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1. invent 10 Remove two screws that secure the Carriage PCA Cover to the Carriage Assembly 11 Remove the Carriage PCA Cover from the Carriage Assembly 12 Move the Carriage Assembly out of the Capping Station 13 Remove two screws that secure the metal bracket to the Carriage Assembly 14 Remove the metal bracket from the Carriage Assembly 15 Remove four screws that secure the Rail Guide to the Printer invent 16 Remove the Rail Guide from the Printer 17 Remove two screws that secure the metal bracket to the Printer 18 Remove the metal bracket from the Printer invent CA Removal and Installation 19 Remove a Cable Clip that secures the Trailing Cable to the Printer Taio Cable to x hand side of the Printer 21 Disconnect the first Trailing Cable from the Carriage PCA invent 22 Flatten the Trailing Cable 23 Using a piece of tape attach the first new Trailing Cable to the old Trailing Cable already disconnected 24 Make sure that the tape does not touch the electrode part of the Trailing Cable and ensure the two Trailing Cables are securely attached 25 Disconnect one by one the remaining Trailing Cables and attach them to the new Trailing Cables 26 Disconnect the Trailing Cable from the Main PCA 27 While holding the transparent plastic strip begin to carefully pull the old
2. Service Tools Service Tools Quantity Description Comments Reference HP Part Number on Drawing Q6693 60024 Carriage Height Adjustment Tools Q6665 60071 Printhead Position Adjustment Tools Q6665 60075 Capping Height Adjustment Tools 4 Platen Flatness Adjustment Tools includes Shims and Dummy Heater Sensor Shims included are 30 small Shims mm 100 um 30 small Shims 0 2 mm 200 um B 15 large Shims mm 100 pm B 15 large Shims 0 2 mm 200 um Q6693 60037 If any of the above tools are required please contact the HP Response Center or the nearest HP Support Office Figure 17 Service Tools invent Removal and Installation Introduction 8 2 Covers 8 3 Front Panel 8 25 Heater Panel 8 27 Front Heater 8 29 Rear Heater 8 32 Center Platen 8 34 Vacuum Fan 8 35 Main PCA 8 36 NVRAM 8 41 Head Relay Board 8 42 Add On HEB2 Control PCA 8 45 Switching Power Supply Unit 8 47 Power Supply Unit 8 50 Heater Relay Assembly 8 52 Waste Bottle Sensor 8 54 Front Media Sensor 8 56 Rear Media Sensor 8 58 Media Lever Sensor 8 59 Rear Cover Sensor 8 61 Home Position Sensor 8 66 Paper Axis Motor and Belt 8 68 Scan Axis Motor and Belt 8 72 Carriage Drive Assembly Includes Carriage Belt 8 75 Encoder Strip 8 78 Trailing Cable 8 79 Printhead Cooling Fans 8 87 Printhead 8 91 Printhead Connector Assembly 8 94 Carriage PCA 8 96 Air Damper 8 100
3. invent Waste Ink Bottle Disposal The Waste Ink Bottle should be checked on a daily basis to make sure that it is not full The Waste Ink Bottle should be emptied as follows 1 Loosen the screw and lift up the lever to release the Waste Ink Bottle Loosen Screw Pti 2 Carefully pull out the Waste Ink Bottle taking care not to spill any on the Printer or on the floor 3 Securely screw on the top on the full Waste Ink Bottle and store in a safe place until it can be taken for disposal 4 Install a new Waste Ink Bottle into position invent 5 Lower the lever and tighten the screw making sure that the Waste Ink Bottle is securely in position 9 4 J Lower Lever 7 6 Once the Waste Ink Bottle is correctly installed the Front Panel will request you to reset the Waste Counter BOTTLE EMPTY NO 7 Select Yes and press the OK key to reset the Waste Counter by indicating that the Waste Bottle is empty BOTTLE EMPTY YES IQ Print The IQ Print can be used to check for Print Quality problems like banding and can be used to isolate the root cause of the problem 1 When the Printer Ready message appears on the Front Panel press the Online key to take the Printer offline PRINTER READY ROLL 64 PAPER 2 When the following screen is displayed on the Front Panel press the Shift key twice AINK MEDI
4. RECOVERY In the PH Main submenu scroll to Wiper Cleaning and press the OK key WIPER CLEANING gt You will need to confirm that you want to perform the Wiper Cleaning procedure by pressing the OK key WIPER CLEANING OK invent 6 The Wiper Blade will automatically come up for cleaning during which the following message will be displayed on the Front Panel Wiper Blade WIPER MOVING PLEASE WAIT 7 When the following message is displayed on the Front Panel open the Rear Cover and the Wiping Door Rear Cover OPEN REAR COVER WIPER CLEANING Wiping Door t E 8 Make sure that there is no dried ink stuck on the Wiper Blade Also make sure that the Wiper Blade is not damaged 9 Dip a new cleaning swab into the Wiper Cleaning Liquid Ee 10 Use the cleaning swab to clean the front and back parts of the Wiper Blade Wiper Blades 11 After the Wiping Blades have been thoroughly cleaned close the Wiping Door and the Rear Cover to automatically return the Wiping Blades to their original position Moistening the Wiper Sponge The Wiper Sponge has to always be moist so that the Wiper Blade can correctly clean the Printheads The following should be done on a daily basis 1 Before printing check if the Wiper Sponge is moist by pressing a dry swab down on the sponge 2 Ifthe Wiper Sponge is dry apply a few drops of the Wiper Cleaning Liq
5. invent For HP Internal Use Only Copyright Hewlett Packard Company 2006 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 September 2006 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 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 fro
6. 2 Remove one screw from the Take Up Reel Emission Unit 3 Remove the Take Up Reel Emission Unit from the Printer Once the Take Up Reel Emission Unit has been installed correctly you must perform the Take Up Reel Sensor Adjustment For further information refer to Page 5 38 HP Designjet 10000s Series Printer Service Manual 8 189 invent White Nets For Front and Rear Heaters Removal Front White Net 1 2 7 Remove the Upper Side Cover Left Page 8 4 Remove the Lower Side Cover Left Page 8 8 Remove the Subtank Side Cover Left Page 8 9 Caretully pull out the Left Subtank Station slightly gt Page 8 115 Remove the Front Heater Page 8 29 Pull the side of the White Net so that the Velcro strip detaches from the Front Heater Unhook the White Net from the Hooks in the Front Heater Rr a son 8 Remove the White Net from the Front Heater Rear White Net 1 Loosen the screw that secures each Tension Bar Holder and remove the five Holders from the Printer 2 loosen nine screws that secure the bottom of the Rear Heater to the Printer 3 Remove ll screws that secure top of the Rear Heater to the Printer 4 Pull the side of the White Net so that the Velcro strip detaches from the Rear Heater 5 Remove the White Net from the Rear Heater Rr a son Sub Scroller Flange Removal
7. Check manually by turning the Wiper Gears to see if the Wiper turns If it does not turn then replace the Wiping Station Check whether 24 V is supplied to the Main PCA with the circuit tester If the Wiper Motor does not turn even though the 24 V is supplied there is a possibility of a failure in the Wiper Motor Replace the Wiping Station gt Page 8 145 Make sure the Wiper Sensor Cable is connected correctly and is not damaged If the error continues replace the Main gt Page 8 36 B f the Wiper does turn once Check whether the Wiper Sensor can be switched ON and OFF by manually rotating the Wiper Check whether the lever type switch is not loose Make sure the Wiper Sensor Cable is connected correctly and is not damaged Make sure that the Wiper Sensor is clean If the error continues replace the Main PCA gt Page 8 36 invent System Error System Error 11 0 Temperature Sensor Error Problem The Temperature Sensor detects abnormal temperatures 10 or lower or Description 85 C or higher Corrective Action Try the following Make sure that the Printer is in an environment where the temperature is between 10 C and 85 C Make sure the Ambient Temperature Sensor Cable is connected correctly and is not damaged Replace the Main PCA Page 8 36 System Error System Error 1180 Capping Motor Error Problem Capping Motor over current is detec
8. System Error 121x Printhead Temperature Error The Printhead temperature is too high 85 C or higher or too low 10 or lower x 0 Printhead Number 1 Black x 1 Printhead Number 2 Light Magenta x 2 Printhead Number 3 Light Cyan x 3 Printhead Number 4 Yellow x 4 Printhead Number 5 Magenta x 5 Printhead Number 6 Cyan Try the following Check the failing Printhead to make sure that it is not damaged and that the cable are correctly connected E Replace the Carriage PCA Page 8 96 E Replace the Printhead Page 8 36 System Error 1220 Edge Sensor Error The Printer has problems detecting the edge of the Media Try the following E Enter the Sensors Menu in Maintenance Mode and select Printer Sensors Then execute the Line Sensor option and check if the Line Sensor is functioning correctly by inserting a white piece of paper underneath it If the Line Sensor responds then it is functioning correctly B f the Line Sensor does not respond to the white piece of paper then replace the Line Sensor Page 8 106 E Replace the Carriage PCA Page 8 96 System Error 123x Sub Tank Sensor Error Full or Half The Full and Half Sensors on the Sub Tanks are defective x 0 Printhead Number 1 Black x 1 Printhead Number 2 Light Magenta x 2 Printhead Number 3 Light Cyan x 3 Printhead Number 4 Yellow x 4 Printhead Number 5 Magenta x 5 Printhe
9. 1 Turn the Flange counter clockwise to loosen it from the Sub Scroller 2 Remove the Flange from the Sub Scroller Installation If the Locking Wheel of the Flange is unscrewed completely and is removed from the Flange there is a risk that the two metal plates inside the Flange may fall out and that the Flange Hub will get unclipped from the Flange If this happens please follow these steps to re install the parts 1 Align the clips of the Flange Hub with the Align Clips with Guides guides on the Flange 2 Once the Flange Hub is correctly clipped into the Flange position the two metal plates into the Flange 3 Make sure the two metal plates are securely positioned as shown 4 Screw the Locking Wheel onto the Flange invent Preventive Maintenance Printheads Maintenance 9 2 Daily Inspection and Maintenance 9 3 Wiper Blade Cleaning 9 3 Moistening the Wiper Sponge 9 5 Capping Unit Cleaning 9 6 Waste Ink Bottle Disposal 9 8 IQ Print 9 10 Normal Printhead Recovery 9 11 When Leaving the Printer Off for more than 2 weeks 9 13 When Returning to the Printer after more than 2 weeks 9 13 If the Printer is Switched Off for less than 2 weeks 9 14 If the Printer is Switched Off for more than one Month 9 14 HP Designjet 100005 Series Printer Service Manual 9 1 invent Preventive Maintenance In order to keep the Printer in an optimal condition it is recommen
10. 1 In the System Inf submenu scroll to History Print and press the OK key HISTORY PRINT gt 2 You will need to confirm that you want to print the History Print by pressing the OK key HISTORY PRINT OK 3 While the History Print is being printed the following message will be displayed on the Front Panel HISTORY PRINT EXECUTING 4 cancel the print press the Cancel key invent COUNTER This menu can be used to view and reset the different counters that are used to track the usage of various parts which need to be replaced as a preventive measure Also this menu can be used to check if Non HP or Expired Ink is being used in the printer The different options available in this menu are as follows Media Used Page 4 82 Prime Assembly Page 4 83 Pump Tube Page 4 84 Wiper Cleaning Page 4 84 Wiper Belt Page 4 85 Wiper Blade Page 4 86 Capping Unit Page 4 87 Scan Axis belt Page 4 87 Non HP Ink Used Page 4 88 Expired Ink Used Page 4 89 To enter in to the Counter menu enter in to the Maintenance Mode and press the Shift key three times and then the key Media Used This option allows you to view and change the amount of media used in the Printer In the Counter submenu scroll to Media Used and press the OK key to view the media used since the last reset MEDIA USED gt 0000350m Use the and keys to change
11. 2 You will need to confirm that you want to test the Ink EEPROM by pressing the OK key INK EEPROM OK 3 While the Ink EEPROM is being tested the following message will be displayed on the Front Panel INK EEPROM EXECUTING 4 If the Ink EEPROM test passes the Front Panel will display the following Message INK EEPROM PASS 5 If the Ink EEPROM test fails the Front Panel will display the following Message INK EEPROM INK ERR If the Ink EEPROM test fails try the following Replace the Ink Cartridge s B Replace the Ink Supply Station Left or Right Page 8 110 B Replace the Main Page 8 36 ATG Band Memory Address Generator This option allows you to test the ATG contained in the Main PCA 1 In the Elect submenu scroll to ATG and press the OK key AIG gt 2 You will need to confirm that you want to test by pressing the OK key AIG OK While the ATG is being tested the following messages will be displayed on the Front Panel AIG AIG FILL OO CHECK 00 00 00 It the ATG test passes the Front Panel will display the following message AIG PASS If the ATG test fails the Front Panel will display the following message AIG ATG ERR If the ATG test fails try the following B Replace the Main PCA Page 8 36 DRAM This option allows you to test the DRAM contained in the Main PCA In the Elect submen
