p. 1

hp designjets 500 and 800 series large-format printers service manual

[close]

p. 2

for hp internal use only ©copyright hewlett-packard company 2000 this document contains proprietary information that is protected by copyright all rights are reserved no part of this document may be photocopied reproduced or translated to another language without the prior written consent of hewlettpackard company first edition august 2000 warranty warning 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 the information contained in this the procedures described in this document is subject to change manual are to be performed by without notice hp-qualified service personnel only 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 electrical shock hazard serious shock hazard leading to death or injury may result if you do not take the following precautions ensure that the ac power outlet mains has a protective earth ground terminal disconnect the printer from the power source prior to performing any maintenance prevent water or any other liquids from running onto electrical 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 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 technical marketing barcelona division hewlett-packard espanola s.a avda graells 501 08190 sant cugat del valles spain

[close]

p. 3

1 hp designjets 500 and 800 series large-format printers service manual

[close]

p. 4

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 2 hp designjets 500 and 800 series printers service manual

[close]

p. 5

table of contents table of contents troubleshooting 1-1 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

[close]

p. 6

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 4 hp designjets 500 and 800 series printers service manual

[close]

p. 7

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

[close]

p. 8

table of contents removal and installation 8-1 introduction 8-2 safety precautions 8-2 electrostatic discharge esd precautions 8-3 required tools 8-3 screw types 8-4 left hand cover 8-5 right hand cover 8-7 front panel 8-9 window and top cover 8-10 media deflectors 8-11 left end roll-feed 8-13 right end roll-feed 8-15 back platen 8-17 media sensor 8-19 formatter 8-20 lan card 8-21 spittoon 8-23 electronics module 8-24 power supply 8-27 scan-axis motor assembly 8-29 cutter assembly 8-32 left encoder holder 8-33 cutter bushing 8-35 cutter guide bracket 8-36 drive roller encoder sensor 8-38 trailing cable 8-40 ink supply station 8-48 interconnect pca 8-50 service station and aerosol fan 8-52 cutter guide 8-55 print platen 8-56 service station holder 8-57 interconnect cable 8-59 ink supply tubes 8-60 vacuum fan 8-64 pinch-arm 8-66 pinch-arm mechanism 8-67 pinch-arm lever 8-69 6 hp designjets 500 and 800 series printers service manual

[close]

p. 9

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 hp designjets 500 and 800 series printers service manual 7

[close]

p. 10

table of contents 8 hp designjets 500 and 800 series printers service manual

[close]

p. 11

troubleshooting 1 introduction 1-2 troubleshooting system error codes 1-2 performing a service test on a failed assembly 1-2 performing the necessary service calibrations 1-2 solving print quality problems 1-3 the printer does not power on 1-3 cover sensors are not working 1-3 the line sensor has problems detecting media 1-3 troubleshooting paper-axis shutdowns 1-4 problems with the vacuum fan 1-5 vacuum suction much lower at high altitudes 1-5 hp-gl/2 color differences in different hp designjet printers 1-6 banding at variable extreme environmental conditions 1-6 the priming procedure fails 1-7 using the power switch led to troubleshoot 1-10 using the boot-up sequence to troubleshoot 1-12 hp designjets 500 and 800 series printers service manual 1-1

[close]

p. 12

troubleshooting guide to troubleshooting the printer 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 contains a list of system error codes and their respective descriptions and recommended corrective actions only try one recommended action at a time and check if the error code has disappeared performing a service test on a failed assembly if possible always perform a service test on the component assembly that you are about to replace just to make sure that is the component/assembly that has failed note if the test on that component/assembly passes you should not replace it for information on the service tests and how to use them see chapter 4 service tests and utilities performing the necessary service calibrations is the printer calibrated correctly after replacing a component note remember that certain calibrations are required even if an assembly has been disassembled to gain access to another assembly or component for information on the service calibrations and how to use them see chapter 5 service calibrations 1-2 hp designjets 500 and 800 series printers service manual

