HP DesignJet 500, 800 Series Large-Format Printers Service Manual

For the complete PDF manual
please visit www.LaserPros.com
HP
DesignJets 500 and 800 Series
Large-Format Printers
Service Manual
For HP Internal Use Only
Warranty
WARNING
The information contained in this The procedures described in this
manual are to be performed by
document is subject to change
HP-qualified service personnel
without notice.
This document contains
only.
Hewlett-Packard makes no
proprietary information that is
protected by copyright. All rights warranty of any kind with
Electrical Shock Hazard
regard to this material,
are reserved. No part of this
including, but not limited to,
document may be photocopied,
Serious shock hazard leading to
the implied warranties of
reproduced, or translated to
death or injury may result if you
merchantability and fitness for
another language without the
do not take the following
prior written consent of Hewlett- a particular purpose.
precautions:
Packard Company.
Hewlett-Packard shall not be
- Ensure that the ac power outlet
liable for errors contained herein
First Edition, August 2000
(mains) has a protective earth
or for incidental or consequential
(ground) terminal.
damages in connection with the
- Disconnect the Printer from the
furnishing, performance, or use
power source prior to performing
of this material.
any maintenance.
©Copyright Hewlett-Packard
Company 2000
- 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 Chapter
8 of this manual, for precautions
you should take to prevent
damage to the Printer circuits
from electrostatic discharge.
Safety Symbols
General definitions of safety
symbols are given immediately
after the table of contents.
Technical Marketing,
Barcelona Division,
Hewlett-Packard Espanola, S.A.
Avda. Graells, 501
08190 Sant Cugat del Valles
Spain
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.
1
HP
DesignJets 500 and 800 Series
Large-Format Printers
Service Manual
Using this Manual
Purpose
This Service Manual contains information necessary to test,
calibrate and service:
n HP DesignJet 500 Printer - 24” Model (P/N C7769B)
n HP DesignJet 500 Printer - 42” Model (P/N C7770B)
n HP DesignJet 500PS Printer - 24” Model (P/N C7769C)
n HP DesignJet 500PS Printer - 42” Model (P/N C7770C)
n HP DesignJet 800 Printer - 24” Model (P/N C7779B)
n HP DesignJet 800 Printer - 42” Model (P/N C7780B)
n HP DesignJet 800PS Printer - 24” Model (P/N C7779C)
n HP DesignJet 800PS Printer - 42” Model (P/N C7780C)
For information about using these printers, refer to the
corresponding User and Quick Reference Guides.
Readership
The procedures described in this Service Manual are to be
performed by HP Certified Service Personnel only.
Part Numbers
Part Numbers for Printer options, accessories and service parts are
located in Chapter 7.
Conventions
A small arrow ⇒ is used to indicate other parts of the Service
Manual where you can find information related to the topic you are
consulting.
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HP DesignJets 500 and 800 Series Printers Service Manual
Table of Contents
Table of Contents
1
Troubleshooting 1-1
Introduction 1-2
Troubleshooting System Error Codes 1-2
Solving Print Quality Problems 1-3
Cover Sensors are not Working 1-3
The Line Sensor has Problems Detecting Media 1-3
Troubleshooting Paper-Axis Shutdowns 1-4
Problems with the Vacuum Fan 1-5
Vacuum suction much lower at high altitudes 1-5
HP-GL/2 color differences in different HP DesignJet Printers 1-6
Banding at variable extreme environmental conditions 1-6
The Priming Procedure Fails 1-7
Using the Power Switch LED to Troubleshoot 1-10
Using the Boot-Up Sequence to Troubleshoot 1-12
Using the Formatter/Accessory Card LEDs to Troubleshoot 1-14
System Error Codes 2-1
Introduction 2-2
Continuable and Non-Continuable Error Codes 2-2
System Error Codes - Explanation 2-2
Error Log Utility 2-5
Accessing the Error Log Utility 2-5
Ink Supplies Troubleshooting 3-1
What are the Ink Supplies? 3-2
Ink Cartridges 3-2
Printheads 3-3
Identifying the Components 3-3
General Information About the Ink Supplies 3-4
Some General Precautions When Handling the Ink Supplies 3-5
When Should You Replace the Ink Cartridges? 3-6
When Should You Replace the Printheads? 3-7
Obtaining Ink Cartridge Information 3-9
HP DesignJets 500 and 800 Series Printers Service Manual
3
Table of Contents
