit to remove two allen screws that secure the Service Station to the Carriage Rod E NOTE Support the Service Station so it does not fall when you remove the attachment screws 216 Chapter6 Removal and Installation ENWW 11 Unclip the clip to release the Service Station from the printer Sy Tea i A A we Ma 4 E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Drop Detector Removal ENWW Drop Detector 217 E NOTE Switch off the printer and remove the power cable 1 Remove the Right Cover refer Right Cover on page 185 2 Remove the Se
18. 7 a Haa SEX FTL Cite e BO Oisk Wipe 000 5220 220 2 The Front Panel tells you whether sleep mode is currently enabled or disabled Press OK to continue or Cancel to leave the sleep mode status unchanged Enabdle Disable Sleep Mode Sleep mode is enabled Do you want to disable it Press k to continue or to xit 3 The Front Panel displays the sleep mode status Press OK to return to the menu Enable Disable Sleep Mode Diagnostic result OK Sleep mode is disabled Press m to continue 9 SNMP Language Write Access ENWW The purpose of this utility is to prevent SNMP tools from changing the printer language remotely This is provided as a possible workaround to a rare issue that has been seen with some SNMP tools that set the printer language in order to control the localization applied to some SNMP OIDs but do not restore the printer language afterwards 1 Inthe Service Utilities submenu scroll to SNMP Language Write Access and press OK Service utilities FCMaVLEfUISaDlLe sleep Mude Disk Wipe DoD 5220 220M Hard Disk Recovery File System Check gt SNMP Language Write Access gt 1 0 Tests Show Hide Front Panel Info Entering the Service Utilities Menu 135 2 The utility checks whether the printer language can currently be changed using SNMP and shows one of the following messages SNMP Language Write Access Printer localization CAN be _ changed remotely by SNMP Press
19. To do this you will need Media Advance Drive Adjustment Tool from the HP Designjet Printer Tool KIt Q6683 67001 1 If you are in installing the Encoder Sensor after replacing the Media Advance Drive with a new unit first fully loosen the Encoder Sensor position adjustment screw Ignore this step if you are replacing the previously removed Media Advance Drive 2 Position the Media Advance Drive Adjustment Tool on the end Media Advance Roller shaft push it firmly onto the shaft and maintain a constant pressure to ensure it is flush to the Media Advance Drive 3 While still maintaining pressure on the Media Advance Drive Adjustment Tool fully tighten the Encoder Sensor position adjustment screw 4 Remove the Media Advance Drive Adjustment Tool 5 Complete the installation of the Encoder Sensor and a new Encoder Disk 310 Chapter 6 Removal and Installation ENWW Media Advance Drive Removal NOTE Switch off the printer and remove the power cable 1 Remove the Left Cover refer Left Cover on page 188 2 Remove the Electronics Module Main PCA and PSU refer Electronics Module Main PCA and PSU on page 298 3 Remove the Left Spittoon refer Left Spittoon on page 306 4 Remove the Encoder Disk and Encoder Sensor refer Encoder Disk and Encoder Sensor on page 308 5 Unroute the Media Advance Drive power cable p 6 Remove three T 15 screws that secure the Media Advance Drive to the print
20. To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Cutter Assembly Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Left Cover Finishing Panel refer to step 3 for the removal procedure of the Left Cover on page 188 ENWW Cutter Assembly 199 2 Fully loosen the cutter rail end cap attachment screw 3 Remove the cutter rail end cap 4 Slide the Cutter Assembly out of the printer E NOTE When you install the new Cutter Assembly follow the installation instructions provided with the new Cutter Assembly Right Rear Tray Support Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Rear Tray refer Rear Tray on page 194 2 Remove the Right Cover refer Right Cover on page 185 200 Chapter6 Removal and Installation ENWW 3 Remove the Left Cover refer Left Cover on page 188 4 Remove the Rear Cover refer Rear Cover on page 195 5 Remove two T 15 screws that secure the Right Rear Tray Support to the printer 6 7 T 4 l y i 4 7 Remove the Right Rear Tray Support from the printer i Left Rear Tray Support Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Rear Tray refer Rear Tray on page 194 2 Remove the Right Cover refer Right Cover on page 185 ENWW Left Rear Tray Support 201 3 Remo
21. e 2 Paper Drive on page 87 e 3 Electronics Module on page 90 e 4 Carriage Assembly on page 95 e 5 Sensors on page 101 e 6 Color Sensor ESP on page 104 e nk Delivery System IDS on page 106 o Ink Delivery System on page 106 o Check Ink Supplies on page 109 o Check Leakage on page 110 e 8 Service Station on page 110 e 9 I O Information on page 117 e 10 Unit Information on page 117 e 11 EEROM Reset on page 119 e 12 Set Unit Configuration on page 120 e 13 Error 71 19 Recovery on page 120 o Set Serial Number on page 120 o Select Right S N on page 122 ENWW 73 Introduction This chapter explains how to use the built in diagnostic menus and what to do if any of the Service Tests FAIL EY NOTE 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 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 refer to the chapter System Error Codes on page 46 Phone Support Ef NOTE Incertain 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 d
22. terminal e Disconnect the Printer from the power source prior to performing any maintenance e Prevent water or any other liquids from running onto electrical components or circuits or through Openings in the enclosure Electrostatic Discharge Refer to the beginning of Diagnostic Menu on page 73 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 iV Notices ENWW Using this Manual ENWW Purpose This Service Manual contains information necessary to test calibrate and service e HP Designjet Z5200 Photo Printer 44 inch Model CQ113A For information about using this product refer to the corresponding User and Quick Reference Guides Readership The procedures descri
23. 00 j 20 ee se ee eo 22 Carefully lift out the Ink Supply Tubes and close the carriage cover at the same time 248 Chapter6 Removal and Installation ENWW 24 Loosen the T 10 uncapping screw sufficiently so you can manually move the Carriage Assembly in step 26 25 26 ENWW Carriage Assembly with or without Trailing Cable 249 27 Remove the small cover of the Carriage PCA 28 29 250 Chapter6 Removal and Installation ENWW 30 Slide the Trailing Cables out of the attachment clips of the Carriage Assembly 31 32 Leave the Belt Tensioner in place with all the tension removed Ef NOTE The belt tensioner has a spacer between the tensioner and the right end plate Ee me fi j ty NOY bie ENWW Carriage Assembly with or without Trailing Cable 251 33 Remove the Belt Assembly from the Scan Axis Motor drive wheel ee 34 Remove the two T 15 screw that secure the Media Lever attachment plate 252 Chapter 6 Removal and Installation ENWW 36 Disconnect the Pinchwheel Lifter Sensor PE i E F a h sl Es Sa Ap byt ri ka S F aN k mi 7 a Ny r 4 i kets CNN 7 a Ns oe i Pi 2 a a i ENWW Carriage Assembly with or without Trailing Cable 253 39 Remove the Scan Side Panel 40 Carefully slide the Carriage Assembly and Belt Assembly out of the printer and the Trailing Cable i
24. 3 The area to check is the junction marked with of the black with the rest of colors The ThetaZ of the printhead are checked in the area marked as 4 It checks in forward and reverse direction The area to check Is the junction marked with The lines have to be continuous The arrows show the printing direction The area marked as number 5 is a reference legend that shows junction misalignments of 2 4 and 6 dots The junction to check has to be equal to or below 2 in all the cases If the error we appreciate is above 2 dots then realign the printheads again SSE SF KE KF KE SK KH KF HS SK HE HK HK SS 4 dots 0 dot 5 Error legend 1 1 I ts l dots i L L I i I I I Ue dieS AD Rer In the next example the Pen2Pen both Fwd and Rev is above these 2 dots and the unit should be realigned Same happens with the ThetaZ die2dieSAD The rest of the pattern shows a right alignment Pen Pen WA wr Pen Pen Re a 2 dots i 4 dots l M 6 dots H die2dieSAD Fwd i Error legend dots printing res 1 Bidir PAD die2dieSAD Rev x f 3 x x x X S gt launch Printhead Alignment Nozzle Health The print contains three separate parts 34 Chapter 1 Ink Supplies Troubleshooting amp Print Quality ENWW Ee al al ng a ANE E ENE ll meee R 1 The Variable Frequency Nozzle health plot with odd even nozzles separation This is used to detect misdirec
25. 89 23 The Front Panel prompts you to shutdown the printer to complete the test Media Drive Press any key to shutdown the system 24 Press any key to shutdown the printer 3 Electronics Module The Electronics Module test diagnoses Failures of the following components Main PCA components Electronics Module to Carriage interfacing Print Mech PCA components Power Supply Unit voltages Diagnostic tests also need to be performed after removing or replacing certain printer componenis If you have removed or replaced printer components check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform Refer to Service Calibration Guide to Removal and Installation on page 170 Perform the Electronics Module test as follows 1 In the Diagnostics menu scroll to2 Electronics Module and press OK Scan Axis Paper Drive 3 Electronics Module Carriage Assembly Sensors SUL The printer starts the Electronics Module test to verify the subsystem and prompts you to test the Power Supply Electronics Module Do you want to check the Power Supply YES Press UP DOWN to change and ENTER to select Press OK to the test the Power Supply If you do not wish to test the power supply use the Arrow keys to select NO and press OK 90 Chapter3 Diagnostic Menu ENWW ENWW 10 11 12 The Power supply test starts and the Front Panel di
26. Carriage PCA Covers Carriage Latch Carriage Cover includes Carriage Latch Carriage PCA Carriage Rear Bushing Line Sensor Color Sensor ESP Carriage Assembly includes Line Sensor Carriage Cover Carriage Latch Carriage PCA Carriage Rear Bushing and Color Sensor ESP Trailing Cable amp PCA Cover Page Carriage Cover includes Carriage Latch on page 272 Carriage Cover includes Carriage Latch on page 272 Carriage Cover includes Carriage Latch on page 272 Carriage PCA on page 276 Carriage Rear Bushing on page 254 Line Sensor on page 267 Carriage Assembly with or without Trailing Cable on page 244 Carriage Assembly Color Sensor ESP on page 262 159 Scan Axis Assemblies Reference on Figure HP Part Number Part Description Page 1 Q6677 60007 Ink Supply Tubes Ink Supply Tubes on page 288 2 Q6677 60024 Encoder Strip including Encoder Strip with spring and Encoder Strip Spring and Nut attachment nut on page 231 3 LQ113 67014 Trailing Cable 4 CH538 67018 Belt with tensioner Belt Assembly on page 256 160 Chapter5 Parts and Diagrams ENWW Paper Path Assemblies Front Reference on Figure HP Part Number Part Description Page 1 Q6659 67016 Starwheel with Actuator Starwheel Assembly on page 301 2 Q6718 67006 Overdrive Print Zone Overdrive on page 302 3 Q5669 67054 Starwheel Support Left Starwheel Lifter on page 320 Assembly 4 Q5669 60713 Cutter Assembly Cutte
27. Cover Reference on Figure HP Part Number Part Description Page 1 CQ113 67005 Right Cover Right Cover on page 185 2 Q6675 60109 Integrated front Trim Right Front Trim on page 179 3 CQ113 67015 Right Ink Cartridge Door Right Ink Cartridge Door on page 182 ENWW Right Cover 155 Left Cover Reference on Figure HP Part Number Part Description Page 1 CQ113 67006 Left Ink Cartridge Door Left Ink Cartridge Door on page 183 2 Q6675 60109 Left Front Trim Right Front Trim Left Front Trim Right not shown on page 181 3 CQ113 67007 Left Side Panel Left Cover on page 188 4 CQ113 67004 Left Cover Left Cover on page 188 Aa Ih ATI Ml Hi un E ii ull ji T Seu a Ti 156 Chapter5 Parts and Diagrams ENWW Right Hand Assemblies ENWW Referen ce 1 HP Part Number Q6675 60043 Q5669 60677 CH538 60141 Q6675 60018 Q5669 60667 Q5669 60664 Q6718 67025 Q5669 60666 Q6675 60020 Part Description Carriage Rail Oiler Pen to Paper Space PPS Solenoid Scan Axis Motor PrintMech PCA Service Station Spittoon Aerosol Fan Assembly Service Station Includes Drop Detector Aerosol Fan Assembly Primer Assembly and Service Station Spittoon Drop Detector Right Ink Supply Station Page Carriage Rail Oiler on page 260 Pen to Paper Space PPS Solenoid on page 221 Scan Axis Motor on page 257 PrintMech PCA on page 220 Service Station on page 214 Aerosol Fan Assem
28. ENWW If the Alignment fails again check the Alignment pattern to see if any of the Printheads are printing incorrectly If necessary perform a Printhead Recovery through the Front Panel and retry the Printhead Alignment Line Sensor Calibration Carriage PCA The purpose of this Service Calibration is to reset the ink short thresholds after replacing the Carriage PCA This calibration is integrated into the Scan Axis diagnostic test See 4 Carriage Assembly on page 95 Perform the Carriage Setup as follows 1 In the Service Calibrations submenu scroll to Carriage PCA and press OK Service calibrations DCdil AXIS Cal IDPa lL TUT gt Service Station gt Paper advance calibration gt Drop Detector calibration gt Line Sensor calibration gt Carriage PCA gt SOL calibration To calibrate the Carriage PCA run the Carriage Assembly diagnostic test See 4 Carriage Assembly on page 95 Carriage PCA Calibration Please go to the Diagnostics Carriage Assembly Press OK to exit Color Sensor ESP Calibration The purpose of this Service Calibration is to calibrate the Color Sensor Color Sensor ESP ENWW Service calibrations also need to be performed after removing or replacing certain printer components If you have removed or replaced printer components check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform Refer to Service Calibrat
29. Electronics Module on page 90 Ink Supplies Troubleshooting amp Print Quality ENWW What to do if the Front Panel is blank The LEDs of the formatter visible through the cover and the power supply can help you troubleshoot a problem when the Front Panel is blank ENWW 1 The following image shows the Power Supply LED looking through the cover Tr ere 7 P em 2 2 2 6 o Ce ee o o E nin a The following image shows the Formatter LEDs which are marked I II and III Use the following table to interpret the LEDs and find the source of the problem Remember that you should read these LEDs when you push the Power button Some combinations may require the replacement of two or more components In this case always replace one component at a time Test the printer to see if the problem has disappeared check the LEDs again If the same LED sequence continues replace the next component indicated in the table Power Formatter Formatter Formatter Front Panel Solution part replacement Supply LED LED 1 LED 2 LED 3 Status Off Off Off Off Off Power Electronics Module Main PCA and PSU on page 298 On Off Off Off Off Main PCA Electronics Module Main PCA and PSU on page 298 On On Off N A N A Formatter Formatter on page 296 On On Off Off N A Hard Disk Hard Disk Drive on page 297 Flashing On On On flashing Off N A Hard Disk Hard Disk Drive on page 297 On On On Off N A 1 Formatter
30. Formatter on page 296 2 Main PCA Electronics Module Main PCA and PSU on page 298 On On On On flashing N A Main PCA Electronics Module Main PCA and PSU on page 298 What to do if the Front Panel is blank 5 6 8 On On On On Front Panel 1 Front Panel Front Panel Light on on page 203 2 Formatter Formatter on page 296 3 Main PCA Electronics Module Main PCA and PSU on page 298 4 Front Panel Cable Front Panel on page 203 9 On On On On Off Front Panel Front Panel on page 203 Cover Sensors are not Working 1 Perform the Sensors Test Refer 5 Sensors on page 101 2 Check if the cable for the faulty sensor is not damaged and is connected correctly 3 Replace the faulty 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 The Line Sensor is not calibrated correctly Perform the Line Sensor Calibration Refer Line Sensor Calibration on page 146 3 The Line Sensor is damaged or faulty Replace the Line Sensor Line Sensor on page 267 Problems with Color Accuracy The Color Sensor ESP is a powerful tool unique to the Z series printers to maintain color accuracy If you notice any problems with colors perform the Color Sensor ESP calibration Refer to Color Sensor
31. Front Panel Press the OK key to reset the selected Life Counter or press Back Cancel to exit without resetting the Life Counter Scan Axis Tubes Usage Tubes O Distance Covered 0 Trailing cable O Reset these life counters Press ENTER to accept or BACK CANCEL to exit If the Usage Counter information cannot be read the Front Panel will display Unable to get usage counter This could be a possible Firmware error In this case make sure you have the latest version of the Firmware 4 Ifthe utility exits correctly OK will be displayed on the Front Panel 5 Diagnostic Print The purpose of this Service Utility is to print the Diagnostic Print in order to identify Print Quality problems Information regarding the Diagnostic Print is located in the following sections The procedure to make a Diagnostic Print can be found at Printing the Diagnostic Print on page 24 The procedure to make an Advanced Diagnostic Print can be found at The Advanced Diagnostic Prints on page 29 Additional print quality information such as troubleshooting and corrective measures can be found at Print Quality on page 23 6 Set Date and Time The purpose of this Service Utility is to set the internal clock of the Printer 132 Chapter 4 Service Menu ENWW Perform the Set Date and Time utility as follows 1 Inthe Service Utilities submenu scroll to Set Date and Time and press OK Service utilities gt Turn Drive Roller
32. Print Quality Problems Introduction This chapter will guide you through the relevant steps to take when troubleshooting the printer Troubleshooting System Error Codes Chapter 2 System Error Codes on page 46 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 If you have an error code which is not documented in this Service Manual or you have an error which you cannot resolve then report the error to the HP Response Center or the nearest HP Support Office When reporting the error have the following information ready e Model and Serial Number of the printer e Which firmware revision the printer is using See Note below Check firmware in Utilities Statistics Code rev e The complete error number See Note below e The Service Configuration Print e The Current configuration sheet e Which software application the customer is using name version etc E NOTE When reporting the System Error Code make sure that you supply the full Error Code and the firmware version Without this information HP Support Personnel cannot help you 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 E NOTE Ifthe test on that componen
33. Prints in the previous step use the Arrow keys to make the required selection Paper Advance Visual Alignment Diagnostic Nozzle Health Force Drop Detection or Print Banding Plot and press the Enter key to start printing gt Paper Advance gt Visual Alignment Diagnostic gt Nozzle Health gt Force Drop Detection gt Print Banding Plot 4 Make sure media is loaded the Media Lever is lowered and that the Ink System is correctly installed Press the OK key to print the Diagnostic Print or press Back Cancel to exit without printing the Diagnostic Print Image Quality Service Normal Check that media is loaded pinch lever is closed and ink is ready Proceed Press ENTER to accept or BACK CANCEL to exit 5 The selected Diagnostic Print will now be printed Reading the Diagnostic Print Results Diagnostic Part 1 Printhead Reliability The Nozzle Print Test is designed to check if the Printhead nozzles print correctly The nozzles bottom of the plot are printed in a one pass full swath mode The diagnostics test prints out every single nozzle of each Printhead without applying an error hiding or alignment algorithm For each Printhead you can see both the adjacent and the consecutive nozzles ENWW Reading the Diagnostic Print Results 25 If any nozzles are not printing correctly they will be shown on the right of each Printhead Nozzle test There is a series of numbered stepped diagonal lines If one or more
34. Scan Axis submenu scroll to Cutter and press OK to start the test The Printer will start the Scan Axis subsystem Common Initialization and Cutter test initialization If there is a Failure at any point during the tests the Front Panel will display the relevant System Error Code To trouble shoot any displayed error codes refer System Error Codes Full Descriptions on page 50 The printer then starts the Cutter test to verify the subsystem As the test executes the Front Panel displays the following messages e Starting Horsburgh e Starting TestsGPIO e Starting Nvm Motor e Getting Part Number e Starting SvsMotor e Starting CarriageMotor e Starting ServiceStation e Moving SVS to rear bump e Homing Scan Axis e Move Carriage out of SVS e Homing Service Station e Starting ServicingServices e Capping Service Station e Uncapping Service Station Service Tests Diagnostics 85 5 The Front Panel prompts you to load roll media raise the pinch Load the paper roll and Lower the pinch lever Press any key to proceed Mt 6 Raise the Media Lever load roll media lower the Media Lever and press any key to continue 7 The printer then starts an actual test cut of the media As the test executes the Front Panel displays the following messages e Advance paper e Engaging cutter e Cutting paper e Disengaging cutter 8 Once the test has completed the Front Panel displays the test re
35. Service Tests Diagnostics 83 23 The Front Panel displays the PWM check results PWM Average got Fw Bw 11750 036 11518 189 PaM min diff Limit 4 PWM min diff got Fw Bw 11004 00 11246 00 Press any key to finish 24 Press any key finish 25 The printer then continues the Scan Axis test As the test executes the Front Panel displays the following messages e Moving PRS to High Position 26 The Front Panel displays the PRS position check results Scan Axis PRS Position HIGH Press any key to finish 27 Press any key finish 28 The Front Panel shows the test complete display for a few seconds Scan Axis 29 The Front Panel prompts you to shutdown the printer to complete the test Scan Axis Press any key to shutdown the system 30 Press any key to shutdown the printer Cutter test The Cutter is designed to cut roll media after printing for the size of sheet defined Before executing this test you should run the Scan Axis Media Drive and Carriage tests to ensure that each of these subsystems is operating correctly 84 Chapter3 Diagnostic Menu ENWW ENWW Perform the Scan Axis Cutter test as follows 1 In the Diagnostics menu scroll to1 Scan Axis and press OK Paper Drive Electronics Module Carriage Assembly sensors SOL The Front Panel will show the1 Scan Axis submenu Star Wheel Lifter b PRS gt Scan Axis gt Cutter In the
36. Should You Replace the Ink Supplies ee ccceeececeseeeeeeeeeeeeaeeeeeeseaeeesseaeeeesaaes 11 Ink Cartridge Levels Information and Replacement cccccccccsesceceeceeseeeeseeceeeeeeeseueessneeeseeeesaaees 11 INK Cartridge Levels ccccccccccecccecceeseceeeeceeseceeeeeeeseeeeesseesceeeeseseaseeeesseeaeeeeesseaseeeesssageeeees 11 Obtaining Ink Cartridge Information cccccceeeseceecaeeeeeeeeeeeeceeeeseeeeeeeeseueeseeeeeseaeeeeessaaaes 12 Changing an Ink Cartridge ccccccccccsssecececceeeeeeeeeeseeeceeeseseeeeeeeeasaeseeeeesseueeeesseeaeseeessaaaes 13 Printhead Information Replacement and Alignment ccccseccceeceeseeeeeeeeeeeseeeseeseeeeeeeeaaeeeeesaeeeessaees 15 Obtaining Printhead Information cccccccccccecsssseeeeceeeeeeeceeceeeeeeeeeeesseeeeeeeeseeeeeeesssaeeseeeeeaas 15 Changing a Printhead 5 lt doscccdocsescats crcecacnnesleciextachedelanedugonodeleeautwccnaaceheene aa iaai aa 16 AllgNiNO FP AIS AGS erensia E E E 18 Ink Cartridge and Printhead Status Messages cccecccceceaseeeeeeeseeeeceeeseeeeeeeeesseeseeeeeesseaeeeeesaseeeeees 20 Ink Cartridge Status Messages ccccccseeeecceceeeeeeeceeeeeeeeeceeseaseeeceeeesseeseeeessssaaseeeeessageeeeees 20 ENWW vii vill Printhead Status messages narda cae au laa ain cee ene 20 SOWING Nk SUPPISS Proble MS ica xiacetedc sas enaces ds pasate tose ag hes T adacanane ac basausaniameendce 21 You Cannot Insert the In
37. Standard Tool Requirements Description Comments Long Torx Screwdriver Torx Bit 75 mm Phillips Screwdriver Pliers Snips Pipe Spanner Flat Bladed Screwdriver Size 1 4 inch drive N A N A 5 5mm N A Service Calibration Guide to Removal and Installation Using the Service Calibration Guide When you remove most printer components you will need to perform a particular set of Service Calibrations and Diagnostic tests to ensure proper printer performance The Service Calibration Matrix shows which service calibrations and diagnostic tests need to be performed whenever you remove and install particular printer components left most column The calibrations must be performed in the order they are shown in the row Start by locating the component you have removed and installed in the left most column 170 Chapter6 Removal and Installation ENWW EY NOTE Even if you do not replace the removed component with a new component you still need to perform the calibrations indicated by the matrix The Service Calibration Matrix Service Calibration or Test Perform in the order shown Service Station 8 Service Station test Drop Detector Calibration Aerosol Fan 8 Service Station test Drop Detector Calibration Assembly Drop Detector 8 Service Station test Drop Detector Calibration Service Station 8 Service Station test Drop Detector Calibration Spittoon Primer Assembly 8 Service Station test Drop
38. Starting ColorSensor The Front Panel displays the I O Information 16 235 118 24 16 23 112 1 255 255 246 0 Fress any key to finish Press any key to finish The Front Panel shows the test complete display for a few seconds I0 Information The Front Panel prompts you to shutdown the printer to complete the test IO Information Press any key to shutdown the system Press any key to shutdown the printer 10 Unit Information 1 ENWW The Unit Info test recovers the Firmware Version Serial Number and Part Number of the printer Service Tests Diagnostics 117 2 Inthe Diagnostics menu scroll to 10 Unit Information and press OK Diagnostics menu gt 4 Cartilage ASselpLy Sensors SOL IDS Service Station IZO Information a Unit Information 3 The Unit Information test starts and the front Panel displays the following message e Starting Horsburgh e Starting Nvm e Getting FW version e Getting Serial e Getting Part Number 4 The Front Panel shows the result of the test FW version TR8_1 0 0 4 Serial Number MY6761C001 Part Number 066754 Press any key to finish 5 Press any key to continue 6 The Front Panel shows the test complete display for a few seconds Unit Information 7 The Front Panel prompts you to shutdown the printer to complete the test Unit Information Press any key to shutdown the system 8 Press any key to shutdown the
39. Try the following failed e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Check that the cables between the Right Ink Supply Station and PrintMech PCA the are not damaged and are correctly connected e Try purging the Ink Supply Tubes again once the Printer has been restarted e Install new Cartridges in the printer and try purging the Ink Supply Tubes again 26 n YZ color n Cause Solution Order of Ink Supplies incorrect Try the following e Remove the Ink Supply Cartridges and check that they are the correct ones for this printer and are in the proper order e Check that the Printer has the latest firmware If not update the firmware to the latest version 56 Chapter2 System Error Codes ENWW 27 YZ Cause Solution An error has occurred in Printhead detection Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Remove the Printheads from the Carriage Assembly and reinsert them e Replace the Printheads e Replace the Carriage Cover Flex Circuit gt refer Carriage Cover includes Carriage Latch on page 272 e Replace the Carriage PCA 5 refer Carriage PCA on page 276 e Replace the Formatter refer Formatter on page 296 29 n YZ Cause Solution An error has occurred in P
40. and Installation Chapter of this Service Manual as a guide to replace the necessary parts Preventive Maintenance Kits Preventive Maintenance Kit 1 The Preventive Maintenance Kit 1 is available using the following part number CQ113 67009 and contains the following parts P N CQ113 67009 Part Number Description CQ113 67010 Carriage Assy SV CQ113 67014 Trailing Cable 44 SV Q6677 60007 Ink Supply Tubes 44 SV CH538 67018 Belt CH538 60141 Scan Axis Motor Q5669 60692 Lubrication Kit SV 330 Chapter 7 Preventive Maintenance ENWW Preventive Maintenance Kit 2 The Preventive Maintenance Kit 2 is available using the following part number Q6675 67012 and contains the following parts Part Number Description Q6718 67025 Service Station SV Q5669 67049 Left spittoon SV ENWW Preventive Maintenance Kits 331 8 Printer menu Map The following pages show the Menu Map print which is available through the front panel Internal Printsr gt User Information Prints gt Print menu Map These menus can be used for guiding the customer through the menu system when troubleshooting a printer issue remotely Figure 8 1 Paper Menu Paper Paper Load Unload p p r ler Load roll Load sheet View loaded paper Change loaded paper type lt category gt for each paper Paper types list jH lt category gt for each paper lt name gt foreach paper Move paper View paper details Figure 8 2 Job Ma
41. clean the encoder strip Dampen the cloth and remove any excess water so that the cloth is damp but not wet 3 Open the window 234 Chapter6 Removal and Installation ENWW 4 Hold the cloth in an inverted U shape around the encoder strip and carefully wipe until no ink residue appears on the cloth Be very careful not to scratch the encoder strip with your fingernail or any other object 5 Do not hold the cloth as shown 6 Hold the cloth as shown in the appropriate U shape 7 Donot move the carriage assembly away from the service station ENWW Clean Encoder Strip Procedure 235 8 Close the window Encoder Strip Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Right Cover refer Right Cover on page 185 2 Remove the Left Cover refer Left Cover on page 188 3 Remove the Encoder Strip with spring and attachment nut refer Encoder Strip with spring and attachment nut on page 231 4 Use the spanner provided in the tool kit to remove the 13 mm locking nut that secures the Encoder Strip to the Encoder Strip Spring 236 Chapter6 Removal and Installation ENWW 5 Remove the Encoder Strip Spring E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Trailing Cable Remova
42. colors then it is more than likely a Printhead problem In this case try the following 1 Check that the appropriate print quality settings are being used refer to the User s Guide for more information 2 Recover the printheads using the option through the Front Panel Main Menu Image Quality Maintenance Clean Printheads Reprint the Diagnostic Print or the print file and if the problem persists replace the faulty Printhead 28 Chapter 1 Ink Supplies Troubleshooting amp Print Quality ENWW If banding does occur in ALL the colors then it is more than likely a Paper Advance problem e Ifthe bands are light it means that the paper has advanced too much e Ifthe bands are dark it means that the paper hasn t advanced enough e n high quality modes graininess in ALL colors can indicate problems either with alignment or Paper Advance Corrective Action In order to solve problems that result in banding try the following 1 Check that the appropriate print quality settings are being used refer to the User s Guide for more information Check that the loaded media is the same type as selected in the printer You can verify the media type selected through the Front Panel Main Menu Paper menu View loaded paper If the customer is using low quality paper try recommending better quality paper preferably HP paper Printer performance can only be guaranteed by using recommended papers Perform the Paper Advance Cal
43. components If you have removed or replaced printer components check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform Refer to Service Calibration Guide to Removal and Installation on page 170 Perform the Line Sensor Calibration as follows E NOTE Make sure you load one of the following media into the Printer before performing this calibration e HP Bond Paper e HP Glossy Media e HP Coated Paper e HP Productivity Photo Gloss e HP Heavyweight Coated Paper e HP Super Heavyweight Coated Paper e HP Bright White Inkjet Paper 1 Inthe Service Calibrations submenu scroll to Line Sensor Calibration and press OK Service calibrations re Scan AX15 calibration Service Station gt Paper advance calibration Drop Detector calibration Line Sensor calibration 146 Chapter4 Service Menu ENWW 2 When the following message appears on the front panel you must select whether you would like to continue with the calibration by pressing the OK key Press Back or Cancel to exit the calibration Lin Sensor Calibration Press ENTER to proceed with Line Sensor calibration or BACK CANCEL to exit 3 If media is not loaded the following message appears on the front panel Load media in to the Printer and start again from step 1 Line Sensor Calibration Before continuing the Printer will check the following e The Media Lever is in the lower
44. disconnect the Power cord Check the Primer Tubes Reconnect the power cord and power On the Printer e Perform the Service Station diagnostic test to troubleshoot the problem further 8 Service Station on page 110 e Ifthe System Error continues replace the Service Station refer Service Station on page 214 e Ifthe System Error continues replace the PrintMech PCA refer PrintWech PCA on page 220 54 Chapter2 System Error Codes ENWW ENWW 22 0 YZ Cause Solution ISS Left BPSO error Supplies 0 1 2 Module 0 left Try the following 22 0 e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer module 0 module 1 module 2 e Check that the cables between the Left Ink Supply Station and Main PCA the are not damaged and are correctly connected e Perform the Ink Delivery System diagnostic test to troubleshoot the problem further 7 Ink Delivery system IDS on page 106 e Ifthe System Error continues replace the Left Ink Supply Station refer Left Ink Supply Station on page 284 e Ifthe System Error continues replace the Main PCA refer Electronics Module Main PCA and PSU on page 298 22 1 YZ Cause Solution ISS Left BPS1 error Supplies 3 4 5 Module1 middle right Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the pow
45. display the relevant System Error Code To trouble shoot any displayed error codes refer System Error Codes Full Descriptions on page 50 The printer then starts the PRS test to verify the subsystem As the test executes the Front Panel displays the following messages e Starting Horsburgh e Starting Tests PWM e Starting Tests GPIO e Booting up the Carriage e Starting SVS Motor e Starting Carriage Motor e Starting PosMotor e Starting Service Station e Starting Scan Axis e Moving SVS out of Scan e Homing Scan Axis e Move Carriage out of SVS e Homing SVS e Starting Servicing Services e Reading PRS Position e Moving PRS position to HIGH position Service Tests Diagnostics 79 If there is a Failure at any point during the test the Front Panel will display the relevant System Error Code To trouble shoot any displayed error codes refer System Error Codes on page 46 5 Once the test has completed the Front Panel displays the test result PRS seems to be OK Did the PRS move Press OK to accept or BACK CANCEL to reject PRS subsystem OK Press any key to finish 6 Press any key finish 7 The Front Panel shows the test complete display for a few seconds Press any key to shutdown the system 9 Press any key to shutdown the printer Scan Axis Test The Scan Axis subsystem is designed to move the carriage assembly between two predetermined horizontal positions with res