12. E For the Upper Sensor the Front Panel will indicate 1 when it is receiving the red LED light and O when it is not receiving it For the Lower Sensor the Front Panel will indicate O when it is receiving the red LED light and 1 when it is not receiving it 15 If the light is not received adjust the sensor s by tightening adjusting screw clockwise by 0 25 of a turn Adjusting Screw 16 Repeat steps 14 and 15 until the light is received 17 Remove the Light Emission Unit and install it on the top hole of the Mounting Bracket Top Mounting Position 18 Using the TUR Sensors Menu Page 4 58 check that both the upper and lower limit sensors receive the light the red LED lights E For the Upper Sensor the Front Panel will indicate 1 when it is receiving the red LED light and when it is not receiving it B For the Lower Sensor the Front Panel will indicate O when it is receiving the red LED light and 1 when it is not receiving it 19 If the light is not received adjust the sensor s by tightening the adjusting screw clockwise by 0 25 of a turn Adjusting Screw 20 Repeat steps 18 and 19 until the light is received invent 21 Repeat steps 11 to 20 so that the Light Emission Unit of both the upper and lower limit sensors can receive the light irrespective of it s mounting position either at the top or the bottom on the Mounting Bracket 22 Remove the light emission u
13. Page 8 13 4 Remove the Printhead Cooling Fan Assembly Page 8 87 5 Disconnect the Printhead Connector Cable from the Carriage PCA 6 Remove two screws that secure the Printhead Connector Assembly to the Printhead 7 Disconnect the Printhead Connector Assembly from the Printhead and remove from the Printer Carriage Removal 1 Remove the Upper Side Cover Right gt Page 8 4 2 Remove the Top Side Cover Right Page 8 5 3 Remove the Capping Door Page 8 13 4 Remove the Printhead Cooling Fan Assembly Page 8 87 5 Remove two screws that secure the Carriage PCA Cover to the Carriage Assembly 6 Remove the Carriage PCA Cover from the Carriage Assembly Rr a son 7 Remove two screws that secure the metal bracket to the Carriage Assembly 8 Remove the metal bracket from the Carriage Assembly 9 Disconnect the Trailing Cable from the Carriage PCA 10 Disconnect ALL the Printhead Connector Cables from the Carriage PCA 11 Disconnect ALL cables from the Carriage PCA 12 Remove four screws that secure the Carriage PCA to the Carriage Assembly 13 Remove the Carriage PCA from the Printer Air Damper Removal 1 Remove the Upper Side Cover Right gt Page 8 4 2 Remove the Top Side Cover Right Page 8 5 3 Remove the Capping Door Page 8 13 4 Remove the Printhe
14. f the error continues replace the Main PCA Page 8 36 System Error 11 CO Cap Position Error The Carriage position sensors have detected more than a 2mm gap during the capping operation Try the following Make sure that the Encoder Strip is not stained Make sure that the Encoder Sensor is mounted correctly and that the cable is connected correctly B Make sure that the Trailing Cable is connected correctly E Replace the Carriage PCA Page 8 96 m f the error continues replace the Main Page 8 36 System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action invent System Error 100 Cooling Fan Error When the Printhead temperature reaches above 43 C the Printer will check whether the temperature drops below 43 C during printing This error will appear if the temperature does not drop below 43 C after 10 minutes Try the following Make sure that the Printhead Cooling Fans are working correctly If the Printhead Cooling Fans are not working correctly replace them Page 8 87 Make sure that the Printer Cooling Fans are connected and working correctly System Error 11EQ Long Term Storage Error This error is displayed when the Printer has been left switched OFF for more than 31 days Tr
15. P key BOTTLE SENSOR PRESENT 2 In the Bottle Sensor submenu press the OK key If you would like to exit the Bottle Sensor submenu press the key BOTTLE SENSOR PRESENT gt 3 The Front Panel will show the status of the Waste Bottle Sensor By activating and deactivating the Waste Bottle Sensor the status will change 0 Present 1 Not present and a buzzer will make a sound BOTTLE SENSOR PRESENT O 4 If you would like to exit the Bottle Sensor submenu first press the Cancel key and then press key invent Media Supply Reel MSR Sensors This option allows you to check the status of the sensors related to the Media Supply Reel in real time so that faulty sensors can be replaced as necessary 1 Inthe Sensors submenu scroll to MSR Sensors and press P key MSR SENSORS DIRECTION 2 Inthe MSR Sensors submenu select the Sensor that you would like to test and press the OK key If you would like to exit the MSR Sensors submenu press the key MSR SENSORS ME SENSOR gt 3 The Front Panel will show the status of the selected Sensor By activating and deactivating the selected Sensor the status will change and a buzzer will make a sound MSR SENSORS ME SENSOR O The Sensors that can be tested in this menu are as follows Direction Displays the status of the Direction Switch on the Media Feed Drive Unit Inner wi
16. The Printer will extract the ink which could take at least 10 minutes and the following message will be displayed on the Front Panel PURGING XXX Once the ink has been extracted from the system the following message will be displayed on the Front Panel Power Off the Printer by pressing the Cancel and the Power Off keys together INK PURGE END POWER OFF CP rites ede Ink System Options Store Ink System This option allows you to fill the ink system with Storage Liquid so that the Printer can be stored for a period of up to four weeks while switched Off In order to perform the Store Ink System procedure you will need to have the HP 790 Ink System Storage Kit available 1 In the Printhead Maintenance submenu scroll to Ink System Opt and press the OK key INK SYSTEM OPT gt STORE INK SYS 2 Inthe Ink System Opt submenu scroll to the Store Ink Sys option and press the OK key INK SYSTEM OPT STORE INK SYS 3 When the following message appears on the Front Panel check whether the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked INK SYSTEM OPT BOTTLE OK 4 When the following message is displayed on the Front Panel open the Left Ink Cartridge Door and remove ALL 3 Ink Cartridges OPEN L INKCOVER REMOVE CARTRIDGE 5 Once the Ink Cartridges have been removed install a Purging Cartridge in to each slot and close the Left Ink Cartrid
17. 2 Disconnect ALL the cables connected to the Center Platen 3 Remove 55 screws that secure the Center Platen to the Printer Remove the Center Platen from the Printer Removal and Installation invent Vacuum Fan Removal 1 Remove the Rear Heater Page 8 32 2 Disconnect the Vacuum Fan Cable 3 Using a small 5mm Allen Key remove 3 screws that secure the Vacuum Fan to the Printer 4 Remove the Vacuum Fan from the Printer HP Designjet 10000s Series Printer Service Manual 8 35 Removal 1 Remove the Electronics Module Cover gt Page 8 2 2 Remove five screws that secure the Main PCA Tray to the Printer from the rear 3 Remove three screws that secure the Main PCA Tray to the front of the Printer 4 Disconnect ALL the cables connected to the Main PCA Rr a son 5 Disconnect ALL the cables connected to the Add On Control PCA no need to disconnect cables connected between the Add On Control PCA and the Switching Power Supply Unit 6 Remove one screw that secures the Grounding Strip and disconnect the cable from the Switching Power Supply Unit 7 Remove the Main PCA Tray from the Printer invent 8 Pull up and remove the NVRAM from the Main PCA 9 Remove four screws that secure the Head Relay Board to the Main PCA 10 Remove the Head Relay Board from the Main PCA
18. BACK PATTERN NORMAL The Back Adjust patterns available in this menu are as follows B Normal Prints using a Standard 4 pass printmode H Quality Prints using a High Quality 8 pass printmode H Density Prints using a High Density 8 pass printmode 3 Times Prints using a Triple Density 12 pass printmode H Quality2 Prints using a High Quality2 16 pass printmode H Density2 Prints using a High Density2 16 pass printmode Draft Prints using a Draft 2 pass printmode 3 You will need to confirm that you want to print the selected Back Adjust pattern by pressing the OK key BACK PRINT OK 4 The Printer will start printing the selected Back Adjust pattern and the following message will appear on the Front Panel BACK PRINT EXECUTING Back Adjust Value This option allows you to correct the media back feed value based on the back adjust print 1 In the Printer Adjustment submenu scroll to Back Adj Value and press the P key BACK ADJ VALUE MNFG 2 Inthe Back Adj Value submenu select the media that you would like to correct and press the OK key If you would like to exit the Back Adj Value submenu press the key BACK ADJ VALUE PAPER 240000P 3 Use the and keys to change the digits and use the and P keys to select the digits The value can be changed in a range of 2000P 5 mm 1 pulse 2 5 micromillimeters BAC
19. Encoder Sensor 8 104 Line Sensor 8 106 Ink Pump Assembly 8 108 Ink Supply Station Left or Right 8 110 IC Door Sensor Left or Right 8 113 Subtank Sensors 8 115 Capping Station Assembly 8 120 Capping Unit 8 129 Prime Assembly 8 130 Solenoid Assembly 8 134 Waste Bottle Holder and Sensor Assembly 8 139 Wiping Station Assembly 8 145 Wiper Cleaning Assembly 8 149 Wiper Blade 8 150 Wiper Belts 8 152 Pinchwheel Assembly 8 156 Drive Roller 8 160 Media Feed Drive Unit Assembly 8 165 Take Up Reel Drive Unit Assembly 8 169 Drive Unit Rollers 8 174 Drive Unit Timing Belt 8 180 Media Sensors Media End Media Slack and Take Up Reel 8 184 White Nets For Front and Rear Heaters 8 190 Sub Scroller Flange 8 193 HP Designjet 100005 Series Printer Service Manual 8 1 invent Introduction This chapter is a step by step guide to the removal and installation of the key components in the printer You may find it useful to tick off the steps as they are performed Use the illustration at each procedure to identify the parts referred to in the text The procedures appear in order of removal So the whole machine can be stripped down by starting at the beginning of this chapter and working through the subsequent procedures Safety Precautions Review WARNING and CAUTION symbols and instructions before you service the printer Follow these warnings and cautions for your protection and to avoid damaging the printer
20. Front Panel 9 VOLT Voltage Check Page 4 71 10 n This menu can be used to turn the Voltage check to high or low The different options available in this menu are as follows Voltage Check MOTORS Page 4 72 This menu contains the necessary diagnostics that can be used to test the various Motors in the Printer The different options available in this menu are as follows Media Advance Motor Capping Station Motor Wiping Station Motor Solenoid Left or Right Vacuum Fans Left Right or Center Exhaust Fans Printhead Cooling Fan MSR Motor TUR Motor Pump Motors SYSTEM INF Page 4 80 This menu can be used to print various information pages The different options available in this menu are as follows B System Print Error Log Print History Print 12 13 invent COUNTER Page 4 82 This menu can be used to view and reset the different counters that are used to track the usage of various parts which need to be replaced as a preventive measure Also this menu can be used to check if Non HP or Expired Ink is being used in the printer The different options available in this menu are as follows Media Used Prime Assembly Pump Tube Wiper Cleaning Wiper Belt Wiper Blade Capping Unit Scan Axis belt Non HP Ink Used Expired Ink Used Heater Panel Maintenance Mode Page 4 90 The Heater Panel has a separate Maintenance Mode which can used to set ce
21. PH ROW VAL Lm 4 n the PH Row Val submenu select the color of the Printhead that you would like to adjust and press the OK key If you would like to exit the PH Row Val submenu press the key PH ROW VAL gt gt 00 5 Use and V keys to change the digits and use the and P keys to select the digits Enter the value that you noted down in step 2 PH ROW VAL gt Lm gt 01 Press the OK key once you have entered the new value OS Locate the Printhead to Printhead pattern in the Printhead Adjustment pattern ALEVE E EP EE EH E EE ELLE LLLI CANAN OCCUR 8 Select the pattern that looks the best aligned and note down the value either TIT m Lines well digne Lines well arene 9 In the Printhead Adjustment submenu scroll to PH to PH Val and press the P key PH TO PH VAL Lm CP shes 10 n the PH to PH Val submenu select the color of the Printhead that you would like to adjust and press the OK key If you would like to exit the PH to PH Val submenu press the key PH TO PH VAL gt gt 00 11 Use the and V keys to change the digits and use the lt and P keys to select the digits Enter the value that you noted down in step 8 PH TO PH VAL gt Lm gt 01 12 Press the OK key once you have entered the new value LCA Print the Check Printhead Pattern In or
22. Unit Assembly on the left hand side 9 Remove two screws that secure the Drive Unit Assembly on the right hand side 10 Remove the Drive Unit Assembly from the Printer invent 95 Take Up Reel Drive Unit Assembly Removal 1 Remove the Waste Ink Bottle from the Printer 2 Remove two screws that secure the Waste Bottle Locking Bracket 3 Remove three screws that secure the Waste Bottle Holder to the Drive Unit 4 Remove the Waste Bottle Holder from the Drive Unit 5 Remove the Main Scroller from the Take Up Reel Feed side of the Printer 6 Remove one screw that secures the Grounding Cables UJ invent 7 Remove one screw from the Cable Clamp and release the Foot Switch Cable from the Cable Clamp 8 Disconnect the Foot Switch Cable from the Drive Unit Assembly and remove the Foot Switch from the Printer 9 Release the Connector from the mounting bracket 10 Remove a screw that secures each Grounding Cable to the side of the Drive Unit 11 Disconnect ALL Cables connected to the Drive Unit Assembly 12 Remove two screws that secure the Drive Unit Assembly on the left hand side A Rr a son 13 Remove two screws that secure the Tension Bar Guide and remove it from the Printer 14 Remove one screw that secures the Drive Unit Assembly on the right hand side 15 Remove the Drive Unit Assembly fr
