HPDesignJets 500, 510 and 800 Series Large-Format PrintersService Manual

For HP Internal Use OnlyWarrantyWARNINGThe information contained in this The procedures described in thismanual are to be performed bydocument is subject to changeHP-qualified service personnelwithout notice.This document containsonly.Hewlett-Packard makes noproprietary information that isprotected by copyright. All rights warranty of any kind withElectrical Shock Hazardregard to this material,are reserved. No part of thisincluding, but not limited to,document may be photocopied,Serious shock hazard leading tothe implied warranties ofreproduced, or translated todeath or injury may result if youmerchantability and fitness foranother language without thedo not take the followingprior written consent of Hewlett- a particular purpose.precautions:Packard Company.Hewlett-Packard shall not be- Ensure that the ac power outletliable for errors contained hereinFirst Edition, August 2000(mains) has a protective earthor for incidental or consequentialSecond Edition, November 2001(ground) terminal.damages in connection with theThird Edition, August 2008- Disconnect the Printer from thefurnishing, performance, or usepower source prior to performingof this material.any maintenance. Copyright Hewlett-PackardCompany 2000- Prevent water or any otherliquids from running ontoelectrical components or circuits,or through openings in theenclosure.Electrostatic DischargeRefer to the beginning of Chapter8 of this manual, for precautionsyou should take to preventdamage to the Printer circuitsfrom electrostatic discharge.Safety SymbolsGeneral definitions of safetysymbols are given immediatelyafter the table of contents.Technical Marketing,Barcelona Division,Hewlett-Packard Espanola, S.A.Avda. Graells, 50108190 Sant Cugat del VallesSpainWARNINGThe Warning symbol callsattention to a procedure, practice,or the like, which, if not correctlyperformed or adhered to, couldresult in personal injury. Do notproceed beyond a Warningsymbol until the indicatedconditions are fully understoodand met.CAUTIONThe Caution symbol callsattention to an operatingprocedure, practice, or the like,which, if not correctly performedor adhered to, could result indamage to or destruction of partor all of the product. Do notproceed beyond a Cautionsymbol until the indicatedconditions are fully understoodand met.

1HPDesignJets 500, 510 and 800 Series Large-Format PrintersService Manual

Using this ManualPurposeThis Service Manual contains information necessary to test,calibrate and service: HP DesignJet 500 Printer - 24” Model (P/N C7769B) HP DesignJet 500 Printer - 42” Model (P/N C7770B) HP DesignJet 500PS Printer - 24” Model (P/N C7769C) HP DesignJet 500PS Printer - 42” Model (P/N C7770C) HP DesignJet 500Plus – 24” Model (P/N C7769F) HP DesignJet 500Plus – 42” Model (P/N C7770F) HP DesignJet 500Mono – 24” Model (P/N C7769E) HP DesignJet 500Mono – 42” Model (P/N C7770E) HP Designjet 510 – 24” Model (P/N CH336A) HP Designjet 510 – 42” Model (P/N CH337A) HP Designjet 510ps – 24” Model (P/N CJ996A) HP Designjet 510ps – 42” Model (P/N CJ997A) HP DesignJet 800 Printer - 24” Model (P/N C7779B) HP DesignJet 800 Printer - 42” Model (P/N C7780B) HP DesignJet 800PS Printer - 24” Model (P/N C7779C) HP DesignJet 800PS Printer - 42” Model (P/N C7780C)For information about using these printers, refer to thecorresponding User and Quick Reference Guides.ReadershipThe procedures described in this Service Manual are to beperformed by HP Certified Service Personnel only.Part NumbersPart Numbers for Printer options, accessories and service parts are2HP DesignJets 500, 510 and 800 Series Printers Service Manual

located in Chapter 7.ConventionsA small arrow is used to indicate other parts of the ServiceManual where you can find information related to the topic you areconsulting.HP DesignJets 500, 510 and 800 Series Printers Service Manual3

Table of ContentsTable of Contents1Troubleshooting 1-1Introduction 1-2Troubleshooting System Error Codes 1-2Solving Print Quality Problems 1-3Cover Sensors are not Working 1-3The Line Sensor has Problems Detecting Media 1-3Troubleshooting Paper-Axis Shutdowns 1-4Problems with the Vacuum Fan 1-5Vacuum suction much lower at high altitudes 1-5HP-GL/2 color differences in different HP DesignJet Printers 1-6Banding at variable extreme environmental conditions 1-6The Priming Procedure Fails 1-7Using the Power Switch LED to Troubleshoot 1-10Using the Boot-Up Sequence to Troubleshoot 1-12Using the Formatter/Accessory Card LEDs to Troubleshoot 1-14System Error Codes 2-1Introduction 2-2Continuable and Non-Continuable Error Codes 2-2System Error Codes - Explanation 2-2Error Log Utility 2-5Accessing the Error Log Utility 2-5Ink Supplies Troubleshooting 3-1What are the Ink Supplies? 3-2Ink Cartridges 3-2Printheads 3-3Identifying the Components 3-3General Information About the Ink Supplies 3-4Some General Precautions When Handling the Ink Supplies 3-5When Should You Replace the Ink Cartridges? 3-6When Should You Replace the Printheads? 3-7Obtaining Ink Cartridge Information 3-94HP DesignJets 500, 510 and 800 Series Printers Service Manual