Obtaining Printhead Information 3-10
Ink Cartridge Status Messages 3-12
Ink Cartridge Status While Replacing 3-12
Printhead Status Messages 3-13
Printhead History Utility 3-14
Accessing the Printhead History Utility 3-14
Is the Printer Causing Repetitive Printhead Problems? 3-16
Is the User Replacing the Printheads too Early? 3-18
Troubleshooting Repetitive Ink Cartridge Messages 3-20
Troubleshooting Repetitive Printhead Error Messages 3-21
Printhead Error Codes 3-22
Summary of Solving Ink Supplies Problems 3-23
Service Tests and Utilities 4-1
Introduction 4-2
Phone Support 4-2
Diagnostics - Self Test 4-2
Service Tests (Diagnostics) 4-3
Entering the Service Tests Menu 4-4
Ink Supply Station 4-6
Carriage Movement 4-8
Paper Advance Test 4-10
Service Utilities 4-13
Entering the Service Utilities Menu 4-14
EEROM Setup 4-16
Turn Drive Roller 4-21
Unlock Carriage 4-22
Prime Tubes 4-23
Change Cutter 4-24
Change Ink Tubes 4-25
Printer Information 4-26
Service Calibrations 5-1
Entering the Service Calibrations Menu 5-3
Printhead Alignment (includes PPS Calibration) 5-5
Color Calibration 5-7
Advance Calibration 5-9
Factory Advance Calibration 5-11
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HP DesignJets 500 and 800 Series Printers Service Manual
Table of Contents
Print Quality 6-1
Print Quality 6-2
Print Quality Troubleshooting Checklist 6-2
How to Use the Troubleshooting Procedure 6-4
What is the Troubleshooting Procedure? 6-4
Considerations for Using the Troubleshooting Procedure. 6-4
Performing the Troubleshooting Procedure 6-4
Troubleshooting Procedure Flowchart 6-7
No Printing Defects Found Using the Troubleshooting Procedure 6-8
Solving Color Accuracy problems 6-9
Color Consistency problems 6-9
Long Term Color Bleeding (Glossy Papers) 6-9
Media 6-10
There are Smears or Scratching on the Printed Media 6-10
Parts and Diagrams 7-1
Printer Support 7-2
Right Hand Cover 7-4
Left Hand Cover 7-6
Top Cover and Deflectors 7-8
Rollfeed Module 7-10
Back Platen Assembly 7-12
Electronics Module 7-14
Power Supply 7-16
Cutter Assemblies 7-18
Ink Delivery System 7-20
Service Station and Spittoon 7-22
Service Station Holder 7-24
Pinch-Wheel Assemblies 7-26
Scan-Axis Motor 7-28
Drive Roller Encoder Sensor 7-30
Print Platen Assembly 7-32
Carriage Assembly 7-34
Vacuum Fan 7-36
Interconnect Cable 7-38
Paper-Axis Motor 7-40
Drive Roller 7-42
Miscellaneous Items 7-44
HP DesignJets 500 and 800 Series Printers Service Manual
5
Table of Contents
Removal and Installation 8-1
Introduction 8-2
Safety Precautions 8-2
Electrostatic Discharge (ESD) Precautions 8-3
Required Tools 8-3
Screw Types 8-4
Left Hand Cover 8-5
Right Hand Cover 8-7
Front Panel 8-9
Window and Top Cover 8-10
Media Deflectors 8-11
Left End Roll-Feed 8-13
Right End Roll-Feed 8-15
Back Platen 8-17
Media Sensor 8-19
Formatter 8-20
LAN Card 8-21
Spittoon 8-23
Electronics Module 8-24
Power Supply 8-27
Scan-Axis Motor Assembly 8-29
Cutter Assembly 8-32
Left Encoder Holder 8-33
Cutter Bushing 8-35
Cutter Guide Bracket 8-36
Drive Roller Encoder Sensor 8-38
Trailing Cable 8-40
Ink Supply Station 8-48
Interconnect PCA 8-50
Service Station and Aerosol Fan 8-52
Cutter Guide 8-55
Print Platen 8-56
Service Station Holder 8-57
Interconnect Cable 8-59
Ink Supply Tubes 8-60
Vacuum Fan 8-64
Pinch-Arm 8-66
Pinch-Arm Mechanism 8-67
Pinch-Arm Lever 8-69
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HP DesignJets 500 and 800 Series Printers Service Manual
Table of Contents
Pinch-Arm Sensor 8-71
Fork Idler, Tensioner and Idler Pulley 8-74
Encoder Strip 8-76
Carriage Assembly (Including Belt) 8-78
Paper-Axis Motor 8-84
Drive Roller 8-86
Gear Assemblies 8-92
Preventive Maintenance 9-1
Moisture on the Printer 9-2
Noisy Carriage Bushing 9-2
Belt Swelling 9-2
Cleaning the Printer 9-2
General Cleaning 9-2
Cleaning the Drive Roller/Print Platen 9-3
Scheduled Maintenance 9-3
Level of Printer Usage 9-3
Scan-Axis Maintenance 9-4
Functional Overview 10-1
Introduction 10-2
SKU Overview 10-2
Electrical System 10-3
Introduction 10-3
Hardware Description 10-3
Power Supply Unit (PSU) 10-5
Front Panel 10-6
Ink Delivery System (IDS) 10-7
Ink Supply Station (ISS) 10-7
Tubes Assembly 10-9
Service Station 10-10
Glossary
Index
For the complete PDF manual
please visit www.LaserPros.com
HP DesignJets 500 and 800 Series Printers Service Manual
7
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