23. occurred Try the following Reload the ASIC program from the IC Card B Make sure that the Carriage Cable is correctly connected E Replace the Carriage PCA Page 8 96 E Replace the Main PCA Page 8 36 DRAM 0200 The read write of the image band memory on the Main PCA was diagnosed and an error was detected Try the following Replace the Main PCA Page 8 36 Boot Up Error Problem Description Corrective Action Boot Up Error Problem Description Corrective Action invent USB Register 0400 The read write of the USB controller on the Main PCA was diagnosed and an error was detected Try the following Replace the Main PCA Page 8 36 Power Supply 36V 24V 12V 0800 The power supplies of 36 24 and 12 V were diagnosed and could not be detected Try the following Open the Electronics Cover and check LED 11 and LED 13 f both LED 11 and LED 13 are OFF then try the following Check the Interlock Switches to make sure they are installed connected correctly Make sure that the Rear Cover lips that activate the Interlock Switches are not bent and that the Rear Cover is closed correctly If the Interlock Switches are installed and connected correctly then replace the Main PCA Page 8 36 B f both LED 11 and LED 13 are ON then try the following Check whether the correct voltages are supplied from the power source refer to the tab
24. you should connect the Ink Tube and Printhead Connector Assembly to the Printhead 12 You should now continue the Printhead Adjustment procedure from Page 3 9 invent Maintenance Mode Introduction 4 2 Diagnostics Self Test 4 2 Phone Support 4 2 Maintenance Mode Menus 4 3 Entering the Maintenance Mode 4 7 Basic Menu Operation 4 8 P ADJ Printer Adjustment 4 10 PH ADJ Printhead Adjustment 4 17 PH MAIN Printhead Maintenance 4 23 MNFG PRN Manufacturing Patterns 4 44 SETUP 4 45 FEED 4 52 SENSORS 4 53 ELECT Electronics 4 60 VOLT Voltage Check 4 71 MOTORS 4 72 SYSTEM INF 4 80 COUNTER 4 82 Heater Panel Maintenance Mode 4 90 HP Designjet 100005 Series Printer Service Manual 4 1 invent Maintenance Mode Introduction This chapter explains how to use the built in Maintenance Mode which is designed to assist Service Personnel to make any necessary factory adjustments or to perform Service Tests to verity if certain components of the Printer are functioning correctly 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 consult Chapter 2 System Error Codes Phone Support invent Maintenance Mode Menus The following is a list of all internal
25. 11 Remove 10 screws that secure the Main PCA to the Tray 12 Remove one screw that secures the USB Connector to the Tray 13 Remove the Main PCA from the Tray Make sure that you re install the NVRAM and the Head Relay Board on the NEW Main PCA Once the NEW Main PCA is installed power ON the Printer and do the following 1 Enter into the Maintenance Mode Page 4 7 2 Press the Shift key once and then the key to enter in to the Setup menu 3 In the Setup submenu scroll to Save Calibs and press the OK key SAVE CALIBS gt 4 You will need to confirm that you want to save the NVRAM Calibrations by pressing the OK key SAVE CALIBS OK 5 In the Setup submenu scroll to Save and press the OK key SAVE NVRAM gt 6 You will need to confirm that you want to save the NVRAM contents by pressing the OK key SAVE NVRAM OK Rr a son NVRAM Removal 1 Remove the Electronics Module Cover gt Page 8 2 2 Carefully pull up and remove the from the Main PCA Once the NEW NVRAM is installed power ON the Printer and do the following 1 Enter into the Maintenance Mode Page 4 7 2 Press the Shift key once and then the key to enter in to the Setup menu 3 In the Setup submenu scroll to NVRAM Init and press the OK key NVRAM INIT gt 4 You will need to confirm that you want to initialize the by pressin
26. 3 Install the Printhead Adjustment Jigs in the Carriage 3 5 Set Printhead Voltage 3 9 Print the Printhead Adjustment Pattern 3 10 Perform Printhead Position Correction 3 11 Print the Check Printhead Pattern 3 14 Adjust the Printhead 3 15 Tip to Speed Up the Printhead Adjustment 3 19 HP Designjet 100005 Series Printer Service Manual 3 1 invent Printhead Adjustment Introduction The mechanical adjustment of a Printhead must be done every time a Printhead is removed or replaced If the adjustment of the Printheads is not done you could get Print Quality problems like banding The Printhead Adjustment should be done in the following order Calibrate the Printhead Adjustment Jig Install the Printhead Adjustment Jigs in to the Carriage Set Printhead Voltage Print the Printhead Adjustment pattern Perform Printhead Position correction Print the Check Printhead pattern XO UB WON Mechanically adjust the Printhead Tools Required The Tools required to perform the Printhead Adjustment procedure are shown below Without these tools the Printhead Adjustment procedure cannot be completed correctly 57 Printhead Adjustment Jig 1 Printhead Adjustment Reference Plate S Printhead Positioning Pins Printhead Adjustment Jig 2 Small Flat Head Screwdriver i zr gt Measuring Loupe i Cross Head Screwdriver invent Calibrate the Printhead Adjustment Jig Before installing
27. 44 This menu contains the test patterns which are used during the manufacturing process SETUP Page 4 45 This menu contains the necessary option to set the different system parameters like language or system time The different options available in this menu are as follows Language Beeper Settings End of Ink Beeper Settings System Date System Time Serial Number NVRAM Initialization Save Calibrations Restore Calibrations Save NVRAM Restore NVRAM Boot Version Printer Firmware Version Main PCA Version Carriage PCA Version ASIC Version Heater Hardware Version Heater Firmware Version Add ON HEB2 Control PCA Version Heater Upgrade Install Done FEED Page 4 52 This option allows you to feed the media manually in to the Printer SENSORS Page 4 53 This menu can be used to check the status of the various sensors and thermistors in the Printer in real time The different options available in this menu are as follows Printer Sensors Ink Sensor Sub Tank Sensor Bottle Sensor Media Supply Reel MSR Sensors TUR Sensors Temperature Sensors invent 8 ELECT Electronics gt Page 4 60 This menu contains the necessary diagnostics that can be used to test the various electronic components in the Printer The different options available in this menu are as follows Flash ROM PIO NVRAM Ink EEPROM AIG DRAM RSM PTC PDD HEB ALL VDD
28. Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action invent System Error Codes A System Error Code appears on the Front Panel when a component of the Printer has failed during normal usage Each System Error Code and it s appropriate corrective actions are explained on the following pages System Error 1110 GA_ATG Block Clear Error The ATG band memory block erase does not end This error is checked during Boot Up sequence and printing Try the following E Replace the Main PCA Page 8 36 System Error 1111 GA ATG DMA Transfer Error There is a problem in the data path This error is checked during printing Try the following Make sure that the host PC and the Printer are connected correctly via a USB Cable Replace the Main Page 8 36 System Error 112x Vacuum Fan Error x 0 The Vacuum Fan Wiping Side has failed x 1 The Vacuum Fan 2nd Fan from Wiping Side has failed x 2 The Vacuum Fan Center of the Platen has failed x 3 The Vacuum Fan 2nd Fan from Capping Side has failed x 4 The Vacuum Fan Capping Side has failed Try the following Make sure that the failing Vacuum Fan Cable is connected correctly and is not damaged Replace the failing Vacuum Fan Page 8 35 B f the error continues replace the Add On H
29. Carriage UNCAP CARRIAGE gt Cap Carriage This option allows you to cap the Carriage in the Capping Station 1 In the Printhead Maintenance submenu scroll to Cap Carriage and press the OK key The Capping Station will move upwards capping the Carriage CAP CARRIAGE gt invent MNFG PRN Manufacturing Patterns This menu contains the necessary test patterns to check that the Printer is functioning correctly The different options available in this menu are as follows MNFG Pattern Pattern 1 MNFG Pattern 2 MNFG Pattern 3 MNFG Pattern 4 MNFG Pattern 5 MNFG Pattern 6 MNFG Pattern 7 MNFG Pattern 8 MNFG Pattern 9 MNIFG Pattern 10 MNFG Pattern 11 MNFG Pattern 12 To enter in to the Manufacturing Pattern menu enter in to the Maintenance Mode and press the Shift key once and then the key Press the Up Arrow invent SETUP This menu contains the necessary option to set the different system parameters like language or system time The different options available in this menu are as follows B language Page 4 45 s m m B E Bg E E E B g E El B B E B i To enter in to Setup menu enter to the Maintenance Mode and press the Shift key once and then the key Beeper Settings Page 4 46 End of Ink Beeper Settings Page 4 46 System Date Page 4 46 System Time Page 4 47 OEM or H
30. Cover Left or Right Page 8 8 3 Remove the Rear Ink Cartridge Cover Left or Right Page 8 20 4 Disconnect the Ink Supply Station cables 5 Remove the Ink Pump Tubes for ALL three colors from the cable clip Rr a son 6 Carefully disconnect the Ink Pump Tube for ALL three colors from the top side 7 Loosen two screw that secure the Ink Supply Station to the Printer 8 Remove two screws that secure the Ink Supply Station to the Printer 9 Remove the Ink Supply Station from the Printer UJ invent Ror and Installation IC Door Sensor Left or Right Removal 1 Open the Ink Cartridge Door 2 Remove two screws that secure the metal cover to the Ink Supply Station 3 Remove the metal cover from the Ink Supply Station 4 Remove the Lower Side Cover Left or Right Page 8 8 5 Disconnect IC Door Sensor cable 6 Remove two screws that secure the IC Door Sensor to the Ink Supply Station 7 Remove the IC Door Sensor from the Ink Supply Station Rr a son Subtank Sensors Removal 1 Remove the Upper Side Cover Left or Right Page 8 4 2 Remove the Lower Side Cover Left or Right Page 8 8 3 Remove the Subtank Side Cover Left or Right Page 8 9 4 Disconnect the Subtank Station cables 5 Cut the cable tie that secures the Ink Tubes 6 Loose
31. Electrostatic Discharge ESD Precautions To prevent damage to the Printer circuits from high voltage electrostatic discharge ESD 1 Do not wear clothing that is subject to static build up 2 Do not handle integrated circuits ICs in carpeted areas 3 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 4 Ground earth your body while disassembling and working on the Printer 5 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 6 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 Rr a son Rear Cover Removal 1 Remove two screws that secure the Rear Cover to the right hinge 2 Remove two screws that secure the Rear Cover to the left hinge 3 Remove the Rear Cover from the Printer Upper Side Cover Left or Right Removal 1 Remove four screws that secure the Upper Side Cover to the Printer 2 Remove the Upper Side Cover from the Printer UD Rr a son Top Side Cover Left or Right Removal 1 Remove the Upper Side Cover Left or Right Page 8 4 2 Remove four screws that secure the Top Side Cover to the Pri
32. Emission Units 4 Remove one screw from each Media End Slack Emission Unit 5 Remove both Media End Slack Emission Units from the Printer Removal and Installation D invent Media End Slack Light Receiving Units 1 Disconnect the two connectors for the Media End Slack Receiving Units 2 Remove one screw from each Media End Slack Receiving Unit 3 Remove both Media End Slack Receiving Units from the Printer Once the Media End Slack Receiving Units have been installed correctly you must perform the Media End Slack Sensor Adjustment For further information refer to Page 5 32 and Page 5 35 8 186 HP Designjet 10000s Series Printer Service Manual UJ invent Take Up Reel Light Receiving Units 1 Remove two screws that secure the Tension Bar Guide and remove it from the Printer 2 Remove two screws that secure the Sensor Cover to the Drive Unit Assembly 3 Remove the Sensor Cover from the Drive Unit Assembly invent 4 Remove one screw from each Take Up Reel Receiving Unit 5 Remove the Take Up Reel Receiving Units and pull out the cables so that the connectors are accessible 6 Disconnect the two connectors for the Take Up Reel Receiving Units and remove both units from the Printer D Removal and Installation invent Take Up Reel Light Emission Unit 1 Disconnect the connector for the Take Up Reel Emission Unit