46. drive the printer displays a System Error and will not start successfully 5 Replace all screws that you removed earlier Electronics Module Main PCA and PSU Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Left Cover refer Left Cover on page 188 2 Disconnect all the connectors on the Electronics Module 298 Chapter6 Removal and Installation ENWW 3 Unroute all the cables disconnected in the previous step ll _ iz P a ge ee 7 Fp A by ile ig g Fy F a F k 4 Remove two T 15 screws that secure the Electronics Module to the Printer 5 Remove one T 15 screw that secures the Electronics Module to the Printer ENWW Electronics Module Main PCA and PSU 299 6 Remove one I 15 screw that secures the Electronics Module to the Printer T 8 Remove one T 15 screw that secures the Electronics Module to the printer 300 Chapter6 Removal and Installation ENWW 9 Carefully lift the Electronics Module out of the printer E NOTE When you install the Electronics Module make sure it is correctly aligned with the mounting rail E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Starwheel Assembly Removal E NOTE Switch off the printer and remove the power ca
47. each Setup Printhead does NOT contain ink then you may need to repeat the Prime Tubes process from the beginning Lift printhead cover Remove full setup printheads Remove ALL the Setup Printheads from the Carriage and install the previously removed Printheads Entering the Service Utilities Menu 129 12 Once ALL the Printheads are installed the Front Panel will instruct you to close the Carriage cover and close the Window Close printhead cover and window 13 The Printer will now perform the Printhead Alignment and Front Panel will prompt you to continue with the Printhead Alignment select Align now and press the OK key 14 Once the Printhead Alignment is completed the following message will be displayed on the Front Panel Press the OK key to continue Calibration successfully completed Press to continue 3 Set SN The purpose of this Service Utility is to set the Serial Number of the Printer Perform the Set SN utility as follows 1 Inthe Service Utilities submenu scroll to Set SN and press OK Service utilities gt Turn Orive Roller gt Purge Tubes Reset life counters Diagnostic Print Set Date and Time 2 The Printer will display the current Serial Number and the new Serial Number of the Printer Use the Up and Down keys to go through the digits and press the OK key to go to the next digit You can press the Cancel key at any time to exit the utility without making any changes
48. following messages Starting Horsburgh Booting up Carriage Starting SVS Motor Starting Nvm Getting Part Number Starting Service Station Starting Scan Axis Moving SVS out of Sax Homing Scan Axis Moving Carriage out of SVS Homing Service Station Moving to Spit Rear pos Moving to Spit Front pos Moving to Wipe forward pos Moving to Wipe reverse pos Moving to Cleaner pos Moving to Color Sensor ESP pos Service Tests Diagnostics 111 e Homing Scan Axis e Starting ServicingServices e Capping Service Station e Uncapping Service Station e Starting Mechanical Init 5 The Front Panel then prompts you to check the status of the printer Service Station Please check Window Closed Pinchwheel Lowered All Pens Inserted Valid Cartridges Inserted Press any key to continue 6 Check that e The Window is closed e The Media Lever is lowered e All Printheads are inserted e Valid Cartridges are inserted 7 Press OK to continue 8 The Front Panel then displays test results Service Station Moving SVS to wiping bidir Service Station OK Press any key to finish 9 Press any key to finish the test 10 The Front Panel shows the test complete display for a few seconds Service Station 112 Chapter 3 Diagnostic Menu ENWW 11 The Front Panel prompts you to shutdown the printer to complete the test Service Station Press any key to shutdown the system 12 Pre
49. neutral Consider printing in grayscale color options submenu inside the printing preference menu See the Usefs Guide for more information Horizontal lines at the end of a cut sheet print There is a type of defect that only affects the end of a print within approximately 30 mm of the trailing edge of the paper Some very thin horizontal lines may be seen across the print Corrective Action 1 Print the Service Image Diagnostics Print and clean any printheads that need cleaning Reprint the job in case the problem has been solved 2 Try printing with roll paper 3 Try using larger margins around the image Vertical lines of different colors The print has vertical bands of different colors along it Corrective Action 1 Try using a heavier paper type When printing dense colors it is recommended to use HP Heavyweight Coated Paper HP Super Heavyweight Coated Paper or thicker Digital Fine Art papers 2 Use higher print quality settings refer to the User s Guide for more information White spots on the print White spots are seen on the print This is probably due to paper fibers dust or loose coating material Corrective Action 1 Clean the paper manually with a brush before printing to remove any loose fibers or particles 2 Always keep the cover of the printer closed 3 Protect paper rolls and sheets by storing them in bags or boxes Problems with Color Accuracy ENWW Troubleshooting Print Quality Problem
50. of the nozzles are clogged malfunctioning or mispositioned you will see that the stepped lines are broken or misdirected in one or more places Below the stepped lines highlighted in yellow are broken When the line is completely broken this means the nozzle is out Below the stepped lines highlighted in yellow are misdirected When the line is misdirected this means the nozzle is malfunctioning or out of position On the left of each Printhead Nozzle test there is a series of horizontal straight lines If one or more nozzles are misdirected there will be unequal spaces between the corresponding lines Corrective Action If the printer has nozzle defects you can still get perfect print quality results The printer can automatically compensate for nozzle defects so there is no need to replace the Printhead The method of improving Nozzle Defects is to 1 Recover the Printheads using the Front Panel Main Menu Image Quality Maintenance Clean Printheads option 2 Reprint the Printhead Nozzles Test Plot to verify that the defective nozzles have been corrected 3 Ifthe problem continues replace the defective Printhead Diagnostic Part 2 Printhead Alignment This test is designed to check any color to color and bi directional misalignment the printer may have 26 Chapter 1 Ink Supplies Troubleshooting amp Print Quality ENWW 1 Ifthe Printer is experiencing horizontal misalignment problems the Alignment Test wil
51. page 174 Remove the Right Cover refer Right Cover on page 185 Remove the Left Cover refer Left Cover on page 188 Remove the Rear Tray refer Rear Tray on page 194 Remove the Rear Cover referRear Cover on page 195 Remove the Front Panel refer Front Panel on page 203 ey Se P N Remove the four T 15 top screws that secure the Top Cover to the printer ENWW Top Cover 205 8 Remove the front T 15 screw that secures the front left side of the Top Cover to the printer 9 Carefully pull the attachment clip forward until you can lift the bottom left corner of the Top Cover approximately 10 mm 10 206 Chapter6 Removal and Installation ENWW 11 Carefully pull the attachment clip forward until you can lift the bottom left corner of the Top Cover approximately 10 mm 13 Unroute the Front Panel ribbon cable from the two cable clamps on the bottom surface of the Top Cover ENWW Top Cover 207 14 Lift the Top Cover off the printer E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Window Position Sensor Removal E NOTE Switch off the printer and remove the power cable 1 2 3 4 5 Remove the Right Cover refer Right Cover on page 185 Remove the Left Cover refer to Left Cover on page
52. printer 118 Chapter 3 Diagnostic Menu ENWW 11 EEROM Reset The EEROM Reset test resets the printer to the factory defaults and delete any user information files ENWW 1 In the Diagnostics menu scroll to 11 EEROM and press OK SEMSUrS OO SOL 47 IDS Service Station 140 Information ry 10 Unit Information EEROM Reset The EEROM Reset test starts and the front Panel prompts you to request if you want to continue EEROM Reset All user information files Will be removed Proceed YES Press UP DOWN to change and ENTER to select vv If you do want to continue the test use the Arrow keys to select YES and press OK If you do NOT want to continue select NO and press OK The EEROM Reset test continues and the front Panel displays the following message e Starting Horsburgh e Starting Nvm e Getting Part Number e Setting default config The Front Panel shows the result of the test EEROM Reset Press any key to shutdown the system Press any key to continue The Front Panel warns you that you will have to calibrate the printheads after rebooting the printer EEROM Reset Press any key to shutdown the system Press any key to continue Service Tests Diagnostics 119 10 11 The Front Panel shows the test complete display for a few seconds EEROM Reset The Front Panel prompts you to shutdown the printer to complete the test EEROM Reset Press any key t
53. printer and remove the power cable 1 Remove the Rear Tray refer Rear Tray on page 194 2 Remove the Right Cover refer Right Cover on page 185 3 Remove the Left Cover refer Left Cover on page 188 4 Remove ten T 15 screws that secure the Rear Cover to the printer 5 Remove the Rear Cover from the printer ENWW Rear Cover 195 Media Lever Removal E NOTE Switch off the printer and remove the power cable 1 Open the Ink Cartridge Door 2 Press the clip to release the Left Cover Finishing Panel 3 Remove the Left Cover Finishing Panel 196 Chapter6 Removal and Installation ENWW 4 Unclip the spring from the attachment points on the Media Lever and Left Cover 5 Remove three T 15 screws that secure the Media Lever 6 Lift the Media Lever of the mounting ENWW Media Lever 197 7 Remove the Media Lever from the printer Media Lever Position Sensor Removal E NOTE Switch off the printer and remove the power cable 1 Raise the Media Lever 2 Remove the Left Cover refer Left Cover on page 188 3 Disconnect the Media Lever Position Sensor 4 198 Chapter6 Removal and Installation ENWW 5 Rotate the Media Lever Position Sensor vertically to disengage the attachment lug from the Scan Side Panel 6 Remove the Media Lever Position Sensor E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations
54. the Service Utilities Menu 133 Perform the Enable Disable Firewall utility as follows 1 In the Service Utilities submenu scroll to Enable Disable Firewall and press OK Service utilities L UID UI rve ULLGCI Purge Tubes Set SN H Reset life counters 4 Diagnostic Print Set Date and Time gt Enable Disable Firewall The utility checks to see if the firewall is enabled or disabled and the Front panel displays the following message e Getting Information of Firewall When the following message appears on the front panel you must select whether you would like to enable or disable the firewall Use the UP and Down keys to make your selection and press the OK key Enable Disable Firewall The Firewall is enabled Do you want to disable the Press UP DOWN to change and ENTER to select The system upgrades the internal memory to reflect the chosen selection Enable Disable Firewall Setting Firewall The Front Panel shows the test complete display for a few seconds Enable Disable Firewall 8 Enable Disable Sleep Mode The purpose of this Service Utility is to enable or disable the system sleep mode of the printer 134 Chapter 4 Service Menu ENWW Configure the Enable Disable Sleep mode utility as follows 1 Inthe Service Utilities submenu scroll to Enable Disable Sleep Mode and press OK Service utilities B Diagnostic Print Set OSte and Time b Enatle Oisable Firewall Ff
55. the problem persists after using valid paper cleaning the printheads and keeping the window closed there may be a Failure in the scanning system needing reparation or the printheads although clean may not work and need to be replaced Printhead Information Replacement and Alignment 19 Ink Cartridge and Printhead Status Messages Ink Cartridge Status Messages OK Missing Low Very Low Empty Reseat Replace Altered Expired The Ink Cartridge is operating correctly and no action is required There is no Ink Cartridge present or it is not properly connected to the printer The Low message is an early warning sign and it is advisable that new supplies should be obtained of that particular color The amount of ink remaining in the Ink Cartridge depends on it s capacity but there is approximately 14 of ink available for the user When theVery Low message is displayed overnight printing should not be attempted Changing the Ink Cartridge is strongly recommended to prevent the printer from stopping halfway through a print There is approximately 8 of ink available for the user The printer will stop and will not be able to continue printing until a new Ink Cartridge has been installed If this occurs halfway through printing an image you should check the quality of this image as stopping mid plot can affect the print It would be recommended to reprint the image once a new Ink Cartridge has been installed
56. to anything else that it contacts soon after printing depending on the amount of ink used and the environmental conditions at the time of printing Corrective Action 1 Handle prints carefully 2 Avoid stacking prints on top of each other 3 Disable the automatic cutter before printing so that the print will not fall into the basket Ink marks on the paper ENWW This problem may occur for several different reasons Horizontal smears on the front of coated paper If a lot of ink is used on plain or coated paper the paper absorbs the ink quickly and expands As the printheads move over the paper the printheads may come into contact with the paper and smear the printed image This problem is normally seen only on cut sheets of paper not on roll paper Corrective Action 1 Check that the paper type loaded corresponds to the paper type selected in the front panel and in the software You can verify the paper type selected through the Front Panel Main Menu Paper menu View loaded paper 2 Use a recommended paper type and the correct print settings 3 If using sheet paper try rotating the sheet 90 degrees The orientation of the paper fibers may affect performance Troubleshooting Print Quality Problems 41 4 Try using a heavier paper type When printing dense colors it is recommended to use HP Heavyweight Coated Paper HP Super Heavyweight Coated Paper or thicker Digital Fine Art papers 5 Try to increase the ma
57. to the left disengage the center coupling 10 ENWW Print Zone Overdrive 305 11 Use a flat bladed screwdriver to unclip the left Print Zone Overdrive retaining clip and rotate the clip vertically y 12 Carefully lift the right Print Zone Overdrive out of the printer E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Left Spittoon Removal This procedure describes how to remove the complete Left Spittoon which is necessary to gain access to other components If you only need to replace the Foams of the Left Spittoon use the protective gloves and the tweezers provided in the Tool Kit to remove them with it in place E NOTE Switch off the printer and remove the power cable 1 Remove the Left Cover refer Left Cover on page 188 2 Remove the Electronics Module Main PCA and PSU refer Electronics Module Main PCA and PSU on page 298 306 Chapter6 Removal and Installation ENWW 3 Remove two T 8 screws that secure the Left Spittoon to the printer 4 Use protective gloves and remove the top segment of foam from the Left Spittoon to gain access to the last attachment screw 5 Remove one T 10 screw that secures the Left Spittoon to the printer ENWW Left Spittoon 307 6 Rotate the Left Spittoon clockwis
58. 1 Remove the Front Cover refer Front Cover on page 177 Remove the Right Cover refer Right Cover on page 185 Remove the Left Cover refer Left Cover on page 188 Remove the Cutter Assembly refer Cutter Assembly on page 199 Remove the Front Panel refer Front Panel on page 203 Remove the Top Cover refer Too Cover on page 205 Remove the Window Position Sensor refer Window Position Sensor on page 208 Remove the Ink Supply Tubes Support Rail refer Ink Supply Tubes Support Rail on page 209 Manually uncap the Service Station before removing the Encoder Strip with spring and attachment nut refer Encoder Strip with spring and attachment nut on page 231 10 Remove the Encoder Strip with spring and attachment nut refer Encoder Strip with spring and attachment nut on page 231 11 If necessary manually move the Carriage Assembly fully right into the docking station ra STS mN 244 Chapter6 Removal and Installation ENWW 12 Use a short torx screwdriver to remove the two T 10 screws that secure the center attachment of the Trailing Cables ENWW Carriage Assembly with or without Trailing Cable 245 15 Unroute the Trailing Cables iilis 246 Chapter 6 Removal and Installation ENWW 18 Unroute the Trailing Cables ENWW Carriage Assembly with or without Trailing Cable 247 21 Remove the four T 15 screws that secure the Ink Supply Tubes to the Carriage Assembly de
59. 188 Remove the Front Panel refer Front Panel on page 203 Remove the Top Cover refer Top Cover on page 205 Disconnect the Window Position Sensor 208 Chapter 6 Removal and Installation ENWW 6 Remove one T 15 screw that secures the Window Position Sensor to the printer 7 Remove the Window Position Sensor to the printer E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Ink Supply Tubes Support Rail Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Right Cover refer Right Cover on page 185 Remove the Left Cover refer Left Cover on page 188 2 3 Remove the Front Panel refer Front Panel on page 203 4 Remove the Top Cover refer Top Cover on page 205 5 Remove the Window Position Sensor refer Window Position Sensor on page 208 ENWW Ink Supply Tubes Support Rail 209 6 Remove the Ink Supply Tubes from the Ink Supply Tubes Support Rail 7 Remove the T 15 screws that secure the rear attachment brackets to the Ink Supply Tubes Support Rail 210 Chapter6 Removal and Installation ENWW 9 Remove the T 15 screw that attaches the left bonding cable 11 Remove two T 15 screws that secure the Ink Supply Tubes Support Rail to the right Top Cover Support ENWW Ink S
60. 53A CN629A HP 70 Yellow C9442A C9454A CN630A HP 70 Light Magenta C9443A C9455A CN631A HP 70 Light Cyan C9389A C9390A CN632A Printheads The Printheads are extremely durable and do not need to be replaced every time an Ink Cartridge 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 If you notice a decline in print quality such as lines or dots missing from text graphics go to Troubleshooting Print Quality Problems on page 36 Available Printheads Printhead Type Part number HP 70 Matte Black amp Cyan C9404A HP 70 Light Magenta amp Light Cyan C9405A HP 70 Magenta amp Yellow C9406A HP 70 Photo Black amp Light Gray C9407A 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 e _ Always install the Ink Cartridges and Printheads before the expiration date which is on the packaging e Install Ink Cartridges and Printheads in their color coded slots e _ Follow the instructions on the front panel of the Printer during installation e Avoid unnecessary removal of the Ink Cartridges and Printheads 10 Chapter1 Ink Supplies Troubleshooting amp Print Quality ENWW When turning off the Printer always use the power Off button on the front panel The Printheads are then stored correctly which preve
61. 6675 60062 to lubricate the Carriage Rail and the Carriage Slider Rod 3 Replace the Carriage Rail Oiler refer to Carriage Rail Oiler on page 260 with the new one contained in the kit and add 2 3 drops of oil to the foam of the Carriage Rail Oiler 4 Use an Oil Dispenser Q6675 60062 to lubricate the Carriage Rear Bushing General Cleaning Proper general cleaning should include the following NOTE Topreventan electric shock make sure that the Printer is switched OFF and unplugged before any cleaning is performed Do NOT let any water get inside the Printer 1 Blow 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 Cleaning the Drive Roller and Overdrive E NOTE If ink is spilled on the Overdrive remove the ink immediately Due to the ink s reflectance ink on the Overdrive can disrupt the Printer s edge sensing function To remove any ink from the Overdrive perform the following procedure Prevent water or other liquids from running onto electrical components or circuits or through openings in the Electronics Module 1 Perform the Turn Drive Roller Utility Refer to 1 Turn Drive Roller on page 126 2 Open the window and apply any common household cleaning solution water based only to a soft lint free ra
62. Assembly with or without Trailing Cable on page 244 11 Squeeze the left hand clip of the Carriage Rear Bushing sufficiently to be able to release it from the Carriage Assembly 12 Rotate the Carriage Rear Bushing vertically and remove it from the Carriage Assembly Pig E NOTE When you reinstall the Carriage Rear Bushing use the Oil and Oil Dispenser from the Lubrication Kit to add 2 3 drops of oil to the small depression in it E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 ENWW Carriage Rear Bushing 255 Belt Assembly Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Carriage Assembly with or without Trailing Cable refer Carriage Assembly with or without Trailing Cable on page 244 2 Slide the Belt Assembly out of the attachment on the Carriage Assembly 3 Remove the pulley to release the Belt Assembly from the Belt Tensioner E NOTE There is a spacer between the right end plate and the tensioner NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Installation 256 Chapter6 Removal and Ins
63. Carriage Interconnect Wiper 22 Chapter1 Ink Supplies Troubleshooting amp Print Quality ENWW NOTE Do not touch wipe or attempt to clean the printhead nozzles This can damage the printhead and reduce print quality Print Quality Print Quality Troubleshooting Actions E NOTE Phone support For some Print Quality problems a Call Agent can try and troubleshoot the Printer by requesting the Customer to perform certain actions Using this process most problems can resolved without the need of an on site visit When faced with a Print Quality problem perform the following actions in order to resolve the problem 1 Printer Configuration e Check that the paper type loaded corresponds to the paper type selected in the front panel and in the software You can verify the paper type selected through the Front Panel Main Menu Paper menu View loaded paper e Make sure that the correct Print Quality settings are used for different types of print content e Dry time should be set to Optimal 2 Perform Printhead recovery Main Menu Image Quality Maintenance Clean Printheads 3 Media e Select the correct media type through the front panel when loading it e Make sure that HP or HP approved media is being used 4 Perform the Printhead Alignment Main Menu Image Quality Maintenance Align Printheads using the same paper type with which you were experiencing unacceptable image quality if feasible Some paper types are not s
64. Cause Solution Possible Paper Jam Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e _If the problem persists contact HP support Open the Window and check for any visible obstacles restricting the movement of the Drive Roller If there is a wrinkled mass of media inside the paper path lift the Pinch wheels using the Media Lever and clear the obstruction 70 Chapter2 System Error Codes ENWW 87 YZ Cause Solution Problem finding the Scan axis encoder reading Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Movement jam e Possible paper jam e Mechanical Initiator scan axis measure error e Check that the Scan Axis Motor is correctly connected e Check that the Encoder Sensor is correctly connected e Remove the Encoder Strip and clean it e Perform the Scan Axis diagnostic test to troubleshoot the problem further gt 1 Scan Axis on page 76 93 YZ Cause Solution Unable to pressurize the Ink Delivery System Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Perform the Ink Delivery System diagnostic test to further troubleshoot the problem gt 7 Ink Delivery System I
65. Chapter 6 Removal and Installation ENWW 5 Push the Carriage Assembly into the print path 6 7 Rotate the Drop Detector vertically to gain access to the two screws that secure the Right Starwheel Lifter ENWW Right Starwheel Lifter 323 8 Remove two T 8 screws that secure the Right Starwheel Lifter to the printer 10 324 Chapter6 Removal and Installation ENWW 11 Remove the Right Starwheel Lifter from the printer E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 starwheel Motor Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Front Cover refer Front Cover on page 177 2 Remove the Left Cover refer Left Cover on page 188 3 Remove the Electronics Module Main PCA and PSU refer Electronics Module Main PCA and PSU on page 298 4 Remove the Left Spittoon refer Left Spittoon on page 306 5 Disconnect the Starwheel Motor electrical connector ENWW Starwheel Motor 325 6 Carefully pull the two gear wheels off their shafts to gain access to the Starwheel Motor attachment Screws 7 Remove three T 15 screws that secure the Starwheel Motor to the printer mo 8 Lift the Starwheel Motor out of the printer 29 E NOTE When you finish installing or replac
66. DS on page 106 e Ifthe problem persists contact HP support 94 YZ Cause Solution Color calibration Error Try the following e Profiling failed due to a different error not algorithm data processing e Perform the Color Sensor ESP calibration You must use glossy paper for this calibration e fthe System Error continues replace the Carriage PCA refer Carriage PCA on page 276 e fthe System Error continues replace the Formatter refer Formatter on page 296 ENWW System Error Codes Full Descriptions 71 94 1 YZ Cause Solution Profiling algorithm failed Try the following e Profiling failed due to a different error not algorithm data processing e Perform the Color Sensor ESP calibration You must use glossy paper for this calibration e Ifthe System Error continues replace the Carriage PCA refer Carriage PCA on page 276 e fthe System Error continues replace the Formatter refer Formatter on page 296 98 YZ Cause Solution Automatic backup print mode enabled Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Recover the printheads 72 Chapter2 System Error Codes ENWW 3 Diagnostic Menu Diagnostic Mode UP OK e 1 Scan Axis on page 76 o Star Wheel Lifter test on page 76 o PRS Test on page 78 o Scan Axis Test on page 80 o Cutter test on page 84
67. Detector Calibration Left Ink Supply 7 Ink Delivery System Test IDS Station Right Ink Supply 7 Ink Delivery System Test IDS Station Carriage Cover 4 Carriage Assembly Line Sensor Calibration 3 Electronics Module Carriage Latch 4 Carriage Assembly Line Sensor Calibration 3 Electronics Module Carriage PCA 4 Carriage Assembly Line Sensor Calibration 3 Electronics Module PrintMech PCA 3 Electronics Module Front Panel 3 Electronics Module Power Supply Unit 3 Electronics Module PSU Main PCA 3 Electronics Module Ink Supply Tubes Scan Axis Test 3 Electronics Module Media Advance 2 Paper Drive Paper Advance Calibration Electronics Module Drive Encoder Disk 2 Paper Drive Paper Advance Calibration Electronics Module Encoder Sensor 2 Paper Drive Paper Advance Calibration Electronics Module Media Advance 2 Paper Drive Paper Advance Calibration Electronics Module Sensors Roller Carriage Assembly 4 Carriage Assembly Scan Axis Test Line Sensor Calibration 5 Sensors Cutter Test Belt Tensioner 4 Carriage Assembly Scan Axis Test Line Sensor Calibration 5 Sensors Belt Assembly 4 Carriage Assembly Scan Axis Test Line Sensor Calibration 5 Sensors Scan Axis Motor 4 Carriage Assembly Scan Axis Test Line Sensor Calibration 5 Sensors Trailing Cable 4 Carriage Assembly Scan Axis Test Line Sensor Calibration 5 Sensors Carriage Rear 4 Carriage Assembly Scan Axis Test Line Sensor Calibra
68. Flex Contacts Cleaning Tool This is a delicate process and may damage the printhead Do not touch the nozzles on the bottom side of the printhead especially not with any alcohol ENWW Solving Ink Supplies Problems 21 5 Reinsert the printhead 6 Check the front panel display message If the problem remains try a new printhead Maintaining and Cleaning the Printheads Clean the printheads As long as the printer is kept turned on an automatic cleaning is performed periodically This ensures there is fresh ink in the nozzles and prevents nozzle clogs which ensures color accuracy If you have not already done so please refer to Horizontal lines across the image banding and The Image Diagnostics Print before proceeding To clean the printheads press the Menu key to return to the main menu and select the Image Quality Maintenance menu icon then Clean printheads If you have gone through the Image Quality Diagnostic print process you know which colors are failing Select to the pair of printheads which contain the failing colors If you are not sure which colors to clean you can also select to clean all printheads Cleaning all printheads takes about nine minutes Cleaning a single pair of printheads takes about six minutes Cleaning all printheads uses more ink than cleaning a single pair If you have cleaned the printheads using the Clean printheads procedure from the front panel and are still experiencing image quality probl
69. M Diagnostic Print Set Date and Time 2 SelectReset Maintenance Kit usage to reset the Life Counter for ALL parts included in a Preventative Maintenance Kit PMK SelectReset usage counters to reset the Life Counter of a single part Reset Life counters Reset Maintenance Kit usage H Reset usage counters alf you select Reset Maintenance usage which will reset the Life Counter for ALL parts included in a Preventive Maintenance Kit PMK you can choose from the following Preventive Maintenance Kits e Preventive Maintenance Kit 1 PMK1 See Preventive Maintenance Kit 1 Preventive Maintenance Kit 1 on page 330 e Preventive Maintenance Kit 2 PMK2 See Preventive Maintenance Kit 2 Preventive Maintenance Kit 2 on page 331 E NOTE The counters that are reset are show Preventive Maintenance 4 Carriage Assembly on page 95 NOTE Itis also advisable to check the status of the Life Counters related to the other Preventive Maintenance Kits to avoid multiple trips to the customer bif you select to Reset usage counters which will reset the Life Counter of a single part you can choose from the following parts e Trailing Cable and Tubes e Scan Axis Belt ENWW Entering the Service Utilities Menu 131 e Scan Motor e Left Spittoon e Right Spittoon e Full Bleed Foams e Aerosol Fans e Carriage e Service Station 3 Once you have selected a Life Counter to reset the following message will be displayed on the
70. Media Advance Drive 313 5 While maintaining pressure on the Media Advance Drive Adjustment Tool fully tighten the three T 15 attachment screws in the order shown Pinchwheel Assembly Removal EY NOTE Switch off the printer and remove the power cable 1 Remove the Window refer Window on page 174 2 Remove the Spindle refer Spindle on page 223 3 Remove the Left Roll Guide refer Left Roll Guide on page 229 4 Remove the Right Roll Guide refer Right Roll Guide on page 230 314 Chapter 6 Removal and Installation ENWW 5 Raise the Media Lever 6 Use the Pinchwheel Insertion Tool to remove the spring from the attachment on the printer 7 Remove two I 15 screws that secure the Pinchwheel Assembly to the printer ENWW Pinchwheel Assembly 315 8 Remove the Pinchwheel Assembly from the printer Installation 39 E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 NOTE Use the following procedure to align the Pinchwheel Assembly using the Pinchwheel Alignment Tool during reassembly 1 Insert the Pinchwheel Insertion Tool through the appropriate access hole for the Pinchwheel Assembly you are installing This tool is provided with the kit part number Q6687 60084 NOTE Bevery careful not to damage the Encoder S
71. Panel prompts you to shutdown the printer to complete the test Sensors Press any key to shutdown the system 28 Press any key to shutdown the printer 6 Color Sensor ESP The Color Sensor ESP test diagnoses Failures of the Color Sensor located on the carriage Always run this test before replacing the Color sensor Diagnostic tests also need to be performed after removing or replacing certain printer componenis If you have removed or replaced printer components check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform Refer to Service Calibration Guide to Removal and Installation on page 170 1 Inthe Diagnostics menu scroll to 6 Color Sensor ESP and press OK Diagnostics menu 2 The Color Sensor ESP test starts and the front Panel displays the following messages Scan Axis Paper Drive Electronics Module Carriage Assembly Starting Horburgh Starting Carriage Starting Nvm Getting Part Number Getting Scan Axis size Starting Service Station Starting Scan Axis Moving SVS out of Sax Homing Scan Axis Moving Carriage out of SVS Homing Service Station Starting Servicing Services Capping Service Station Starting ColorSensor 104 Chapter 3 Diagnostic Menu ENWW 3 The Front Panel then prompts you to enable the Color Sensor ESP SOL Disabled Do you want to enable YES Press UP DOWN to change a
72. Paper Space PPS Solenoid on page 221 e Ifthe System Error continues replace the PrintMech PCA refer PrintWech PCA on page 220 51 YZ Cause Solution Window Sensor failure Try the following e Check that the Window Position Sensor cable is not damaged and is correctly connected to the PrintMech PCA e Perform the Sensors Test to troubleshoot the problem further 5 Sensors on page 101 e Replace the Window Position Sensor refer Window Position Sensor on page 208 System Error Codes Full Descriptions 61 52 YZ Cause Solution The printer has detected a problem with the Drop Detector Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Check that the Drop Detector cable is not damaged and is correctly connected to the PrintMech PCA e Check that the Service Station cable is not damaged and is correctly connected to the PrintMech PCA e Replace the Drop Detector refer Drop Detector on page 217 e Reset the Calibration Flag of the Drop Detector Drop Detector Calibration on page 145 e Ifthe System Error continues replace the PrintMech PCA refer PrintWech PCA on page 220 e fthe System Error continues replace the Formatter refer Formatter on page 296 55 YZ Cause Solution Problem with the Line Sensor Tetris The printer has detected Try the following a fai
