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HP DesignJets 500, 510 and 800 Series Large-Format Printers
Service Manual
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For HP Internal Use Only Warranty WARNING WARNING The Warning symbol calls ©Copyright Hewlett-Packard The information contained in this The procedures described in this attention to a procedure, practice, Company 2000 document is subject to change manual are to be performed by or the like, which, if not correctly without notice. HP-qualified service personnel This document contains performed or adhered to, could only. proprietary information that is Hewlett-Packard makes no result in pe
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1 HP DesignJets 500, 510 and 800 Series Large-Format Printers Service Manual
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Using this Manual Purpose This Service Manual contains information necessary to test, calibrate and service: HP DesignJet 500 Printer - 24” Model (P/N C7769B) HP DesignJet 500 Printer - 42” Model (P/N C7770B) HP DesignJet 500PS Printer - 24” Model (P/N C7769C) HP DesignJet 500PS Printer - 42” Model (P/N C7770C) HP DesignJet 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 C7
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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. HP DesignJets 500, 510 and 800 Series Printers Service Manual 3
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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 Fa
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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
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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 Pap
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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
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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 Int
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Troubleshooting 1 1 Introduction 1-2 Troubleshooting System Error Codes 1-3 Performing a Service Test on a Failed Assembly 1-3 Performing the Necessary Service Calibrations 1-3 Solving Print Quality Problems 1-4 The Printer does not Power ON 1-4 Cover Sensors are not Working 1-4 The Line Sensor has Problems Detecting Media 1-4 Troubleshooting Paper-Axis Shutdowns 1-5 Problems with the Vacuum Fan 1-6 Vacuum suction much lower at high altitudes 1-6 HP-GL/2 color differences in differe
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Troubleshooting Guide to Troubleshooting the Printer Introduction This chapter will guide you through the relevant steps to take when troubleshooting the printer. Front Panel Difference for the HP DesignJet 500, 510 and 800 Series Printers Front Panel for the HP DesignJet 500 and 800 Series Front Panel for the HP DesignJet 510 Series Cancel Menu Form Feed Back and cut Enter HP DesignJets 500, 510 and 800 Series Printers Service Manual 1-2
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Troubleshooting NOTE The layout shown below will be used to refer to both types of front panels 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
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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
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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. It is possible to determine whether the Paper-Axis is faulty by performing
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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
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Troubleshooting HP-GL/2 color differences in different HP DesignJet Printers Color differences between one image printed on the HP DesignJet 500/510/800 Series and the rest of the DesignJet platforms are due to the different chemistry of the 500/510/800 series inks compared with the rest of the inks for other printers. This color variability among different HP DesignJet Series Printers has always been present. To solve the problem, try the following: Perform the color calibration from t
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Troubleshooting The Priming Procedure Fails When the customer first receives the Printer, it is supplied with a set of four Start-up Printheads pre-installed in the Printhead Carriage. These Start-up Printheads are used for the priming of the tubes in the Ink Delivery System. When the Printer is powered ON for the first time, the Printer will automatically perform the priming process. Without the priming process, the customer will NOT be able to use the Printer. The initial startup assumes
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Troubleshooting message on the Front Panel: Unable to prepare ink system. Open window to check SETUP printheads Open the Window and you will see the following message on the Front Panel: Menu 1. Lift printhead cover 2. Check if there is ink Back inside printhead windows 3. Press ENTER to continue Enter Check for ink Open the Carriage Cover and check if there is ink inside the Start-up Printheads. On the Front Panel you will see the following question and you will need to select the answ
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Troubleshooting NOTE If you need to reseat the Start-up Printheads, make sure you re- insert them in the same color slot in the Carriage. The Printer will request you to reseat the Start-up Printheads (or in the case of missing Start-up Printheads you should install them or order new ones) and then retry the priming process (if the priming process fails 3 times because of the same problem, it will display a System Error). In this situation, the problem could be the following: 1 The Start-u