[close]

p. 13

troubleshooting solving print quality problems the printer contains an internal troubleshooting procedure which helps you to diagnose and resolve the possible source of any image quality or line quality defects if print quality is poor before the minimum life expectancy of the printhead has been reached the troubleshooting procedure should be performed which will determine whether the printhead needs replacing or not after performing various levels of recovery actions for information on solving print quality problems see chapter 6 print quality the printer does not power on 1 check that the power cord is connected correctly to the printer and to the power socket 2 check that the front-panel cable is correctly connected to the interconnect pca also make sure that the front-panel cable is not damaged 3 check that the interconnect cable is properly connected at the both ends of the printer cover sensors are not working 1 check if the faulty sensor is installed correctly 2 check if the cable for the faulty sensor is connected correctly 3 replace the faulty sensor or the assembly that contains the sensor the line sensor has problems detecting media 1 check the type of media that is being used since the line sensor may have problems detecting transparent media or some types of non-hp media try loading white hp media in to the printer and check if the line sensor detects it 2 excessive ink deposits on the print platen surface can fool the sensor by reflecting the light clean the print platen 3 the line sensor is damaged or faulty replace the carriage assembly page 8-78 hp designjets 500 and 800 series printers service manual 1-3

[close]

p. 14

troubleshooting troubleshooting paper-axis shutdowns a paper-axis shutdown can happen when the printer detects that the drive roller is not moving but at the same time power is being supplied to the paper-axis motor which should be turning the drive roller the reasons for the paper-axis shutdown and their solutions are explained as follows 1 the paper-axis motor does not respond to the electrical simulation n it is possible to determine whether the paper-axis is faulty by performing the paper advance test refer to page 4-10 the printer will move the motor backwards and forwards and measure directly from the motor encoder whether the paper-axis motor responded to the force if the paper-axis motor did not respond the solution would be to replace the paper-axis motor page 8-84 2 the transmission gears which transmit the movement to the drive roller are not turning this problem could be caused either by blockage of the gears caused by an obstacle or by one of the gears being damaged to solve the problem try the following n remove the back platen page 8-67 and check if there are any obstacles blocking the gears remove the obstacles if necessary n remove the back platen page 8-67 and check if the transmission gears are damaged if the gears are damaged replace the gear assemblies page 8-92 3 the drive roller cannot move because of an obstacle or because it is damaged to solve the problem try the following n remove the back platen page 8-67 and check if there are any obstacles blocking the drive roller remove the obstacles if necessary n remove the back platen page 8-67 and check if the drive roller is damaged if the drive roller is damaged replace the drive roller page 8-86 4 the drive roller encoder sensor is faulty n it is possible to determine whether the encoder sensor is faulty by loading a sheet of paper from the front of the printer if the drive roller is working the sheet will be loaded correctly and the printer will detect that media has been loaded using the media sensor therefore the problem must be the encoder sensor and the solution would be to replace the encoder sensor page 8-38 1-4 hp designjets 500 and 800 series printers service manual

[close]

p. 15

troubleshooting problems with the vacuum fan if you have problems loading either roll or sheet media then there could be a problem with the vacuum fan to verify if there really is a problem with the vacuum fan try the following 1 with the printer on open the window of the printer and place a sheet of hp high gloss photo paper must be d-size aligned with the blue lines on the center platen if the vacuum fan holds the sheet in place and then loads it correctly then the vacuum fan functions correctly if the vacuum fan does not hold the sheet in place no suction then try the following n check that the holes in the center platen are not blocked n check that the vacuum fan is installed correctly n replace the vacuum fan page 8-64 2 if the vacuum fan held the sheet in place but couldn t correctly load it then there could be a problem with the drive roller in this case replace the drive roller page 8-86 vacuum suction much lower at high altitudes sometimes at high altitudes the vacuum force holding down the media will be lower therefore the media will not be held in place properly causing n ink smearing on the media n printhead crashes against the media n cut sheet loading problems high probability n roll media loading problems low probability the solution to this would be to change the vacuum force by changing the altitude setting this can be done via the front panel set-up menu altitude hp designjets 500 and 800 series printers service manual 1-5

[close]