73. S Test Refer to PRS Test on page 78 e Scan Axis Test Refer to 1 Scan Axis on page 76 e Cutter test Refer to Cutter test on page 84 e Star Wheel Lifter test Refer to Star Wheel Lifter test on page 76 e 2 Paper Drive Refer to 2 Paper Drive on page 87 e 3 Electronics Module Refer to 3 Electronics Module on page 90 e 4 Carriage Assembly Refer to 4 Carriage Assembly on page 95 e 5 Sensors Refer to 5 Sensors on page 101 172 Chapter6 Removal and Installation ENWW e 6 Color Sensor ESP Refer to 6 Color Sensor ESP on page 104 e 7 Ink Delivery System IDS Refer to 7 Ink Delivery System IDS on page 106 e 8 Service Station Refer to 8 Service Station on page 110 e Paper Advance Calibration Refer to Paper Advance Calibration on page 140 e Drop Detector Calibration Refer to Drop Detector Calibration on page 145 e Line Sensor Calibration Refer to Line Sensor Calibration on page 146 ENWW Service Calibration Guide to Removal and Installation 173 Window Removal E NOTE Switch off the printer and remove the power cable NOTE The Window can also be removed with the Top Cover to avoid scratching the Window To remove the Window with the Top Cover refer to op Cover on page 205 1 Open the Window 174 Chapter6 Removal and Installation ENWW 4 Remove the Damper Rotary from the Top Cover 5 Remove the T 15 screws that secure each of the remaining three Window hinge locking plat
74. Set Serial Number Current unit SN MyY6591C aP New unit SN MyY6591Ce aP Use UP DOWN to scroll BACK to move cursor ENTER to confirm or CANCEL to exit lf the Serial Number or the Part Number cannot be read the Front Panel will display the relevant System Error code Refer System Error Codes Full Descriptions on page 50 3 Once the new Serial Number has been entered the Front Panel will display the Serial Number and Model Number of the Printer Press the OK to confirm the Serial Number or the Cancel key to exit the utility without making any changes or the Back key to modify again 130 Chapter4 Service Menu ENWW 4 Ifthe utility exits correctly OK will be displayed on the Front Panel 5 When the printer is restarted after a serial number change an NVM setting sequence is initiated to synchronize the serial number stored in the backup memory 4 Reset Life Counters The purpose of this Service Utility is to reset the internal life counters There are two submenus that allow you to e Reset ALL the counters related to a Preventive Maintenance Kit PMK e Reset only the counters related to a specific replaced part EY NOTE ALWAYS RESET THE LIFE COUNTER OF A CORRESPONDING PART AFTER REPLACING IT Perform the Reset Life Counters utility as follows 1 Inthe Service Utilities submenu scroll to Reset Life Counters and press Service utilities Turn Orive Roller e Purge Tubes er Set SN H Reset life counters H
75. Starting Mips e Starting Nvm e Getting Part Number e Starting ISS Motors e Moving Bongos down e Reading Bongos down e Moving Bongos up e Reading Bongos up e Starting OutOflnk sensors e Reading OutOflnk 8 The Front Panel then prompts you push down BongoO 9 Checking OutOfiInk sensors Push Bongo down Press any key to continue 9 Press and hold down BongoO which is located at the furthest left Ink Cartridge position 10 Press any key ENWW Service Tests Diagnostics 107 11 Release BongoO 12 Press any key 13 The Front Panel then displays the BongoO test results Ink Delivery System Checking OutOfInk Press any key to continue F 14 Press any key to continue 15 Repeat steps 8 through 14 for the remaining Out of Ink sensors for each of the Ink Cartridges 16 The front Panel prompts you to insert all the Ink Supplies Ink Delivery System insert all the Ink Press any key to proceed 17 Install all the Ink Cartridges 18 Press OK to continue 19 The Acumen Supplies test and the front Panel displays the following messages e Starting AcumenSupplies e Reading AcumenSupplies 20 The Front Panel then displays Acumen Supplies test results Ink Delivery System Starting AcumenSupplies Reading Acumen Supplies Acumen Supplies OK Press any key to finish 21 The Front Panel shows the test complete display for a few seconds Ink Delivery System
76. Z Action to perform 1 digit System Error Code Table The following table explains the XX part of the System Error Code or Warning Code Component System 01 0 Main PCA Electronics module 01 1 Add on Electronics module printmech 01 2 Print Mech PCA 02 1 Carriage PCA 02 2 Carriage PCA 03 Power supply 05 1 Fan of the Formatter 06 Formatter 08 Front panel 11 Trailing cable 12 n Carriage flex circuit n to pens 21 Service station 21 1 Service station 22 0 Bongo error BPSO ISS Left 22 1 Bongo error BPS1 ISS Left 22 2 Bongo error BPS2 ISS Right 24 Tube assembly IDS ENWW Continuable and Non Continuable Error Codes 47 26 n 2 31 38 41 41 1 42 44 47 48 51 o2 55 56 58 61 62 63 64 65 66 67 68 71 71 19 72 73 74 74 1 75 1 75 2 76 17 78 78 1 79 79 1 81 Ink Cartridge color n Printhead error Cutter Output Tray Paper axis motor Paper axis motor Scan axis motor Aerosol fan Star wheel motor PPS mechanism Window Sensor Drop detector Line sensor Drive roller analog encoder sensor Color sensor ESP Error job PC Interface Input output through LAN card Input output through USB port Input output not known what port Input output not known what port Input output through FireWire port Loss of engine counters tracking Memory management PrintMech PCA Formatter Firmware error Servo F
77. ack to the previous menu or reject test results Solving Ink Supplies Problems 3 4 Service Key Combinations Diagnostic mode With the printer OFF press and hold the UP and OK keys While holding the Up and OK keys down press and hold the Power key to turn on the printer Hold all three keys until the Power key stops flashing usually about 5 seconds Service Menu Service Engineers Only From the main menu press and hold the Up and Cancel keys Service Menu For users From the main menu press and hold the Down and Cancel keys The Printer does not Power ON 1 2 3 4 Check that the power cord is connected correctly to the Printer and to the Power Socket Check that the Power Switch on the BACK of the Printer is in the ON position Check to see the LED on the Front Panel Power Switch are On Check that the Front Panel Cable is correctly connected to the Electronics Module Also make sure that the Front Panel cable is not damaged Replace the Power Supply Unit Refer Electronics Module Main PCA and PSU on page 298 The Printer Continuously Rejects Printheads 1 Chapter 1 Clean the flex contacts on the Printhead and in the Carriage Assembly using the Carriage Interconnect Wiper Refer to Flex Contacts Cleaning Tool on page 22 and try again lf ALL the Printheads are rejected the status message on the Front Panel does NOT show OK for ALL the Printheads then perform the Electronic Module Test Refer 3
78. age 165 ENWW 151 Printer Support Reference on HP Part Number Figure 1 Q5669 60718 2 Q5669 60716 3 Q5669 60715 4 Q6659 60237 5 Q5669 60236 7 Q5669 60715 6 amp 8 Q5669 67063 Part Description Leg Cover Legs Assembly Foot Assembly includes 1 foot and 1 support tube Bin assembly includes the Bin Support X Brace Foot Bracket part of Foot Assembly Tube Basket amp Rear Basket Bracket Includes screws for Legs Assembly Page N A N A N A N A N A N A N A 152 Chapter 5 Parts and Diagrams ENWW Center Covers Front Reference on Figure HP Part Number Part Description Page 1 CH538 67030 Window Window on page 174 2 CQ113 67002 Top cover 3 CH538 67071 Window Position Sensor with Window Position shield Sensor on page 208 4 Q6659 60089 Anti ESD Media Output Media Output Assembly Assembly on page 178 5 Q6659 60165 Front cover Front Cover on page 177 6 Q6675 60060 Front Panel Front Panel on page 203 ENWW Center Covers Front 153 Center Covers Rear Reference on Figure HP Part Number Part Description Page 1 Q5669 60660 Rear Tray Supports Right Rear Tray Support on page 200 2 Q6687 67801 Clean Out Assembly Clean Out Assembly on page 225 3 Q5669 67801 Out Of Paper Sensor Out Of Paper Sensor on page 226 4 Q6659 601 70 Rear Tray Rear Tray on page 194 5 Q6659 60 164 Rear cover Rear Cover on page 195 154 Chapter5 Parts and Diagrams ENWW Right
79. age 226 e Left Roll Guide on page 229 e Right Roll Guide on page 230 e Encoder Strip with spring and attachment nut on page 231 e Encoder Strip on page 236 e Trailing Cable on page 237 e Carriage Assembly with or without Trailing Cable on page 244 e Carriage Rear Bushing on page 254 e Belt Assembly on page 256 e Scan Axis Motor on page 257 e Carriage Rail Oiler on page 260 e Color Sensor ESP on page 262 e Line Sensor on page 267 e Carriage Cover includes Carriage Latch on page 272 e Carriage PCA on page 276 e Right Ink Supply Station on page 280 e Left Ink Supply Station on page 284 e Ink Supply Tubes on page 288 e Formatter on page 296 e Hard Disk Drive on page 297 e Electronics Module Main PCA and PSU on page 298 e Starwheel Assembly on page 301 e Print Zone Overdrive on page 302 e Left Spittoon on page 306 e Encoder Disk and Encoder Sensor on page 308 e Media Advance Drive on page 311 e Pinchwheel Assembly on page 314 e Pinch Roller on page 319 e Left Starwheel Lifter on page 320 e Right Starwheel Lifter on page 322 ENWW 167 e Starwheel Motor on page 325 e Full Bleed Foam on page 326 168 Chapter6 Removal and Installation ENWW Introduction This chapter is a step by step guide to the removal and installation of the key components of the printer You may find it useful to check off the steps as they are performed Use the illustrations for each procedure to identify the parts referred to in the
80. ages e Clear GPIO psu_sleep e Clear GPIO psu_Carr e Clear GPIO psu_fanspeed e Checking Voltage e Set GPIO psu_Carr e Set GPIO psu_sleep e Checking Voltage Service Tests Diagnostics 81 6 The Front Panel prompts you to confirm that the carriage supply LED is switched on Scan Axis Has the carriage supply LED been switched on YES Press UP DOWN to change and ENTER to select v 7 Open the Window and verify that the LED is on The LED can be seen through the slots in the carriage cover 8 Press OK if the LED is on If the LED is not on or use the Arrow keys to select NO and press OK 9 The printer then continues the Scan Axis test As the test executes the Front Panel displays the following messages e Booting Up Carriage e Getting Part Number e Getting Scan Axis Size e Preparing SVS e Prog slow PWM scan e Moving Carriage middle 10 The Front Panel prompts you to confirm that the Carriage has moved Scan Axis Preparing SVS Prog slow PWM scan Moving carriage middle Did the motor move YES Press UP DOWN to change and wi 11 Use the Arrow keys to select whether or not the motor moved the carriage 12 Press OK to continue 13 The Front Panel prompts you to confirm that the Carriage has moved to the middle position Scan Axis Preparing SVS Prog slow PWM scan Moving carriage middle Did the motor move Is carriage at middle YES Press UP DOWN to change an
81. ain PCA Replace the Media Advance Drive refer Media Advance Drive on page 311 If the System Error continues replace the Main PCA refer Electronics Module Main PCA and PSU on page 298 42 YZ Cause Solution Electrical fault or current limit in Scan Axis Motor Try the following Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer Open the Window and check for any visible obstacles restricting the movement of the Media Advance Roller If there is a wrinkled mass of media inside the paper path lift the Pinch wheels using Media Lever and clear the obstruction Perform the Scan Axis diagnostic test to troubleshoot the problem further 1 Scan Axis on page 76 Check that the Scan Axis Motor cable is not damaged and is correctly connected to the PrintWech PCA Replace the Scan Axis Motor refer Scan Axis Motor on page 257 If the System Error continues replace the PrintMech PCA refer PrintWech PCA on page 220 ENWW System Error Codes Full Descriptions 59 44 YZ Cause Solution Electrical fault or current limit in Scan Axis Motor Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Check that the Aerosol Fan cable is not damaged and is correctly connected to the PrintMech PCA e Replace the Aeroso
82. and remove the power cable 1 Remove the Right Cover refer Right Cover on page 185 Remove the Left Cover refer Left Cover on page 188 Remove the Front Panel refer Front Panel on page 203 Remove the Top Cover refer Too Cover on page 205 Remove the Window Position Sensor refer Window Position Sensor on page 208 Remove the Ink Supply Tubes Support Rail refer Ink Supply Tubes Support Rail on page 209 hs Open the Carriage Cover 8 Remove all the Printheads 9 Remove the four T 15 screws that secure the Ink Supply Tubes to the Carriage Assembly oo ee se ee ee 268 Chapter6 Removal and Installation ENWW 10 Carefully lift out the Ink Supply Tubes and close the carriage cover at the same time 11 12 ENWW Line Sensor 269 13 Unclip and slide off the small cover of the Carriage Assembly Carriage PCA 14 Remove one T 15 screws that secures the large cover of the Carriage PCA 270 Chapter6 Removal and Installation ENWW 16 Disconnect the Line Sensor electrical connection from the Carriage PCA ENWW Line Sensor 271 19 Remove the Line Sensor from Carriage Assembly j cn b Ey i i 4 yA a j k E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Carriage Cover includ
83. aneeesaeeeeeas 5 Cover Sensors are NOt Working cccccceeeecceecseeeeceeceeeeeceeeeeeseeeeceaeeseeeeeseaeeeeeeaeaeeeeessaaaeeeeessaaueeeeeeaaees 6 The Line Sensor has Problems Detecting Media cccccccceseecceeceeeeeeeeeaaeeeeeeeeeeeeeeeesseeeeeeessaaeeeeeeeaas 6 PTODIGMIS WEA COIT PC CUI ACY airsan E E E N E E 6 Troubleshooting Media Jams Printhead Crashes ccccccceeccccseseeeseeceecaeeeeeeeeeeesseeeeeeseeeessaeeeesaeeeeeas 6 Banding at variable extreme environmental conditions ccccseccesseeecceeeeeceeeecseueeeeeeesseeeeeseeeesaeeeenees 7 Worm marks on HP Coated media with light area fills ccc ccccseeceecseeeeeeeeeeeeaeeeeeseaeeeeeseeeeesaaeeeeaaees 7 Solving Media Handling Problems ccccccsssecceceeeeeeeeeceeeeeeeseeeeeeeseueeeeeeeseaeeeeesauaeeeesseaseeeeesseesaaees 7 What to do when plastic parts on the Media Basket become damaged during printer setup 8 SOVNE nK SUppIES ProD S sssrinin aE A E 9 NWA CSS A E A EEE A E T ES E ET 9 Av alabie mik O Al IOC S iora e a E E E a 9 FANCIO eee a A detsecedcenneeatedeaemsbeacaeacaunenedte 10 Available Printheads ccccccsssecccceeeeecceeceeeceeeceeceauceesseseeesaaeeeseuseeesssaueeessageeessaaeeessaags 10 General Information About the Ink Supplies 2 0 0 cececeecceeeeeeeeeeeeeeeeeseaeeeeeeseeeeeeeeeaaaees 10 General Precautions When Handling Ink Supplies ccccceceeseeeeeeeeseeeeeeeeeeeneeeeeeeneaees 11 When
84. bed 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 Parts and Diagrams on page 151 Conventions A small arrow indicates a link to other parts of the Service Manual where you can find information related to the topic you are consulting vi Using this Manual ENWW Table of contents 1 Ink Supplies Troubleshooting amp Print Quality MOCC UO aster este e circ a eeitclom css tes E aaema dane taser ete aad E E E EA E E ea 2 Troubleshooting System Error Codes ccccccccccccceeeeecceeeceeeeeeeeeaeeeeeeeeeeeeeeeeseeaeseeeeseaeseeeeesaaeeeesssageeees 2 Performing a Service Test on a failed Assembly ccccccccccccsseeeeeeeeeaeeeeceeeeeaaeeeeeseeeaeeeeeeessaaeeseeeeseaas 2 Performing the Necessary Service Calibrations cccccccceccccecceaseeeceeeeeeeeceeeseeeeeeeeeeeseeeeeeessaaeeeeeeeseeas 2 SOWING NK SUPPIES ProDIETIS sssrini a E a a E 3 SONG PAA AWAY ProDIEMIS seiss aane AEE EE 3 USNO S FON Pan aasan EE E E 3 The Printer does not Power ON cccccsssceccceeeecceeseeccsaueeceseseesaueeeesseaeeeseaseeessaaseeseaueeesseneeessaeeeeeas 4 The Printer Continuously Rejects Printhead cccccccccseseeeeeeeeeeseeeeeeeseeseceeeseaeeeeeeeeeseaeeeeeesensaaeeeeees 4 What to do if the Front Panel is blank cc ccccccccseececceeeeeeeeeeeeeeeeeeeeseeeeeeseaeeeeseaeeeeseeeesseeeess
85. ble 1 Open the Window ENWW Starwheel Assembly 301 2 Remove one T 15 screw that secures the Starwheel Assembly to the Printer 3 4 Carefully lift the Starwheel Assembly out of the printer E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Print Zone Overdrive Removal 302 Chapter6 Removal and Installation ENWW E NOTE Switch off the printer and remove the power cable 1 Remove the Starwheel Assembly refer Starwheel Assembly on page 301 E NOTE The Print Zone Overdrive is in two sections left and right This procedure describes the removal of both of the sections If you only want to remove one of the sections skip the steps for the other section 2 Remove one T 15 screw that secures the left clamp of the Print Zone Overdrive to the Platen 3 4 Remove the clamp ENWW Print Zone Overdrive 303 5 Repeat steps 2 to 4 to remove the remaining five attachment clamps 6 Use a flat bladed screwdriver to unclip the left Print Zone Overdrive retaining clip and rotate the clip vertically 7 Carefully lift the left Print Zone Overdrive enough 10 mm so you can slide it to the left i gt C 304 Chapter 6 Removal and Installation ENWW 8 Slide the left Print Zone Overdrive
86. bly on page 219 Service Station on page 214 Drop Detector on page 217 Right Ink Supply Station on page 280 Right Hand Assemblies 157 Left Hand Assemblies Referen ce 10 11 12 158 Chapter5 Parts and Diagrams HP Part Number Q6675 60019 Q6718 67017 Q5669 60703 Q5669 60702 CH538 67027 Q5669 67049 Q5669 60693 Q6677 67005 CK837 67026 Q5669 60705 Q5669 60706 CQ113 67013 Part Description Starwheel Motor Encoder Sensor Encoder Disk Media Advance Transmission Left Spittoon Formatter Media Lever Media Lever Position Sensor Page Left Ink Supply Station Left Ink Supply Station on page 284 Starwheel Motor on page 325 Encoder Disk and Encoder Sensor on page 308 Encoder Disk and Encoder Sensor on page 308 Media Advance Drive on page 311 Left Spittoon on page 306 Electronics Module Main PCA and PSU on page 298 Power Supply Unit PSU Assembly Electronics Module Main PCA and PSU on page 298 Main PCA with Power Supply Unit PSU Assembly Formatter on page 296 Media Lever on page 196 Media Lever Position Sensor on page 198 HDD 160 GB Contains Z5200 firmware Hard Disk Drive on page 297 ENWW Carriage Assembly ENWW Reference on Figure 1 HP Part Number CQ113 67011 Q5669 60685 Q5669 60686 Q5669 60682 Q5669 60687 Q5669 60683 Q5669 60684 CQ113 67010 CQ113 67014 Part Description
87. coder Strip with spring and attachment nut Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Right Cover refer Right Cover on page 185 2 Remove the Left Cover refer Left Cover on page 188 3 Remove the T 15 screw that secures Encoder Strip to the printer ENWW Encoder Strip with spring and attachment nut 231 4 Grip the Encoder Strip and move it towards the left to take off the tension until you have completed the next step 5 Unclip the Encoder Strip from it s attachment lugs 6 Loosen the T 10 uncapping screw sufficiently so you can manually move the Carriage Assembly in step 7 232 Chapter6 Removal and Installation ENWW 7 Push the Carriage Assembly into the print path 8 Unclip the Encoder Strip tensioner from the right hand end 9 Carefully pull the Encoder Strip out of the printer from the right hand end E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 ENWW Encoder Strip with spring and attachment nut 233 Clean Encoder Strip Procedure 1 Make sure that the printer is OFF and that the carriage assembly is located at the service station on the far right side of the printer 2 Use tap water and a small cloth that will not leave fibers in the printer to
88. connect the power cord and power On the Printer e Check that the Trailing Cable is not damaged e Check that the Trailing Cable is correctly connected between the Main PCA and Carriage PCA o Check that the Printhead has not failed and is not erroneous e Check that the Flex circuit contacts and Printhead contacts are clean e Ifthe System Error continues replace the Carriage PCA refer Carriage PCA on page 276 e Ifthe System Error continues replace the Main PCA refer Electronics Module Main PCA and PSU on page 298 System Error Codes Full Descriptions 53 21 YZ Cause Solution Fail moving Service Station Try the following Switch the Power OFF from the back of the Printer and disconnect the Power cord Check the Primer Tubes Reconnect the power cord and power On the Printer e Make sure that the Service Station path is clear Remove any visible obstacles e g screws plastic parts etc restricting the movement of the Service Station e Perform the Service Station diagnostic test to troubleshoot the problem further gt 8 Service Station on page 110 e Ifthe System Error continues replace the Service Station refer Service Station on page 214 e Ifthe System Error continues replace the PrintMech PCA refer PrintWech PCA on page 220 21 1 YZ Cause Solution service Station servo shutdown Try the following Switch the Power OFF from the back of the Printer and
89. csececceseeceeeeceeceesseeeceueessueeessaeeessueeesees 26 Diagnostic Part 3 Printheads amp Paper Advance ccccccseeceeceeeeeeeeeeeeseeseeeseeeeeseeseeeaaeees 28 No Printing Defects Found in the Diagnostic Print cccsseeccseeeeeeeeeeeeeeeeeeeeeesseeeeesaaees 29 TheAdyanced Diagnostic PNIS cecer a E N A 29 What are the Advanced Diagnostic Prints cccccccccseeceeceeeeeeceeeeeeseeeeesseeeeeeeeeeessaeeeeeas 29 Printing the Advanced Diagnostics Print cccccceccccseeeeeeceeeeeeeaeeeeeeeseeeeesseaeeeeeeseeeeessaaes 30 Reading the Advanced diagnostic Print Results cccccccceceecseeeeeeeeeeeeseeeeeeeeeeeesaeeeeeseaeeeseaeeeesaeeeeeas 30 Paper POV ANG C rivets ctustnentaaaniatt cance E E 30 PRPS AG ANAME rie a a a reat taanvmw eu a N anole ianete 33 INOZZICN GON UN eceaceosanatatudveasnctenencteesageqnstascocasiashataadeos a duedaneneeeenadedea nace ues vencn sheds tes 34 FOr Ce Drop Del llOM rc cnxtartnck hs han vantecdin a le mngianctamieweduanues 35 Froubleshooting Print Quality ProDIGIS nersini enn eden eedenaaeee eels a Ae ede ieee 36 Print Quality Genet LAVICE cect te A a yeti steseeseaaet ke 36 Horizontal Lines Across the Image Banding ccccsececseeeeeeeeeeeeeseeeeeseeseseueeseeeeeaeeesees 36 Lines are Missing Too Thin OF Too Thick wsciceinsoataxaveadinaecsddaievancatanendecadaedsecaxoseondeeesbdadeed 37 Problems with Stepped Lines cecccccecccecceccceeeeeeeceeeeeeeeseee
90. d ENTER to select n 14 Use the Arrow keys to select whether or not the carriage has moved to the middle 15 Press OK to continue 82 Chapter 3 Diagnostic Menu ENWW ENWW 16 17 18 19 20 21 22 The printer then continues the Scan Axis test As the test executes the Front Panel displays the following messages e Preparing SVS e Prog slow PWM scan e Moving Carriage middle e Starting Carriage e Encoder The Front Panel prompts you to move the carriage to check the encoder readings Scan Axis Checking encoder readings Please keep out from platen zone and press UP left DOWN right to move the carriage Remaining movements 10 Last movement eu Use the Arrow keys to move the Carriage left or right as prompted to by the Front Panel Repeat step 18 to complete the ten Carriage movements used to check the encoder The Front Panel displays the encoder check results 21 Scan Ax1s Max Min mov 526 464 eu AVG MOV 493 eu There is encoder feedback Encoder seems to be OK Press any key to continue Press any key to continue The printer then continues the Scan Axis test As the test executes the Front Panel displays the following messages e Starting Carriage Motor e On Off Carriage Motor e Doing aright side bump e Doing a left side bump e Exit bump position e Checking scan axis length e Starting PosMotor e Starting Scan Axis e Doing PWM test
91. dge Door 184 Chapter6 Removal and Installation ENWW Right Cover Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Front Cover refer Front Cover on page 177 2 Open the Right Ink Cartridge Door 3 Remove the Ink Cartridges from the printer 4 Remove one T 15 screw that secures the Right Cover to the printer at the rear of the Printer ENWW Right Cover 185 5 Remove one T 15 screw that secures the Right Cover to the printer at the rear of the Printer 6 Remove one T 15 screw that secures the Right Cover to the printer at the rear of the printer 7 Remove one T 15 screw that secures the Right Cover to the printer accessible under the Front Cover 186 Chapter6 Removal and Installation ENWW 8 Remove one T 15 screw that secures the Right Cover to the printer accessible from within the cartridge bay 10 Remove the Right Cover from the printer ENWW Right Cover 187 Left Cover Removal 39 E NOTE Switch off the printer and remove the power cable 1 Remove the Front Cover refer Front Cover on page 177 2 Open the Left Ink Cartridge Door 3 Press the clip to release the Left Cover Finishing Panel 4 Remove the Left Cover Finishing Panel 188 Chapter6 Removal and Installation ENWW 5 Unclip the spring from the attachment points on the Media Lever and Left Cover 6 Remove three T 15 screws that secure the Media Lever
92. dule Carriage Assembly Sensors S L 2 The printer starts the Paper Drive test to verify the subsystem As the test executes the Front Panel displays the following messages e Starting Horsburgh e Starting Tests PWM e Starting Tests GPIO e Booting up the Carriage e Starting DelSol1 e Starting Carriage e Starting AnalogEncoder e Starting Nvm e Getting Part Number e Part Number e Getting PCA revision Service Tests Diagnostics 87 3 The Front Panel then displays the Main PCA Revision this value should be always between 0 and 3 3 and prompts you to press any key to continue edia Drive lain PCA Revision Press any key to continue 4 Press any key to continue 5 The Front Panel displays the following messages e Starting Nvm e Getting Part Number e Checking PCA rev e Prog slow PWM paper 6 The Front Panel then prompts you to remove the media Please remove the media for testing and keep out from the platen zone Press any key to continue 7 Remove the media 8 Press any key to continue 9 The Front Panel then displays the Open Loop ROLL test result Checking Open Loop ROLL Movement done 417095 eu Press any key to continue 10 Press any key to continue 11 The Front Panel then displays the Open Loop UNROLL test result Checking Open Loop UNROLL Movement done 5588659 eu Press any key to continue 12 Press any key to continu
93. e 88 Chapter3 Diagnostic Menu ENWW ENWW 13 14 15 16 17 18 19 20 21 22 The Front Panel then displays e Starting Paper Motor e Starting Paper Axis e Calib Analog Decoder The Front Panel then displays the Analog Decoder calibration results Analog Encoder results CHANNEL GAIN OFFSET A 1 0 3 8 B 1 9 8 8 Press BACK CANCEL to reject or ENTER to accept F e The GAIN for channel A must be between 0 and 3 5 e The GAIN for channel B must be between 0 and 4 5 e The OFFSET for channel A must be between 63 5 and 63 5 e The OFFSET for channel B must be between 63 5 and 63 5 If the results are correct press OK to accept the results If the results are not correct press Back Cancel to reject the results and FAIL the test e Starting Media Path e Homing and repeatability test The Front Panel then prompts you to remove the media Media Drive Please remove the media for testing and keep out from the platen zone Press any key to continue Remove the media Press any key to continue The Front Panel then displays e PWM test without paper The Front Panel then displays the test results Press any key to continue PWM avg 6176 16 7700 49 Speed error 46 25 51 25 PWM StDev 98 52 121 22 PWM max 6456 00 647 00 Press any key to finish The Front Panel shows the test complete display for a few seconds Service Tests Diagnostics
94. e sevau scenic ect carted eased a A Sah ebceletanent 262 HAG SS NSO Fe tavce tae actuator tose eucmsutnctc N 267 Carriage Cover includes Carriage Latch cccccccccscccecseeeeceeeeeeeeeeeaeeeeceeesseseeeeeseeeseeeessaeeeesssaaes 272 SAAC POA reseed cade te ide aac E E aa a A E E E adni ie eat ae 276 RIG MAK SUDDIV LATION narrari a ce aitechtu cane a Scars nana ler N A 280 en IAK SUDDIV StallOM a zctust se santos esect a a 284 POY UDG Shirt tate E E ea tatl concn letrsde Anal E An alacancatstecs senesced 288 FONA le eee e A aioe nsec eaisse ek ce sarge E A ae esha nos ee etbaecasenls 296 Hard DISK MOINS ah her cice ciate dee tia e eA eE E cet creda cnt oaedat caateaetetdane ave 297 Electronics Module Main PCA and PSU emasdim a N 298 Starwheel ASSCIMDIY sear sshite etnies tages A e sete muda LE Gah tne See tL Sar 301 PRIME Zoe OVE VE 2555 foes dam hdissnagumiancareen neues cametaatustncaassaes aad nd noe A AA 302 LEONON iee eet aT Re E 306 Encoder Disk and Encoder S nsoOf csssscccccseeeeceeeceeeeececceeeeceeseeeeseeeesseeeeeeesseseeesssueeeeessaeeseeees 308 veda Advance DIVE caor a ete Ries eet Satin eases Se nd ath eee ce eee deeds 311 PINCHWHECLASSOMDIY titivereccivertatretueideardineideviat sont aeae e eroe 314 PICMG ROUGE serisinin eed icici ivan cheat dios dteletecinine suns ea e tached tase aceaiacedacssueaeticedencs 319 Let Stanwheel iter ipsci nesses ea te i See aa oes eee eat at eel oe hash ae ene 320 RGM Stanwe
95. e Front Panel will display the relevant System Error Code To troubleshoot any displayed error codes refer System Error Codes Full Descriptions on page 50 5 Once the test has been completed the Front Panel displays the test results 6 Press any key to finish 7 The Front Panel shows the test complete display for a few seconds Star Wheel Lifter 8 The Front Panel prompts you to shutdown the printer to complete the test Star Wheel Lifter Press any key to shutdown the system 9 Press any key to shutdown the printer PRS Test The PRS subsystem is designed to move the carriage assembly between two predetermined vertical positions with respect to print platen plane This allows different media of different thicknesses to be used without losing print quality Perform the Scan Axis PRS test as follows 78 Chapter 3 Diagnostic Menu ENWW NOTE Perform this test with the Printheads and the Tubes System installed in order to get values _ that can be compared correctly ENWW 1 In the Diagnostics menu scroll to1 Scan Axis and press OK Diagnostics menu Paper Drive Electronics Module Carriage Assembly Sensors SOL Scan axis Star Wheel Lifter In the Scan Axis submenu scroll toPRS and press OK to start the test The Printer will start the scan Axis subsystem Common Initialization and PRS test initialization If there is a Failure at any point during the tests the Front Panel will
96. e Moving Carriage middle e Initializing LineSensor ENWW Service Tests Diagnostics 97 18 The Front Panel then prompts you to load roll media Carriage Assembly raise the pinch Load Roll paper and lower the pinch lever Press any key to proceed F 19 Load roll media NOTE For the LED test to work properly the paper must be loaded completely through the carriage path 20 Press any key to continue 21 The Carriage Assembly test continues and the Front Panel displays the result of each phase of the test e Setting LS low intensity For each color LED Blue Green Red and Amber e Setting LS max intensity For each color LED Blue Green Red and Amber e Checking Tolerance e Starting NvmLineSensor e Initializing NvmLineSensor e Getting LS Serial Number e Reading LS Nvm e Writing new LS Nvm e Checking LS Serial Number e Starting Service Station e Starting Scan Axis e Moving SVS out of sax e Homing Scan Axis e Moving Carriage out of SVS e Homing Service Station e Starting Servicing Services e Starting ColorSensor 98 Chapter3 Diagnostic Menu ENWW ENWW 22 23 24 25 26 27 28 29 The Front Panel then prompts you to enable the Color Sensor ESP SOL Disabled Do you want to enable YES Press UP DOWN to change and ENTER to select Press OK to the enable the Color Sensor ESP If you do not wish to enable the Color Sensor ESP use t
97. e Roller begins to turn slowly and the following message is displayed on the Front Panel Turn Drive Roller Rotation started Please clean the DRIVE ROLLER Turn s 2 8 Timeout 567 Press CANCEL key to finish J Refer to the Cleaning Instructions on Cleaning the Drive Roller and Overdrive on page 329 Once you have finished cleaning the Drive Roller and the Overdrive press the Cancel key to finish the utility If the utility exits correctly OK will be displayed on the Front Panel Entering the Service Utilities Menu 127 EY NOTE REMEMBER TO REMOVE THE PIECE OF PAPER FROM THE WINDOW SENSOR BEFORE CLOSING THE WINDOW AS THIS COULD DAMAGE THE WINDOW AND THE SENSOR 2 Purge Tubes The purpose of this Service Utility is to Prime the Tubes when the Ink Tubes are NOT new and they need to be re primed or automatic priming was not completed correctly E NOTE Make sure that NEW Ink Cartridges are installed or that the ink volume remaining in the Ink cartridges is below 88 before starting to prime the tubes If you do not comply you will get a warning message and cannot finish the test 1 Inthe Service Utilities submenu scroll to Purge Tubes and press OK Service utilities Turn Drive Roller H Reset life counters Diagnostic Print Set Date and Time 2 Inthe Service Utilities submenu scroll to Purge Tubes and press OKWhen the front panel prompts you to reboot the system you must select whether you wo
98. e approximately 45 degrees and carefully lift it out of the printer Encoder Disk and Encoder Sensor Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Left Cover refer Left Cover on page 188 2 Remove the Electronics Module Main PCA and PSU refer Electronics Module Main PCA and PSU on page 298 3 Remove the Left Spittoon refer Left Spittoon on page 306 4 Remove the Encoder Disk straight off Media Advance Roller spindle lift it straight out of the printer amp NOTE The Media Advance Roller spindle is delicate Remove the Encoder Disk gently 308 Chapter6 Removal and Installation ENWW 5 Disconnect the Encoder Sensor connector a 7 1 P Wp iF _ y 6 Remove two T 6 screws that secure the Encoder Sensor to the Media Advance Drive 7 Remove the Encoder Sensor PCA from the printer Installation E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 NOTE When you replace the Encoder Disk clean it with the alcohol included in the toolkit ENWW Encoder Disk and Encoder Sensor 309 NOTE If you are installing the Encoder Sensor after replacing the Media Advance Drive with a new unit you will need to adjust the Encoder Sensor position on the Media Advance Drive
99. e printer to complete the test SE 71 19 Recovery Press any key to shutdown the system 9 Press any key to shutdown the printer Select Right S N The purpose of this utility is to set the correct Serial Number and Part Number in case either the Formatter or the Printmech PCA have been replaced Set the correct Serial Number as follows 1 Inthe Diagnostics menu scroll to11 Error 71 19 Recovery and press OK Diagnostics menu ry LIUS Hs Service Station 9 I 0 Information Unit Information EERUM Reset Set Unit configuration Error 71 19 Recovery 2 The Front Panel will show the11 Error 71 19 Recovery submenu 3 Inthe 11 Error 71 19 Recovery submenu scroll to Select Right S N and press OK to start the test 13 Error 71 19 Recovery re Set Serial Number gt Select Right S N 4 The Select Right S N test starts and the front Panel displays the following message e Checking SE Log e Starting Horsburgh e Starting NvmMain e Starting NvmBackup e Getting Serial Number 122 Chapter 3 Diagnostic Menu ENWW 5 The Front Panel prompts choose the correct Serial Number and Part Number SE 71 19 Select Right S N Select the right Serial HDD S N MY6761C001 HDD P N Q66754 EEPROM S N MY6761C002 EEPROM P N Q6675A4 HDD Press UP DOWN to change and ENTER to select 6 Use the Arrow keys to the select the location containing the correct Serial and Part Number HDD for the Formatte