33. Front Panel will return to the Charge Ink System submenu CHARGE INK SYS CP Hitec ade Purge Ink System This option allows you to remove the ink from the complete system or individual inks so that any relevant repair can be done to the Printer e g replace the Ink Pump Assembly 1 In the Printhead Maintenance submenu scroll to Purge Ink Sys and press the OK key PURGE INK SYS gt ALL 2 In the Purge Ink System submenu select whether you would like to purge the complete Ink System part of the Ink System or individual inks and then press the OK key PURGE INK SYS ALL The different options available in this submenu are as follows ALL Purges the complete Ink System Left K Lm Lc Purges the Black Light Magenta and Light Cyan inks Right Y M C Purges the Yellow Magenta and Cyan inks K Purges the Black ink Lm Purges the Light Magenta ink Lc Purges the Light Cyan ink Y Purges the Yellow ink M Purges the Magenta ink C Purges the Cyan ink 3 When the following message appears on the Front Panel check whether the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked PURGE INK SYS BOTTLE OK 4 When the following message is displayed on the Front Panel open the Left Ink Cartridge Door and remove ALL 3 Ink Cartridges OPEN L INKCOVER REMOVE CARTRIDGE 5 Once the Ink Cartridges have been r
34. INK BEEP OFF System Date This option allows you to set the current date 1 In the Setup submenu scroll to Date yy mm dd and press the OK key DATE YY MM DD gt 05 05 08 2 Use the and keys to change the digits and use the lt and P keys to select the digits DATE YY MM DD gt 05 10 01 3 Press the OK key once you have entered the new date CP Hitec ade System Time This option allows you to set the current time 1 In the Setup submenu scroll to System Time and press the OK key SYSTEM TIME gt 01 01 2 Use and keys to change the digits and use the lt and P keys to select the digits SYSTEM TIME Format Hour Minute gt 09 30 3 Press the OK key once you have entered the new time OEM or HP Serial Number This option allows you to set the Serial Number of the Printer 1 In the Setup submenu scroll to HP Serial No OEM Serial No and press the OK key HP SERIAL No gt 0000000000 2 Use the and keys to change the digits and use the and P keys to select the digits HP SERIAL No HP 10 Digits gt 012345678A OEM 8 Digits 3 Press the OK key once you have entered the new serial number NVRAM Initialization This option allows you to initialize the NVRAM with the default values The Printer correction values are returned to the values before adjustment 1 In the Setup submenu scroll to NVRAM Init and
35. Ink Page 4 23 In order to perform the Clean Ink System procedure you will need the HP 790 Ink System Cleaning Kit part number CB296A This kit includes Six Ink System Purging Cartridges Six Ink System Cleaning Liquid Cartridges If the Printer is Switched Off for more than one Month If the Printer is switched On after leaving it switched Off for more than one month 31 days Error Code will be displayed on the Front Panel In order to clear this Error Code perform the following Turn the Printer ON in error skip mode by holding down the Cancel and Shift keys and pressing the ON button When the following screen is displayed on the Front Panel you will be requested to enter a password Press the following keys in this order amp P Shift and OK MAINTENANCE MODE PASSWORD 3 Switch the Printer OFF and then ON again About this Edition This is the 1st edition of this Service Manual Ist edition titled HP Designjet 100005 Series Printers Service Manual Model Q6693A September 2006 What s in this Service Manual This manual contains information necessary to test calibrate and service HP Designjet 100005 Series Printers Model Q66934 For information about using these printers refer to the corresponding User Guide The procedures described in this manual are to be performed by HP qualified Service Personnel only
36. Maintenance Mode Menus available in the Printer Instructions for entering the Maintenance Mode are explained on Page 4 7 1 P ADJ Printer Adjustment Page 4 10 This menu contains the necessary options to set the adjustment parameters of the Printer so that it functions correctly The different options available in this menu are as follows Adjust Print Media Advance Print Manufacturing Print 1 Cap Position Wipe Position Line Sensor Top Adjustment Line Sensor Side Adjustment Media Advance Value Back Adjust Print Back Adjust Value 2 ADJ Printhead Adjustment gt Page 4 17 This menu contains the necessary options to set the adjustment parameters of the Printhead so that it functions correctly The different options available in this menu are as follows Printhead Adjustment Prints Move Carriage Printhead Row Value Printhead to Printhead Value Set Bidirection Media Bidirection Definitions Drive Voltage Manufacturing Print 2 3 PH MAIN Printhead Maintenance Page 4 23 This menu contains the necessary options related to the actual Printheads contained in the Carriage Assembly like cleaning or servicing The different options available in this menu are as follows Charge Ink System Purge Ink System Ink System Options Ink Charge Done Printhead Recovery Uncap Carriage Cap Carriage invent 4 MNFG PRN Manufacturing Test Patterns Page 4
37. Page 8 8 4 Remove the Lower Wiping Cover Page 8 5 5 Remove the Wiping Door Page 8 17 6 Disconnect the Wiping Station cables 7 Release the Wiping Station cables from the cable clip invent 8 Remove two screws that secure the metal bracket to the Wiping Station 9 Remove the metal bracket from the Wiping Station 10 Remove two screws that secure the Gear Cover to the Wiping Station 11 Remove the Gear Cover from the Wiping Station 12 Remove the Black Cover that is stuck over the hole in the Wiping Station 13 Remove three screws that secure the Wiping Station to the chassis 14 Remove one screw that secures Wiping Station to the chassis 15 Remove the Wiping Station from the Printer UD Rr a son Wiper Cleaning Assembly Removal 1 Remove the Upper Side Cover Left Page 8 4 2 Remove the Top Side Cover Left Page 8 5 3 Remove the Lower Side Cover Left Page 8 8 4 Remove the Lower Wiping Cover Page 8 15 5 Remove the Wiping Door Page 8 17 6 Remove the Wiping Station Assembly Page 8 145 7 Remove two screws from both sides that secure the Wiper Cleaning Assembly to the Wiping Station Assembly 8 Unclip the Wiper Cleaning Assembly from the Wiping Station Assembly Wiper Blade Removal 1 Open the Wiping Door 2 Manually turn the Wiper Gear so th
38. Position Calibration Page 5 59 B Margin Position Calibration Page 5 60 In the Printhead Maintenance submenu scroll to Ink Charge Done and press the OK key INK CHARGE DONE gt NO In the Ink Charge Done submenu select Yes to indicate that ink charge has been completed and then press the OK key INK CHARGE DONE YES In the Setup submenu scroll to Save Calibs and press the OK key SAVE CALIBS gt You will need to confirm that you want to save the NVRAM Calibrations by pressing the OK key SAVE CALIBS OK In the Setup submenu scroll to Save NVRAM and press the OK key SAVE NVRAM gt You will need to confirm that you want to save the NVRAM contents by pressing the OK key SAVE NVRAM OK Power Off the Printer wait a few seconds and power On the Printer again invent System Error Codes Introduction 2 2 Self Diagnostic Errors at Power On 2 3 System Error Codes 2 8 Heater Error Codes 2 17 System Error Codes 2 20 HP Designjet 100005 Series Printer Service Manual 2 invent System Error Codes Introduction The following pages contain a list of 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 ca
39. Print and press the OK key ADJUST PRINT LS ADJ PRINT 3 You will need to confirm that you want to print the Adjust Print by pressing the OK key ADJUST PRINT OK CP rites ade 4 The Printer will start printing the Adjust Print and the following message will appear on the Front Panel ADJUST PRINT EXECUTING 5 After printing the Adjust Print you will need to enter the values if necessary for the Line Sensor adjustment Page 4 14 Media Advance Print This option allows you to print the media advance pattern which is then used to calibrate the media advance for the different media used in the printer 1 In the Printer Adjustment submenu scroll to Media Adv Print and press the OK key MEDIA ADV PRINT ROUGH NORMAL 2 Inthe Media Adv Print submenu scroll to Rough Normal and press the OK key MEDIA ADV PRINT ROUGH NORMAL The other Media Advance Prints available in this menu are as follows Rough Normal Prints the media advance adjustment pattern every 0 25 in the 99 0 to 101 1 range Standard 4 pass printmode B Rough H Qual Prints the media advance adjustment pattern every 0 25 in the 99 0 to 101 1 range High Quality 8 pass printmode Rough H Dens Prints the media advance adjustment pattern every 0 25 in the 99 0 to 101 1 range High Density 8 pass printmode Rough 3 Times Prints the media advance adjustment pattern
40. Remove 55 screws that secure the Center Platen to the Printer Tl Move the Center Platen upwards and then towards you slightly 12 Release the Blades from the Pinchwheels and remove from the Printer Rr a son 13 Loosen one screw that secures the Locking Plate on the Wiping side 14 Rotate the Locking Plate away from the Drive Roller 15 Loosen one screw that secures the Locking Plate on the Capping side 16 Rotate the Locking Plate away from the Drive Roller 17 Remove two screws from the Drive Roller 18 Remove the Drive Roller from the Printer UJ invent 95 Media Feed Drive Unit Assembly Removal 1 Remove the Main Scroller from the media Feed side of the Printer 2 Remove one screw that secures the Grounding Cables 3 Remove one screw from the Cable Clamp and release the Foot Switch Cable from the Cable Clamp Removal and Installation LA invent 4 Disconnect the Foot Switch Cable from the Drive Unit Assembly and remove the Foot Switch from the Printer 5 Release the Connector from the mounting bracket 6 Remove a screw that secures each Grounding Cable to the side of the Drive Unit 8 166 HP Designjet 10000s Series Printer Service Manual Rr a slaton Drive Unit Assembly 7 7 Disconnect ALL Cables connected to the ie 8 Remove two screws that secure the Drive
41. and check that the difference between them is less than 0 4 mm 400 um For example using the values for Position 1 row 1 has the lowest value 6 0 mm and row 4 has the highest value 6 3 mm so the difference between the two is 0 3 mm 300 um this is within the tolerance range of 0 4 mm 400 um 4 It the Carriage Height is out of the tolerance range then you must order the Platen Flatness Adjustment Tools and perform the Platen Flatness adjustment 5 The part number for the Platen Flatness Adjustment Tools is Q6693 60037 and includes the following parts E Flatness Measurement Gauge Dummy Heater Sensor B Set of Shims 30 Shims 0 1 mm 100 um 30 Shims 0 2 mm 200 um 15 Shims mm 100 pm 15 Shims 0 2 mm 200 um CD asia ard trons Platen Flatness Measurement Perform the Platen Flatness Measurement as follows 1 Turn On the Printer in the Maintenance Mode by pressing the Cancel and Shift keys and Power On button Enter the password when requested lt gt Shift and OK 2 Make sure that the Media Load Lever is in the lower position amp ha 3 Make sure that the Media Pressure Lever is set in the Normal position 4 Open the Rear Cover Capping Door and the Wiping Door 5 Make sure that the Printhead Height Lever is in the upper position so that the Printhead height is actually in the lower position Make sure you loosen the two Printhead Height Adjustmen
42. below 6 Lift the Carriage slightly and reposition the Carriage Height Tools The front Tools should be positioned so that the Carriage is sitting on top of step C of the tool The rear Tools should be positioned so that the Carriage is sitting on top of step 3 of the tool invent Carriage should sit on top of Step 3 Carriage should sit on TIALS top of Step C secure the Carriage base to the main Carriage Assembly Tighten the left screw first then the right screw and then the middle screw 8 Remove the Carriage Height Tools from the Carriage base 9 Insert the Carriage Height Tools again to check that readings at the different positions are within the following range E Positions and 2 between 6 4 and 6 8 mm E Positions and 4 between 6 0 and 6 4 mm If the error exceeds this range you will need to adjust the Carriage height again invent Scan Axis Belt Tension Adjustment This adjustment must be performed whenever Scan Axis Motor is disassembled or replaced B Scan Axis Belt is disassembled or replaced Perform the Scan Axis Belt Tension Adjustment as follows 1 Make sure that the Scan Axis Motor and Belt are correctly installed 3 Hook the Push Pull Gauge onto the Scan Axis Motor Bracket and tension the Scan Axis Belt to a force of 41 0 N 2 0 N 4 18 kgf 0 2 kgf Hook the Push Pull Gauge onto this hole DU aii ard lios 4 While tensioning the Scan Axis Bel
43. change parameters Used to select menu items and to confirm parameters CE Brite ade Heater Panel Maintenance Menu The different menu options that can be selected in the Heater Panel Maintenance Mode are as follows Menu ltem Description Setting Options F LIMIT Front Heater maximum temperature 15 to 60 C limit preset by User R LIMIT Rear Heater maximum temperature 15 to 60 C limit preset by User P LIMIT Print Heater maximum temperature 15 to 60 C limit preset by User STANDBY TEMP Preset temperature for standby state 15 to 40 C HEATER TEST Turn the Heaters ON OFF On or OFF RESET PARAM Return all parameters to the factory Yes or No default settings EXIT Exit from the Maintenance Mode Yes or No Adjustments and Calibrations Adjustments and Calibrations 5 2 Adjustments 5 3 Belt Tension Adjustment 5 3 Carriage Height Adjustment 5 5 Scan Axis Belt Tension Adjustment 5 12 Paper Axis Belt Tension Adjustment 5 14 Timing Belt for Feed TUR Unit Tension Adjustment 5 16 Wiping Station Height Adjustment 5 18 Wiper Belt Tension Adjustment 5 21 Wiper Blade Height Adjustment 5 22 Capping Station Height Adjustment 5 25 Printhead Capping Limit Adjustment 5 27 Carriage Shield Height Adjustment 5 28 Media Feed and Take Up Reel Unit Adjustment 5 29 Media End Sensor Adjustment 5 32 Media Slack Sensor Adjustment 5 35 Take Up Reel Sensors Adjustment 5 38 Platen Flatness Measurem