Table of ContentsObtaining Printhead Information 3-10Ink Cartridge Status Messages 3-12Ink Cartridge Status While Replacing 3-12Printhead Status Messages 3-13Printhead History Utility 3-14Accessing the Printhead History Utility 3-14Is the Printer Causing Repetitive Printhead Problems? 3-16Is the User Replacing the Printheads too Early? 3-18Troubleshooting Repetitive Ink Cartridge Messages 3-20Troubleshooting Repetitive Printhead Error Messages 3-21Printhead Error Codes 3-22Summary of Solving Ink Supplies Problems 3-23Service Tests and Utilities 4-1Introduction 4-2Phone Support 4-2Diagnostics - Self Test 4-2Service Tests (Diagnostics) 4-3Entering the Service Tests Menu 4-4Ink Supply Station 4-6Carriage Movement 4-8Paper Advance Test 4-10Service Utilities 4-13Entering the Service Utilities Menu 4-14EEROM Setup 4-16Turn Drive Roller 4-21Unlock Carriage 4-22Prime Tubes 4-23Change Cutter 4-24Change Ink Tubes 4-25Printer Information 4-26Service Calibrations 5-1Entering the Service Calibrations Menu 5-3Printhead Alignment (includes PPS Calibration) 5-5Color Calibration 5-7Advance Calibration 5-9Factory Advance Calibration 5-11HP DesignJets 500, 510 and 800 Series Printers Service Manual5

Table of ContentsPrint Quality 6-1Print Quality 6-2Print Quality Troubleshooting Checklist 6-2How to Use the Troubleshooting Procedure 6-4What is the Troubleshooting Procedure? 6-4Considerations for Using the Troubleshooting Procedure. 6-4Performing the Troubleshooting Procedure 6-4Troubleshooting Procedure Flowchart 6-7No Printing Defects Found Using the Troubleshooting Procedure 6-8Solving Color Accuracy problems 6-9Color Consistency problems 6-9Long Term Color Bleeding (Glossy Papers) 6-9Media 6-10There are Smears or Scratching on the Printed Media 6-10Parts and Diagrams 7-1Printer Support 7-2Right Hand Cover 7-4Left Hand Cover 7-6Top Cover and Deflectors 7-8Rollfeed Module 7-10Back Platen Assembly 7-12Electronics Module 7-14Power Supply 7-16Cutter Assemblies 7-18Ink Delivery System 7-20Service Station and Spittoon 7-22Service Station Holder 7-24Pinch-Wheel Assemblies 7-26Scan-Axis Motor 7-28Drive Roller Encoder Sensor 7-30Print Platen Assembly 7-32Carriage Assembly 7-34Vacuum Fan 7-36Interconnect Cable 7-38Paper-Axis Motor 7-40Drive Roller 7-42Miscellaneous Items 7-446HP DesignJets 500, 510 and 800 Series Printers Service Manual

Table of ContentsRemoval and Installation 8-1Introduction 8-2Safety Precautions 8-2Electrostatic Discharge (ESD) Precautions 8-3Required Tools 8-3Screw Types 8-4Left Hand Cover 8-5Right Hand Cover 8-7Front Panel 8-9Window and Top Cover 8-10Media Deflectors 8-11Left End Roll-Feed 8-13Right End Roll-Feed 8-15Back Platen 8-17Media Sensor 8-19Formatter 8-20LAN Card 8-21Spittoon 8-23Electronics Module 8-24Power Supply 8-27Scan-Axis Motor Assembly 8-29Cutter Assembly 8-32Left Encoder Holder 8-33Cutter Bushing 8-35Cutter Guide Bracket 8-36Drive Roller Encoder Sensor 8-38Trailing Cable 8-40Ink Supply Station 8-48Interconnect PCA 8-50Service Station and Aerosol Fan 8-52Cutter Guide 8-55Print Platen 8-56Service Station Holder 8-57Interconnect Cable 8-59Ink Supply Tubes 8-60Vacuum Fan 8-64Pinch-Arm 8-66Pinch-Arm Mechanism 8-67Pinch-Arm Lever 8-69HP DesignJets 500, 510 and 800 Series Printers Service Manual7

Table of ContentsPinch-Arm Sensor 8-71Fork Idler, Tensioner and Idler Pulley 8-74Encoder Strip 8-76Carriage Assembly (Including Belt) 8-78Paper-Axis Motor 8-84Drive Roller 8-86Gear Assemblies 8-92Preventive Maintenance 9-1Moisture on the Printer 9-2Noisy Carriage Bushing 9-2Belt Swelling 9-2Cleaning the Printer 9-2General Cleaning 9-2Cleaning the Drive Roller/Print Platen 9-3Scheduled Maintenance 9-3Level of Printer Usage 9-3Scan-Axis Maintenance 9-4Functional Overview 10-1Introduction 10-2SKU Overview 10-2Electrical System 10-3Introduction 10-3Hardware Description 10-3Power Supply Unit (PSU) 10-5Front Panel 10-6Ink Delivery System (IDS) 10-7Ink Supply Station (ISS) 10-7Tubes Assembly 10-9Service Station 10-10GlossaryIndex8HP DesignJets 500, 510 and 800 Series Printers Service Manual