100. e when the System Error Figure 2 1 Code is displayed on the Front Panel G 56 01 hen escalating a problem Id x1 1021a Description STRING MEDIA JAM File 46 Chapter2 System Error Codes ENWW Continuable and Non Continuable Error Codes Some of the Error Codes are continuable which means you can press OK 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 lf the Error Code reappears then the Printer requires an on site visit in order to resolve the problem E 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 Code Brief Descriptions Reading a System Error Code System Error Codes explain which component system is failing and what action should be taken to resolve the problem System Error Codes are displayed directly on the front panel but can also be seen on the Information Page and have been defined in the format XX YZ or XX n Y Z m e XX Can be a malfunctioning subsystem or process 2 digits e n Subsystem or process Index if more than one used in the product Optional e g Identify the Ink Supply color and number e Y Who should perform the action 1 digit 0 for User or 1 for Service Engineer e
101. eceeeececeeeeeeeeeesseeeeeeeeeess 45 A PDF file is clipped or objects are MISSING cccccseececcseeeeeeeeeeeeeeeeeseeeesaeeeeesseaeeeessaneeeeeas 45 2 System Error Codes OCU ION areren E oct tees acer accnte oe cbc a ep hee eaters actos cana 46 Continuable and Non Continuable Error Codes cccccccccceeeeseeceeeceeeeeeeeeeeeeeseeeeseaaeeeeesseaeeseeeseaaaees 47 System Error Code Brief Descriptions cccecccceeceeeeeeeeeceeeeeeceeeeceeeeeeeeseeseaseeeeeessaeseeesssaaaseeeeseesaaas 47 System Error Codes Full Descriptions 00 0 0 ee ecccccceeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeessessceeesseaseeesseeeeeeeeaaaaes 50 3 Diagnostic Menu MEOCUCION se ersetaegrsticetsceincroce eerste ce hee E do sacar ev Snes vsaueueteateemnneeseaaseane e 74 DIAGNOSTICS Self POS oesau i E aa Tiaa 74 Service Tests Diagnostics cccccccseeeeccceccaeeeeeceeeceeeeseeeeeceeeeeseeeeeeeeseeeeesseeeseeeeeesseeseeeeessaeaseeeeeeeeeaas 74 Entering the Service Tests MEMU cccccccccsssseeceeeceeeeeceeeseeeeeeceeeseeeeseeeeessaeseeeeessaneeeeees 76 Mee AUN AXIS oe ececaaesisecedesnas seaqadiecsaseecdeenaceeeeenostseaueat ses cacesonssadaadaee santecateeenbauconeeasee 76 2 Paper DIVO seccate aE N a E EN EES 87 3 El ctronics NNO CN seca tc erapecanebasecnquececctndsGuane voaacoecesasascesedan icnaeteupessmocntecsoeues 90 4 Carriage Assembly scsicionssscneoncassaudoncsasealecbentesaceechendandaxteeaneteeacauesacheseondeassewsies 95
102. ecessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Carriage Rail Oiler Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Right Cover refer Right Cover on page 185 260 Chapter6 Removal and Installation ENWW 2 Remove the T 15 Carriage Rail Oiler attachment screw 4 _ i Va y G 4 3 Remove the Carriage Rail Oiler from the printer BS B NOTE When you reinstall the Carriage Rail Oiler use the Oil and Oil Dispenser from the Lubrication Kit to add 2 3 drops of oil to the foam of the Carriage Rail Oiler and in the small depression of the Carriage Rear Bushing ENWW Carriage Rail Oiler 261 4 Add 2 or 3 drops of oil in the depression where the Slider fits Color Sensor ESP Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Right Cover refer Right Cover on page 185 Remove the Left Cover refer Left Cover on page 188 Remove the Front Panel refer Front Panel on page 203 Remove the Top Cover refer Top Cover on page 205 Remove the Window Position Sensor refer Window Position Sensor on page 208 Remove the Ink Supply Tubes Support Rail refer Ink Supply Tubes Support Rail on page 209 nM e we e o Open the Carriage Cover 262 Chapter 6 Removal and Installation ENWW 8 Remove all the Printheads
103. ed position e The correct paper type is loaded check list on previous page e Thecorrect paper size minimum paper size 24 inches If these conditions are not met a warning will be displayed on the Front Panel and you will need to restart the Calibration from step 1 E NOTE Make sure you keep your hands away from the Print Platen as the Carriage will be moving at high speed and you could injure yourself or damage the Carriage Assembly 4 The printer will start to calibrate the Line Sensor Once the Line Sensor has been calibrated the results will be displayed on the Front Panel Press OKto continue or press Back or Cancel to exit the calibration VBLACK VWHITE RANGE B 775 700 900 R 650 700 900 0 532 700 900 G 655 700 900 Press ENTER to accept or CANCEL to reject values If the values are not within the range specified an error will appear on the Front Panel In this case try the following e Try the Scan Axis Calibration again e Replace the Line Sensor ENWW Service Calibrations 147 5 The Printer will start to calibrate the Line Sensor position to the Black Printhead The printer will print a line of black dots and then scan them 6 Once the Line Sensor has been calibrated the results will be displayed on the Front Panel If the values are within the range press OK to accept the results If the values are NOT within the range press Back or Cancel to exit and FAIL the calibration Once the Line S
104. eeeeeeseaaseeeesaeseeeeseaeeeeeesaneeeess 37 Lines are Printed Double or in Wrong Colors cccccccseecceceeeeeeeeesaeeeeeeesaeeeeeeeaaaneeeeeaaeeess 38 knes are discontinu US seien a a a idee tenewt eee 38 Lines are Blurred Ink Bleeds from Lines cccccccccceeeecceeeeeceeeeceaeuseesauseesaeeeesseusessanses 39 Problems Witi GrainiNeSS sorar a a 39 Paperi MOU lal eens E a a aeeai SaN E 40 Print Scuffing or Scratching when Touched cccccccseeeeceeeeceaeeeeeeesceeeeeeeeeessuaeeseeeessaaaaes 41 FAK MARKS Ol tile DAN isvtitsavereiad a r r E aaaeentid 41 Problems with the Edges Of objects ccccccccccecsseeeeeeeeeeeeesaeeeeeeeeeseesseeeceeseaeseeseaaaeeeeenees 42 EF OM ZING wccanen cei cwtaped nism ugatan staat datneiuatamshipsaacoanismiuaaa O 42 Black and white prints do not look neutral eee ccceeeeeeceeeeeeeeeeeeeeaeeeeeseeeeeeseeeeeesaeeeesaeeees 43 Horizontal lines at the end of a Cut Sheet print 2 0 ec ccccceeeceeceeeeeeseeeseeeesaeeeeeseaeeeseaaeees 43 Vericallline s OF GNierenl Col S eenen n an a ona exa tera Voneiela de iardecietia 43 WANIG Spots OM INE PINT givimaciaacasancthusscomvcdawhin S E ESA 43 Problems WIE GOlor ACCUlaACY anina a a A 43 Output Oniy Contaims a Partial PMT sispan N 44 ENWW Problems With Image CIDONO s2fcecceccessdcececeal acesdecpednannhdexdeastenedvssduatdzcntelenedsuneheneteeccanddedenes 44 Some objects are missing from the Printed image ccsecccccseeecc
105. eeeeseeeeseeeess 330 Preventive Maintenance Kit 2 cccccccccccseccceeceseeeceseeeeeeeeeeeeseeeeseeeeseesesseeeseeeeseeeeseneess 331 8 Printer menu Map ENWW 1 Ink Supplies Troubleshooting amp Print Quality n Introduction e Troubleshooting System Error Codes e Performing a Service Test on a failed Assembly e Performing the Necessary Service Calibrations e Solving Ink Supplies Problems e Solving Print Quality Problems e Using the Front Panel e The Printer does not Power ON e The Printer Continuously Rejects Printheads e What to do if the Front Panel is blank e Cover Sensors are not Working e The Line Sensor has Problems Detecting Media e Problems with Color Accuracy e Troubleshooting Media Jams Printhead Crashes e Banding at variable extreme environmental conditions e Worm marks on HP Coated media with light area fills e Solving Media Handling Problems e What to do when plastic parts on the Media Basket become damaged during printer setup e Solving Ink Supplies problems e Ink Cartridge Levels Information and Replacement e Printhead Information Replacement and Alignment e Ink Cartridge and Printhead Status Messages e Solving Ink Supplies Problems e Maintaining and Cleaning the Printheads e Print Quality e The Service Image Quality Diagnostic Print ENWW e Reading the Diagnostic Print Results e Ihe Advanced Diagnostic Prints e Reading the Advanced diagnostic Print Results e Troubleshooting
106. eeesceeeseeeceeeaeeceeeseneeeessaeeeeesanes 171 Performing the Service Calibrations and Diagnostic Tests cccccssesceeeseeeeeeeseeeeeaees 172 WIM OW e a ecco yecoe nade tccdage E case eases eeeccec ese E ssteecuaessecceeecatadess 174 FOI OC ssa EE E E ns calc ce E E EE OEE EE E EEE 177 Media Output Assembly seisriersasrnnniecen insidans eaaa EAE SEE a KA ERAAN AENEAN 178 MOR FTOR 1 MINT ae a E E E E E 179 RAST I OTM TEIT sareni E EEE E E E E A 181 PONUKE Camide DOO urere a E E A sacnsusiceecuescs 182 Re Mb o annd e DOO e e E E E AE E EE EE 183 IQUE GOVCN ssena E EET E R E A E EE 185 EOT OOV ra E A E 188 OC NEE AAE TE A E E E E E E A A EE heeceinness 194 Poa OCI a E E E ATE 195 Medid LOVET esere e EE EE E E EES 196 Media Lever Position Sensor ccccsceccceeeceeceesceeceeeeeeceesceseausececeeeceeseeeceeseeeeteeseeetsagecesseeeesaeeeeeas 198 ENWW ENWW G ter ASSEMDIY raat ence ee NEN tee actica aaa E A 199 RIGNt Rear Tray SUDDOM shiek cos E N eae 200 Kell Rear Tray SUDDON tstienesacaagetaneeacuastinltaacueediel R a Wuskcanvaeseiaedaaehaeeueigeareastiey 201 FRONC ANON 20s vee tareere visi tetas ioc ee yencea ete cies aa reesei ca vated once eige T aire a ee 203 TOP COV CR imeen ference eto A r a E N 205 Window POSION SENSO natisni a a eae a 208 Mk Supply Tubes SUPPOR Rail uenra aa ae a a a a 209 SENICA O aana a a a a T 214 Drop DeteClO ernan e E N r vatncnatenebaainians 217 AGroSol Fan ASSEIMDIY aosan
107. efer Front Cover on page 177 2 Remove the Media Output Assembly refer Media Output Assembly on page 178 3 Remove two T 15 screws that secure the Right Front Trim to the printer ENWW Right Front Trim 179 4 Open the Right Ink Cartridge Door 6 Remove Right Front Trim from the printer 180 Chapter6 Removal and Installation ENWW Left Front Trim Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Front Cover refer Front Cover on page 177 2 Remove the Media Output Assembly refer Media Output Assembly on page 178 3 Remove two T 15 screws that secure the Left Front Trim to the printer 5 Unclip the Left Front Trim ENWW Left Front Trim 181 6 Remove Left Front Trim from the printer Right Ink Cartridge Door Removal 99 E NOTE Switch off the printer and remove the power cable 1 Open the Right Ink Cartridge Door 2 Unclip the right side of the Right Ink Cartridge Door 182 Chapter6 Removal and Installation ENWW 3 Unclip the left side of the Right Ink Cartridge Door 4 Remove the Right Ink Cartridge Door Left Ink Cartridge Door Removal E NOTE Switch off the printer and remove the power cable 1 Open the Left Ink Cartridge Door ENWW Left Ink Cartridge Door 183 2 Unclip the left side of the Left Ink Cartridge Door 3 Unclip the right side of the Left Ink Cartridge Door 4 Remove the Left Ink Cartri
108. ems you can try cleaning the printhead nozzles manually using the following procedure E NOTE This is a delicate process and may damage the printhead Do not touch the electrical connections on the backside of the printhead You must remove the printhead see Remove a printhead and using a cotton swab and a little de ionized distilled water or Carriage Interconnect Wiper clean the bottom of the printhead until the residue is removed Flex Contacts Cleaning Tool E NOTE The Flex Contacts Cleaning Tool is part of the Maintenance Tool Kit which can be ordered using Part Number Q5669 60690 All the instructions needed to use the Flex Contacts Cleaning Tool will be packaged with the kit Whenever you replace the Printhead check the empty slots to see if they need cleaning In extreme circumstances when a Printhead is inserted it is possible that the Printer will not recognize it due to the build up of ink on the electrical connection between the Printhead and the Carriage Assembly Included with the Printer is a Flex Contacts Cleaning Tool This tool is provided in a separate package It also contains replacement sponges and an instruction sheet This tool should be used for cleaning the electrical interconnects of both the Carriage Assembly and the Printhead If the front panel displays the message Reseat or Replace next to the offending printhead try cleaning the flex circuits of the Carriage and the Printheads using the
109. ensor Test SOL 5 Refer 6 Color Sensor ESP on page 104 The purpose of this test is to verify the operation of the Color Sensor ESP Ink Delivery Test Refer 7 Ink Delivery System IDS on page 106 The purpose of this test is to verify the operation of components related to the Ink Delivery System The tests verify the operation of the e The Ink Delivery System e The Ink Supplies e Check for leakages Service Station Test Refer 8 Service Station on page 110 The purpose of this test is to verify the operation of the Service Station I O Information Refer 9 I O Information on page 117 The purpose of this test is to verify the TCP IP configuration Unit Information Refer 10 Unit Information on page 117 This option allows you to view the Firmware Version Part Number and Serial Number of the Printer EEROM Reset Refer 11 EEROM Reset on page 119 The purpose of this test is to reset the EEROM values Set Unit Configuration Refer 12 Set Unit Configuration on page 120 Not implemented Error 71 19 Recovery gt Refer 13 Error 71 19 Recovery on page 120 The purpose of this utility is to set the Serial Number and Part Number in case both the Formatter and the PrintWMech PCA are replaced at the same time or select the correct Serial Number and Part Number if only one of the components has been replaced Service Tests Diagnostics 75 Entering the Service Tests Menu E NOTE In order to enter the Service Ut
110. ensor has been calibrated the results will be displayed on the Front Panel Press OK to finish the calibration or press Back or Cancel to exit the calibration Line Sensor Calibration Y Offset Range 30 to 59 Y Offset got 43 X Offset Range 24 to 24 X Offset got 14 X SVS Offset 1050 to 1050 X SVS Offset got 944 Press any key to exit 7 The Printer will now perform the Printhead Alignment When the following message appears on the front panel you must select whether you would like to continue with the calibration by pressing the OK key Press Back or Cancel to exit the calibration Line Sensor Calibration Press ENTER to proceed with Pen Alignment calibration or BACK CANCEL to exit 8 Once the Printhead Alignment is completed the following message will be displayed on the Front Panel Press the OK key to continue Printhead aliqnment Calibration successfully completed PressoK to continue If the Printhead Alignment fails for any reason a warning message will appear on the Front Panel In this case try the following e Enter the Front Panel menu and retry the Printhead Alignment If the Alignment completes successfully then perform the Color Calibration e Ifthe Alignment fails again check the Alignment pattern to see if any of the Printheads are printing incorrectly If necessary perform a Printhead Recovery through the Front Panel and retry the Printhead Alignment 148 Chapter 4 Service Menu
111. ent paper to align the printheads Photo paper is recommended for the best quality Reinsert Printheads Procedure 1 Ifthe realignment process is running and the wrong paper is loaded press the cancel key on the front panel Do not print if the realignment process has been canceled You can restart the alignment with the Image Quality Maintenance menu procedure 2 Load the paper you wish to use You can use a roll or cut sheet 3 Remove and reinsert all the printheads see Remove a printhead and Insert a printhead This will start the printhead alignment procedure 4 Ensure the transparent window closed as a strong light source near the printer during printhead realignment can affect alignment 5 The process will take about six minutes Wait until the front panel display shows the process complete before using the printer Image Quality Maintenance Procedure 1 Load the paper you wish to use You can use a roll or cut sheet however it must be at least a 16 inches roll or an A2 portrait sheet 420mm x 594mm Do not use transparent and semi transparent paper to align the printheads Photo paper is recommended for the best results plain bond and thin coated papers provide acceptable but marginal results 2 Press the Menu key to return to the main menu and select the Image Quality Maintenance menu Icon 3 Select Align printheads The printer will check to see if it has enough paper to run the realignment 18 Chapter1 Ink Su
112. enu mi oCdil BATS Paper Drive Electronics Module Carriage Assembly Sensors SOL 2 The Front Panel will show the7 IDS submenu gt Ink Delivery System gt Check Ink Supplies 3 Inthe IDS submenu scroll to Leakage and press OK to start the test 4 The Check Ink Leakage test checks that there is no ink in the tubes or ink cartridge 8 Service Station The complete Service Station test consists of individual tests for the different components related to this subsystem These tests are e Service Station e Primer Motor o Aerosol Fan 110 Chapter 3 Diagnostic Menu ENWW ENWW Diagnostic tests also need to be performed after removing or replacing certain printer components If you have removed or replaced printer components check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform Refer to Service Calibration Guide to Removal and Installation on page 170 Service Station 1 Inthe Diagnostics menu scroll to 8 Service Station and press OK Diagnostics menu 2 The Front Panel will show the8 Service Station submenu Paper Drive Electronics Module Carriage Assembly Sensors SOL IDS 8 Service Station gt Primer Motor gt Aerosol Fan 3 Inthe 8 Service Station submenu scroll to Service Station and press OK to start the test 4 The Service Station test starts and the front Panel displays the
113. er ENWW Media Advance Drive 311 7 Grip the motor housing of the Media Advance Drive and gently pull it towards you sufficiently to allow you disengage the Media Advance Drive from printer 8 Installation E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 NOTE Use the following procedure to install and correctly adjust a new Media Advance Drive You will need Media Advance Drive Adjustment Tool from the HP Designjet Printer Tool KIt Q6683 67001 If you are installing the Encoder Sensor after replacing the Media Advance Drive with a new unit you will need to adjust the Encoder Sensor position on the Media Advance Drive refer Media Advance Drive on page 311 1 Carefully position the Media Advance Drive in the printer 312 Chapter6 Removal and Installation ENWW 2 Insert the three T 15 attachment screws but do NOT fully tighten them 3 Position the Media Advance Drive Adjustment Tool on the end Media Advance Roller shaft push it firmly onto the shaft and maintain a constant pressure to ensure it is flush to the Media Advance Drive 4 Rotate the Media Advance Drive Adjustment Tool fully counter clockwise to ensure its flat surface of the tool is firmly against the flat surface of the Media Advance Drive mounting ENWW
114. er cord and power On the Printer module 0 module 1_module 2 e Check that the cables between the Left Ink Supply Station and PrintMech PCA the are not damaged and are correctly connected e Perform the Ink Delivery System diagnostic test to troubleshoot the problem further 7 Ink Delivery system IDS on page 106 e Ifthe System Error continues replace the Right Ink Supply Station refer Right Ink Supply Station on page 280 e Ifthe System Error continues replace the PrintMech PCA refer PrintWech PCA on page 220 System Error Codes Full Descriptions 55 22 2 YZ Cause Solution ISS Right BPSO error Supplies 0 1 2 Module 2 far right Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer module 0 module 1_module Check that the cables between the Right Ink Supply Station and PrintMech PCA the are not damaged and are correctly connected e Perform the Ink Delivery System diagnostic test to troubleshoot the problem further 7 Ink Delivery system IDS on page 106 e Ifthe System Error continues replace the Right Ink Supply Station refer Right Ink Supply Station on page 280 e Ifthe System Error continues replace the Main PCA refer Electronics Module Main PCA and PSU on page 298 24 YZ Cause Solution Ink Setup failure Ink Delivery System IDS Tubes purge
115. er2 System Error Codes ENWW 78 1 YZ Cause Solution Media settings area missing in media settings file Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer Check that the Printer has the latest Firmware version If not update the Firmware to the latest version e Update the OMES 79 YZ Cause Solution Generic Firmware error Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Check that the Printer has the latest Firmware version If not update the Firmware to the latest version 79 1 YZ Cause Solution Recoverable firmware error that does not stop the printing Try the following process e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer Check that the Printer has the latest Firmware version If not update the Firmware to the latest version 81 YZ Cause Solution Problem with paper advance Try the following e Open the Window and check for any visible obstacles restricting the movement of the Drive Roller If there is a wrinkled mass of media inside the paper path lift the Pinchwheels using the Media Lever and clear the obstruction e Perform the Media Drive diagnostic test to troubleshoot t
116. es Carriage Latch Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Right Cover refer Right Cover on page 185 Remove the Left Cover refer Left Cover on page 188 Remove the Front Panel refer Front Panel on page 203 Remove the Top Cover refer Top Cover on page 205 Remove the Window Position Sensor refer Window Position Sensor on page 208 Remove the Ink Supply Tubes Support Rail refer Ink Supply Tubes Support Rail on page 209 Open the Carriage Cover Fe e hCUe 272 Chapter6 Removal and Installation ENWW 8 Remove all the Printheads 9 Remove the four T 15 screws that secure the Ink Supply Tubes to the Carriage Assembly idee Ul oo oo oo oo 9o 10 Carefully lift out the Ink Supply Tubes and close the carriage cover at the same time gt _ ENWW Carriage Cover includes Carriage Latch 273 11 Close and lock the Carriage Cover 13 Unclip and slide off the small cover of the Carriage Assembly Carriage PCA 274 Chapter6 Removal and Installation ENWW 14 Remove one T 15 screws that secures the large cover of the Carriage PCA ENWW Carriage Cover includes Carriage Latch 275 17 Remove six T 10 screws that secure the Carriage Assembly Cover hinge 18 Carefully lift the Carriage Cover in the vertical position to remove it from the Carriage Assembly E NOTE When you finish installing or replacing this compo
117. es problems What are Ink Supplies For each of the ink colors used in the printer there are two components the Printhead and Ink Cartridge These components are called Ink Supplies D ate F I Ink Cartridges The printer s Ink Cartridges provide ink to the Printheads The color Ink Cartridges supplied with the printer have a capacity of 69ml but optional 130 ml and 300 ml are also available The Ink Cartridges require no maintenance or cleaning As long as each Ink Cartridge is inserted correctly into its slot the ink will flow to the Printheads Because the Printheads control the amount of ink transferred to the page you will continue to see high quality printing results that require no maintenance or cleaning As long as each Ink Cartridge is inserted correctly into its slot the ink will flow to the Printheads Because the Printheads control the amount of ink transferred to the page you will continue to see high quality printing results even when the ink levels are getting low The front panel displays the status of the Ink Cartridge Using the front panel detailed information can be checked on the Ink Cartridges Available Ink Cartridges Color Part number 69ml Part number 130ml Part number 300ml HP 70 Matte Black C9436A C9448A CN635A ENWW Solving Ink Supplies problems 9 HP 70 Photo Black C9437A C9449A CN633A HP 70 Light Gray C9439A C9451A CN634A HP 70 Cyan C9440A C9452A CN636A HP 70 Magenta C9441A C94
118. es to the Top Cover 6 Remove the remaining three Window hinge locking plates from the Top Cover ENWW Window 175 7 Remove the remaining three Damper Rotary pieces from the Top Cover 8 Grip the Window at the left and right edges and move it horizontally towards the right as far as it will go 9 Pull the Window towards the front to disengage the hinges 176 Chapter6 Removal and Installation ENWW 10 Lift the Window vertically out of the printer Front Cover Removal E NOTE Switch off the printer and remove the power cable 1 Squeeze each of the four attachment clips under the Front Cover to release the cover from the printer 2 Carefully pull the bottom of the Front Cover forwards until you can release it from its attachments ENWW Front Cover 177 3 Unhook the Front Cover from the four attachments and remove it from the printer Media Output Assembly Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Front Cover refer Front Cover on page 177 2 Remove four T 15 screws that secure the Media Output Assembly to the printer 3 Release the four attachment clips 178 Chapter6 Removal and Installation ENWW 4 Lift the front of the Media Output Assembly 5 Slide the Media Output Assembly forwards out of the printer Right Front Trim Removal NOTE Switch off the printer and remove the power cable 1 Remove the Front Cover r
119. essageeeeessaeeeeeseas 153 FOTO OV SS E E T eee doses ed E N E AE T E DEE A E 154 PONCO a E R E EE E E A A E AE E 155 LO OOOI aean A E E E ER E AE AE 156 PAIGE Hand Assembles scssrirsrsisiudiisn digeiner iradia a Norai erna T AE Te Ae ER ETRA iai 157 L n Hand IAS Se HAO NSS serris a E a EEEn EEEE EE 158 Ciao A EDI ene AE T EE E E E 159 CTA IS PASSO MOS Se iussionem aaan nania E iaaa E ENa iaa aa N EAE A Naia iai 160 Paper Path Assemblies Front ccccccccceseccseeeeseeeeeceeeeeneeeeseeeeeseueeeseaeeesseeessueeeseaeessaueesseeeeseeeeesees 161 Paper Pali Assambles ACAL arrens e EE E 162 ToO A e E E E E E eeaetunl alanatahseinltes sintaumncens 163 TOOL Oer a E E E E E A E 164 Miscellaneous PANS cansunadterscatracetarteasrstotciracueiocatiacaviataiueineirseadiacneraiesenebaientaiesnvianriuisaendsunese stamens 165 6 Removal and Installation MPO CO i M EEE EEEE S E E T E E E E E EE N E ET 169 Salety PRECAUTIONS visctsie cores cxcmccdiccdcteainn cen aaa a EE aani a aa iana e 169 Electrostatic Discharge ESD Precautions ccccccceecceeeeeeeceeeeeeeaeeeeeeeeseeeeeeeeseaeeeesaes 169 Reauled TOOG serari E eee ee eee 169 Service Calibration Guide to Removal and Installation ccccccccccssecceceeseeeeeeeeeeceeeeeeeeeeeeseeeesaees 170 Using the Service Calibration Guide ccccccccssseeceeceeeeeceecseeeeeeeeeeseeeeeeesseeseeeeeeeaaaaeees 170 The Service Calibration Matrix ccccccccccccssseceeceseceeceeeecee
120. etermined whether the Printer requires any on site maintenance Remember that the Key combination for the Customer to Enter the Service Tests and Utilities is different from the one that the Customer Engineer will use Service Tests Diagnostics The following is a list of all internal Service Tests available in the Printer Refer Entering the Service Tests Menu on page 76 for instructions to enter the Service Tests menu 1 Scan Axis Test Refer 1 Scan Axis on page 76 The purpose of this test is to verify the operation of components related to the Scan Axis The tests verify the operation of the e Starwheel lifter test e PRS e Scan Axis e Cutter 2 Paper Drive Test Refer 2 Paper Drive on page 87 The purpose of this test is to verify the operation of components related to the Media Axis 3 Electronics Module Refer 3 Electronics Module on page 90 The purpose of this test is to verify the operation of the e Main PCA Formatter e Printer Configuration e Power Supply Unit e PrintMech e Carriage Communication 4 Carriage Assembly Test Refer 4 Carriage Assembly on page 95 74 Chapter3 Diagnostic Menu ENWW 10 11 12 13 ENWW The purpose of this test is to verify the operation of the Carriage Assembly Sensors Test Refer 5 Sensors on page 101 The purpose of this test is to verify the operation of the following Sensors e Window Sensor e Media Lever Sensor e Media Sensor Color S
121. exceeded their expiration dates Horizontal Lines Across the Image Banding Description of problem When you look at the image you have printed there are horizontal lines across the image Shown below is an example of what you might see if you have this problem Corrective Action 1 36 Chapter 1 Check that the paper type loaded corresponds to the paper type selected in the front panel and in the software You can verify the paper type selected through the Front Panel Main Menu Paper menu View loaded paper Check that the appropriate print quality settings are being used refer to the User s Guide for more information and reprint the image In some cases print quality problems can be resolved by selecting a higher print quality level Print the Service Image Diagnostics Print and clean any printheads that need cleaning Reprint the job in case the problem has been solved Ink Supplies Troubleshooting amp Print Quality ENWW 5 Check the paper advance calibration status If the status is PENDING perform the Paper Advance Calibration Main Menu Image Quality Maintenance Paper Advance Calibration Calibrate Paper Advance After calibration reprint the job Lines are Missing Too Thin or Too Thick Description of problem Shown below is an example of what you might see if you have this problem Corrective Action T Check that the paper type loaded corresponds to the paper type selected in the
122. f Window sensor PASS Please close the cover Press any key to continue 8 Close the Window 9 Press any key to continue 10 The Media Lever sensor test starts and the Front Panel prompts you to raise the Media Lever Sensors Test of Pinchwheel Lever Sensor Please raise the lever Press any key to continue 11 Raise the Media Lever 12 Press any key to continue 102 Chapter 3 Diagnostic Menu ENWW ENWW 13 14 15 16 17 18 19 20 21 22 23 24 25 26 The Media Lever sensor test continues and the Front Panel prompts you to lower the Media Lever Sensors Test of Pinchwheel Lever sensor PASS Please lower the lever Press any key to continue Lower the Media Lever Press any key to continue The Media sensor test starts and the Front Panel prompts you load media Sensors Test of Paper sensor Please raise the lever load the paper and lower the lever Press any key to continue Raise the Media Lever Load media Lower the Media Lever Press any key to continue The Media sensor test continues and the Front Panel prompts to remove media Sensors Test of Paper sensor PASS Press any key to continue Raise the Media Lever Unload the media Lower the Media Lever Press any key to continue The Front Panel shows the test complete display for a few seconds Sensors Service Tests Diagnostics 103 27 The Front
123. f nozzles out then replace the defective Printhead Problems with Stepped Lines ENWW Description of problem When you look at the image you have printed there are stepped lines in the borders of arrows and diagonal lines The lines should be straight with no stepping Shown below is an example of what you might see if you have problems with Stepped Lines Troubleshooting Print Quality Problems 37 Corrective Action 1 The problems may be inherent in the image that you are trying to print Try to improve the image with the application that generated the file 2 Check that the appropriate print quality settings are being used refer to the User s Guide for more information 3 Turn On the Maximum Detail option in the Driver 4 Change the image rendering resolution to 300 dpi or 600 dpi depending on the printing needs You can find the Max Application Resolution option in the Windows driver dialog s Advanced tab under Document Options gt Printer Features Lines are Printed Double or in Wrong Colors Description of problem This problem can have various visible symptoms as shown below N OX Borders of colored blocks are wrongly Colored lines are printed double in different colors colored Corrective Action Reseat the Printheads by removing them and then reinserting them NOTE As you reseat the printheads the printer will automatically align the printheads It is important that t
124. f you are removing it with the Carriage Assembly Ef NOTE Before you reinstall the Carriage Assembly use an alcohol dampened cloth to remove all traces of residual adhesive remaining from the double sided pads removed in step 14 from the printer before applying new pads in the same positions as the original pads 99 E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Carriage Rear Bushing Removal 333 E NOTE Switch off the printer and remove the power cable 1 Remove the Front Cover refer Front Cover on page 177 Remove the Right Cover refer Right Cover on page 185 Remove the Left Cover refer Left Cover on page 188 Remove the Cutter Assembly refer Cutter Assembly on page 199 Remove the Front Panel refer Front Panel on page 203 Remove the Top Cover refer Top Cover on page 205 Remove the Window Position Sensor refer Window Position Sensor on page 208 Pr aA eS r p Remove the Ink Supply Tubes Support Rail refer Ink Supply Tubes Support Rail on page 209 254 Chapter6 Removal and Installation ENWW 9 Remove the Encoder Strip with spring and attachment nut refer Encoder Sirip with spring and attachment nut on page 231 10 Remove the Carriage Assembly with or without Trailing Cable refer Carriage
125. fer to Service Calibration Guide to Removal and Installation on page 170 Left Ink Supply Station Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Left Cover refer Left Cover on page 188 284 Chapter6 Removal and Installation ENWW 2 Remove two T 10 screws that secure the Left Side Plate of the Left Ink Supply Station 4 Remove two T 10 screws that secure the Right Side Plate of the Left Ink Supply Station ENWW Left Ink Supply Station 285 5 Remove the Left Ink Supply Station bonding cable 286 Chapter6 Removal and Installation ENWW 8 Remove the two T 15 screws that secure the Left Ink Supply Station to the printer 9 Disconnect the three connectors from the Left Ink Supply Station E NOTE If you need to change the ISS Harness Cable make sure you keep the previously used plastic connector The new cable will arrive with a female end which you will replace with the existing male end ull 10 Unroute the three cables from the Left Ink Supply Station ENWW Left Ink Supply Station 287 11 Carefully lift the Cartridge Tubes Connector out of the Left Ink Supply Station 12 Carefully lift the Left Ink Supply Station enough so that you can rotate it counterclockwise to release the front attachment from the printer 13 Le MO ODA da s i 1a PAM 5 bi vs TA as 33 EE NOTE When you finish installing or replacing this c
126. front panel and in the software You can verify the paper type selected through the Front Panel Main Menu Paper menu View loaded paper Check that the appropriate print quality settings are being used refer to the User s Guide for more information Select the custom print quality options in the Print dialog try turning on the Maximum detail option Reprint the job in case the problem has been solved If the resolution of the image is greater than the printing resolution a loss of line quality may be seen You can find the Max Application Resolution option in the Windows driver dialog s Advanced tab under Document Options gt Printer Features Reprint the job in case the problem has been solved Check the Printhead alignment status If the status is PENDING perform the Printhead Alignment Main Menu Image Quality Maintenance Align Printheads After alignment reprint the job Check the paper advance calibration status If the status is PENDING perform the paper advance calibration Main Menu Image Quality Maintenance Paper Advance Calibration Calibrate Paper Advance After calibration reprint the job Use Part 3 of the Image Quality Diagnostic Print check if there are a significant amount of nozzles out in the color that is actually causing the problem if see you a problem with the Black color in the customer print then only check the Black printhead in the Image Quality Diagnostic Print If there is a significant amount o