44. correctly before you can continue OPEN L INKCOVER LOAD CL CART LOAD XX SLOT LOAD XX SLOT LOAD NEW CL CART LOAD XX SLOT When the following message is displayed on the Front Panel open the Right Ink Cartridge Door and remove ALL 3 Purging Cartridges OPEN INKCOVER LOAD CL CART Once the Purging Cartridges have been removed install a NEW Cleaning Liquid Cartridge in to each slot and close the Right Ink Cartridge Door LOAD CL CART CLOSE R INKCOVER If the Printer detects that a Cleaning Liquid Cartridge has been installed incorrectly or if any of the Cleaning Liquid Cartridges contain less than 500cc of liquid or if an invalid Cleaning Liquid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Cleaning Liquid Cartridge has been installed correctly before you can continue OPEN R INKCOVER LOAD CL CART LOAD XX SLOT LOAD XX SLOT LOAD NEW CL CART LOAD XX SLOT invent 18 The Cleaning Liquid charge process will start and you will need to recheck 19 20 21 22 23 24 whether the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked START FILLING CL BOTTLE OK The Printer will charge the Cleaning Liquid and the following message will be displayed on the Front Panel FILLING CL Once the Cleaning Liquid has been charged the following me
45. individual inks and then press the OK key CHARGE INK SYS The different options available in this submenu are as follows ALL Charges the complete Ink System left Lm Lc Charges the Black Light Magenta and Light Cyan inks Right Y M C Charges the Yellow Magenta and Cyan inks B K Charges the Black ink B m Charges the Light Magenta ink B Lc Charges the Light Cyan ink Y Charges the Yellow ink B M Charges the Magenta ink C Charges the Cyan ink invent 3 When the following message appears on the Front Panel check whether the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked CHARGE INK SYS BOTTLE OK If any of the Ink Cartridges contain less than 350cc of Ink or if a Purging Cartridge has been installed the following message will be displayed on the Front Panel Install a correct Ink Cartridge that contains more than 350cc of Ink in the indicated slot in order to continue LOAD NEW INK CAR LOAD XX SLOT The Charge Ink System process will start and you will need to recheck whether the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked START INK FILL BOTTLE OK The Printer will charge the ink and the following message will be displayed on the Front Panel INK FILLING XXX Once the Ink Charge process has been completed the
46. key PIC OK While the PTC is being tested the following message will be displayed on the Front Panel EXECUTING If the PTC test passes the Front Panel will display the following message PIC PASS If the PTC test fails the Front Panel will display the following message PTC ERR If the PTC test fails try the following B Replace the Carriage PCA Page 8 36 Replace the Trailing Cable Page 8 79 E Replace the Main PCA Page 8 36 PDD This option allows you to test the PDD contained in the Carriage PCA In the Elect submenu scroll to PDD and press the OK key PDD gt You will need to confirm that you want to test the PDD by pressing the OK key PDD OK While the PDD is being tested the following message will be displayed on the Front Panel EXECUTING CP rites ade 4 Ifthe PDD test passes the Front Panel will display the following message PDD PASS 5 f the PDD test fails the Front Panel will display the following message PDD ERR If the PDD test fails try the following B Replace the Carriage Page 8 36 Replace the Trailing Cable Page 8 79 B Replace the Main PCA Page 8 36 HEB This option allows you to test the Add On HEB2 Control PCA 1 In the Elect submenu scroll to HEB and press the OK key HEB gt 2 You will need to confirm that you want to test the HEB by pressing the OK key HEB OK
47. last replaced In the Counter submenu scroll to Wiper Belt and press the OK key to view the date of when the Wiper Belt was last replaced WIPER BELT gt 05 09 09 Use the and V keys to change the digits and use the and P keys to select the digits 06 05 03 Press the OK key once you have entered the new date It the Wiper Belt date needs to be reset to today s date return to the Counter submenu scroll to Reset Wiper Belt and press the OK key RESET WIPER BELT gt invent 5 You will need to confirm that you want to reset the date by pressing the OK key RESET WIPER BELT OK Wiper Blade This option allows you to view and change the usage counter related to the Wiper Blade 1 In the Counter submenu scroll to Wiper Blade and press the OK key to view the usage counter related to the Wiper Blade WIPER BLADE gt 0017800 2 Use the and keys to change the digits and use the and P keys to select the digits WIPER BLADE gt 0013400 3 Press the OK key once you have entered the new usage amount 4 If the Wiper Blade counter needs to be reset return to the Counter submenu scroll to Reset Wipe Blade and press the OK key RESET WIPE BLADE gt 5 You will need to confirm that you want to reset the counter by pressing the OK key RESET WIPE BLADE OK CE rites ade Capping Unit This option a
48. light receiving units receive the light the red LEDs are ON Both LEDs should come ON s AL l1 9 Ex Adjusting Screw 6 Turn the bottom adjusting screw clockwise gradually until the Media End Sensor upper sensor no longer receives the light the red LED light goes OFF LS a Top LED should go OFF Ta Adjusting Screw 7 Turn the adjusting screw clockwise a further two times stmt and Calibrations invent 8 Check that the Media Slack Sensor lower sensor receives the light the red LED light is ON and connect the connector of the light emission unit of the Media End Sensor upper sensor Connect this connector 9 Adjust the direction of the light from the light emission unit of the Media End Sensor Page 5 32 10 Install the Sensor Cover and secure with two screws Sensor Cover invent Take Up Reel Sensors Adjustment This adjustment is necessary to adjust the direction of the light received by the light receiving units upper and lower limit sensors of the Take Up Reel Sensor located on the Take Up Reel side This adjustment must be performed whenever B Take Up Reel Sensor is disassembled or replaced Perform the Take Up Reel Sensors Adjustment as follows 1 Remove the Main Scroller from the Take Up Reel side 2 Remove the two screws that secure the Tension Bar Guide 3 Remove the Tension Bar Guide from
49. make sure that a valid Maintenance Liquid Cartridge has been installed correctly before you can continue OPEN R INKCOVER LOAD SL CART LOAD XX SLOT LOAD XX SLOT LOAD NEW SL CART LOAD XX SLOT The Storage Liquid charge process will start and you will need to recheck whether the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked START FILLING SL BOTTLE OK The Printer will charge the Storage Liquid and the following message will be displayed on the Front Panel FILLINC SL XXX Once the Storage Liquid has been charged the Capping Station will be filled and the following message will be displayed WASH PRINTHEADS EXECUTING Once the Store Ink System process has been completed the Front Panel will return to the Ink SYstem Opt submenu INK SYSTEM OPT gt STORE INK SYS CE Bites ade Ink System Options Clean Ink System This option allows you to clean the ink system with Cleaning Liquid after the Printer is powered On after being stored for a long period In order to perform the Store Ink System procedure you will need to have the HP 790 Ink System Cleaning Kit available 1 In the Printhead Maintenance submenu scroll to Ink System Opt and press the OK key INK SYSTEM OPT gt STORE INK SYS 2 Inthe Ink System Opt submenu scroll to the Clean Ink Sys option and press the OK key INK SYSTEM OPT CLEAN INK SYS
50. move it to the Wiping Station LA Removal and Installation invent 9 Remove the C ring that secures the Linkage to the Pinchwheel Cam 10 Release the Linkage from the Pinchwheel Cam 11 Pull out the Pinchwheel Cam until the Pinchwheel Assembly that you want to remove can be accessed HP Designjet 10000s Series Printer Service Manual invent 12 Remove nine screws that secure the Metal Cover 13 Remove the Metal Cover from the Printer 14 Remove two three screws that secure the Pinchwheel Bracket that secures the Pinchwheel Assembly that you want to remove DU Removal and Installation invent 15 Remove the Pinchwheel Bracket from the Printer 16 Release the Spring from the Pinchwheel Assembly 17 Remove the Pinchwheel Assembly from the Printer HP Designjet 10000s Series Printer Service Manual 8 139 invent Drive Roller Removal 1 Remove the Rear Cover Page 8 3 2 Remove the Upper Side Cover Left and Right Page 8 4 3 Remove the Top Side Cover left and Right Page 8 5 4 Remove the Top Cover Page 8 5 Remove the Paper Axis Motor Page 8 68 6 Raise the Media Lever 7 Remove nine screws that secure the Metal Cover D invent Remove the Metal Cover from the Printer sa 9 Remove ALL the Springs from the Pinchwheels i i od P baer 10
51. not recognize the Heater Control Panel HEATER PANEL ERR POWER OFF ON Try powering Off the Printer and On again and retry the firmware upgrade procedure If the message continues to appear after rebooting several times then replace the Heater Panel Page 8 27 B There is a problem with the IC Card IC CARD ERROR POWER OFF ON Check that the IC Card contains the actual firmware image Make sure that the IC Card is inserted into the Main PCA correctly Try powering Off the Printer and On again and retry the firmware upgrade procedure If the message continues to appear after rebooting several times then replace the Heater Panel Page 8 27 There is a communication problem between the Main PCA and the Heater Panel DATA ERROR POWER OFF ON invent Try powering Off the Printer and On again and retry the firmware upgrade procedure If the message continues to appear after rebooting several times then replace the Heater Panel Page 8 27 The upgrade procedure cannot be performed because the Heater firmware has been deleted WRITING ERROR POWER OFF ON Replace the Heater Panel Page 8 27 Install Done This option allows you to indicate whether the Printer Installation has been performed correctly so that the preventive maintenance counters can activated 1 In the Setup submenu scroll to Install Done and press the OK key INSTALL DONE gt 2
52. of the Printer 23 Remove the Dummy Sensor and re install the Rear Heater 24 Measure the flatness of the Center Platen again Page 5 45 CA Aisa ard iratos Wiping Position Calibration This calibration must be performed whenever B Wiping Station is disassembled or replaced B Wiper Blade is disassembled or replaced B Wiper Belts are disassembled or replaced Perform the Wiping Position Calibration as follows 1 Enter into the Maintenance Mode Page 4 7 2 Move the Carriage Assembly to the Wiping Station Page 4 18 3 Enter into the Wipe Position Menu Page 4 13 WIPE POSITION gt 40 0 mm 4 Manually rotate the Wiper Blade using the Wiping Station Gear until the Wiper Blade touches the Printheads image is shown without the Carriage positioned in the Wiping Station Remove the necessary covers in order to get access to the Wiping Station Gear Wiper Blade Wiper Station Gear 5 Check that the center of the Wiper Blades are aligned with the center of the Printheads Wiper Blade 6 Ifthe center of Wiper Blades not aligned with the center of the Printheads you will need to visually estimate the deviation between the Wiper Blades and the Printheads Measure deviation 7 Manually rotate the Wiper Blades using the Wiping Station Gear so that the Wiper Blades are lowered and not touching the Printheads 8 Enter the deviation measured using the and keys to c
53. old Printhead install the Printhead Adjustment Jig 1 in to position against the Carriage Base Plate Printhead Adjustment Jig 1 Printhead Positioning Pins 3 Tighten the two fixing screws so that the Printhead Adjustment Jig 1 is securely attached to the Carriage Base Plate p invent 4 Turn both Adjustment Screws so that the 2 datum pins touch the Printhead as shown You must not force the Adjustment Screws too much as this could damage the Datum Pins Adjustment Screw 5 Now that the Printhead Adjustment Jig 1 is calibrated to the old Printhead the Printhead can now be removed Page 8 91 6 Install a new Printhead in to the Carriage and position it against the Printhead Adjustment Jig 1 as shown Make sure that the 2 datum pins touch the Printhead as shown 7 Install the two screws to secure the Printhead The screws should not be tightened too much just enough so that the Printhead does not move loosely invent 8 Install the Printhead Adjustment Jig 2 in to position against the Carriage Base Plate Make sure the Printhead Adjustment Jig 2 is located against this pin This corner of the Printhead should Printhead Adjustment Jig 2 9 Tighten the front screw that secures the Printhead to the Carriage Base Plate At this point the new Printhead should now be more or less in the same position as the old Printhead 11 Before continuing