Troubleshooting11Introduction 1-2Troubleshooting System Error Codes 1-3Performing a Service Test on a Failed Assembly 1-3Performing the Necessary Service Calibrations 1-3Solving Print Quality Problems 1-4The Printer does not Power ON 1-4Cover Sensors are not Working 1-4The Line Sensor has Problems Detecting Media 1-4Troubleshooting Paper-Axis Shutdowns 1-5Problems with the Vacuum Fan 1-6Vacuum suction much lower at high altitudes 1-6HP-GL/2 color differences in different HP DesignJet Printers 1-7Banding at variable extreme environmental conditions 1-7The Priming Procedure Fails 1-8Using the Power Switch LED to Troubleshoot 1-11Using the Boot-Up Sequence to Troubleshoot 1-13How to Detect Problems Related to the Encoder Disk 1-17HP DesignJets 500, 510 and 800 Series Printers Service Manual1-1

TroubleshootingGuide to Troubleshooting the PrinterIntroductionThis chapter will guide you through the relevant steps to take whentroubleshooting the printer.Front Panel Difference for the HP DesignJet 500, 510and 800 Series PrintersFront Panel for the HP DesignJet 500 and 800 SeriesFront Panel for the HP DesignJet 510 SeriesCancelMenuBackForm Feedand cutEnter1-2HP DesignJets 500, 510 and 800 Series Printers Service Manual

TroubleshootingNOTEThe layout shown below will be used to refer to both types offront panelsTroubleshooting System Error CodesChapter 2 - System Error Codes contains a list of system errorcodes and their respective descriptions and recommended correctiveactions. Only try one recommended action at a time and check if theerror code has disappeared.Performing a Service Test on a Failed AssemblyIf possible, always perform a Service Test on the component/assembly that you are about to replace, just to make sure that is thecomponent/assembly that has failed.NOTEIf the test on that component/assembly passes, you should NOTreplace it.For information on the Service Tests and how to use them seeChapter 4 - Service Tests and Utilities.Performing the Necessary Service CalibrationsIs the printer calibrated correctly after replacing a component?NOTERemember that certain Calibrations are required even if anAssembly has been disassembled to gain access to anotherAssembly or Component.For information on the Service Calibrations and how to use themsee Chapter 5 - Service Calibrations.HP DesignJets 500, 510 and 800 Series Printers Service Manual1-3

TroubleshootingSolving Print Quality ProblemsThe Printer contains an internal Troubleshooting procedure whichhelps you to diagnose and resolve the possible source of any ImageQuality or Line Quality defects. If Print Quality is poor before theminimum life expectancy of the Printhead has been reached, theTroubleshooting procedure should be performed which willdetermine whether the Printhead needs replacing or not afterperforming various levels of recovery actions.For information on solving Print Quality problems see Chapter 6 Print Quality.The Printer does not Power ON1 Check that the power cord is connected correctly to the Printer andto the Power Socket.2 Check that the Front-Panel Cable is correctly connected to theInterconnect PCA. Also make sure that the Front-Panel cable is notdamaged.3 Check that the Interconnect Cable is properly connected at the bothends of the Printer.Cover Sensors are not Working1 Check if the faulty sensor is installed correctly.2 Check if the cable for the faulty sensor is connected correctly.3 Replace the faulty Sensor (or the assembly that contains the Sensor).The Line Sensor has Problems Detecting Media1 Check the type of media that is being used since the Line Sensormay have problems detecting transparent media or some types ofNon-HP media. Try loading white HP media in to the Printer andcheck if the Line Sensor detects it.2 Excessive ink deposits on the Print Platen surface can fool thesensor by reflecting the light. Clean the Print Platen.3 The Line Sensor is damaged or faulty. Replace the CarriageAssembly Page 8-78.1-4HP DesignJets 500, 510 and 800 Series Printers Service Manual

TroubleshootingTroubleshooting Paper-Axis ShutdownsA Paper-Axis shutdown can happen when the Printer detects thatthe Drive Roller is not moving but at the same time power is beingsupplied to the Paper-Axis Motor (which should be turning theDrive Roller).The reasons for the Paper-Axis shutdown, and their solutions, areexplained as follows:1 The Paper-Axis Motor does not respond to the electrical simulation. It is possible to determine whether the Paper-Axis is faulty byperforming the Paper Advance Test (Refer to Page 4-11). ThePrinter will move the Motor backwards and forwards andmeasure directly from the Motor Encoder whether the Paper-AxisMotor responded to the force. If the