127. g e Check that the Calibration Pattern was not incorrectly cut trimming the actual pattern during the media load process If this is the case perform the Paper Advance Calibration again from step 1 e Perform a Line Sensor Calibration Refer refer Line Sensor Calibration on page 146 and then rescan the Calibration pattern e Replace the Line Sensor gt refer Line Sensor on page 267 e fthe problem continues replace the Media Advance Drive refer Media Advance Drive on page 311 144 Chapter 4 Service Menu ENWW Drop Detector Calibration ENWW The purpose of this Service Calibration is to calibrate the Drop Detector located in the Service Station in relation to the Carriage Assembly Service calibrations also need to be performed after removing or replacing certain printer components If you have removed or replaced printer components check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform Refer to Service Calibration Guide to Removal and Installation on page 170 Calibrate Drop Detector Perform the Drop Detector Calibration as follows 1 Inthe Service Calibrations submenu scroll to Drop Detector Calibration and press OK Service calibrations Scan Axis calibration Service Station Paper advance calibration gt Drop Detector calibration Line Sensor calibration Carriage PCA 2 When the following message appears on the front panel you mus
128. g and apply it to the Drive Roller and Overdrive surface while it is rotating Make sure that you thoroughly clean the Drive Roller and Overdrive surface 3 Press Enter when you have completed the cleaning procedure 4 Allow the Drive Roller to dry before loading media in to the Printer Level of Printer Usage ENWW Normal printer use means 6 000 000 Carriage Cycles which corresponds to approximately 100 000 AO prints on average 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 Preventive Maintenance 329 One of the EEROM counters is assigned to counting the number of carriage cycles Service Part LIFE_VALUE Maintenance Advice Belt Cycles 3000000 PMKIT 1 Bushings Life 3000000 PMKIT 1 Trailing Cable Cycles 3000000 PMKIT 1 Scan Axis Cycles 3000000 PMKIT 1 scan Axis Distance Covered 4500000 PMKIT1 Tubes Cycles 3000000 PMKIT1 Right Spittoon Volume 600000000 PMKIT2 Left Spittoon Volume 51000000 PMKIT2 Cutter Life 25000 PMKIT3 When these components of the Printer exceed this amount the front panel displays the following message Maintenance 1 required Maintenance 2 required Once one of the maintenance advised messages is displayed the relevant preventive maintenance kit must be used to replace the most worn parts of the printer Use the Removal
129. hapter1 Ink Supplies Troubleshooting amp Print Quality ENWW Printhead Information Replacement and Alignment Obtaining Printhead Information 1 Scroll to the Ink Menu icon and press OK DSB Int 2 Inthe Ink Menu submenu scroll to Printhead information and press OK View ink levels Replace ink cartridges Replace printheads Ink cartridge information Printhead information 3 Inthe Printhead Information submenu scroll to the Printhead that you want information on and press OK Printhead information e View M Y printhead 1 View LM LC printhead 2 e View PK LG printhead 3 e View ME C printhead 4 4 The front panel displays information on the selected Printhead M Y printhead 1 Color Magenta vellow Product name HP 7 Product number CS4 64 Serial number 4 1 25694351 26 2007 Status 0K Ink fired 1610 ml Warranty status Out of zi The information supplied is e The make of the printhead e The product number of the Printhead e The serial number of the Printhead e The current status of the printhead e How much ink has been fired consumed by the printhead EY NOTE It is possible for a printhead to consume more than one Ink Cartridge e The current warranty status of the Printhead ENWW Printhead Information Replacement and Alignment 15 Changing a Printhead 1 A 16 Chapter 1 Scroll to the Ink Menu icon and press OK Gal View i
130. he Arrow keys to select NO and press OK The Color Sensor ESP enable test starts and the front Panel displays the following messages e Starting ColorSensor e Starting ColorSensing e Reading Color Sensor ESP status e Enabling Color Sensor ESP The Front Panel then displays Color Sensor ESP enable test result and prompts you to press any key to continue Carriage Assembly Starting ColorSensor Starting ColorSensing SOL enable disable OK Press any key to continue Press any key to continue The Front Panel then prompts you to confirm the information Carriage Assembly FW Revision v4 080D Sensor Type PP2 Serial Number 169857308 Mfg date 0622 YES Press ENTER to confirm and BACK CANCEL to reject Press OK to the confirm the information If you want to reject the information use the Arrow keys to select NO and press OK The Carriage Assembly calibration test starts and the front Panel displays the following messages e Starting ColorSensor e Starting ColorSensing e Reading Color Sensor ESP status e Reading registers e Performing calibration Service Tests Diagnostics 99 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 The Front Panel then displays DeltaE test result and prompts you to press any key to continue Carriage Assembly Maximum DeltaE 2 560 Press any key to continue Press any key to continue The Carriage moves i
131. he alignment is completed properly See Aligning Printheads on page 18 Lines are discontinuous If the lines are broken in the following way 1 Check that the appropriate print quality settings are being used refer to the User s Guide for more information 2 Reseat the Printheads by removing them and then reinserting them E NOTE As you reseat the printheads the printer will automatically align the printheads It is important that the alignment is completed properly See Aligning Printheads on page 18 38 Chapter1 Ink Supplies Troubleshooting amp Print Quality ENWW Lines are Blurred Ink Bleeds from Lines Description of problem This problem is often caused by the ink soaking into the paper making the lines blurred and fuzzy This could be because of the humidity in the air Corrective Action T 4 S 6 T7 Check that the environmental conditions temperature humidity are suitable for high quality printing Make sure that the paper type selected in the Front Panel is the same as the paper type loaded into the Printer Try using a heavier paper type When printing dense colors it is recommended to use HP Heavyweight Coated Paper HP Super Heavyweight Coated Paper or thicker Digital Fine Art papers If glossy paper is being used try changing to a different type of glossy paper Select the custom print quality options in the Print dialog and turn on the More passes option Allow the prints time t
132. he back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Open the Window and check for any visible obstacles restricting the movement of the Media Advance Roller If there is a wrinkled mass of media inside the paper path lift the Pinch wheels using Media Lever and clear the obstruction e Perform the Paper Drive diagnostic test to troubleshoot the problem further 2 Paper Drive on page 87 e Check that the Media Advance Drive cable is not damaged and is correctly connected to the Main PCA e Replace the Media Advance Drive refer Media Advance Drive on page 311 e Ifthe System Error continues replace the Main PCA refer Electronics Module Main PCA and PSU on page 298 58 Chapter2 System Error Codes ENWW 41 1 YZ Cause Solution Electrical fault or current limit in Media Axis Motor Try the following Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer Open the Window and check for any visible obstacles restricting the movement of the Media Advance Roller If there is a wrinkled mass of media inside the paper path lift the Pinch wheels using Media Lever and clear the obstruction Perform the Paper Drive diagnostic test to troubleshoot the problem further 2 Paper Drive on page 87 Check that the Media Advance Drive cable is not damaged and is correctly connected to the M
133. he problem further 2 Paper Drive on page 87 Check the connections on the Main PCA the Media Advance Drive is connected to the connector labeled Paper Motor e _ Ifthe System Error continues replace the Media Advance Drive Media Advance Drive on page 311 System Error Codes Full Descriptions 81 1 YZ Cause Solution Problem finding the Drive Roller zero Try the following e Open the Window and check for any visible obstacles restricting the movement of the Drive Roller If there is a wrinkled mass of media inside the paper path lift the Pinchwheels using the Media Lever and clear the obstruction e Perform the Media Drive diagnostic test to troubleshoot the problem further 2 Paper Drive on page 87 Check the connections on the Main PCA the Media Advance Drive is connected to the connector labeled Paper Motor e _ Ifthe System Error continues replace the Media Advance Drive Media Advance Drive on page 311 84 YZ Cause Solution Back tension servo shutdown roll feeding Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Ifthe problem persists contact HP support 85 YZ Cause Solution Problem finding the Drive Roller zero Try the following e Perform the Media Drive diagnostic test to troubleshoot the problem further 2 Paper Drive on page 87 86 YZ
134. ibration Refer Drop Detector Calibration on page 145 The purpose of this Service Calibration is to calibrate the Drop Detector located in the Service Station in relation to the Carriage Assembly Line Sensor Calibration Refer Line Sensor Calibration on page 146 The purpose of this Service Calibration is to calibrate the intensity of the Line Sensor An incorrect calibration can result in edge detection failures during media loading and incorrect reading of prints that are used for alignment or calibration Carriage Refer Carriage PCA on page 149 The purpose of this Service Calibration is to reset the ink short thresholds after replacing the Carriage PCA Color Sensor Refer Color Sensor ESP Calibration on page 149 E NOTE If ALL the Calibrations need to be performed for example when both the Formatter and the PrintWech PCA have been replaced you must perform them in the following order Drop Detector Service Station Calibration Line Sensor Scan Axis Calibration Paper Advance Calibration 138 Chapter 4 Service Menu ENWW Entering the Service Calibrations Menu 1 A A Once the message Ready or Ready for paper is displayed on the front panel press the Menu key Ready for paper http NPI 4 CAS5B131 http 16 23 94 30 Press E to enter f menu if TE To have the user to perform certain Service Utilities once inside the Main Menu press the Down arrow key and the Ca
135. ibration using the same type of paper that will be used for the final print Main Menu Image Quality Maintenance Paper Advance Calibration Calibrate Paper Advance lf there is white point banding in only one color band and the problem cannot be fixed using the Printhead recoveries in some cases using the force a drop detection option can fix this issue See Force Drop Detection on page 35 No Printing Defects Found in the Diagnostic Print If all the test patterns from the Diagnostic Print are correct and you still experience Image Quality problems you can use the following procedures to resolve the problem Reading the Advanced diagnostic Print Results on page 30 Printhead Alignment on page 33 Nozzle Health on page 34 Force Drop Detection on page 35 The Advanced Diagnostic Prints What are the Advanced Diagnostic Prints ENWW Advanced Diagnostic Plot These tests provide more information of the IQ defects found in the Image Quality Service plot The Advanced Diagnostic Plot is divided into the following parts Visual Media Advanced Diagnostic Used to check advance reliability Visual Alignment Diagnostic Used to check pen alignment reliability Visual Nozzle health Diagnostic Used to check nozzle health reliability Force Drop Detection Used to reset the nozzle health historic data base and force new drop detection The Advanced Diagnostic Prints 29 Printing the Advanced Diagnostics Print 1 Inthe Service Util
136. iisccadanetainceceamaaistoqamens angtacoauneasaer aaa 219 PAMMECTERCA re Se Oo See eed Pe ot 8 eA ed Meas BO oe ag ee acre Alas 220 Fent Paper Space PPS SOlENOIG enn Gasatecwed acces E Ea E a A 221 IO R E PAE e E A eee eee TE E ET 223 Weft Spindle Holder saccade a ca a ed 224 Rint SPINS OIG ON esse dented testa cried emai aadonadicsasansadbagaanankeunnsatecues A T 224 Glean Out Assembly sesce ctieihire os Sacse boven sen tuei senna Rent usagatedoi aE a a a e EA aa A aA a a 225 OULOT Paper ens o acaat o a a a ae ee etc tn N 226 IE at ia 2 G7 00 gt seraa eee ee ee eee ee ee eee ae 229 UE Wis OGG aa ET E E E E T 230 Encoder Strip with spring and attachment nut ccccceccccseeeecceeeeeeceeeseeeaeececseeceessaeeessneeessaeeees 231 Gleam Encoder SmO PrOCCCUIC assocar aa aei era ie a raais toast 234 Encoder SO erases vee eave Aa a a a eet eect ee ee 236 Trailing Gable pect ea crater senate eee Etude cece ean ee cates sake enamel nase waisted adap oe enacaatsee seem oamtuce aaa 237 Carriage Assembly with or without Trailing Cable ccccccccsseeeceeeeeeeeeeaeeeeeeeaeseeeeesaeeeeeseeneeeeeees 244 Gamage Rear BUSHING ernie eaer a a a e tra seue ee aeteun a a 254 BLASS MDIV sonenn a mee dsoann ateecataranediantentosunt 256 CANIS NOON orra a a A esas coateratan ccna Seetancckeceeateaaneeeene 257 Garage Fall Quer asiaa aetna tdeuaesh ves Walle ann Getesestaesh tums an sage an cae noel ee Ale 260 GOO SENSONE SR tinge cak
137. ility Menu please refer to the instructions on Entering the Service Utilities Menu on page 124 1 Make sure the printer is switched OFF from the power switch on the front of the printer andNOT from the power switch on the back of the printer 2 For On Site Engineers hold the Up arrow key and the OK key down and switch the printer ON using the front power switch Wait until the LED of the power switch stops flashing usually after 5 seconds before releasing ALL three keys 3 Once inside the Service Tests Menu use the Arrow keys to scroll through the Service Tests selections Press the OK key to begin a specific test when the required Service Test is highlighted E NOTE Contact Phone support On site support for further assistance NOTE The Service Tests work in a special Mode which does NOT require the full Initialization of the Printer Therefore it is important that once you have finished with the Service Tests you MUST power OFF the Printer and Power ON again before trying to print or before executing another Service Test NOTE In some cases a quick press of a button may not be recognized by the Printer When pressing a button be sure to press it deliberately and all the way to the bottom of its travel NOTE Ifthe Printer hangs up during a test switch the Printer OFF and restart from step 1 1 Scan Axis The complete Scan Axis test consists of individual tests for the different components related to the Scan Axis The
138. image should be converted into SWOP Output Only Contains a Partial Print If the output that was expected only contains a partial image then try the following to resolve the problem 1 4 3 Was the Cancel key pressed before all the data was received by the Printer If so send the file again and make sure that the Cancel key is not pressed The I O Timeout setting may be too short Increase the I O timeout setting Setup Menu l O Setup IO Timeout and then send the file again There might be a communications problem between the Printer and Computer Check the USB or network cable between the computer and the Printer to make sure it is not damaged and is connected correctly Make sure that the software settings are correct for the current page size e g long axis prints If network software is being used make sure it has not timed out Problems with Image Clipping This normally indicates a discrepancy between the actual printable area on the loaded paper and the printable area as understood by the software This kind of problem can often be identified before printing by previewing the print 44 Chapter 1 Check the actual printable area for the paper size that is loaded printable area paper size margins Check what the software understands to be the printable area which it may call printing area or imageable area For example some software applications assume standard printable areas that are large
139. in the 0 offset column with minor variations between 2 and 2 columns If the offset is not positioned on the 0 column or between 2 and 2 columns and the whitest vertical varies greatly the printer requires Paper Advance Calibration Main Menu Image Quality Maintenance Paper Advance Calibration Calibrate Paper Advance 30 Chapter1 Ink Supplies Troubleshooting amp Print Quality ENWW A ENWW Advance The following plot shows correct media advance there is a straight white line positioned close to the 0 column for the majority of the points uf lie vo om tae wo z a P column instead of the 0 column for the majority of the points Reading the Advanced diagnostic Print Results NOTE Itis very important to verify that the loaded media is the same media type as selected in the front panel You can verify the media type selected through the Front Panel Main Menu Paper menu View loaded paper The wrong type of paper selected will produce an offset error in the Paper The following plot shows a bad media advance there is a straight white line positioned close to the 6 31 er ey SS Corrective Action To fix Paper Advance problems try the following 1 Check the Paper Advance Calibration Status This can be done by going to Main Menu Paper View Loaded Paper At the bottom the Front Panel displays the Paper Advance Calibration status There are three status message
140. ind which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Right Ink Supply Station Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Right Cover refer Right Cover on page 185 280 Chapter6 Removal and Installation ENWW 2 Remove two T 10 screws that secure the Right Side Plate of the Ink Supply Station 4 Remove two T 10 screws that secure the Left Side Plate of the Right Ink Supply Station ENWW Right Ink Supply Station 281 5 Remove the Right Ink Supply Station bonding cable n a ye 282 Chapter 6 Removal and Installation ENWW 8 Remove the two T 15 screws that secure the Right Ink Supply Station to the printer 9 Disconnect the three connectors from the Right Ink Supply Station E NOTE If you need to change the ISS Harness Cable make sure you keep the previously used plastic connector The new cable will arrive with a female end which you will replace with the existing male end ENWW Right Ink Supply Station 283 11 Carefully lift the Cartridge Tubes Connector out of the Right Ink Supply Station 12 Carefully lift the Right Ink Supply Station enough so that you can rotate it clockwise to release the front attachment from the printer E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform re
141. indow is closed e The Media Lever is lowered e All Printheads are inserted e Valid Cartridges are inserted 7 Press OK to continue 8 The Primer Motor test continues and the Front Panel shows the progress of the test Moving Primer motor and getting traces Please wait few minutes 9 The Front Panel shows the test complete display for a few seconds 114 Chapter 3 Diagnostic Menu ENWW 10 The Front Panel prompts you to shutdown the printer to complete the test 11 Press any key to shutdown the system Press any key to shutdown the printer Aerosol Fan 1 ENWW In the Diagnostics menu scroll to 8 Service Station and press OK Diagnostics menu Paper Drive Electronics Module Carriage Assembly Sensors SOL IDS 5 Service Station The Front Panel will show the8 Service Station submenu 6 Service Station Service Station Primer Motor Aerosol Fan In the Service Station submenu scroll to Aerosol Fan and press OK to start the test The Aerosol Fan test starts and the front Panel displays the following messages e Starting Horsburgh e Booting TestsGpio e Starting Nvm The front Panel then prompts you switch on the Aerosol Fan Aerosol Fan switched Off Do you want to turn On YES Press UP DOWN to chang and ENTER to select Press OK to switch on the Aerosol Fan If you do not wish to switch on the Aerosol Fan use the Arrow keys
142. ing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Full Bleed Foam Removal E NOTE Switch off the printer and remove the power cable 326 Chapter6 Removal and Installation ENWW The complete Full Bleed Foam is constructed of three separate sections left center and right This procedure only describes how to remove the left section Removal of the other two sections Is identical 1 Open the Window 2 Remove the Left Full Bleed Foam from the left platen 3 Remove the Platen Middle Foams that are exposed once the Full Bleed Foam has been removed EY NOTE When you reinstall the full bleed foams take care to correctly seat them to avoid possible damage to the Carriage Assembly ENWW Full Bleed Foam 327 7 Preventive Maintenance n Preventive Maintenance Preventive Maintenance Kits 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
143. ion Guide to Removal and Installation on page 170 Perform the Color Sensor ESP Calibration as follows 1 In the Service Calibrations submenu scroll to Color Sensor ESP Calibration and press OK Service calibrations akd AxATS Cal iPral iu Service Station Paper advance calibration gt Drop Detector calibration Line Sensor calibration a Carriage PCA gt SOL calibration Service Calibrations 149 2 When the following message appears on the front panel you must select whether you would like to continue with the Carriage Setup by pressing OK Press Back or Cancel to exit the utility SOL Calibration Press ENTER to proceed with SOL calibration or BACK CANCEL to exit 3 The printer will start to calibrate the Color Sensor SOL Calibration SOL calibrating Once the Color Sensor calibration has completed successfully OK will be displayed on the Front Panel SOL Calibration 150 Chapter4 Service Menu ENWW 5 Parts and Diagrams e Printer Support on page 152 e Center Covers Front on page 153 e Center Covers Rear on page 154 e Right Cover on page 155 e Left Cover on page 156 e Right Hand Assemblies on page 157 e LeftHand Assemblies on page 158 e Carriage Assembly on page 159 e Scan Axis Assemblies on page 160 e Paper Path Assemblies Front on page 161 e Paper Path Assemblies Rear on page 162 e Tools 1 on page 163 e Tools 2 on page 164 e Miscellaneous Parts on p
144. irmware upgrade Media Profile Update Preventive Maintenance kit 1 Preventive Maintenance kit 2 Disk Full Web access application Borderless Media Settings Assertion uncontrolled FW error Recoverable Firmware Error Media advance 48 Chapter2 System Error Codes ENWW 81 1 Media advance 84 Roll Feed 85 Media axis encoder reading 86 Carriage Movement 87 Scan axis encoder reading 93 Ink Pumping 94 Color calibration 94 1 Profiler 95 Printhead alignment 97 Paper advance calibration Corrective Actions Table The following table explains the YZ part of the System Error Code or Warning Code Recovery Action Response 00 Replace Possible for customer to perform action 01 Reseat Reconnect Clean Adjust manually 02 Calibrate Adjust using Automatic Process 03 Power OFF and Restart the Printer 04 Upgrade System Firmware 05 Upgrade Driver or Computer Software 06 Add Accessory 07 Escalate 08 Send Plot Again 09 Wrong Part Installed 10 Replace hp qualified personnel assistance required 11 Reseat Reconnect Clean Adjust manually 12 Calibrate Adjust using Automatic Process 13 Power OFF 14 Upgrade System Firmware 15 Upgrade Driver or Computer Software 16 Add Accessory 17 Escalate 18 Send Plot Again 19 Wrong Part Installed ENWW System Error Code Brief Descriptions 49 System Error Codes Full Descriptions This sections describes each of the system error codes and warnings that could be encountered
145. irst try the Paper Advance Calibration from the user menu which will calibrate the printer to a specific paper type E NOTE you must order the Paper Advance Calibration Kit which contains two sheets of HP Universal Instant Dry Photo Gloss paper For the correct part number of the media refer to the Parts and Diagrams on page 151 Perform the Service Accuracy Calibration whenever e Banding is detected in prints Service calibrations also need to be performed after removing or replacing certain printer components If you have removed or replaced printer components check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform Refer to Service Calibration Guide to Removal and Installation on page 170 The Paper Advance Calibration is split into three parts and should always be done in this order 1 Print Calibration Pattern The Printer first calibrates the Analog Encoder and then prints the Paper Advance Calibration pattern 2 Scan Calibration Pattern The Printer scans the Paper Advance Calibration pattern in order to calibrate the nominal advance of the media E NOTE Only scan the Calibration Pattern in the Printer that was used to actually print it Using the Calibration in a different Printer could cause it to experience media advance problems After scanning the Calibration Pattern it should be discarded 3 Clean Drive Roller After loading media that the customer wil
146. ities submenu scroll to Diagnostic Print and press OK Service utilities gt Turn Drive Roller 2 You will be given three options Use the Arrow keys to select the Advanced Diagnostics menu gt Image Quality Service Best gt Image Quality Service Normal Advanced Diagnostic Print 3 From the displayed options use the Arrow keys to make the required selection Paper Advance Visual Alignment Diagnostic Nozzle Health Force Drop Detection or Print Banding Plot and press the ENTER key to start printing Advanced Diagnostic Print gt Paper Advance gt Visual Alignment Diagnostic Nozzle Health Force Drop Detection Print Banding Plot 4 Make sure media is loaded the Media Lever is lowered and that the Ink System is correctly installed Press the OK key to print the Diagnostic Print or press Back Cancel to exit without printing the Diagnostic Print Visual Media Advanced Print Check that media is Loaded pinch Lever is closed and ink is ready Proceed Press ENTER to accept or BACK CANCEL to exit 5 The selected Advanced Diagnostic Print will now be printed Reading the Advanced diagnostic Print Results Paper Advance This plot helps you to visually check any alignment problems of the printer You use it to precisely measure the media advance error with a one dot row accuracy and to verify the stability of the media advance The whitest vertical line should be positioned
147. k Cartridge Into the Printer cccccseeeeeeeeeeeeeeeeeeeeeseeeeeesaaeeeees 21 You Cannot Insert the Printhead Into the Printer ccccccccccceceeseeseeceeeeeseeeeeseeeeeeseeeaeas 21 The front panel says to reset or replace a Printhead cccccceccceeceeeeeseeeceeeeseeeseeeeaeeeees 21 Maintaining and Cleaning the Printheads ccccccccccssssecceeeeeeeeeeeeeecaeeeeceeeseaeeuseeeeesseeeeeeesssuaeeeeeess 22 GIG ANIME printheads sscsscuetnetcecSicatedetal uctdeeh titat eeu as neta onees diet itavec rien cautsa tice Daas 22 Flex Contacts Cleaning Tool cccccccssseeccceceeeeeeceeeeeeeeeeeeeeesaaeeeeeeesseeseeeeeessaaaeeeeeesaaseeeeees 22 PUAN OU ANY eiai a N NA 23 Print Quality Troubleshooting Actions scceciccondsectstsoerneavarcconayeteraeunasncdetoasteaedacoceiconienexasheveeee 23 The Service Image Quality Diagnostic Print cccccccccsseeccceeeeeeeeeseeececeeeeeeaeeeeesceeeeeeeeeeeeeeseeeeeseeaaas 24 What is the Service Image Quality Diagnostic Print cccccccceccsseeeeeeeeaeseeeeeeeaaeeeeeees 24 Considerations for Printing the Diagnostic Print ccccccsseeeeeeeeeeeseeeeeeaeeeeeseaeeeseaeeeeas 24 Pinuno the Diagnostic PUn acraea a a Renee on 24 Reading ne Diagnostic Prnt RESUS sacda a a E 25 Diagnostic Part 1 Printhead Reliability 000nnnn0nnnaaannnnaannnnnennnnnnnnnnannnnnrnnnnsnrnnnsnrnesnnrensennns 25 Diagnostic Part 2 Printhead Alignment cccc
148. l E NOTE Switch off the printer and remove the power cable 1 Remove the Left Cover refer Left Cover on page 188 Remove the Right Cover refer Right Cover on page 185 Remove the Front Panel refer Front Panel on page 203 Remove the Top Cover refer Top Cover on page 205 Remove the Window Position Sensor refer Window Position Sensor on page 208 Remove the Ink Supply Tubes Support Rail refer Ink Supply Tubes Support Rail on page 209 Loosen the T 10 uncapping screw sufficiently so you can manually move the Carriage Assembly in step 8 i E E a E ENWW Trailing Cable 237 8 Push the Carriage Assembly into the print path 238 Chapter6 Removal and Installation ENWW 11 Disconnect the two ribbon cables of the Trailing Cables from the Carriage PCA 12 Straighten the two ribbon cables of the Trailing Cables and remove the Ferrite Core ENWW Trailing Cable 239 14 Remove the lower part of the trailing cable 15 16 Use a short torx screwdriver to remove the two T 10 screws that secure the center attachment of the Trailing Cables 240 Chapter6 Removal and Installation ENWW 17 Unclip the center attachment of the Trailing Cables il Hl ii iss Ss 19 Unroute the Trailing Cables ENWW Trailing Cable 241 20 Unclip and remove the cable clamp of the Trailing Cables 21 l Maki itu f ea ee a 1 aN q A r D 22 Unroute the Trailing Cables
149. l Fan Assembly refer Aerosol Fan Assembly on page 219 e Ifthe System Error continues replace the PrintMech PCA refer PrintWech PCA on page 220 47 YZ Cause Solution Star wheels motor error Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Check that the Starwheel Assembly cable is not damaged and is correctly connected to Main PCA e Open the Window and check for any visible obstacles restricting the movement of the Starwheel Assembly then clear the obstruction e Perform the Scan Axis Starwheel diagnostic test to troubleshoot the problem further Star Wheel Lifter test on page 6 e Replace the Starwheel Motor refer Starwhee l Motor on page 329 e Ifthe System Error continues replace the Main PCA refer Electronics Module Main PCA and PSU on page 298 60 Chapter 2 System Error Codes ENWW ENWW 48 YZ Cause Solution PPS system failure Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Check that the Pen to Paper Space PPS Solenoid cable is not damaged and is correctly connected to the PrintMech PCA e Perform the Scan Axis PRS diagnostic test to troubleshoot the problem further PRS Test on page 8 e Replace the Pen to Paper Space PPS Solenoid refer Pen to
150. l show something like this 2 Ifthe Printer is experiencing vertical misalignment problems the Alignment Test will show something like this 3 Ifthe Printer is experiencing bi directional misalignment problems the Alignment Test will show something like this Corrective Action Perform the Printhead Alignment Main Menu Image Quality Maintenance Align Printheads using the same paper type with which you were experiencing unacceptable image quality if feasible some paper types are not suitable for Printhead Alignment ENWW Reading the Diagnostic Print Results 27 Diagnostic Part 3 Printheads amp Paper Advance This test is designed to check whether the Printheads and the Paper Advance Mechanism are working correctly This part of the Image Quality Test should NOT be used to check for color consistency or accuracy Banding If the Printer is experiencing a banding problem you will see repetitive horizontal bands within the printed image e Darker horizontal bands or lines repeated along the vertical band from top to bottom at the same distance e Whiter horizontal bands or lines along the vertical band from top to bottom at the same distance The plot is printed in Best or Normal mode according to the menu option selected with Error Hiding ON The top band has 100 ink density patches while the bottom band has 50 ink density patches Troubleshooting Banding Problems If banding does NOT occur in ALL the
151. l use the Printer prepares the media path to prevent any future advance problems Perform the Paper Advance Calibration as follows E NOTE Make sure that you unload media from the Printer before performing the Paper Advance Calibration 1 Inthe Service Calibrations submenu scroll to Paper Advance Calibration and press OK Service calibrations Scan Axis calibration Service Station gt Paper advance calibration Drop Detector calibration Line Sensor calibration Carriage PCA 2 Inthe Paper Advance Calibration submenu scroll to Print Calibration Pattern and press OK Paper Advance Calibration Print Calibration Pattern lt Scan Calibration Pattern ENWW Service Calibrations 141 3 When the following message appears on the front panel you must select whether you would like to continue with the calibration by pressing theOK key Press Back or Cancel to exit the calibration Print Calibration Pattern Press ENTER to proceed with Print Calibration Pattern or BACK CANCEL to exit 4 The Printer will start to calibrate the Analog Encoder and the following message will be displayed on the Front Panel Print Calibration Pattern Calibrating Analog Encoder Please wait If the Calibration is not done or if the values are out of the limits a warning message will appear on the Front Panel In this case try the following e Check thatthe Printer has the latest Firmware version If not
152. lace the Formatter refer Formatter on page 296 e Ifthe System Error continues replace the Main PCA refer Electronics Module Main PCA and PSU on page 298 66 YZ Cause Solution Cannot print file on current paper type The paper type has Try the following changed since the file was sent so the file cannot be printed on the paper type currently loaded e Resend the file to be printed on the current paper type e Change the paper type to the type that was loaded when the file was originally sent 67 YZ Cause Solution Input Output problem through a Firewire Port Try the following e Check that the firewire cable is correctly connected to the Printer e Check that the Printer has the latest Firmware version If not update the Firmware to the latest version e Ifthe System Error continues replace the Main PCA refer Electronics Module Main PCA and PSU on page 298 68 YZ Cause Solution Loss of engine counters tracking Try the following e Reboot the printer The printer will continue to function correctly but the life counters will not continue counting until you restart the printer System Error Codes Full Descriptions 71 YZ Cause Solution Out of memory failure Try the following e Itis recommended that you remove any unnecessary files from the Hard Disk Drive of the Formatter using the Web Server 71 19 Cause Solution Default Serial Number found in the mai
153. librations submenu scroll to Scan Axis Calibration and press Enter gt Scan Axis calibration Service Station Paper advance calibration Drop Detector calibration Line Sensor calibration Carriage PCA 2 To calibrate the Scan Axis run the Scan Axis diagnostic test Refer 1 Scan Axis on page 76 Please go to the Diagnostics Scan Axis Press any key to finish Service Station Calibration The purpose of this Service Calibration is to calibrate the Service Station in relation to the Carriage Assembly This calibration is integrated into the Scan Axis diagnostic test Refer 8 Service Station on page 110 1 Inthe Service Calibrations submenu scroll to Service Station and press Enter gt Scan Axis calibration gt Service Station Paper advance calibration Drop Detector calibration Line Sensor calibration Carriage PCA a ih Fala 2 To calibrate the Service Station run the Service Station diagnostic test Refer 8 Service Station on page 110 Service Station Calibration Test not implemented Press any key to finish Paper 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 140 Chapter 4 Service Menu ENWW If you need to perform a Paper Advance Calibration to solve a print quality problem it is recommended that you f