54. or other sources of ignition Never store waste ink in a glass container Never pour waste ink into a container filled with other chemicals The HP Waste Ink Bottle contains organic solvents and must be disposed of in compliance with all local state and federal regulations Always securely replace the cap on a full or partially full the HP Waste Ink Bottle after removing it from the printer to prevent ink spills invent N CAUTION Treat any media paper used cleaning and maintenance supplies and wipes soaked with ink as combustible materials Handle and dispose of properly Do not clean the printer with benzene or paint thinner This may damage the paint Wipe the printer clean with a soft cloth A cloth moistened with a neutral detergent may be used Do not allow liquid to enter the printer This may create risk of fire and electrical shock and cause a malfunction Never touch the printhead nozzles They can be easily damaged or clogged Do not touch heater surfaces in the paper path This may cause burns Take care when touching printer components near the heaters HP Ink Cartridges must be installed before the Install By printed on the cartridge Use of the Ink Cartridge 3 months beyond the Install By date may cause deterioration in print quality or a printer malfunction Do not separate the cap from a new HP Waste Ink Bottle The cap is needed to properly seal the HP Waste Ink Bottle for
55. or low 1 To enter in to the Volt menu enter in to the Maintenance Mode and press the Shift key twice and then the W key Press the Down Arrow Key to select 2 Once in the Voltage Check submenu press the OK key VOLTAGE CHECK gt HIGH 3 In the Voltage Check submenu select either High Low and then press the OK key VOLTAGE CHECK LOW Press the Right Arrow Key to select invent MOTORS This menu contains the necessary diagnostics that can be used to test the various Motors in the Printer The different options available in this menu are as follows Media Advance Motor Page 4 72 Capping Station Motor Page 4 73 Wiping Station Motor Page 4 4 Solenoid Left or Right Page 4 74 Vacuum Fans Page 4 75 Exhaust Fans Page 4 76 Printhead Cooling Fans Page 4 76 MSR Motor Page 4 77 TUR Motor Page 4 77 Pump Motors Page 4 78 To enter in to the Motors menu enter in to the Maintenance Mode and press the Shift key twice and then the P key Online re e Cancel D Shift E Media Advance Motor This option allows you to turn the Media Advance Motor In the Motors submenu scroll to Media Adv Motor and press the OK key MEDIA ADV MOTOR 2 Inthe Media Adv Motor submenu select the direction that you would like the Media Advance Motor to turn and then press the OK key MEDIA ADV MOTOR FORWARD
56. press the OK key NVRAM INIT gt 2 You will need to confirm that you want to initialize the NVRAM by pressing the OK key NVRAM INIT OK invent Save Calibrations This option allows you to save the Calibrations stored in the NVRAM into the Factory Defaults area in the flash memory In the Setup submenu scroll to Save Calibs and press the OK key SAVE CALIBS gt You will need to confirm that you want to save the NVRAM Calibrations by pressing the OK key SAVE CALIBS OK Restore Calibrations This option allows you to restore the Calibrations stored in the Factory Defaults area to the NVRAM In the Setup submenu scroll to Restore Calibs and press the OK key RESTORE CALIBS gt You will need to confirm that you want to restore the contents to the NVRAM by pressing the OK key RESTORE CALIBS OK Save NVRAM This option allows you to save the contents stored in the NVRAM into the NVRAM backup area in the flash memory In the Setup submenu scroll to Save NVRAM and press the OK key SAVE NVRAM gt You will need to confirm that you want to save the NVRAM contents by pressing the OK key SAVE NVRAM OK CP Hitec ade Restore NVRAM This option allows you to restore the contents stored in the NVRAM backup area to the NVRAM 1 In the Setup submenu scroll to Restore and press the OK key RESTORE NVRAM g
57. refer to Page 2 11 B Replace NVRAM Page 8 41 B Replace Main Page 8 36 A Sistem ror codes Boot Up Error Problem Description Corrective Action Boot Up Error Problem Description Corrective Action Boot Up Error Problem Description Corrective Action Boot Up Error Problem Description Corrective Action Boot Up Error Problem Description Corrective Action FPGA Main PCA 0020 The read write of the FPGA ATG Band Memory and FPGA RSM Mask Memory registers on the Main PCA was diagnosed and an error was detected Try the following Replace the Main PCA Page 8 36 FPGA Carriage PCA 0040 The read write of the FPGA PTC Print Timing Controller and FPGA PDD Print Data Distributor registers on the Carriage PCA was diagnosed and an error was detected Try the following E Replace the Carriage PCA Page 8 96 B Make sure that the Carriage Cable is correctly connected Replace the Main PCA Page 8 36 ASIC CONF Main PCA 0080 The program load from the Flash ROM on the Main PCA to the FPGA on the Main PCA or sum check was not performed correctly and an error occurred Try the following Reload the ASIC program from the IC Card Replace the Main PCA Page 8 36 ASIC CONF Carriage PCA 0100 The program load from the Flash ROM on the Main PCA to the ASIC on the Carriage PCA or sum check was not performed correctly and an error
58. settings are correct Measuring points and expected values on the Carriage PCA should be as follows Voltage Selected Measuring point on the carriage PCA EE Sere ee eee Cw Dy p C es 3 ofi 3 85 If the VDD test fails try the following E Replace the Carriage PCA Page 8 96 Front Panel This option allows you to test the Display and keys of the Front Panel 1 In the Elect submenu scroll to Front Panel and press the OK key FRONT PANEL gt KEYS 2 Select whether you want to test the Display or Keys and press the OK key FRONT PANEL KEYS 3 f you select to test the Display the Front Panel will turn ON and Off the LED s in sequence display the different character strings and activate the buzzer 4 f you select to test the Keys you will need to confirm that you want to perform the test by pressing the OK key FRONT PANEL KEYS OK 5 When the following message is displayed on the Front Panel press the different keys on the Front Panel to test if they are working correctly KEY TEST 6 Ifthe key is pressed correctly the Front Panel will display the name of key that was pressed Press the OK key to exit KEY TEST SHIFT KEY If the Front Panel test fails try the following Replace the Front Panel Assembly Page 8 25 CP itr ide VOLT Voltage Check This menu can be used to turn the Voltage check to high
59. the Home Position Sensor 7 Unclip the Home Position Sensor from the Support Bracket Paper Axis Motor and Belt Removal 1 Remove the Upper Side Cover Right gt Page 8 4 2 Remove the Top Side Cover Right Page 8 5 3 Remove the Scan Axis Motor Page 8 72 4 Disconnect the Paper Axis Motor Cables 5 Remove two screws that secure the Paper Axis Gear Plate Rr a son 6 Remove the Paper Axis Gear Plate from the Printer 7 Remove the Spring and Washer from the Paper Axis Gear shaft 8 Loosen three screws that secure the Paper Axis Motor Bracket to the Chassis invent 9 Release the Belt and remove the Paper Axis Gear from the Printer 10 Remove three screws that secure the Paper Axis Motor Bracket to the Chassis Tl Remove the Paper Axis Motor Assembly from the Printer Rr a slaton 12 Remove two screws that secure the Bracket to the Paper Axis Motor 13 Remove the Paper Axis Motor from the Bracket Scan Axis Motor and Removal 1 Remove the Upper Side Cover Right gt Page 8 4 2 Remove the Top Side Cover Right Page 8 5 3 Disconnect the Scan Axis Motor Cable 4 Loosen two screws that secure the Tension Pulley on the right hand side of the Printer Loosening these two screws will release the tension on the Carriage Belt which must always be don
60. the Printhead Adjustment Jig 1 in to the Carriage it needs to be calibrated as follows 1 Retract the datum pins located in the Printhead Adjustment Jig 1 by turning the Adjustment Screws counterclockwise using a small Flat Head Screwdriver ent Screws Adjustm 2 Place the Printhead Adjustment Jig 1 on top of the Printhead Adjustment Reference Plate as shown 3 Insert the two Printhead Positioning Pins in to the Printhead Adjustment Jig 1 invent 4 Tighten the two fixing screws so that the Printhead Adjustment Jig 1 is securely attached to the Printhead Adjustment Reference Plate Fixing Screws 5 Place the Printhead Adjustment Jig on a flat surface and without holding it gently turn the Adjustment Screws clockwise until the Printhead Adjustment Jig begins to move Check that the Datum Pins touch the walls of the Printhead Adjustment Reference Plate Do NOT force the Adjustment Screws too much as this could damage the Datum Pins 6 Once the Printhead Adjustment Jig 1 has been calibrated you can loosen the fixing screws remove the Printhead Positioning Pins and remove the Printhead Adjustment Reference Plate O ses Install the Printhead Adjustment Jigs in the Carriage The next procedure will be to install the Printhead in to the Carriage and install the Printhead Adjustment Jigs as follows 1 Install the new Printhead in to the Carriage and secure it with two screws The scre
61. working correctly Perform the Ink Sensor Test Page 4 54 Abnormal Sound Coming from the Printer One of the Motors in the Printer might be defective Check that the Motors are working correctly Page 4 72 Check that there are no foreign or loose objects inside the Printer Front Panel is Not Working Make sure that the Front Panel Cable is connected correctly to the Front Panel and to the Main PCA Make sure that the Front Panel Cable is NOT damaged Replace the Front Panel Page 8 25 Heater Panel is Not Working Make sure that ALL Heater Panel Cables are connected correctly to the Heater Panel Make sure that the Heater Panel Cables are NOT damaged Replace the Heater Panel Page 8 27 invent Solving Heater Problems Power ON Heater Power Switch appears on Heater Panel Check that the Heater Power Cable is connected and that the heater Power Switch is switched On Replace the Heater Relay Assembly Page 8 52 Replace the Heater Panel Page 8 27 Heater Does NOT become Hot Try performing the Heater Test Page 4 91 If the Heater does not work during the test try the following Make sure that the Cable between the Heater Panel and the Heater Relay Assembly is connected correctly and NOT damaged Make sure that the Heaters are connected correctly to the power voltage alternation switch E Replace the Heater Relay Assembly Page 8 52 Replace the Heater Panel Page
62. 10 Remove the Printhead Cooling Fan Assembly from the Printer Tl Remove two screws that secure the metal bracket to the Printhead Cooling Fan Assembly 12 Remove the metal bracket from the Printhead Cooling Fan Assembly 13 Remove four screws that secure the Printhead Cooling Fan to the Printhead Cooling Fan Assembly 14 Remove the Printhead Cooling Fan from the Printhead Cooling Fan Assembly Rr a son Printhead Removal 1 Remove the Upper Side Cover Right gt Page 8 4 2 Remove the Top Side Cover Right Page 8 5 3 Remove the Capping Door Page 8 13 4 Remove the Printhead Cooling Fan Assembly Page 8 87 5 Remove two screws that secure the Printhead Connector Assembly to the Printhead 6 Disconnect the Printhead Connector Assembly from the Printhead Removal and Installation invent 7 Disconnect the Ink Tube from the Printhead 8 Cover the Ink Tube carefully with a paper cloth and secure it to the Carriage Assembly with some tape 9 Install a Tube Cap on to the Printhead 8 92 HP Designjet 10000s Series Printer Service Manual Rr a son 10 Remove two screws that secure the Printhead to the Carriage Assembly Printhead Connector Assembly Removal 1 Remove the Upper Side Cover Right gt Page 8 4 2 Remove the Top Side Cover Right Page 8 5 3 Remove the Capping Door
63. 13 Remove two screws that secure the metal cover to the side of the Printer 14 Remove two screws that secure the metal cover to the front of the Printer 15 Pull the metal cover down slightly so that the Priming Tubes are exposed Rr ad son 16 Remove two screws that secure the metal bracket to the Capping Station 17 Remove the metal bracket from the Capping Station 18 Disconnect the Capping Station cables 19 Remove four screws that secure the Left Capping Frame at the top 20 Remove two screws that secure the Left Capping Frame to the bottom 21 Remove one screw that secures the metal bracket 22 Remove the Left Capping Frame from the Printer 23 Remove four screws that secure the Right Capping Frame at the top 24 Remove two screws that secure the Right Capping Frame to the bottom wexeumuan M 25 Remove one screw that secures the metal bracket 26 Disconnect the Cable from the Right Rear Cover Sensor 27 Remove the Right Capping Frame from the Printer 28 Loosen one screw from the top and four screws that secure the Capping Station i 29 Loosen one screw from the top and two screws that secure the Capping Station 30 Disconnect ALL six tubes from the Capping Tubes Bracket 31 Remove the Capping Station from the Printer Re a ation Capping Unit Removal 1 Uncap the Ca
64. 17 Locate the screw position that was out of the accepted tolerance range and loosen the five screws Loosen the screws 18 Adjust the gap between the Black Platen Post and the Center Platen by adding or removing Shims until it is within a range of 200 um Using the example on Page 5 48 row 2 on the Back part of the Center Platen needed to be adjusted A Shim of 0 1 mm 100 um could be enough to bring the row within the accepted tolerance range of 300 but it is best to always use the 0 2 mm 200 Shim so that the Platen Flatness is well below the accepted tolerance range and is below or very close to a range of 200 pm Y z Center Platen Black Platen Post 19 The single slot small Shims should be used in the front two screw positions and the triple slot large Shims should be used in the rear three screw positions Single Slot Shims 2 Triple Slot Shim 20 After adding the Shims measure the screw position that was out of the accepted range again to ensure that the gap is within a range of 200 um If the gap is still out of range then you will need to repeat this procedure 21 Turn Off the Printer from the switch at the rear of the Printer 22 Reinstall following components that were removed B Vacuum Fan Mounting Plate reconnect ALL connectors Five Mounting Brackets Grounding Strip and Bracket E Sponge Plates from each end of the Printer E Sponges from each end