154. ll beep If the printer does not beep when you insert the printhead and the Replace message appears on the front panel display the printhead may need to be reinserted The front panel display confirms that all printheads are correctly inserted The printer will start checking and preparing the printheads The front panel display confirms that all printheads are correctly inserted The printer will start checking and preparing the printheads The default routine process when all printheads are changed takes 25 minutes If the printer finds problems in preparing the printheads it will take longer up to 55 minutes For a single printhead insertion the times vary between 15 and 35 minutes After all printheads are checked and prepared for the printhead realignment Printhead Information Replacement and Alignment 17 Aligning Printheads Precise alignment between printheads is essential for accurate colors smooth color transitions and sharp edges in graphical elements Your printer has an automatic printhead alignment process which runs whenever a printhead has been accessed or replaced In cases where the paper has jammed you have used a custom paper or are experiencing problems with color accuracy you may need to align the printheads If the paper has jammed it is recommended that you reinsert the printheads and initiate the realignment procedure with the Image Quality Maintenance menu E NOTE Do not use transparent and semi transpar
155. ll Einer tans serie teste te eotdi aad tes cana fe dicaaiace nd atiamsaerla natu sehatstondatedaetedanset daaeate ten atuiaaammaeencpeeeuianes 322 XI xii Starwheel Motor cise sedis ndacsustnidewtuincaGaddtetuscudaddenIutcudeddeaadonaGadde wctucabiddectuscudiidectusdutandactianateaduamsddeaeseacmsuat 325 Pull Bleed PO ARN sscassenccnsecadserentiesasuasnonlacdencacinuntocaisatetsediaavedd desde aecaubadsats dean desmansbasdceactadbaseseantnade nesuane 326 7 Preventive Maintenance Preventive Maintenance cccccccceecccsscecececsesecceueeeeeseueeseueeseueeseaeesaeeeseeesaeeseueeseueesaueeseeeeseeseeseeeees 328 Moisture On the Printer cccccscccssssccceeeeceeececceecccsaeeeceusecseueeeceusecsueeeseseessagsecseeeessaeeess 328 Noisy Carriage Bushing wsciisesseesssosdecneevensceeanscateneeessseseteuus o5 ceocenesesteesdedseaveesseebdeseunsedeuseeeed 328 Bo Wel ese a E E E E 328 GICANING TNS PMET resserre ann EE 328 Carriag Assembly LUDFICATON ssrrsricinnnnciniananini innuna a eaa 328 General Cleaning rseicsseer innein naain Aieiaia ES 329 Cleaning the Drive Roller and Overdrive cccccseccccccceeeeeceeeeeeseeeeeeaeeeeeeeessaaeseeeesaaeeeeees 329 OVE Or Pinter Usage acest scant anaE EE 329 Preventive Maintenance Kits ccccccecccsececesecceeeeceeecseeeceaeessaeeseueeseaeesaeeesaeeesaeeseueesegeesseeeseeeeeseeeess 330 Preventive Maintenance Kit 17 ccc cc ceccccececeeeeceeeeseeeeceeeeseeeseeeseceseueeseeees
156. llow waves in it you are likely to see visible defects in the printed image such as vertical stripes This can happen when you use thin paper that becomes saturated with ink Shown below is an example of what you might see if you have problems with the paper not being flat Corrective Action 1 Chapter 1 Check that the paper type loaded corresponds to the paper type selected in the front panel and in the software You can verify the paper type selected through the Front Panel Main Menu Paper menu View loaded paper Try using a heavier paper type When printing dense colors it is recommended to use HP Heavyweight Coated Paper HP Super Heavyweight Coated Paper or thicker Digital Fine Art papers Make sure that only genuine HP paper is being used Ink Supplies Troubleshooting amp Print Quality ENWW 4 Check that the appropriate print quality settings are being used refer to the User s Guide for more information 5 Check that the environmental conditions temperature humidity are within the temperature humidity range as specified for the Printer refer to the User s Guide for further information Print Scuffing or Scratching when Touched Description of problem The black ink pigment can smudge when touched by a finger a pen or some other object This is particularly noticeable on coated paper matte proofing paper and fine art material Glossy paper may be extremely sensitive to damage from the basket or
157. lure to access Line Sensor EEPROM e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Perform the Carriage Test to troubleshoot the problem further gt 4 Carriage Assembly on page 95 e Check the Line Sensor connections to the Carriage PCA e Replace the Line Sensor gt refer Line Sensor on page 267 e Ifthe System Error continues replace the Carriage PCA refer Carriage PCA on page 276 62 Chapter2 System Error Codes ENWW 56 YZ Cause Solution Drive roller analog encoder sensor fail or calibration failed Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Perform the Media Path Test to troubleshoot the problem further 2 Paper Drive on page 87 e Replace the Encoder Disk and Encoder Sensor refer Encoder Disk and Encoder Sensor on page 308 e Ifthe System Error continues replace the Main PCA refer Electronics Module Main PCA and PSU on page 298 58 YZ Cause Solution The Color Sensor Spectrophotometer ESP of the printer is Try the following not working well e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e The Color Sensor ESP shutter has not opened e Perform the Color Sensor diagnostic test t
158. memory size test starts and the Front Panel displays the following messages e Starting DelSol1 e Getting PCA Revision e Checking Memory Size 16 The Front Panel then displays Formatter Memory Size and prompts you to press any key to continue Electronics Module Formatter Memory Size 114MB MB Press any key to continue 17 Press any key to continue 18 The Formatter hard disk test starts and the Front Panel displays the following messages e Starting DelSol1 e Getting PCA Revision e Checking Memory Size e Getting HDA info 19 The Front Panel then displays Formatter Hard Disk information test results and prompts you to press any key to continue Electronics Module Blocks 136048 83 1050840 83 3152520 83 11536528 83 9442408 83 10599088 Press any key to continue 20 Press any key to continue 21 The Formatter hard disk file information test starts and the Front Panel displays the following messages e Starting DelSol1 e Getting PCA Revision 92 Chapter3 Diagnostic Menu ENWW ENWW 22 23 24 25 26 27 e Checking Memory Size e Getting HDA Info e Getting File System Info The Front Panel then displays Formatter Hard Disk File information test results and prompts you to press any key to continue Device 1kK Blocks Used 3102972 64 3102972 64 3107972 64 3102972 64 3102972 64 3102972 64 Press any key to continue Press any key to continue
159. moves Lubricate the slider path using the Lubrication Kit refer to the parts and diagrams chapter Tools 2 on page 164 Belt Swelling To prevent new belts from swelling incorrectly keep them in their bags with desiccant 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 Carriage Assembly Lubrication To ensure correct operation of the printer you must lubricate the Carriage Assembly whenever any of the following are encountered if e The Front Panel displays Maintenance 1 required e There is excessive noise when moving the Carriage Assembly e A shut down of the carriage PWM error message appears e There are IQ vertical banding problems 328 Chapter 7 Preventive Maintenance ENWW You should also lubricate the Carriage Assembly whenever you change any of the following service parts e The Carriage Rear Bushing e The Carriage Assembly e The Carriage Rail Oiler To lubricate the Carriage Assembly you will require the Lubrication Kit refer to the parts and diagrams chapter Tools 2 on page 164 Use the following procedure to lubricate the Carriage Assembly 1 Use the IPA alcohol Q6675 60070 and the cleaning cloth to clean the Carriage Rail and the Carriage Slider Rod 2 Use an Oil Dispenser Q
160. mpled or warped or may have irregular edges e If hand cut media is used the edges may not form a right angle or they may be rough If possible hand cut media should not be used Only purchased sheet media should be used in the Printer e _ If you have problems with paper jams check that the Overdrive is not obstructed by bits of paper or using the Turn Drive Roller Service Utility 1 Turn Drive Roller on page 126 ENWW Banding at variable extreme environmental conditions 7 What to do when plastic parts on the Media Basket become damaged during printer setup The following information explains what to do if one or more of the back plastic brackets or the Basket Tube becomes broken The information helps to identify which service parts to order as replacements There are three plastic parts that could break during printer installation and need replacing Use the pictures below to identify with the customer which part needs replacing numbers 1 2 or 3 1 Rear Basket Bracket This 2 Basket Tube This tube supports bracket is used to connect the rear z the weight of the Basket when it is open of the Basket to the X Brace wh 3 Foot Bracket This part attaches the Basket Tube to the I Foot Assembly a to the X Basket Tube includes plastic ends which attaches to the Foot Bracket Foot Bracket Attaches the Basket Tube to 2 oes 8 Chapter 1 Ink Supplies Troubleshooting amp Print Quality ENWW Solving Ink Suppli
161. n and backup NVM It Try the following seems that both the PrintMech PCA and Hard Disk Drive have been replaced together e Perform the Error 71 19 Recovery Service Utility 13 Error 71 19 Recovery on page 120 NOTE You MUST NEVER replace both the Formatter or Hard Disk and the PrintMech PCA at the same time If both parts need to be replaced you MUST first replace one part and then power ON the Printer until it completely initializes Then you can power OFF the Printer and replace the other part 72 YZ Cause Solution Generic Firmware error Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer Check that the Printer has the latest Firmware version If not update the Firmware to the latest version 73 YZ Cause Solution Servo Error Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer 6 Check that the Printer has the latest Firmware version If not update the Firmware to the latest version e Perform the Scan Axis Test to troubleshoot the problem further gt 1 Scan Axis on page 76 e Ifthe System Error continues perform the Media Drive diagnostic test to troubleshoot the problem further gt 2 Paper Drive on page 87 66 Chapter 2 System Error Codes ENWW ENWW 74 YZ Cause Solution
162. nagement Menu Job management menu Reprint last job Pause printing J h gueuse Queue is empty View information lt name gt for each job Cantinwe Move io iran Copies Reprints Cancel delete 332 Chapter 8 Printer menu Map ENWW Figure 8 3 Ink Menu a e Replace ink cartridges Replace printheads Ink carinidge information Printhead information View lt color gt printhead Figure 8 4 Setup Menu ee Select graphics language phies evel Select gra Print Quality tli Enable marimi detail i Enable more passes Color options ColorGrayscale Select RGB source profile Emulate printer Select CMYK input profile Select rendering intent Black point Compensation HF PANTONE emulation Selec paper size Paper options we top botiom blanks Enable minor image Enable crop lines Shee load check skew Enable track media hength Sitit mangas Savlect margars layout Select borderless method Select encoding Margins PS Options Print rebiewal Select drying time Enable cutter Job management options Enable queue When to start printing Nest options Enable nesting Max number of printed jobs Select wai tine Enable crop lines g Front panel options Select language Select display conirasi Enable buzzer Date and time options Select units 1 Wew current d vice time Set date Re
163. ncel key together You are now in the Service Tools Menu ain Menu NOTE Contact the Phone support for further assistance For On Site Engineers once inside the Main Menu press the UP arrow key and the Cancel key together You are now in the Service Menu Menu lain Menu DAAE Ink NOTE Contact the On site support for further assistance EY NOTE Ifthe printer is not used for 135 seconds the printer exits out of the Service Utilities Menu and you must repeat the above steps to enter Service Calibrations again NOTE In some cases a quick press of a button may not be recognized by the Printer When pressing a button be sure to press it deliberately and all the way to the bottom of its travel Scan Axis Calibration The purpose of this Service Calibration is to carry out a PWM check calibrate the intensity of the Line Sensor and calibrate the Line Sensor position to the Black Printhead This calibration is integrated into the Scan Axis diagnostic test Refer 1 Scan Axis on page 76 Perform the Scan Axis Calibration as follows amp NOTE Make sure you load one of the following media into the Printer before performing this calibration ENWW HP Bond Paper HP Glossy Media HP Coated Paper HP Productivity Photo Gloss Service Calibrations 139 e HP Heavyweight Coated Paper e HP Super Heavyweight Coated Paper e HP Bright White Inkjet Paper 1 Inthe Service Ca
164. nd ENTER to select ha 4 Press OK to the enable the Color Sensor ESP If you do not wish to enable the Color Sensor ESP use the Arrow keys to select NO and press OK 5 The Color Sensor ESP enable test starts and the front Panel displays the following messages e Starting ColorSensor e Starting ColorSensing e Reading Color Sensor ESP status e Enabling Color Sensor ESP 6 The Front Panel then displays Color Sensor ESP enable test result and prompts you to press any key to continue Starting ColorSensor Starting ColorSensing Reading SOL status Enabling SOL SOL enable disable OK Press any key to continue 7 Press any key to continue 8 The Front Panel then displays the Color Sensor ESP details and prompts you to press any key to continue FW Revision V4 8 D Sensor Type PP2 Serial Number 169857226 Mfg date e622 YES Press ENTER to confirm and BACK CANCEL to reject 9 The Front Panel then prompts you load media Load ROLL paper and Lower the pinch lever Press any key to proceed vv 10 Raise the Media Lever 11 Load media 12 Lower the Media Lever ENWW Service Tests Diagnostics 105 13 Press any key to continue 14 The Front Panel then displays the DeltaE test result and prompts you to press any key to continue Maximum DeltaE 2 735 Press any key to continue 15 Press any key to continue 16 The Front Panel shows the test complete dis
165. nent you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Carriage PCA Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Right Cover refer Right Cover on page 185 Remove the Left Cover refer Left Cover on page 188 Remove the Front Panel refer Front Panel on page 203 2 3 4 Remove the Top Cover refer Top Cover on page 205 5 Remove the Window Position Sensor refer Window Position Sensor on page 208 6 Remove the Ink Supply Tubes Support Rail refer Ink Supply Tubes Support Rail on page 209 276 Chapter6 Removal and Installation ENWW 7 Open the Carriage Cover 8 Remove all the Printheads 9 Remove the four T 15 screws that secure the Ink Supply Tubes to the Carriage Assembly i eda oo oo 99 99 99 ENWW Carriage PCA 277 10 Carefully lift out the Ink Supply Tubes and close the carriage cover at the same time 278 Chapter6 Removal and Installation ENWW 13 Unclip and slide off the small cover of the Carriage Assembly Carriage PCA 14 Remove one T 15 screws that secures the large cover of the Carriage PCA ENWW Carriage PCA 279 16 Disconnect the ten ribbon cables from the Carriage Assembly PCB E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To f
166. nk levels Replace ink cartridges Replace printheads Ink cartridge information Printhead information The printer moves the Carriage to the correct position to replace Printheads NOTE Ifthe carriage is left in the removal position for more than three minutes without inserting or removing any printheads it will try to move back to its normal position at the right hand end When the carriage has stopped moving the front panel display will prompt you to open the window and lift the carriage cover Open window to access print heads or press to quit Open the window Lift the Carriage cover to access the printheads Lift the blue handle and pull the Printhead straight up out of the Carriage Ink Supplies Troubleshooting amp Print Quality ENWW ENWW 8 10 11 12 To insert a new printhead first remove the orange protective caps The printhead is designed to prevent you from accidentally inserting it into the wrong slot Check that the colored label on the printhead matches the colored label of the carriage slot into which the printhead is to be inserted Insert the printhead slowly and vertically straight down It may be damaged if you insert it too fast or at an angle or if you rotate it as you insert it Insert all other printheads that need to be installed and close the carriage cover When all the printheads have been inserted correctly and accepted by the printer the printer wi
167. nnected to the Formatter e Check that the Printer has the latest Firmware version If not update the Firmware to the latest version e fthe System Error continues replace the Formatter refer Formatter on page 296 e Ifthe System Error continues replace the Main PCA refer Electronics Module Main PCA and PSU on page 298 64 YZ Cause Solution Input Output problem through the USB Port Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Check that the USB cable is correctly connected to the Printer Check that the Printer has the latest Firmware version If not update the Firmware to the latest version e If the System Error continues replace the Formatter refer Formatter on page 296 e Ifthe System Error continues replace the Main PCA refer Electronics Module Main PCA and PSU on page 298 64 Chapter2 System Error Codes ENWW 65 YZ Cause Solution Memory Driver Internal I O error I O Socket Manager Internal Try the following I O error e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Check that the unknown port cable is correctly connected to the Printer Check that the Printer has the latest Firmware version If not update the Firmware to the latest version e Ifthe System Error continues rep
168. nt 32 Chapter 1 Ink Supplies Troubleshooting amp Print Quality ENWW 3 If Calibrate Paper Advance has mostly solved the problem try Adjust Paper Advance to fine tune the Paper Advance Main Menu Image Quality Maintenance Paper Advance Calibration Adjust Paper Advance Select the percentage of change from 100 to 100 To correct light banding decrease the percentage To correct dark banding increase the percentage 4 The Paper Advance calibration from the service menu will calibrate the Paper Advance for ALL paper types This action is recommended when e The Paper Advance calibration from the user menu does not solve the problem e The Paper Advance problems affect ALL paper types The procedure for Paper Advance Calibration is in the service menu Paper Advance Calibration on page 140 Printhead Alignment ENWW This plot helps you to visually check any alignment problems of the printer You use it to precisely measure the alignment error with a one dot row accuracy For the printer to be considered correctly aligned the results must be within 2 dot row The illustration shows the complete Printhead Alignment that identifies each of the specific alignment test results covered The plot is split into four areas printed at different soeeds and resolutions 25ipS 1200dpi 35ips 1200dpi 36ips 600dpi and 50ips 600dpi 25ips 1200dpi 35ips 1200dpi 36ips 600dpi soips eooapi A E T A In order to know the p
169. nto the print path and the front Panel then prompts you to remove all pens Carriage Assembly Please remove all pens Press any key to continue F Open the Window Open the Carriage cover Remove all the Printheads from the Carriage Press any key to continue The Carriage Assembly pens test executes and checks the pens status The Front Panel then prompts you to replace all the Printheads Carriage Assembly Please insert all pens Press any key to continue Replace all the Printheads Close the Carriage Cover Close the Window Press any key to continue The Carriage Assembly pens test continues and checks the pens status The Front Panel then displays the test result Carriage Assembly Pens status OK Press any key to continue Press any key to continue 100 Chapter 3 Diagnostic Menu ENWW 46 The Encoder Manager test starts and the Front Panel displays the result of each phase of the test 47 The Front Panel then displays Encoder Difference Left Right test result and prompts you to press any key to finish Carriage Assembly Encoder Difference Left Right 6376 8352 eu Press any key to finish 48 Press any key to finish 49 The Front Panel shows the test complete display for a few seconds Carriage Assembly 50 The Front Panel prompts you to shutdown the printer to complete the test Carriage Assembly Press any key to shutdown the system 51 Pre
170. nts them from drying out The Ink Cartridges should never be removed while the printer is printing They 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 General Precautions When Handling Ink Supplies Use the following precautions when handling Ink Supplies Handle the ink supplies with care In particular the Printhead which is a high precision device and must be handled carefully Do not touch the Printhead nozzles Do not put the Printhead down on the nozzles Do not be rough when handling the Printheads Always set them down gently Do not drop the Printheads Proper handling will assure optimum performance throughout the Printhead life 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 Avoid storing partially used Ink Cartridges on their ends When Should You Replace the Ink Supplies When to change the ink supplies 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 supplies The Printer will also display the ink level and will tell you when the ink supply is low on ink This means you have constantly updated information about the ink supplies
171. o dry separately do NOT cover or stack them Align the printheads See Image Quality Maintenance Procedure on page 18 Problems with Graininess ENWW Description of problem Shown below is an example of what you might see if you have problems with graininess Corrective Action 1 Check that the paper type loaded corresponds to the paper type selected in the front panel and in the software You can verify the paper type selected through the Front Panel Main Menu Paper menu View loaded paper Check that printing is on the correct side of the paper Troubleshooting Print Quality Problems 39 6 Check that the appropriate print quality settings are being used refer to the User s Guide for more information Select the custom print quality options in the Print dialog and try turning on the More passes detail option Reprint the job in case the problem has been solved Check the Printhead alignment status If the status is PENDING perform the Printhead Alignment Main Menu Image Quality Maintenance Align Printheads After alignment reprint the job Check the paper advance calibration status If the status is PENDING perform the paper advance calibration Main Menu Image Quality Maintenance Paper Advance Calibration Calibrate Paper Advance After Paper Advance Calibration reprint the job Paper is not Flat Description of problem If the paper does not lie flat when it comes out of the Printer but has sha
172. o shutdown the system Press any key to shutdown the printer Recover the Printheads See Image Quality Maintenance Procedure refer mage Quality Maintenance Procedure on page 18 12 Set Unit Configuration The purpose of this test is to automatically configure the Printer either as Standard or Productivity 1 2 FS e m a In the Diagnostics menu scroll to 12 Set Unit Configuration and press OK The Set Unit Configuration test starts and the front Panel prompts you to request if you want to continue If you do want to continue the test use the Arrow keys to select YES and press OK If you do NOT want to continue select NO and press OK The Set Unit Configuration continues and the front Panel displays the several messages The Front Panel shows the result of the test Press any key to continue The Front Panel shows the test complete display for a few seconds The Front Panel prompts you to shutdown the printer to complete the test Press any key to shutdown the printer 13 Error 71 19 Recovery This diagnostic test utility is used to set the Serial Number and Part Number if either the Formatter or the Printmech PCA or both have been replaced The complete Error 71 19 Recovery utility consists of individual utilities to handle different serial and part number setting requirements These tests are Set Serial Number Select Right S N Set Serial Number 120 Chapter 3 Diagnostic Menu ENWW ENWW The
173. o troubleshoot the problem further gt 6 Color Sensor ESP on page 104 e __If the System Error continues replace the Color Sensor ESP refer Color Sensor ESP on page 262 61 YZ Cause Solution The file format is incorrect and the Printer cannot process the Try the following job e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Check the graphic language setting of the Printer Refer to the User s Guide e Resend the file to the printer e Check that the Printer has the latest Firmware version If not update the Firmware to the latest version e The PostScript fonts are missing Upgrading the Firmware will re install the fonts e The file cannot be printed because it is password protected Resend the file without password protection ENWW System Error Codes Full Descriptions 63 62 YZ Cause Solution PC Interface Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer Get the latest version of the firmware 63 YZ Cause Solution Input Output problem through the Network Card Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Check that the Network cable is correctly co
174. omponent you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Ink Supply Tubes Removal 288 Chapter 6 Removal and Installation ENWW E NOTE Switch off the printer and remove the power cable 1 Remove the Right Cover refer Right Cover on page 185 Remove the Left Cover refer Left Cover on page 188 2 3 Remove the Front Panel refer Front Panel on page 203 4 Remove the Top Cover refer Top Cover on page 205 5 Open the Carriage Cover 6 Remove all the Printheads 7 Remove the four T 15 screws that secure the Ink Supply Tubes to the Carriage Assembly beau oo oo 29 of oo ENWW Ink Supply Tubes 289 8 Carefully lift out the Ink Supply Tubes and close the carriage cover at the same time 9 Close and lock the Carriage Assembly cover ae oe ges r a i ba _ k e Sas M 4 7 P i d 290 Chapter 6 Removal and Installation ENWW 11 Remove the top T 15 screw that secures Ink Supply Tubes guide to the printer ENWW Ink Supply Tubes 291 14 Gently move the Ink Supply Tubes from the printer 292 Chapter6 Removal and Installation ENWW 17 Remove the Right Side Plate of the Right Ink Supply Station ENWW Ink Supply Tubes 293 20 Remove the left Side Plate of the Right Ink Supply Station 21 Carefully lif
175. on can be found in the Advanced tab under Document Options gt Printer Features Some objects are missing from the printed image Large quantities of data may be necessary to print a high quality large format print job and in some specific workflow there may be issues that can lead to some objects missing from the output Corrective Action In the Advanced tab select Document options Printer features and set Send job as bitmap to Enabled HP GL 2 driver only In the Advanced tab select Document options Printer features and set 16 bit App Compatibility to Enabled In the Advanced tab select Document options Printer features and set Max Application resolution to 300 The above settings are mentioned for troubleshooting purposes and may adversely affect the final output quality or the time necessary to generate the print job Therefore they should be restored to their default values if they do not help to solve the problem When working under Mac OS the above settings are not available Instead try reducing the resolution of bitmap images in the application software being used A PDF file is clipped or objects are missing In older versions of Adobe Acrobat or Adobe Reader large PDF files could be clipped or lose some objects when printing with the HP GL 2 driver at high resolution Upgrade the Adobe Acrobat or Adobe Reader software to the latest version From version 7 onwards these problems should be solved ENWW Tr
176. ont Panel on page 3 Ready for paper http NPI 040CA95B1 31 http 16 23 94 30 Press B to enter Ot To have the user to perform certain Service Utilities once inside the Main Menu press the Down arrow key and the Cancel key together You are now in the Service Tools Menu ain Menu 5 GS H Ink amp NOTE Contact Phone support for further assistance 124 Chapter 4 Service Menu ENWW A For On Site Engineers once inside the Main Menu press the Up arrow key and the Cancel key together You are now in the Service Menu Menu ain Menu H Ink NOTE Contact On site support for further assistance Use the Arrow keys to scroll to the Service Utilities menu option and press the OK key Service menu MA Service utilities Service calibrations BH Service tests Use the Arrow keys to scroll through the Service Utilities selections and press the OK key to begin a specific operation when the required Service Utility is highlighted Service utilities gt Turn Drive Roller Reset life counters Diagnostic Print gt Set Date and Time EY NOTE Ifthe printer is not used for 135 seconds the printer exits out of the Service Utilities Menu and you must repeat the above steps to enter Service Utilities again NOTE In some cases a quick press of a button may not be recognized by the Printer When pressing a button be sure to press it deliberately and all the way to the bot
177. ore the second cut and press OK Borderless cut distance M Default V Select value 3 Use the up and down keys to select the amount in mm before the media is cut Minimum 15mm maximum 75mm ENWW Entering the Service Utilities Menu 137 Service Calibrations The Printer has several calibration procedures that must be performed under certain conditions EY NOTE REMEMBER THAT CERTAIN CALIBRATIONS ARE REQUIRED EVEN IF AN ASSEMBLY HAS BEEN DISASSEMBLED TO GAIN ACCESS TO ANOTHER ASSEMBLY OR COMPONENT The following is a list of all internal service calibrations available in the Printers Instructions for entering the service calibrations menu are given on Entering the Service Calibrations Menu on page 139 1 T Scan Axis Calibration Refer Scan Axis Calibration on page 139 The purpose of this Service Calibration is to carry out a PWM check and calibrate the intensity of the Line Sensor Service Station Calibration s Refer Service Station Calibration on page 140 The purpose of this Service Calibration is to calibrate the Drop Detector located in the Service Station in relation to the Carriage Assembly Paper Advance Calibration Refer Paper Advance Calibration on page 140 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 Drop Detector Cal
178. oubleshooting Print Quality Problems 45 2 System Error Codes n Introduction e Continuable and Non Continuable Error Codes e System Error Code Brief Descriptions e System Error Codes Full Descriptions 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 If you have an error code which is not documented in this Service Manual or you have an error which you cannot resolve then report the error to the HP Response Center or the nearest HP Support Office When reporting the error have the following information ready e Model and Serial Number of the printer e Which firmware revision the printer is using See Note below Check firmware in Setup Menu Information Menu Show Printer Information e The complete error number See Note below e The Service Configuration Print e The Current configuration sheet e Which software application the customer is using name version etc Ef NOTE When reporting the System Error Code make sure that you supply the full Internal Error Code and the firmware version Without this information HP Support Personnel cannot help you To view the Internal Error Code hold the UP key and press the CANCEL key at the sam
179. pect to the print platen plane This allows media of different widths to be used without losing print quality Perform the Scan Axis Scan Axis test as follows 80 Chapter3 Diagnostic Menu ENWW E NOTE Perform this test with the Printheads and the Tubes System installed in order to get values ENWW that can be compared correctly In the Diagnostics menu scroll to 1 Scan Axis and press OK Diagnostics menu Paper Drive Electronics Module Carriage Assembly Sensors SOL Scan Axis gt Cutter In the Scan Axis submenu scroll to Scan Axis and press OK to start the test The Printer will start the Scan Axis subsystem Common Initialization If there is a Failure at any point during the tests the Front Panel will display the relevant System Error Code To trouble shoot any displayed error codes refer System Error Codes Full Descriptions on page 50 The printer then starts the Scan Axis test initialization As the test executes the Front Panel displays the following messages e Starting Horsburgh e Starting PWMManagerDelSol e Starting Tests PWM e Starting Tests GPIO e Starting Nvm If there is a Failure at any point during the test the Front Panel will display the relevant System Error Code To trouble shoot any displayed error codes refer System Error Codes Full Descriptions on page 50 The printer then starts the PSU check As the test executes the Front Panel displays the following mess
180. play for a few seconds 17 Press any key to shutdown the system 18 Press any key to shutdown the printer 7 Ink Delivery System IDS The complete Ink Delivery System test consists of individual tests for the different components related to this subsystem These tests are e Ink Delivery System e Check Ink Supplies Diagnostic tests also need to be performed after removing or replacing certain printer components If you have removed or replaced printer components check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform Refer to Service Calibration Guide to Removal and Installation on page 170 Ink Delivery System 1 In the Diagnostics menu scroll to 7 IDS and press OK Diagnostics menu stan AXIS Paper Drive Electronics Module Carriage Assembly Sensors SOL 106 Chapter 3 Diagnostic Menu ENWW 2 The Front Panel will show the 7 IDS submenu f IDS e Ink Delivery System Check Ink Supplies 3 In thelDS submenu scroll to Ink Delivery System and press OK to start the test 4 The Ink Delivery System test starts and the front Panel prompts you to remove all the Ink Supplies Ink Delivery System remove all the Ink Press any key to proceed 5 Remove all the Ink Cartridges 6 Press OK to continue 7 The test continues and the front Panel displays the following messages e Starting Horsburgh e
181. pplies Troubleshooting amp Print Quality ENWW ENWW 4 5 If the loaded paper is satisfactory the printer will run the realignment and print a realignment pattern Ensure the transparent window is closed as a strong light source near the printer during printhead realignment can affect alignment Figure 1 1 25200 Plot HU I 0 MANI SORE BI I Cae TU a HAUL IIL T a a oc rs eS Malt wT a wa i wht TM i ie j aj ni jbr na j ea ii aa ve a at ai Oo ij i wa ih i Pan he ii oka i i oe oon oe ay h Ba e Sa as i Ua aaj aa a ote Be ai di ea E a a a aa se aa i ia ayj u fia we BN G le CH H i i PIi a l a ala dfar pa a oh iona i ify feta ote i e a e sasas aas ia ak ai aia A di h a ane a a m a ma m e m The process will take about eight minutes Wait until the front panel display shows the process complete before using the printer Scanning errors during alignment If the alignment process fails a Scanning problems message appears on the front panel This means that the alignment has not completed successfully Therefore the printer is not aligned and the alignment should be repeated before printing with good image quality The problem may be due to The paper used was not valid repeat the alignment with valid paper Printhead health problems clean printheads The alignment was done with the transparent window open repeat the alignment with the window closed If
182. pt you to continue 10 Press the Enter key to continue lf the Paper Advance Calibration fails for any reason a warning message will appear on the Front Panel In this case try the following e Retry the Paper Advance Calibration e f necessary perform a Printhead Recovery through the Front Panel and retry the calibration NOTE Remove the pattern from the printer and leave it to dry for a few minutes before continuing with the Calibration MAKE SURE NO MEDIA IS LOADED INTO THE PRINTER BEFORE STARTING TO SCAN THE CALIBRATION PATTERN 11 You will need to re enter the Paper Advance Calibration submenu and scroll to Scan Calibration Pattern and press OK Paper Advance Calibration Print Calibration Pattern Scan Calibration Pattern lt 12 When the following message appears on the front panel you must select whether you would like to continue with the calibration by pressing the OK key Press Back or Cancel to exit the calibration Scan Calibration Pattern Press ENTER to proceed with Scan Calibration Pattern or BACK CANCEL to exit ENWW Service Calibrations 143 13 A message will appear advising you that you will need to load the Calibration Pattern in to the Printer Make sure that you rotate the printed pattern 90 clockwise and reload it printed side down so that the black arrows go into the printer first Press the OK key to continue can Calibration Pattern Press ENTER to proceed wit the load of the p
183. purpose of this utility is to set the Serial Number and Part Number in case both the Formatter and the PrintWech PCA are replaced at the same time Set the Serial Number as follows 1 In the Diagnostics menu scroll to 11 Error 71 19 Recovery and press OK Diagnostics menu Uo m f L BS Service Station gt 9 I 0 Information Unit Information EEROM Reset Set Unit configuration 3 Error 71 19 Recovery The Front Panel will show the 1 Error 71 19 Recovery submenu 13 Error 71 19 Recovery Set Serial Number gt Select Right S N In the11 Error 71 19 Recovery submenu scroll to Set Serial Number and press OK to start the test The Set Serial Number test starts and the front Panel displays the following messages e Checking SE Log e Starting Horsburgh amp Mips e Starting NvmBackup e Starting NvmMain e Getting Serial Number e Checking Serial Number e Starting Nvm e Getting Part Number e Setting default config The Front Panel prompts you to enter the Serial Number Current Serial Number SG A New Serial Number _ BHOOVOOO Use UP DOWN to scroll BACK to move cursor or ENTER to confirm Use the UP DOWN and BACK keys to select each character of the Serial Number and use the OK to confirm Service Tests Diagnostics 121 7 The Front Panel shows the test complete display for a few seconds SE 71 19 Recovery 8 The Front Panel prompts you to shutdown th
184. r Assembly on page 199 5 Q6659 60182 Full Bleed Foam Kit Full Bleed Foam on page 326 1 ENWW Paper Path Assemblies Front 161 Paper Path Assemblies Rear Reference on Figure 1 2 162 Chapter5 Parts and Diagrams HP Part Number Q6718 67006 Q6677 60019 Q5669 6071 1 Q5669 60712 Q6659 60183 Q6675 60044 Q5669 60708 Q6675 60093 Part Description Pinchwheel Assembly Left Roll Guide Left Spindle Holder Right Spindle Holder Spindle Right Roll Guide Pinch Roller 3 inch Spindle Adaptor Kit Page Pinchwheel Assembly on page 314 Left Roll Guide on page 229 Left Spindle Holder on page 224 Right Spindle Holder on page 224 Spindle on page 223 Right Roll Guide on page 230 Pinch Roller on page 319 N A ENWW Tools 1 HP Part Number Part Description Printer Model Q6675 67018 Media Driver Tool Kit includes the Handle for Media Driver Tool Support and the Media Driver Adjustment Tool ma 05669 60690 Flex Contacts Cleaning Teol CSR A Q6687 60084 Pinchwheel Insertion Tool ee ee ENWW Tools 1 163 Tools 2 HP Part Number Part Description Printer Model Q6683 67001 Tool Kit includes pinchwheel alignment tool paper driver tool spanner 13 oil dispenser insert spring tool tweezers T15 screwdriver 100 cc isopropyl alcohol lubricant oil plastic gloves flex contacts cleaning tool and cleaning kit Dispenser Oil Lubricant Oil Cleaning cloth Alcohol 164 Chapter5 Par
185. r is pressed down to prevent the printer from moving Change an ink cartridge using the following procedure 1 Scroll to the Ink Menu icon and press OK ain Menu H Ink ENWW Ink Cartridge Levels Information and Replacement 13 2 Inthe Ink Menu submenu scroll to Replace ink cartridges and press OK gt View ink levels Replace ink cartridges Replace printheads H Ink cartridge information H Printhead information 3 The front panel displays the status of the Ink Cartridges Press ok to continue THOU T MY dte pk ET E hnd i heal Press OK to continue Open the relevant Ink Cartridge cover for the Ink Cartridge you want to replace Pull the required Ink Cartridge straight up to remove it from the printer a a The front panel indicates the missing Ink Cartridge Ink cartridge missing Install ink cartridge an 00000 a SEnELI Jj l 8 Before removing the cartridge from its wrapping shake it vigorously 9 Unwrap the new ink cartridge find the label identifying the ink color Check that the letter or letters marking the empty slot matches the letter or letters on the cartridge label 10 Insert the ink cartridge into its slot 11 Push the cartridge into the slot until it snaps into position You should hear a beep and see confirmation that the cartridge has been inserted Press w to continue 12 When all cartridges have been inserted close the cover 14 C
186. r or EEPROM for the PrintMech PCA 7 Press OK to confirm your choice 8 The Select Right S N test continues and the front Panel displays the following messages as the correct Serial Number and Part Number are copied from the selected location to the other memory location e Starting NvmMain e Starting NvmBackup e Getting Serial Number e Checking Serial Number e Getting Part Number e Writing the right S N 9 The Front Panel shows the test complete display for a few seconds SE 71 19 Select Right S N 10 The Front Panel prompts you to shutdown the printer to complete the test SE 71 19 Select Right S N Press any key to shutdown the system 11 Press any key to shutdown the printer ENWW 123 4 Service Menu Service Utilities Down Cancel Service Engineers remote support 1 Turn Drive Roller on page 126 2 Purge Tubes on page 128 5 Diagnostic Print on page 132 6 Set Date and Time on page 132 7 Enable Disable Firewall on page 133 8 Enable Disable Sleep Mode on page 134 9 SNMP Language Write Access on page 135 10 Borderless Cut Distance on page 137 Service Utilities UP Cancel Service Engineers only 3 Set SN on page 130 4 Reset Life Counters on page 131 Entering the Service Utilities Menu 1 Once the message Ready or Ready for paper is displayed on the front panel press the Main Menu key For information regarding the front panel buttons Refer Using the Fr
187. r than those used in this Printer If a custom page size with very narrow margins has been defined the printer may impose its own minimal margins clipping the image slightly Consider using a larger paper size or border less printing Ink Supplies Troubleshooting amp Print Quality ENWW If the image contains its own margins it may be possible to print it successfully by using the Clip Contents by Margins option If a very long image needs to be printed on a roll check that the software is capable of printing an image of that size The page may have been rotated from portrait to landscape on a paper size that is not wide enough If necessary change the printable area in the software If necessary reduce the size of the image or document in your software application so it fits between the margins Another Possible Explanation Some applications such as Adobe Photoshop Adobe Illustrator and CorelDRAW use an internal 16 bit coordinate system which means that they cannot handle an image of more than 32 768 pixels If you try to print an image larger than this from these applications the bottom of the image will be clipped In this case the only way to print the whole image is to reduce the resolution so that the whole image requires fewer than 32 768 pixels The HP GL 2 printer driver contains an option called Compatibility with 16 bit applications which can be used to reduce the resolution of such images automatically This opti
188. re information refer to he Advanced Diagnostic Prints on page 29 Considerations for Printing the Diagnostic Print 1 The IQ Diagnostic Print prints in A3 and B sizes so you must have media loaded roll or sheet that is this size or larger 2 Use the same type of media that the customer was using when they found the image quality problem 3 Ifthe customer is using non HP media and after the Image Quality Test you still have the same image quality problems change to genuine HP media and repeat the Image Quality Test 4 Ifyou do not see any problems with the Image Quality Test the problem may not be with the printer itself The problem may be with the RIP or the driver If you do see problems with the Image Quality Test continue with the Advanced Diagnostic procedures which will help you diagnose the problem Printing the Diagnostic Print 1 Inthe Service Utilities submenu scroll to Diagnostic Print and press OK Turn Orive Roller gt Purge Tubes Set 5H H Reset life counters Diagnostic Print Set Date and Time 24 Chapter 1 Ink Supplies Troubleshooting amp Print Quality ENWW 2 You will be given three options Use the Arrow keys to make the selection and press the OK key to start printing the required Diagnostic Print or to enter the Advanced Diagnostics menu gt Image Quality Service Best gt Image Quality Service Normal BH Advanced Diagnostic Print 3 Ifyou selected the Advanced Diagnostics
189. results are not correct press Back Cancel to reject the results and FAIL the test 8 The Carriage Assembly Vaux test starts and the Front Panel displays e Getting Vaux Carriage Voltage 9 The Front Panel then displays the Carriage Voltage Vaux test results Carriage Assembly Carriage Voltage Vaux 3 729 Press any key to continue 10 Press any key to continue 96 Chapter3 Diagnostic Menu ENWW 11 The Carriage Assembly UVC flag test starts and the Front Panel displays e Clearing UVC flag e Reading UVC flag e Checking UVC flag 12 The Front Panel then displays the UVC flag test results U C Flag is OK Press any key to continue 13 Press any key to continue 14 The Carriage Assembly Pens Voltage test starts and the Front Panel displays e Getting Vpp 15 The Front Panel then displays the Pens Voltage test results The result must be between 26 5 and 33 Volts Carriage Assembly Pens Voltage Vpp 3 315 Press ENTER to confirm and BACK CANCEL to reject 16 Ifthe results are correct press OK to accept the results If the results are not correct press Back Cancel to reject the results and FAIL the test 17 The Carriage Assembly test continues and the Front Panel displays e Starting Line Sensor Leds e Starting Light Sensor e Starting Line Sensor System Error Code 55 YZ Refer 55 YZ on page 62 e Starting SVS Motor e Starting Carriage Motor e Moving SVS out of Sax
190. rgins by relocating the image to the center of the page with the software application being used Ink marks on the back of the paper This can happen after a lot of border less printing especially with nonstandard paper sizes Ink residues on the platen are likely to mark the back of the paper Corrective Action Clean the platen with a soft cloth Clean each rib separately without touching the foam between the ribs Problems with the Edges of objects Stepped or not sharp The edges of objects or lines appear to be poorly defined or lighter in density than expected Corrective Action lf the print quality slider has already been set to Quality in the Print dialog select the custom print quality options and try setting the quality level to Normal refer to the User s Guide for more information Darker than expected The edges of objects seem darker than expected Corrective Action If the print quality slider has already been set to Quality in the Print dialog select the custom print quality options and try setting the quality level to Normal Bronzing When printing on photo paper with gray and black ink only a gloss differential problem can be encountered when light is directly reflected from the print producing bronzed reflections where ink has been laid Corrective Action Use the Full set of inks option 42 Chapter1 Ink Supplies Troubleshooting amp Print Quality ENWW Black and white prints do not look
191. rint Quality ENWW 4 The front panel displays information on the selected Ink Cartridge Use the Arrow keys to scroll through the information M ink cartridge Color Magenta Product name HP 772 Product number CN6294 Serial number 1327136 26 13 Status OK Ink level 298 ml Capacity 300 ml Hi M ink cartridge Status OK Ink level 296 ml Capacity 308 ml Expiration date Jan 4 2013 Warranty status In warranty Manufacturer HP The information supplied is e The make of the Ink Cartridge e The product number of the Ink Cartridge e The serial number of the Ink Cartridge e The current status of the Ink Cartridge e The current ink level of the ink cartridge in milliliters e Original capacity of the ink cartridge in milliliters e The manufacturer of the Ink Cartridge hp is recommended e The current warranty status of the Ink Cartridge Changing an Ink Cartridge There are two occasions when you need to remove an ink cartridge e The ink cartridge is very low and you want to replace it with a full cartridge for unattended printing you can use up the remaining ink in the first cartridge at a more convenient time e The ink cartridge is empty or faulty and you must replace it to continue printing E NOTE Do not try to remove an ink cartridge while printing Remove an ink cartridge only if you are ready to insert another one Make sure the printer wheels are locked the brake leve
192. rint modes associated to the speeds and resolutions refer to the following table Level 1 Paper Type Level 2 Paper Type Superbest Genenc HP Commercial name ips HP Professional Satin Photo paper 50 600dpi 50 600dpi 50 600dpi 25 1200dpi Fast ips Normal ips Best ips Photo Paper Photo Gioss Semi Glossisatin Paper less ink 50 S00dpi 50 600dpi 50 600dpi 25 1200dpi Photo Goss Seni Gloss Sain Paper more 1n S0 600dpi 50 600dp 25 12000 Coated Paper 50 600dpi 50 600dpi 35 1200dpi 25 1200dpi Sree ds lester aril sd 20 o00dpi W 00dpi_ 39 1200dpi 29 1200dpi 50 600dpi 50 600dpi 35 1200dpi 25 1200dpi NOTE For the other types of media and print modes use the reference of 25ips 1200dpi Bond amp Coated Reading the Advanced diagnostic Print Results 33 What to see in the AutoPen Alignment Diagnostics 1 Pen2Pen wd Pen2Pen Rev oe At the left we have two checks for the pen to pen alignment in scan axis direction Pen2Pen Fwd amp Pen2Pen Rev It is forward and reverse The area to check is the junction marked with of the black with the rest of colors The arrows show the printing direction The bidirectional check is at the top marked as number 2 Bidir Check that the lines are continuous without a gap The junction is marked with The arrows show the printing direction The pen to pen alignment in paper axis direction PAD is marked as number
193. rinte atter ut sheet as roll for scan q Rotate the sheet 20 degrees clockwise and press ENTER to proceed E NOTE Take note that the Calibration Pattern will be loaded as a Roll and NOT as a Sheet NOTE Only scan the Calibration Pattern in the Printer that was used to actually print it Using the Calibration in a different Printer could cause it to experience media advance problems After scanning the Calibration Pattern it should be discarded When Loading the Calibration Pattern use the Cutter blade on the Print Platen to align the edge of the sheet If you follow this advice you will prevent the cutter from cutting a section of the Calibration Pattern which could cause the Calibration to FAIL 14 Load the Calibration Pattern following the instructions on the Front Panel Once the Calibration Pattern is loaded correctly the following message will be displayed on the Front Panel Press the OK key to continue Scan Calibration Pattern Press ENTER to proceed with pattern scanning 15 The Printer will scan the Calibration Pattern which could take several minutes Once the calibration is completed successfully the following message will be displayed on the Front Panel Press the OK key to continue can Calibration Pattern Calibration Ssuccessrully cOpl eted ressOKto continue If the Paper Advance Calibration fails for any reason a warning message will appear on the Front Panel In this case try the followin
194. rinthead detection Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Remove the Printheads from the Carriage Assembly and reinsert them e Replace the Printheads e Replace the Carriage Cover Flex Circuit refer Carriage Cover includes Carriage Latch on page 272 e Replace the Carriage PCA refer Carriage PCA on page 276 e Replace the Formatter s refer Formatter on page 296 31 YZ Cause Solution An error has been detected with the cutter Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Check the Cutter Assembly for blockage or any other obvious problems e Replace the Cutter Assembly refer Cutter Assembly on page 199 ENWW System Error Codes Full Descriptions 57 38 YZ Cause Solution An error has been detected with the Media Output Tray Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Check the Media Output Assembly for blockage or any other obvious problems e Replace the Media Output Assembly refer Media Output Assembly on page 178 41 YZ Cause Solution Electrical fault or current limit in Media Axis Motor Try the following e Switch the Power OFF from t
195. rrectly 1 In the Diagnostics menu scroll to 1 Scan Axis and press OK 2 The Front Panel will show the1 Scan Axis submenu 3 IntheScan Axis submenu scroll to Star Wheel Lifter and press OK to start the test If there is a Failure at any point during the tests the Front Panel will display the relevant System Error Code To trouble shoot any displayed error codes refer System Error Codes Full Descriptions on page 50 4 The printer then starts the Star wheel lifter PWM control test to verify the subsystem As the test executes the Front Panel displays the following messages e Starting Horsburgh e Starting Tests PWM e Starting Tests GPIO e Booting up the Carriage e Starting SVS Motor e Starting Carriage Motor e Starting Service Station e Starting Scan Axis e Moving SVS out of Scan e Homing Scan Axis e Move Carriage out of SVS path e Starting Servicing Services e Capping SVS e Uncapping SVS e Starting Star Wheels Motor e Checking SVS capped e Getting SWL path length e Checking SWS length e Checking SWL PWM Forward e Moving amp Getting traces e Moving SWL Motor e Dumping motor traces Service Tests Diagnostics 11 e Analyzing motor traces e Checking PWM results e Checking SWL PWM Backward e Moving amp Getting traces e Moving SWL Motor e Dumping motor traces e Analyzing motor traces e Checking PWM results lf there is a Failure at any point during the test th
196. rvice Station refer Service Station on page 214 3 Unroute the Drop Detector ribbon cable from the Service Station cable clamps 4 Remove the T 15 screw that secures the Drop Detector to the Service Station 5 Lift the Drop Detector off the Service Station E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 218 Chapter6 Removal and Installation ENWW Aerosol Fan Assembly Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Right Cover refer Right Cover on page 185 2 Disconnect the Aerosol Fan Assembly inline connector 3 Remove the four T 15 screws that secure the Aerosol Fan Assembly to the Service Station E NOTE The four access holes in the Aerosol Fan Assembly housing are the same size as the attachment screw diameter so you will need a normal Torx Screwdriver not a multi tool to remove the screws ENWW Aerosol Fan Assembly 219 4 Remove the Aerosol Fan Assembly from the Service Station E NOTE When you reinstall the Aerosol Fan Assembly make sure you position it so that the power cable is on the outside exiting to the right roy E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations yo
197. s e DEFAULT The paper loaded is recognized as HP paper which is already optimized and calibrated for the printer Do not calibrate the Paper Advance for this paper e RECOMMENDED The paper loaded is NOT recognized as HP paper and Paper Advance values have NOT been customized for this paper type In this case calibrate the Paper Advance from the user menu e OK This indicates that the paper loaded has been calibrated before If the printer continues to have banding and graininess problems calibrate the Paper Advance from the user menu EY NOTE Whenever the printer s firmware is upgraded the paper advance calibration values will be reset to factory default 2 To calibrate the Paper Advance from the user menu go to Main Menu Image Quality Maintenance Paper Advance Calibration Calibrate Paper Advance E NOTE Itis very important to verify that the loaded media is the same media type as selected in the front panel You can verify the media type selected through the Front Panel Main Menu Paper menu View loaded paper The wrong type of paper selected will produce an offset error in the Paper Advance NOTE Some paper types are not suitable for Paper Advance Calibration Do not use colored papers or transparent materials such as translucent bond clear film matte film tracing paper or vellum Paper Advance calibration from the user menu will only calibrate the Paper Advance for the paper type loaded in the printer at that mome
198. s To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Left Starwheel Lifter Removal 393 E NOTE Switch off the printer and remove the power cable 1 Remove the Front Cover refer Front Cover on page 177 2 Remove the Left Cover refer Left Cover on page 188 3 Remove the Electronics Module Main PCA and PSU refer Electronics Module Main PCA and PSU on page 298 4 Remove the Left Spittoon refer Left Spittoon on page 306 5 Remove the Starwheel Assembly refer Starwheel Assembly on page 301 320 Chapter 6 Removal and Installation ENWW 6 Remove two T 8 screws that secure the Left Starwheel Lifter to the printer ENWW Left Starwheel Lifter 321 9 Remove the Left Starwheel Lifter from the printer 39 E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Right Starwheel Lifter Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Front Cover refer Front Cover on page 177 2 Remove the Right Cover refer Right Cover on page 185 3 Remove the Starwheel Assembly refer Starwheel Assembly on page 301 4 Loosen the T 10 uncapping screw sufficiently so you can manually move the Carriage Assembly in step 5 322
199. s 43 Corrective Action 1 Ensure that the paper type being used has been color calibrated which will give color consistency from print to print and from Printer to Printer Check that printing is on the correct side of the paper Check that the appropriate print quality settings are being used refer to the User s Guide for more information Reprint the job in case the problem has been solved If the problem consists of color differences between your print and your monitor please follow the instructions in the How to calibrate your monitor section of the HP Color Center At this point you may wish to reprint your job in case the problem has been solved Select suitable options in the application refer to the User s Guide for more information Print the Service Image Diagnostics Print and clean any printheads that need cleaning Reprint the job in case the problem has been solved Color accuracy using EPS or PDF images in page layout applications Page layout applications such as Adobe InDesign and QuarkXPress do not support color management of EPS PDF or grayscale files If these types of files have to be used try to ensure that the EPS PDF or grayscale images are already in the same color space that is intended to be used later on in Adobe InDesign or QuarkXPress For instance if the final objective is to print the job in a press that follows the SWOP standard at the time of creating the EPS PDF or grayscale the
200. sembly out of the printer Double check that the Out Of Paper Sensor on the left side of the Clean Out Assembly has not been damaged 39 E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Out Of Paper Sensor Removal 226 Chapter6 Removal and Installation ENWW E NOTE Switch off the printer and remove the power cable 1 Remove the Spindle refer to Spindle on page 223 2 Remove the Clean Out Assembly refer Clean Out Assembly on page 225 3 Unroute the Out Of Paper Sensor electrical cables from the Clean Out Assembly 4 Unroute unwind the Out Of Paper Sensor electrical cables from the Out Of Paper Sensor cover 5 Press the clip to remove the Out Of Paper Sensor cover from the Clean Out Assembly ENWW Out Of Paper Sensor 227 6 Rotate the Out Of Paper Sensor cover approximately 45 degrees 7 Remove the Out Of Paper Sensor cover from the Clean Out Assembly 8 Squeeze the Out Of Paper Sensor attachment clips to remove it from the Clean Out Assembly 228 Chapter6 Removal and Installation ENWW 9 Lift the Out Of Paper Sensor out of the Clean Out Assembly E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you mu
201. splays the following messages e Starting Horsburgh e Starting DelSol7 e Starting Carriage e Getting PSU voltages The Front Panel then displays the Power Supply test results Power supply voltages Volt 45 32 75 43 70 31 586 5 03 VOLT 3 3 3 3_F 2 5 3 313 3 313 2 436 Volt 1 254 1 25 B 1 199 1 225 Press any key to continue Press any key to continue The Fan Speed test starts and the Front Panel displays e Starting Horsburgh e Starting Tests PWM e Starting Tests GPIO e Booting up the Carriage The Front Panel then displays the Fan Speed test result and prompts you to press any key to continue Electronics Module PSU Fan Speed OK Press any key to continue Press any key to continue The Front Panel then prompts you to test the Formatter Electronics Module Do you want to check the Formatter YES Press UP DOWN to change and ENTER to select Press OK to the test the Formatter If you do not wish to test the Formatter use the Arrow keys to select NO and press OK The Formatter voltage test starts and the front Panel displays the following messages e Starting DelSol1 e Getting PCA revision Service Tests Diagnostics 91 13 The Front Panel then displays PCA Rev Voltage test result and prompts you to press any key to continue Electronics Module PCA Rev Voltage 1 42 Press any key to continue hai 14 Press any key to continue 15 The Formatter
202. ss any key to shutdown the printer 5 Sensors The Sensors test diagnoses Failures of any sensors of the printer Always run this test before replacing any of the following sensors e Window sensor e Media Lever position sensor Media sensor Diagnostic tests also need to be performed after removing or replacing certain printer components If you have removed or replaced printer components check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform refer to Service Calibration Guide to Removal and Installation on page 170 1 Inthe Diagnostics menu scroll to 5 Sensors and press OK Diagnostics menu 1 Scan Axis Paper Drive Electronics Module Carriage Assembly Sensors ENWW Service Tests Diagnostics 101 2 The Sensors test starts and the Front Panel prompts you to verify default sensor positions Sensors Default conditions are Window Closed Pinchwheel Lowered Paper Unloaded Press any key to continue 3 Verify that the sensors are in the default positions and any key to continue 4 The Window sensor test starts and the Front Panel prompts you to open the Window Sensors Test of Window sensor Please open the cover Press any key to continue 5 Open the Window 6 Press any key to continue 7 The Window sensor test continues and the Front Panel prompts you to close the Window Sensors Test o
203. ss any key to shutdown the printer Primer Motor 1 Inthe Diagnostics menu scroll to 8 Service Stationand press OK Diagnostics menu Paper Drive Electronics Module Carriage Assembly Sensors SOL IDS 8 Service Station 2 The Front Panel will show the 8 Service Station submenu 8 Service Station gt Service Station gt Primer Motor gt Aerosol Fan 3 Inthe 8 Service Station submenu scroll to Primer Motor and press OK to start the test 4 The Primer Motor test starts and the front Panel displays the following messages e Starting TestsGpio e Starting Horsburgh e Booting up Carriage e Starting SVS Motor e Starting Nvm e Getting Part Number e Starting Service Station e Starting Scan Axis e Moving SVS out of Sax e Homing Scan Axis e Moving Carriage out of SVS e Homing Service Station e Moving to Spit Rear pos ENWW Service Tests Diagnostics 113 e Moving to Spit Front pos e Moving to Wipe forward pos e Moving to Wipe reverse pos e Moving to Cleaner pos e Moving to Color Sensor ESP pos e Homing Scan Axis e Starting ServicingServices e Capping Service Station e Uncapping Service Station e Starting Mechanical Init 5 The Front Panel then prompts you to check the status of the printer Please check Window Closed Pinchwheel Lowered Pens Inserted Valid Cartridges Inserted Press any Key to continue F 6 Check that e The W
204. st perform refer to Service Calibration Guide to Removal and Installation on page 170 Left Roll Guide Removal EY NOTE Switch off the printer and remove the power cable 1 Remove the Spindle refer to Spindle on page 223 2 Remove the Clean Out Assembly refer Clean Out Assembly on page 225 3 Remove five T 15 screws that secure Left Roll Guide to the printer ENWW Left Roll Guide 229 4 Lower the left end and remove the Left Roll Guide from the printer E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Right Roll Guide Removal 39 E NOTE Switch off the printer and remove the power cable 1 Remove the Spindle refer to Spindle on page 223 2 Remove the Clean Out Assembly refer Clean Out Assembly on page 225 3 Remove the Left Roll Guide refer Left Roll Guide on page 229 4 Remove seven T 15 screws that secure Right Roll Guide to the printer 230 Chapter6 Removal and Installation ENWW 5 Lower the right end and remove the Right Roll Guide from the printer E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 En
205. stic to troubleshoot the problem further 3 Electronics Module on page 90 e fthe System Error continues replace the Power Supply Unit PSU refer Electronics Module Main PCA and PSU on page 298 ENWW System Error Codes Full Descriptions 51 05 1 YZ Cause Solution CPU Fan is stopped or burnt Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Replace the Power Supply Unit PSU refer Electronics Module Main PCA and PSU on page 298 e Ifthe System Error continues replace the Main PCA refer Electronics Module Main PCA and PSU on page 298 06 YZ Cause Solution Main NVM failure not detected read write failed or readback Try the following error e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e fthe System Error continues replace the Formatter refer Formatter on page 296 08 YZ Cause Solution Problem with the Front Panel Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer Check that the Front Panel interface cable is not damaged and is correctly connected between the Main PCA and the Front Panel e Check that the memory module in the Formatter is installed correctl
206. stis a Reset cutter life counter Restore factory settings Set line Fore ENWW 333 Figure 8 5 Image quality maintenance menu Image quality maintenance Calibrate Color Align printheads Printhead diagnostic image Paper advance calibration Calibrate paper advance Adjust paper advance Reset paper advance Clean printheads Clean all Clean M Y amp MEK C Enable color Calibration Purge ink Clean LM LC amp PK LG Figure 8 6 Connectivity Menu View information View configuration Modify configuration Restore factory sethngs USB View information Jeidirect El View information View configuration Modify configuration Restore factory settings Advanced Select AO timeout Allow SHP Embedded Web Sener Color amp paper management Web Services Restore factory settings 334 Chapter 8 Printer menu Map ENWW Figure 8 7 Internal Prints Menu Print color photo Print color design demo Printer GIS map User information prints Print configuration Print usage report Print PS font list Service information prints Print current information Ee Print all pages Figure 8 8 Information Menu System wamings Printheads Ink cartridges ENWW 335
207. subsystem that are included in this assembly are e Star Wheel Lifter e Automatic PPS Adjustment e Scan Axis Servosystem e Cutter You must perform the Scan Axis Test after e System Error Code 87 XZ e System Error Code 42 XZ e System Error Code 47 XZ e System Error Code 73 XZ e System Error Codes related to Scan Axis shutdown or Carriage jam Diagnostic tests also need to be performed after removing or replacing certain printer componenis If you have removed or replaced printer components check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform Refer to Service Calibration Guide to Removal and Installation on page 170 E NOTE ALL THE COVER SENSORS ARE DISABLED WHEN IN THE SERVICE TESTS MENU IF THE CARRIAGE IS MOVING IT WILL NOT STOP IF THE WINDOW IS OPENED SO BE VERY CAREFUL NOT TO PUT YOUR HANDS INSIDE NOTE IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE REPLACING ANY COMPONENT OF THE SCAN AXIS Star Wheel Lifter test 76 Chapter 3 Diagnostic Menu ENWW The Star Wheel Lifter subassembly is designed to move the Start Wheel support to the up and down positions This is used to load roll or sheet media and avoid damage to the Star Wheel caused by paper jams etc Perform the Scan Axis Starwheel lifter test as follows Ef NOTE Perform this test with the Printheads and the Tubes System installed in order to get values ENWW that can be compared co
208. sult Functional Test OK Press any key to finish 9 Press any key finish 10 The Front Panel shows the test complete display for a few seconds 11 Press any key to shutdown the system 12 Press any key to shutdown the printer 86 Chapter3 Diagnostic Menu ENWW 2 Paper Drive The Paper Drive test diagnoses Failures of components of the Media Axis You must perform the Paper Drive Test after e System Error Code 81 XZ e System Error Code 41 XZ e System Error Code 73 XZ Diagnostic tests also need to be performed after removing or replacing certain printer components If you have removed or replaced printer components check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform Refer to Service Calibration Guide to Removal and Installation on page 170 EY NOTE ALL THE COVER SENSORS ARE DISABLED WHEN IN THE SERVICE TESTS MENU IF THE CARRIAGE IS MOVING IT WILL NOT STOP IF THE WINDOW IS OPENED SO BE VERY CAREFUL NOT TO PUT YOUR HANDS INSIDE NOTE IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE REPLACING ANY COMPONENT OF THE MEDIA AXIS Perform the Paper Drive test as follows NOTE Perform this test with the Printheads and the Tubes System installed in order to get values _ ENWW that can be compared correctly 1 In the Diagnostics menu scroll to2 Paper Drive and press OK Diagnostics menu Scan Axis 2 Paper Drive Electronics Mo