65. 3 When the following message appears on the Front Panel check whether the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked INK SYSTEM OPT BOTTLE OK 4 When the following message is displayed on the Front Panel open the Left Ink Cartridge Door and remove ALL 3 Storage Liquid Cartridges OPEN L INKCOVER REMOVE CARTRIDGE 5 Once the Storage Liquid Cartridges have been removed install a Purging Cartridge in to each slot and close the Left Ink Cartridge Door LOAD PURGING CAR CLOSE L INKCOVER 10 n 12 invent If the Printer detects that a Purging Cartridge has been installed incorrectly or if an invalid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Purging Cartridge has been installed correctly before you can continue OPEN L INKCOVER LOAD PURGING CAR LOAD XX SLOT LOAD XX SLOT When the following message is displayed on the Front Panel open the Right Ink Cartridge Door and remove ALL 3 Storage Liquid Cartridges OPEN INKCOVER REMOVE CARTRIDGE Once the Storage Liquid Cartridges have been removed install a Purging Cartridge in to each slot and close the Right Ink Cartridge Door LOAD PURGING CAR CLOSE R INKCOVER If the Printer detects that a Purging Cartridge has been installed incorrectly or if an invalid Cartridge has been installed on
66. 3 While the HEB is being tested the following message will be displayed on the Front Panel EXECUTING 4 If the HEB test passes the Front Panel will display the following message HEB PASS 5 If the HEB test fails the Front Panel will display the following message HEB ERR If the HEB test fails try the following Replace the Add On HEB2 Control Page 8 45 invent ALL This option allows you to perform all the previous tests in one go In the Elect submenu scroll to ALL and press the OK key ALL You will need to confirm that you want to perform all the test by pressing the OK key ALL OK While all the tests are being performed the following message will be displayed on the Front Panel EXECUTING If all the tests pass the Front Panel will display the following message ALL PASS If any of the tests fails the Front Panel will display the name of the part that has failed In this case refer to the corrective action for the failing part VDD This option allows you to test the VDD voltage either 24V 17V or 6V of the Carriage PCA In the Elect submenu scroll to VDD and press the OK key VDD gt 24V Select the Voltage of the Head Relay Board that you want to test and press the OK key VDD 17 invent 3 Measure the voltage using a tester of the different points on the Head Relay Board to verify that the voltage
67. 6 The Cleaning Liquid purge process will start and you will need to recheck whether the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked START PURGING BOTTLE OK 27 The Printer will extract the Cleaning Liquid which could take at least 10 minutes and the following message will be displayed on the Front Panel PURCING XXX 28 Once the Cleaning Liquid has been purged from the system the following message will be displayed on the Front Panel Open the Left Ink Cartridge Door and remove ALL 3 Purging Cartridges OPEN L INKCOVER LOAD CL CART 29 Once the Purging Cartridges have been removed install a used Cleaning Liquid Cartridge in to each slot and close the Left Ink Cartridge Door LOAD CL CART CLOSE L INKCOVER Ifthe Printer detects that a Cleaning Liquid Cartridge has been installed incorrectly or if any of the Cleaning Liquid Cartridges contain less than 500cc of liquid or if an invalid Cleaning Liquid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Cleaning Liquid Cartridge has been installed correctly before you can continue OPEN L INKCOVER LOAD CL CART LOAD XX SLOT LOAD XX SLOT LOAD NEW CL CART LOAD XX SLOT 31 32 33 34 35 36 When the following message is displayed on Front Panel open the Right Ink Cartridge Door a
68. 8 27 If the Heater does work during the Heater test try the following B Make sure that ALL Heater Panel Cables are connected correctly to the Heater Panel B Make sure that the Heater Panel Cables are NOT damaged Replace the Heater Panel Page 8 27 E Replace the Main Page 8 36 Abnormal Temperature is Displayed Make sure that the Heater that is experiencing the abnormal temperature is installed correctly Check that the Heater Cable is connected correctly Replace the Heater Panel Page 8 27 Replace the Heater that is experiencing the abnormal temperature The Heater Temperature Becomes Extremely High Make sure that the Heater that is experiencing the high temperature is installed correctly Check that the Heater Cable is connected correctly Replace the Heater Panel Page 8 27 Replace the Heater Relay Assembly Page 8 52 Initializing Continuously Appears on the Heater Panel Make sure that the Cable between the Heater Panel and the Main PCA is connected correctly and NOT damaged Replace the Heater Panel Page 8 27 Replace the Main PCA Page 8 36 Power Save Mode Continuously Appears on the Heater Panel Make sure that the Cable between the Heater Panel and the Power Supply Unit is connected correctly and NOT damaged Replace the Heater Panel Page 8 27 Replace the Power Supply Unit Page 8 45 Replace the Main PCA Page 8 36 Special Power On Procedure When turning On th
69. A REG W MEDIA M ADV gt 3 When the following screen is displayed on the Front Panel press key to enter into the Adjust Menu A PRINTER SETUPW ADJUST 4 n the Adjust submenu scroll to Test Prints and press the OK key TEST PRINTS gt IQ PRINT 5 n the Test Prints submenu scroll to IQ Print and press the OK key TEST PRINTS IQ PRINT 6 You will need to confirm that you want to print the IQ Print by pressing the OK key TEST PRINTS IQ PRINT OK Reine Minorca 7 The Printer will start to print the IQ Print and the following message will appear on the Front Panel TEST PRINTS EXECUTING 8 The IQ Print can be cancelled at any time by pressing the Cancel key TEST PRINTS CANCELING If problems are found in the IQ Print try the following E If the problem detected is banding in one or several colors it is recommended to perform the Printhead Recovery procedure B If the problem detected is banding across ALL the colors it is recommended to perform the Media Advance adjustment on the media that is currently being used Refer to the User s Guide For further information regarding Print Quality problems please refer to Chapter 6 Print Quality Normal Printhead Recovery Printhead Recovery should be performed only if a Print Quality defect has been found in the IQ Print Otherwise Printhead Recovery should only be performed once a month 1 When
70. EB2 Control PCA for errors where x O or 1 and the Main PCA for errors where x 2 3 or 4 System Error 1140 Flash ROM Write Error A time out error occurs when the NVRAM contents are being saved in the flash memory in Maintenance Mode and erasing does not end Try the following Replace the Main PCA Page 8 36 Sistem ror codes System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error 1150 Home Position Sensor Error The Carriage cannot be moved to it s home position Try the following E Enter the Sensors Menu in Maintenance Mode and select Printer Sensors Then execute the Home Position option which will display the state of the home position sensor If the home position is detected 1 will be displayed on the Front Panel If the home position is not detected manually move the Carriage and check the Front Panel to see if the 1 is displayed Make sure the Home Position Sensor Cable is connected correctly and is not damaged Replace the Home Position Sensor Replace the Main Page 8 36 System Error 1160 Wiping Error When the Wiping Motor has been running for a while the sensor fails to detect that the Motor has made one turn Check whether the Wiper turns once and the Wiper Sensor detects the turn when the Printer is initializing when it is powered On B f the Wiper does not turn once
71. In the Install Done submenu scroll to Yes and press OK key This will indicate that the Printer has been successfully installed INSTALL DONE T YES FEED This option allows you to feed the media manually in to the Printer To feed the media manually 1 Enter in to the Maintenance Mode and press the Shift key once and then keep the W key pressed in order to manually feed the media n Press the Down Arrow Key to select Online lt c Cancel 2 During the manual feed process the following message will appear on the Front Panel FEEDING MEDIA 3 Once the W key is released the media stops feeding and the top menu will appear on the Front Panel CP rites ade SENSORS This menu can be used to check the status of the various sensors and thermistors in the Printer in real time The different options available in this menu are as follows To enter in to the Sensors menu enter in to the Maintenance Mode and press the Shift key twice and then the key Printer Sensors Page 4 53 Ink Sensor Page 4 54 Sub Tank Sensor Page 4 55 Bottle Sensor Page 4 56 Media Supply Reel MSR Sensors Page 4 57 TUR Sensors Page 4 58 Temperature Sensors Page 4 59 n Press the Up Arrow Key to select Online C Cancel Printer Sensors This option allows you to check the status of the Printers sensors in real time so that faulty sensors can be replace
72. K ADJ VALUE PAPER 240100P 4 Press the OK key once you have entered the new value intone Mode PH ADJ Printhead Adjustment This menu contains the necessary options to set the adjustment parameters of the Printhead so that it functions correctly The different options available in this menu are as follows Printhead Adjustment Prints Page 4 17 Move Carriage Page 4 18 Printhead Row Value Page 4 19 Printhead to Printhead Value Page 4 19 Set Bidirection Media Page 4 20 Bidirection Definitions Page 4 21 Printhead Voltage Page 4 22 Manufacturing Print 2 Page 4 22 To enter in to the Printhead Adjustment menu enter in to the Maintenance Mode and press the key Printhead Adjustment Prints This option allows you to print the different adjustment patterns that need to be used to adjust the Printhead In the Printhead Adjustment submenu scroll to PH Adj Prints and press the OK key PH PRINTS gt NOZZLE CHECK In the Printhead Adjustment Prints submenu scroll to the pattern that you would like to print and press the OK key PH PRINTS NOZZLE CHECK The Printhead Adjustment Prints available in this menu are as follows B Nozzle Check Prints a nozzle check pattern that can be used to determine which nozzles are missing if any Printhead Adj Prints a Printhead adjustment pattern that can be used to adjust the printh
73. NSORS AMBIENT 24 2 The Temperature Sensors that can be tested in this menu are as follows Ambient Displays the environment temperature K PH Displays the temperature of the Black Head Lm PH Displays the temperature of the Light Magenta Head Lc PH Displays the temperature of the Light Cyan Head Y PH Displays the temperature of the Yellow Head M PH Displays the temperature of the Magenta Head C PH Displays the temperature of the Cyan Head Carriagel Displays the temperature read by the sensor located at position 1 on the Carriage PCA Carriage2 Displays the temperature read by the sensor located at position 2 on the Carriage PCA Carriage3 Displays the temperature read by the sensor located at position 3 on the Carriage PCA Carriage4 Displays the temperature read by the sensor located at position 4 on the Carriage PCA Carriage5 Displays the temperature read by the sensor located at position 5 on the Carriage PCA Displays the temperature read by the sensor located at position 6 on the Carriage PCA Carriage7 Displays the temperature read by the sensor located at position 7 on the Carriage PCA 4 If you would like to exit the Temp Sensors submenu first press the Cancel key and then press the key invent ELECT Electronics This menu contains the necessary diagnostics that can be used to test the various electronic component
74. P Serial Number Page 4 47 NVRAM Initialization Page 4 47 Save Calibrations Page 4 48 Restore Calibrations Page 4 48 Save Page 4 48 Restore Page 4 49 Boot Version Page 4 49 Printer Firmware Version Page 4 49 Main PCA Version Page 4 49 Carriage PCA Version Page 4 49 ASIC version Page 4 50 Heater Hardware Version Page 4 50 Heater Firmware Version Page 4 50 Add ON HEB2 Control PCA Version Page 4 50 Heater Upgrade Page 4 50 Install Done Page 4 52 Press the Left Arrow Key to select Language This option allows you to select the language of the Front Panel display 1 In the Setup submenu scroll to Language and press the OK key LANGUAGE gt ENGLISH 2 Inthe Language submenu select English or Japanese and press OK key LANGUAGE JAPANESE Beeper Settings This option allows you to turn On Off the beeper 1 In the Setup submenu scroll to Beep and press the OK key BEEP gt ON 2 Inthe Beep submenu select On Off and then press the OK key BEEP OFF End of Ink Beeper Settings This option allows you to turn On Off the beeper that alerts you to end of ink during printing 1 In the Setup submenu scroll to End of Ink Beep and press the OK key END OF INK BEEP gt ON 2 Inthe End of Ink Beep submenu select On or Off and then press the OK key END OF