209. t assembly passes you should NOT replace it For information on the Service Tests and how to use them see Diagnostic Menu on page 73 amp Service Menu on page 124 Performing the Necessary Service Calibrations Is the printer calibrated correctly after replacing a component For information on the Service Calibrations and how to use them see Chapter 5 Service Calibrations E NOTE Remember that certain Calibrations are required even if an Assembly has been disassembled to gain access to another Assembly or Component Chapter 1 Ink Supplies Troubleshooting amp Print Quality ENWW Solving Ink Supplies Problems For information on solving Ink Supplies problems see Solving Ink Supplies problems on page 9 in this section Solving Print Quality Problems For information on solving Print Quality problems see Print Quality on page 23 in this section Using the Front Panel Below is a diagram of the front panel ENWW View Loaded Paper Arrow Keys View Ink Levels Cancel d B OK j J ic Power Form Feed and Cut Unload Paper Back Key Function Arrow Keys Use the Arrow keys to scroll through a menu or toggle between YES or NO when prompted Cancel Use the Cancel key to abort or stop a procedure or reject test results OK Use the OK key to select a menu option Power Use the Power key to turn the printer ON and OFF Menu Use the Menu key to enter the main menu Back Use the Back key to go b
210. t select whether you would like to continue with the calibration by pressing the OK key Press Back or Cancel to exit the calibration Drop Detector Calibration Press ENTER to proceed with Drop Detector calibration or BACK CANCEL to exit 3 The Printer will start to calibrate the Drop Detector Drop Detector Calibratio Drop Detector calibrating 4 Once the Drop Detector has been calibrated the results will be displayed on the Front Panel Press OK to finish the calibration Drop Detector Calibration DD Offset Range 96 to 96 DD Offset got 8 in window width 15 Jindow width got Press ENTER to accept or CANCEL to reject values Service Calibrations 145 5 Once the calibration is completed OK will be displayed on the Front Panel Drop Detector Calibration Line Sensor Calibration The purpose of this Service Calibration is to calibrate the intensity of the line sensor in the Carriage PCA An incorrect calibration can result in edge detection failures during media loading and incorrect reading of prints that are used for alignment or calibration Perform the Line Sensor Calibration whenever e Edge detect procedure fails during media loading e Carriage is disassembled or replaced e Line Sensor is disassembled or replaced e Banding is detected in prints e Misalignment between colors is detected Service calibrations also need to be performed after removing or replacing certain printer
211. t the Cartridge Tubes Connector out of the Right Ink Supply Station 294 Chapter6 Removal and Installation ENWW 23 Remove the left Side Plate of the Left Ink Supply Station ENWW Ink Supply Tubes 295 26 Remove the right Side Plate of the Left Ink Supply Station 27 Carefully lift the Ink Supply Tubes out of the printer kk E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Formatter Removal E NOTE Switch off the printer and remove the power cable 1 Fully loosen the two locking thumbscrews that secure the Formatter in the printer 296 Chapter6 Removal and Installation ENWW 2 Begin lifting the Formatter from the printer Push the clips and provide upward force at the same time 3 Lift the Formatter out of the printer NOTE When you install a new formatter follow the instructions provided on the Flyer that accompanies it to set up the printer Hard Disk Drive Removal and installation 1 Remove the Formatter on page 296 2 Unscrew four screws in the formatter ENWW Hard Disk Drive 297 3 Remove the hard disk drive from the formatter by applying force in the direction of the arrow 4 Insert a new hard disk drive NOTE If you try to insert a previously used hard disk
212. tallation ENWW A When installing the new belt make sure the belt is correctly installed under the carriage assembly Scan Axis Motor Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Right Cover refer Right Cover on page 185 2 Remove the Left Cover refer Left Cover on page 188 3 Loosen the T 10 uncapping screw sufficiently so you can manually move the Carriage Assembly in step 4 4 Push the Carriage Assembly into the print path ENWW Scan Axis Motor 257 5 Loosen the T 15 screw Belt Tensioner to the printer to remove the tension from the belt KA OY amn fy a F E amp NOTE There is a spacer between the right end plate and the tensioner 7 Remove the Belt Assembly from the drive wheel of the Scan Axis Motor i a 258 Chapter6 Removal and Installation ENWW 8 Remove three T 15 screws that secure the Scan Axis Motor to the printer 9 Unroute the Scan Axis Motor supply cable from the cable clamp D ia ij 10 Disconnect the Scan Axis Motor supply connector from PrintMech PCA Y a Ha ENWW Scan Axis Motor 259 11 Remove three T 15 screws that secure the Scan Axis Motor to the printer 12 Carefully pull the Scan Axis Motor out of the printer 10 mm until you can rotate it approximately 30 degrees counterclockwise 99 EE NOTE When you finish installing or replacing this component you must perform the n
213. te and Time Refer 6 Set Date and Time on page 132 The purpose of this Service Utility is to set the Real Time Clock RTC of the Printer 7 Enable Disable Firewall Refer 7 Enable Disable Firewall on page 133 The purpose of this Service Utility is to enable or disable the built in system firewall 8 Enable Disable Sleep Mode enables or disables Sleep Mode Refer 8 Enable Disable Sleep Mode on page 134 9 Enable Disable SNMP Refer 9 SNMP Language Write Access on page 135 10 Borderless Cut Distance s Refer 10 Borderless Cut Distance on page 137 1 Turn Drive Roller The purpose of this Service Utility is to rotate the Drive Roller and the Overdrive in order to clean them Ef NOTE REMOVE THE MEDIA BEFORE PERFORMING THIS OPERATION NOTE OPEN THE WINDOW OF THE PRINTER AND ACTIVATE THE WINDOW SENSOR USE A PIECE OF PAPER TO COVER THE SENSOR BEFORE PERFORMING THIS SERVICE UTILITY 126 Chapter4 Service Menu ENWW ENWW Perform the Turn Drive Roller utility as follows 1 In the Service Utilities submenu scroll to Turn Drive Roller and press OK Service utilities Turn Drive Roller Purge Tubes Set SN Reset life counters 4 Diagnostic Print Set Date and Time The Printer checks to see if media is loaded and the Front panel displays the following message If media is loaded the Front Panel will display a message Unload the media and start again from step 1 e Checking Media Presence Sensor The Driv
214. ted or weak nozzles nozzles not working correctly at all frequencies or even Gloss Enhancer GE color problems 2 Inspector measuring tool test plot E NOTE Test 2 should NOT be used by Service Engineers 3 Nozzle Print Test which is also part of the Image Quality Service Plot This test is designed to check that the Printhead nozzles print correctly The test prints out every single nozzle of each Printhead No error hiding or Printhead Alignment algorithm is applied For each Printhead you can see both the adjacent and the consecutive nozzles This is what you would see in the Nozzle Print Test part if there are nozzles not printing correctly 1 On the right of each Printhead Nozzle test there is a series of numbered stepped diagonal lines If one or more of the nozzles are malfunctioning or out of position you will see that the stepped lines are broken or misdirected in one or more places 2 Onthe left of each Printhead Nozzle test there is a series of horizontal straight lines If one or more nozzles are misdirected there will be unequal spaces between the corresponding lines Corrective Action for Nozzle Defects If the printer has nozzle defects it does not mean that you will not get perfect print quality results The printer has automatic procedures to hide many nozzle defects 1 Recover the Printheads using the option through the Front Panel Main Menu Image quality maintenance Clean printheads 2 Reprint the Noz
215. text The procedures appear in order of removal The whole machine can be stripped down by starting at the beginning of this chapter and working through the subsequent procedures amp NOTE Before using this chapter to remove and install a new component always make sure that you have performed the relevant service test If the test passes you will not need to replace the component Safety Precautions Review the instructions identified by WARNING and CAUTION symbols before you service the printer Follow these warnings and cautions for your protection and to avoid damaging the printer EY NOTE Serious shock hazard leading to death or injury may result if you do not take the following precautions Ensure that the ac power outlet mains has a protective earth ground terminal Switch the plotter off and disconnect it from the power source prior to performing any maintenance Prevent water or other liquids from running onto electrical components or circuits or through openings in the module Electrostatic Discharge ESD Precautions To prevent damage to the Printer circuits from high voltage electrostatic discharge ESD pP m m 6 o Do not wear clothing that is subject to static build up Do not handle integrated circuits ICs in carpeted areas 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
216. the following messages e Starting Micci2Bus e Starting Micci2BusProxy e Checking Communications 33 The Front Panel then displays Formatter Communications test results and prompts you to press any key to continue Electronics Module Device name DeLlSoll Del5015 DelSol Luna Press any key to continue 34 Press any key to continue 35 The Plotter information test starts and the Front Panel displays the following messages e Starting Nvm e Accessing Nvm e Getting Plotter info 94 Chapter3 Diagnostic Menu ENWW 36 The Front Panel then displays the Plotter Information results and prompts you to press any key to finish Electronics Module Proto Name LP1 Proto Product TROYA 8 Scan Axis size 24 Press any key to finish 37 Press any key to finish 38 The Front Panel shows the test complete display for a few seconds Electronics Module 39 The Front Panel prompts you to shutdown the printer to complete the test Electronics Module Press any key to shutdown the system 40 Press any key to shutdown the printer 4 Carriage Assembly The Carriage assembly test diagnoses Failures of any components of the Carriage Always run this test before replacing the Carriage Assembly Diagnostic tests also need to be performed after removing or replacing certain printer components If you have removed or replaced printer components check the Service Calibration Guide to Removal and Installation
217. tion 5 Sensors Cutter Test Bushing Line Sensor Line Sensor Calibration 5 Sensors Electronics module Window Position 5 Sensors Electronics module Sensor Out of Paper 5 Sensors Sensor ENWW Service Calibration Guide to Removal and Installation 171 Right Roll Guide 5 Sensors Left Roll Guide 5 Sensors Clean Out 5 Sensors Assembly Pen to Paper Space PRS Test PPS Solenoid Encoder Strip Scan axis Starwheel Starwheel Lifter Test Assembly Starwheel Motor Starwheel Lifter Test Electronics Module Left Starwheel Starwheel Lifter Test Electronics Module Lifter Right Starwheel None Lifter Print Zone Starwheel Lifter Test Overdrive Media Lever 5 Sensors Position Sensor Pinchwheel 2 Paper Drive 5 Sensors Assembly Pinch Roller 2 Paper Drive 5 Sensors Preventive 4 Carriage Assembly Scan Axis Test Line Sensor Calibration 5 Sensors Maintenance Kit 1 Preventive 8 Service Station Calibration Drop Detector Calibration Maintenance Kit 2 Cutter Assembly Cutter Test Color Sensor ESP Color Sensor ESP Calibration 5 Sensors Electronics Module Top Cover Electronics Module Ink Supply Tubes Electronics Module 5 Sensors Support Rail Performing the Service Calibrations and Diagnostic Tests When you are ready to perform the service calibrations and diagnostic tests that correspond to the component you have installed or replaced consult the following page numbers for procedures e PR
218. to see which tests and calibrations you need to perform Refer to Service Calibration Guide to Removal and Installation on page 170 1 Inthe Diagnostics menu scroll to4 Carriage Assembly and press OK Diagnostics menu Scan Axis Paper Drive Electronics Module 4 Carriage Assembly Sensors SOL 2 The Power supply test starts and the Front Panel displays the following messages e Starting Horsburgh e Starting AdcManagerHorus e Starting Carriage ENWW Service Tests Diagnostics 95 e Getting Carriage PCA Rev e Starting Nvm 3 The Front Panel prompts you to verify the Carriage Assembly PCA revision The PCA Rev must be between 0 823 and 1 005 Carriage PCA Rev 0 929 Is the PCA Revision OK YES Press ENTER to confirm and BACK CANCEL to reject 4 Ifthe results are correct press OK to accept the results If the results are not correct press Back Cancel to reject the results and FAIL the test 5 The Carriage Assembly test starts and the Front Panel displays the following messages followed by their results e Getting Part Number e Getting Scan Access size e Getting Vs Carriage Voltage 6 The Front Panel then displays the Carriage Voltage Vs test results The vs Voltage should be between 43 6 and 46 3 Carriage Assembly Carriage Voltage Vs 44 968 Press ENTER to confirm and BACK CANCEL to reject 7 Ifthe results are correct press OK to accept the results If the
219. to select NO and press OK Service Tests Diagnostics 115 10 11 12 13 14 15 16 The test continues and the Front Panel displays the results Aerosol Fan On Off OK Press any key to continue F Press any key to continue The front panel prompts you to check if the Aerosol Fan is operating Aerosol Fan Is the Aerosol Fan switched Press UP DOWN to change and ENTER to select v Listen carefully to check if the Aerosol Fan is operating If it is operating use the Arrow keys to select YES and press OK If it is NOT operating select NO and press OK The Front Panel shows the test result Aerosol Fan Aerosol Fan OK Press any key to finish Press any key to finish The Front Panel shows the test complete display for a few seconds Aerosol Fan The Front Panel prompts you to shutdown the printer to complete the test Aerosol Fan Press any key to shutdown the system Press any key to shutdown the printer 116 Chapter 3 Diagnostic Menu ENWW 9 I O Information The I O Information test retrieves the TC IP Network configuration parameters from the printer 1 f In the Diagnostics menu scroll to 8 I O Information and press OK Diagnostics menu Carriage Assembly Sensors SUL LDS Service Station 9 IZO Information The I O Information test starts and the front Panel displays the following message e Getting IO Interface e
220. tom of its travel Introduction ENWW The following is a list of all internal Service Utilities available in the Service Menu Instructions for entering the Service menu are given on Entering the Service Utilities Menu on page 124 1 Turn Drive Roller Refer 1 Turn Drive Roller on page 126 The purpose of this Service Utility is to rotate the Drive Roller and the Overdrive in order to clean them Purge Tubes Refer 2 Purge Tubes on page 128 The purpose of this Service Utility is to Prime the Tubes when the Ink Tubes are NOT new and they need to be re primed or automatic priming was not completed correctly Set SN Refer 3 Set SN on page 130 The purpose of this Service Utility is to set the Serial Number of the Printer Reset Life Counters Reset 4 Reset Life Counters on page 131 Entering the Service Utilities Menu 125 The purpose of this Service Utility is to reset the internal life counters There are two submenus that allow you to e Reset ALL the counters related to a Preventive Maintenance Kit PMK e Reset only the counters related to a specific replaced part 5 Diagnostic Print Refer 5 Diagnostic Print on page 132 The purpose of this Service Utility is to print the Diagnostic Print in order to identify image quality problems e Image Quality Service Best e Image Quality Service Normal o Paper Advance o Printhead alignment o Nozzle Health o Force Drop Detection o Print Banding Plot 6 Set Da
221. trip or the Belt Assembly with the Pinchwheel Insertion Tool 2 Position the new Pinchwheel Assembly correctly on its hanger 316 Chapter 6 Removal and Installation ENWW Hook the spring of the Pinchwheel Assembly you are installing with the Pinchwheel Insertion Tool liij iy Niii gt Attach the spring to its attachment point on the hanger and remove the Pinchwheel Insertion Tool 4 Attach the new Pinchwheel Assembly with the two T 15 screws that secure to the printer but do 5 fully NOT tighten the screws Pinchwheel Assembly 317 ENWW 6 Compress the Pinchwheel Alignment Tool 7 Position the Pinchwheel Alignment Tool on the platen so it is aligned with the two adjacent Pinchwheels to the one you are installing 8 Push the replacement Pinchwheel Assembly fully forward so it is firmly against the Pinchwheel Alignment Tool to align it correctly 318 Chapter 6 Removal and Installation ENWW 9 Fully tighten the two T 15 attachment screws tighten 10 Remove the Pinchwheel Alignment Tool Pinch Roller Removal NOTE Switch off the printer and remove the power cable 1 Open the Window 2 Raise the Media Lever ENWW Pinch Roller 319 3 Apply enough downward pressure to the Pinch Roller to release it from the Pinchwheel Assembly a j a E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibration
222. ts and Diagrams ENWW Miscellaneous Parts HP Part Number Part Description CQ113 67009 Preventive Maintenance Kit 1 Q6675 67012 Preventive Maintenance Kit 2 Q6675 60068 Serial Number Label Q6675 67004 Ink System Purgers 6 Units Q6675 67005 Ink System Purgers 100 Units ENWW Miscellaneous Parts 165 6 Removal and Installation e Introduction on page 169 e service Calibration Guide to Removal and Installation on page 170 e Window on page 174 e Front Cover on page 177 e Media Output Assembly on page 178 e Right Front Trim on page 179 e Left Front Trim on page 181 e Right Ink Cartridge Door on page 182 e Left Ink Cartridge Door on page 183 e Right Cover on page 185 e Left Cover on page 188 e Rear Tray on page 194 e Rear Cover on page 195 e Media Lever on page 196 e Media Lever Position Sensor on page 198 e Cutter Assembly on page 199 e Right Rear Tray Support on page 200 e Left Rear Tray Support on page 201 e Front Panel on page 203 e lop Cover on page 205 e Window Position Sensor on page 208 e Ink Supply Tubes Support Rail on page 209 e Service Station on page 214 e Drop Detector on page 217 e Aerosol Fan Assembly on page 219 e PrintMech PCA on page 220 e Pento Paper Space PPS Solenoid on page 221 166 Chapter6 Removal and Installation ENWW e Spindle on page 223 e Left Spindle Holder on page 224 e Right Spindle Holder on page 224 e Clean Out Assembly on page 225 e Out Of Paper Sensor on p
223. u must perform refer to Service Calibration Guide to Removal and Installation on page 170 PrintMech PCA Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Right Cover refer Right Cover on page 185 2 Disconnect all the electrical connectors from the PrintWech PCA 220 Chapter6 Removal and Installation ENWW 3 Remove the grounding cable attachment screw from the PrintWech PCA 4 Remove the three T 15 screws that secure the PrintWech PCA to the Service Station 5 Remove the PrintMech PCA from the printer E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170 Pen to Paper Space PPS Solenoid Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Right Cover refer Right Cover on page 185 ENWW Pen to Paper Space PPS Solenoid 221 2 Unroute the Pen to Paper Space PPS Solenoid cable from the cable clamp 3 222 Chapter6 Removal and Installation ENWW 5 Remove the Pen to Paper Space PPS Solenoid from the printer E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform refer to Service Calibration Guide to Removal and Installation on page 170
224. uitable for Printhead Alignment 5 Check if the latest version of the firmware is installed If not install the latest firmware revision ENWW Print Quality 23 The Service Image Quality Diagnostic Print What is the Service Image Quality Diagnostic Print The Printer contains an internal Image Quality Test which helps you to diagnose the possible source of any image quality defects The Service IQ Diagnostic Print is available in the following options 1 Image Quality Service Best Plot This plot helps you to diagnose in more detail the possible source of any image quality defects It is accessible through the Service Utility Menu The Image Quality Service Best Plot uses the Best Print Mode and is divided in to three parts as follows e Diagnostic Part 1 Printhead Reliability Test The purpose of this test is to identify which Printhead is faulty e Diagnostic Part 2 Printhead Alignment Test This test is designed to check any color to color and bi directional misalignment the printer may have e Diagnostic Part 3 Printheads and Paper Advance test This test is designed to check whether the Printheads and the Media Advance Mechanism are working correctly 2 Image Quality Service Normal Plot This plot is the same as the Image Quality Service Best Plot but uses the Normal Print Mode 3 Advanced Diagnostic Plot These tests provide more information of the IQ defects that we could find in the Image Quality Service plot For mo
225. uld like to continue with the procedure by pressing the Enter key in which case the Printer will reboot Press Back or Cancel to exit the procedure at this point 3 The Front Panel displays a message to say the Printer is going to reboot Prine Tubes OOO E The system is going to reboot After then the procedure for priming the tubes will start automatically 4 Once the Printer has rebooted the Front Panel will instruct you to open the Window and remove ALL the Printheads installed in the Carriage Lift printhead cover Replace printheads M y im te Fd ig od 5 Once ALL the Printheads have been removed the Front Panel will instruct you to install the Setup Printheads into the Carriage 128 Chapter 4 Service Menu ENWW 6 f 10 11 ENWW Install the Setup Printheads in the carriage Once all the Setup Printheads are installed the following message will appear on the front panel Close the carriage cover and close the window Close printhead cover and window The printer will begin to purge the tubes system Once the tubes system has been purged the following message will instruct you to open the Window and the carriage to access the printheads When the following message appears on the Front Panel open the Carriage cover and check the window on top of each Setup Printhead If the Ink Supply Tubes have been primed correctly the windows will contain ink If the windows on top of
226. update the Firmware to the latest version e Retry the Paper Advance Calibration 5 Once the Analog Encoder has been calibrated correctly the following message will appear on the Front Panel Press the OK key in order to start the media load process Print Calibration Pattern Press ENTER to load paper 6 Load a sheet of HP Productivity Gloss Media that was included in the Paper Advance Calibration Kit refer to Parts and Diagrams on page 151 following the instructions on the Front Panel If the kit is not available cut a piece of HP Productivity Gloss Media that is 36 inches wide and at least 45 inches long 7 Once the media is loaded into the Printer the following message will appear on the Front Panel If roll media has been used instead of cut sheet media you will need to unroll a minimum of 1 meter of media in order to prevent any back tension which could cause any media advance problems Press the OK key to continue Print Calibration Pattern WARNING If roll 18 used unroll i meter of media to avoid back tension Press ENTER to proceed with pattern printing 142 Chapter4 Service Menu ENWW 8 The Printer will start to print the Paper Advance Calibration Pattern This could take several minutes during which the following message will be displayed on the Front Panel Print Calibration Pattern Printing pattern 9 Once the Accuracy Calibration Pattern has been printed successfully the Front panel will prom
227. upply Tubes Support Rail 211 12 Remove two T 15 screws that secure the Ink Supply Tubes Support Rail to the left Top Cover Support 13 Slide the rail enough to disengage it from the attachment lug 14 Carefully slide the Ink Supply Tubes Support Rail to the left until the right end is clear of the right Top Cover Support 212 Chapter6 Removal and Installation ENWW 15 Remove the Ink Supply Tubes Support Rail from the printer Ey NOTE When you reinstall the Ink Supply Tubes Support Rail make sure that the attachment lug is correctly engaged with the right Top Cover Support E NOTE When you reinstall the Ink Supply Tubes Support Rail make sure all the attachment brackets and bonding leads are correctly connected These are important to avoid electrostatic interference being generated E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform Refer to Service Calibration Guide to Removal and Installation on page 170 ENWW Ink Supply Tubes Support Rail 213 Service Station Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Right Cover refer Right Cover on page 185 2 Disconnect the Ink Supply Station ribbon connector and two lower connectors from the PrintMech PCA E NOTE The Ink Supply Station ribbon connector has to be disconnected so the other cables can an be unrouted
228. ution Preventive Maintenance Kit 2 counter active Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Change theLeft Spittoon foams and Belt Assembly the Scan Axis Motor the Ink Supply Tubes and Carriage Assembly this does not include the Carriage PCA and Color Sensor ESP but it does include the Trailing Cable You should change Preventive Maintenance Kit 2 Refer to Preventive Maintenance Kit 2 on page 331 e Once the parts have been changed use the Service Menu to reset the counters that affect PMKit 2 See 4 Reset Life Counters on page 131 76 YZ Cause Solution Hard disk drive is full Try the following e Remove any unnecessary files from the hard disk using the web server 77 YZ Cause Solution Web access application The web server is not functioning Try the following correctly e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer n Check that the Printer has the latest Firmware version If not update the Firmware to the latest version 78 YZ Cause Solution Borderless printing not possible Setting ignored Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Send the plot again 68 Chapt
229. ve the Left Cover refer Left Cover on page 188 4 Remove the Rear Cover refer Rear Cover on page 195 5 Remove two T 15 screws that secure the Left Rear Tray Support to the printer 6 Rotate the Left Rear Tray Support clockwise approximately 30 degrees t A T i 202 Chapter 6 Removal and Installation ENWW Front Panel Removal E NOTE Switch off the printer and remove the power cable 1 Open the Window gt 2 With strong pressure squeeze the top edge of the front panel enough to release the attachment clips and begin rotating the Front Panel vertically in the next step ENWW Front Panel 203 4 Disconnect the interface cable from the Front Panel 5 Push in the clip that prevents the Ferrite Core from being removed 6 Slide the Ferrite Core out of the brackets 204 Chapter6 Removal and Installation ENWW 7 Remove the Front Panel E NOTE When you reinstall the Front Panel you must make sure that the Ferrite Core is correctly positioned The Ferrite Core is necessary to avoid electrostatic interference being generated E NOTE When you finish installing or replacing this component you must perform the necessary Service Calibrations To find which calibrations you must perform Refer to Service Calibration Guide to Removal and Installation on page 170 Top Cover Removal E NOTE Switch off the printer and remove the power cable 1 Remove the Window refer Window on
230. was done in To solve the problem try the following Perform the Accuracy Calibration in the new environmental conditions Refer to the User s Guide Worm marks on HP Coated media with light area fills Light bands S shaped in Paper axis direction where light area fills are printed causing unacceptable Image Quality defect e Print the Service Configuration Print and check if the level of Humidity is very low below 30 Increasing humidity may help in reducing the severity of the problem E NOTE The media is causing the problem and NOT the Printer Do not attempt to try and replace Printer parts to solve this problem Solving Media Handling Problems The Front Panel indicates that media is misaligned or incorrectly positioned Roll media e The roll may be loaded the wrong way The paper should load over the roll toward you e Check that the paper is correctly loaded onto the spindle e The paper may be loaded at an angle The right hand edge must be aligned with the blue line on the Print Platen E NOTE Ensure that the paper is wrapped tightly on the roll This is a very important step to remember because if this is not done the media may be loaded at an angle causing the media to be rejected Sheet media e Always load sheet media using the Rear Input Tray Do NOT load the media as you would load roll media e t must be loaded with the right hand edge against the blue line on the Print Platen e The media may be cru
231. while using the printer and provides the remedial action required to solve the problem detected amp NOTE Only replace one component at a time and check if the error has gone before replacing another component Using this procedure you will be able to determine exactly which component failed 01 0 YZ Cause Solution HCI queue does not end after 2 seconds Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e fthe System Error continues replace the Formatter See Formatter on page 296 e Ifthe System Error continues replace the Main PCA See Electronics Module Main PCA and PSU on page 298 01 1 YZ Cause Solution NVM backup not found read write or read back error Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Ifthe System Error continues replace the PrintMech PCA See PrintWech PCA on page 220 e fthe System Error continues replace the Formatter See Formatter on page 296 01 2 YZ Cause Solution PrintMech PCA fault or NVM backup failure Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Ifthe System Error continues replace the PrintMech PCA See PrintWech PCA on page 220
232. while disassembling and working on the Printer 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 After removing any PCA from the Printer place it on a conductive foam pad or into its conductive packaging to prevent ESD damage to any ICs on the PCA Required Tools All the special tools and equipment required to disassemble service and repair the Printer are provided in the Toolkit P N Q6683 67001 Some tools can be ordered separately from the toolkit Refer to Parts and Diagrams on page 151 The Toolkit contains the following tools Table 6 1 Toolkit P N Q6683 67001 Description Comments HP Part Number 13 mm Combination Spanner Q6675 67011 Alcohol Q6675 60070 ENWW Introduction 169 Table 6 1 Toolkit P N Q6683 67001 continued Allen Key 2 Cleaning Cloth Flex Contacts Cleaning Support Lubricant Oil Media Driver Adjustment Tool Handle for Media Driver Tool Support Spanner Oil Dispenser Pinchwheel Alignment Tool Pinchwheel Insertion Tool Protective Plastic Gloves Screwdriver Tweezers Cleaning Assembly Q6675 60041 9300 2531 Q1271 40384 Q6675 60061 Q6675 67009 Q6675 67010 Q6675 6701 1 Q6675 60062 Q5669 20595 Q5669 20594 Q6675 60035 8710 2456 Q6675 60037 C6071 60218 You will also need the following standard hand tools Table 6 2
233. xts 133 8 Enable Disable Sleep Mode srcani neasa a a A NNE Enia aa 134 9 SNMP Language Write ACCESS ccccseeeccceeeecceeeeeeaeeeecseuseeseaeseeseusessaeesessnsessaaeeeess 135 10 Borderless Cut Distance cccccccccccccsesecceeeeeeeeeeeseeeeeeseeesceeseeeeeeeesseaeeeesssaeeeessaaeess 137 Sea eeo e e S A E E E E E E E E E E E 138 Entering the Service Calibrations Menu ccccccseecceceeeseceeeseeeeeeeseeeeeeeeaeeeeeesaaeeeeseaaees 139 ENWW Scan Axis Calibration was cwcateaecisdanadaavevekericnatenshsoaaiddudeadsania haveudsautinwasatiadianteestesdhiabaateadensdns 139 SGIC Slaton Gali allo sessionerna a AE A EA S 140 Paper Advance Calibration cccccccccssesccceeeeeseceeceeeeeeceeeseeeseceeesaeaeeeeeeseeseeeessseageeeeeesaages 140 Drop Detector Calibration sn00ennnnneeoeeenneeeeesrteterreerrrtrtrreesstrrtnrrnssnnnrrnessrnnnnrnnnssnnnn eneee 145 Line Sensor Calibration ccccccccccssseeceeceeeeceeeeeeeeeeeeseeeeeeeceeeeeesseeseeesseaeeeeesseaeeeeessaseeees 146 Eeee E E N E E E E I E tues 149 Color Sensor ESP Calibration cccccccesscsssseeeeeeeseeeesssseeeeeeesseasssseneeeeeseecuseeeeeseees 149 5 Parts and Diagrams Pnr SUID ONE wanccedacoacesecieocaveateciancntaeseahasetnecsclaecancednanarsieesacteasceseaestqsstueedeasnscevectsclessans nesuesuecctnesacs 152 Center Covers Front ccccccssseccecccesseceeeceeeeeeeeeeeeeeeeeseeeeeeeseseeeceesesaeeeeseeaeeeeseuaeeee
234. y e Check that the connections between the Formatter the Formatter and the Formatter are not damaged and are correctly connected Check that the Printer has the latest Firmware version If not update the Firmware to the latest version e _ If the System Error continues replace the Main PCA refer Electronics Module Main PCA and PSU on page 298 e fthe System Error continues replace the Formatter refer Formatter on page 296 e fthe System Error continues replace the Front Panel refer Front Panel on page 203 52 Chapter2 System Error Codes ENWW ENWW 11 YZ Cause Solution Trailing Cable does not seem to be detected Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer e Check that the Trailing Cable is not damaged e Check that the Trailing Cable is correctly connected between the Main PCA and Carriage PCA e fthe System Error continues replace the Formatter refer Formatter on page 296 e Ifthe System Error continues replace the Main PCA refer Electronics Module Main PCA and PSU on page 298 e __ If the System Error continues replace the Carriage PCA refer Carriage PCA on page 276 12 n YZ Cause Solution Carriage amp PCA Main doesn t detect pens Try the following e Switch the Power OFF from the back of the Printer and disconnect the Power cord Re
235. zle Print test to check that the defective nozzles have been corrected 3 Ifthe problem continues replace the defective Printhead Force Drop Detection If the Nozzle Print Test plot has persistent white point banding in only one color that cannot be fixed with a printhead recovery you can use this option to resolve the problem by resetting the nozzle health data base so that all nozzles are assumed to be correct Once the nozzle health data base has been reset drop detection is forced The normal cause of this white point banding in a single color is the incorrect detection of failed nozzles by the drop detector Reading the Advanced diagnostic Print Results 35 Troubleshooting Print Quality Problems Print Quality General Advice 1 5 To achieve the best performance from the printer only genuine HP accessories and supplies should be used Make sure that the paper type selected in the Front Panel is the same as the paper type loaded into the Printer Make sure to use the most appropriate print quality settings for your purposes A lower print quality is likely to be seen if the print quality slider has been moved to the Speed end of the scale or the custom quality level set to Fast Check that the environmental conditions temperature humidity are within the temperature humidity range as specified for the Printer refer to the User s Guide for more information Check that the ink cartridges and printheads have not

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