75. Remove the Right Electronics Module Side Trim from the Printer 5 Remove eight screws that secure the top and the side of the Electronics Module Cover to the Printer 6 Loosen eight screws that secure the bottom of the Electronics Module Cover to the Printer invent 7 Remove the Electronics Module Cover from the Printer invent Firmware Access Cover Removal 1 Remove two screws that secure the Firmware Access Cover to the Printer 2 Remove the Firmware Access Cover from the Printer UD Rr a son Front Panel Removal 1 Remove the Upper Side Cover Right gt Page 8 4 2 Remove the Lower Side Cover Right Page 8 8 3 Remove the Subtank Cover Right Page 8 9 4 Disconnect the Front Panel Cable from the Front Panel 5 Loosen two screws that secure the Front Panel to the Printer invent 6 Remove two screws that secure the Front Panel to the Printer 7 Remove the Front Panel from the Printer Rr a son Heater Panel Removal 1 Remove the Upper Side Cover Left Page 8 4 2 Remove the Lower Side Cover Left Page 8 8 3 Remove the Subtank Cover Left Page 8 9 4 Disconnect ALL the Heater Panel Cables from the Heater Panel 5 Loosen two screws that secure the Heater Panel to the Printer invent 6 Remove two screws that secure the Heater Pa
76. S The different directions that you can turn the Media Advance Motor are as follows Off Stops the Motor turning E Forwards Turns the Motor in the media feeding direction Backwards Turns the Motor in the reverse direction CP Hitec ade 3 You will need to confirm that you want to turn the Media Advance Motor the selected direction by pressing the OK key MEDIA ADV MOTOR FORWARDS OK To stop the motor turning select Off in the Media Adv Motor submenu and then press the OK key MEDIA ADV MOTOR OFF Capping Station Motor This option allows you to control the Capping Station Motor 1 In the Motors submenu scroll to Cap Stat Motor and press the OK key CAP STAT MOTOR STOP 2 Inthe Cap Stat Motor submenu select the direction that you would like the Capping Station Motor to run and then press the OK key CAP STAT MOTOR UNCAP The different directions that you can run the Pump Motor are as follows Stop Stops the Motor running Prime Runs the Motor in the normal direction causes priming Uncap Moves the Capping Station downwards and then turns the Motor in the reverse direction 3 You will need to confirm that you want to run the Capping Station Motor in the selected direction by pressing the OK key CAP STAT MOTOR UNCAP OK 4 To stop the Capping Station Motor turning select Stop in the Camp Stat Motor submenu and the
77. SCAN BELT OK Non HP Ink Used This option allows you to view whether Non HP Ink has been used in the Printer In the Counter submenu scroll to Non HP Ink Used and press the OK key to view whether Non HP ink has been used in the Printer XX gt YES It Non HP ink has been used in some or all of the colors then you can check which date the Non HP ink was used Return to the Counter submenu scroll to Non HP Ink Date and press the OK key NON HP INK DATE Format Year Month Day XX gt 06 12 22 CP rites de Expired Ink Used This option allows you to view whether expired ink has been used in the Printer 1 In the Counter submenu scroll to Expire Ink Used and press the OK key to view whether expired ink has been used in the Printer EXPIRE INK USED Ink Color XX gt YES 2 If expired ink has been used in some or all of the colors then you can check which date the expired ink was used Return to the Counter submenu scroll to Expire Ink Date and press the OK key EXPIRE INK DATE Format Year Month Day XX gt 06 12 22 invent Heater Panel Maintenance Mode Entering Heater Panel Maintenance Mode Press the following keys on the Heater Panel in the order shown in the drawing Basic Menu Operation To operate the Heater Panel Maintenance Menu only the Front keys are used Used to Cancel confirmation Used to scroll through menu and to
78. Trailing Cable through the Tube Rail making sure not to detach the tape from the Trailing Cables invent 28 Pass the Trailing Cable through the hole as shown in the drawing 29 Once the new Trailing Cable has been routed through the Printer detach the tape and connect the Trailing Cable to the Carriage PCA and the Main PCA 30 Once the Trailing Cable has been correctly connected and all the different components have been re installed you will need to move the Carriage Assembly across the Printer from left to right three or four times to ensure that the Ink Tubes and Trailing Cable are well seated within the Tube Rail Rr a son Printhead Cooling Fans Removal 1 Remove the Upper Side Cover Right gt Page 8 4 2 Remove the Top Side Cover Right Page 8 5 3 Remove the Capping Door Page 8 13 4 Remove two screws that secure the Carriage Cover to the Carriage Assembly 5 Remove the Carriage Cover from the Carriage Assembly invent 6 Remove two screws that secure the Printhead Cooling Fan Assembly to the Carriage Assembly 7 Remove two screws that secure the L Ii Printhead Cooling Fan Assembly to the gu h Carriage Assembly _ n a 8 Raise the Printhead Cooling Fan Assembly slightly Rr a slaton 9 Disconnect the cables from the Printhead Cooling Fan Assembly
79. Val and press the OK key LS ADJ SIDE VAL gt 0 0 mm 2 Use the and keys to change digits and use the and P keys to select the digits The value can be changed in a range of 5 0 to 5 0 mm LS ADJ SIDE VAL 1 1 mm 3 Press the OK key once you have entered the new value Media Advance Value This option allows you to enter the media advance value which is needed to calibrate the media advance for the different media used in the printer In the Printer Adjustment submenu scroll to Media Adv Value and press the key MEDIA ADV VALUE MNFG In the Media Adv Value submenu select the media that you would like to correct and press the OK key If you would like to exit the Media Adv Value submenu press the key MEDIA ADV VALUE PAPER gt 099 80 Use the and V keys to change the digits and use the lt and P keys to select the digits The value can be changed in a range of 097 00 to 103 00 MEDIA ADV VALUE PAPER gt 098 40 Press the OK key once you have entered the new value Back Adjust Print This option allows you to print an adjustment pattern so that the media back feed can be mechanically adjusted In the Printer Adjustment submenu scroll to Back Adj Print and press the OK key BACK PRINT gt NORMAL In the Back Adj Print submenu scroll to the pattern that you would like to print and press the OK key
80. ad Cooling Fan Assembly Page 8 87 5 Remove the Carriage Page 8 96 6 If necessary disconnect the Printhead Connector Cables from the Printheads in order to get better access to the Ink Tubes 7 Identity the failing Air Damper and select the same Air Damper from the Air damper support Kit each Air Damper has a different color tape and tube length 8 Remove the cap from the new Air Damper that will connect to the Ink Supply Tubes UD 9 Remove one screw that secures the Air Damper to the Carriage Assembly 10 Pull up the Air Damper slightly so you can access the Ink Supply Tube connector 1 Disconnect the Ink Supply Tube from the Air Damper 12 Quickly connect the Ink Supply Tube to the new Air Damper 13 Disconnect the Air Damper Tube from the Printhead 14 Remove the failing Air Damper from the Printer 15 Remove the cap from the tube of the new Air Damper that will connect to the Printhead invent 16 Quickly connect the tube of the new Air Damper to the Printhead 17 Install the new Air Damper into the Carriage and secure with one screw Encoder Sensor Removal 1 Remove the Rear Cover Page 8 3 2 Remove the Upper Side Cover Left and Right Page 8 4 3 Remove the Top Side Cover left and Right Page 8 5 4 Remove the Top Cover Page 8 5 Disconnect the Encoder Sensor Cable f
81. ad Number 6 Cyan Try the following Enter the Sensors Menu in Maintenance Mode and select Sub Tank Sensor Then execute ALL the Full x and Half x options and check if the Sub Tank Sensors are functioning correctly Manually move the Sub Tank Sensor Plate and if the Sensor responds it means that it is working correctly B f any of the Sub Tank Sensors fail to respond then replace the corresponding Sub Tank Sensor Page 8 115 Make sure that the Sub Tank Sensor Relay Cables Left Right and Sub Tank Sensor Cables are connected correctly and are not damaged Replace the Main Page 8 36 invent System Error System Error 124x Ink Supply Sensor Error Problem The Ink Supply Sensor does not change even though the specified time has Description passed after driving the Ink Supply Motor for the Sub Tank B x 0 Printhead Number 1 Black x 1 Printhead Number 2 Light Magenta x 2 Printhead Number 3 Light Cyan x 3 Printhead Number 4 Yellow x 4 Printhead Number 5 Magenta x 5 Printhead Number 6 Cyan Corrective Action Try the following Enter the Sensors Menu in Maintenance Mode and select Sub Tank Sensor Then execute the XX Ink Pump option for each color and check it the Ink Supply Sensor is functioning correctly Manually move the gear and if the Sensor responds it means that it is working correctly If any of the Ink Supply Sensors fail to
82. age Height is judged correct when the readings at the different positions are within the following range E Positions and 2 between 6 4 and 6 8 mm E Positions and 4 between 6 0 and 6 4 mm D Aisi nd trons Adjust the Carriage Height Before you adjust the Carriage Height you must do the following B Make sure that the Media Load Lever is in the lower position and that the Media Pressure Lever is set in the Normal position Enter the Heater Panel Maintenance Mode and the activate the Heater Test Page 4 90 Set the temperature of the Heaters at 45 C Front 40 C Center and 45 C Rear Adjust the Carriage Height as follows 1 Make sure that the following parts have been removed B Upper Side Cover Right Top Side Cover Right B Capping Door Cooling Fan Assembly 1 Move the Carriage Assembly to the middle of the Center Platen so that it is positioned between the 6th and 7th screw position on the center Platen a 2 Insert the Carriage Height Adjustment Tool with hole under the Carriage at positions 3 and 4 as shown below Position tool between 00 the two grooves PT a Cer PRAE ne jhe Ee the Center Platen I EA ar bt T dr ab n gt 00 9 up n et a y invent 3 Insert the Carriage Height Adjustment Tool without hole under the Carriage at positions 1 and 2 as shown
83. agenta B C Cyan 3 Use the and keys to change the digits and use the lt and P keys to select the digits The value can be changed in a range of 12 0 to 20 0 V in increments of V PH VOLTAGE le L gt 16 6V 4 Press the OK key once you have entered the new value Manufacturing Print 2 igen Mode Press the Down Arrow Key to select PH MAIN Printhead Maintenance This menu contains the necessary options related to the actual Printheads contained in the Carriage Assembly like cleaning or servicing The different options available in this menu are as follows Charge Ink System Page 4 23 Purge Ink System Page 4 25 B Ink System Options Store Ink System Page 4 27 Clean Ink System Page 4 33 Ink Charge Done Page 4 42 Printhead Recovery gt Page 4 42 B Uncap Carriage Page 4 43 B Cap Carriage Page 4 43 To enter in to the Printhead Maintenance menu enter in to the Maintenance Mode and press the W key n Online C 7 Cancel Charge Ink System This option allows you to charge the complete ink system e g when the Ink Tubes are empty or individual inks e g after replacing a Printhead In the Printhead Maintenance submenu scroll to Charge Ink Sys and press the OK key CHARGE INK SYS In the Charge Ink System submenu select whether you would like to charge the complete Ink System part of the Ink System or
84. ance Mode Performing the Necessary Service Calibrations or Adjustments Is the printer calibrated or adjusted correctly after replacing a component For information on the Service Calibrations and Adjustments and how to use them see Chapter 5 Adjustments and Calibrations Solving Print Quality Problems Whenever a Print Quality problem appears it is advisable to print the Test Print to help diagnose the problem The Test Print will help you differentiate between possible Printhead errors or mechanical problems For information on solving Print Quality problems see Chapter 6 Print Quality The Printer does not Power ON 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 Replace the Power Supply Unit Page 8 45 Cover Sensors are not Working Perform the Sensors Test Page 4 53 Check if the cable for the faulty sensor is not damaged and is connected correctly Replace the faulty Sensor The File Sent is Not Processed Immediately Check that the USB Cable is connected correctly to the Computer and the Printer and that it is NOT damaged Check that the Data LED on the Front Panel is flashing If it is flashing and nothing is printed then maybe the file sent is corrupted or too big Make sure that the Printer is in the Online state when the file is sent The file will be rejected if the f
85. ance adjustment pattern every 0 06 in the current setting value 0 12 range Draft 2 pass printmode B Detail 2 prints are only used in the Manufacturing process so should not be used You will need to confirm that you want to print the selected Media Advance print by pressing the OK key MEDIA ADV PRINT OK The Printer will start printing the selected Media Advance Print and the following message will appear on the Front Panel You can press the Cancel key at any time to stop printing MEDIA ADV PRINT EXECUTING The Media Advance Print will show 9 patterns printed in 0 25 steps in a range from 99 00 to 101 00 example shown using Black color 99 00z 100 25z 101 00z A Dark lines are visible so the value is too low B No line are visible so the value is correct C light lines are visible so the value is too high From the printed pattern select the best media advance calibration value Enter the Media Adv Value submenu and enter the value selected in the previous step Page 4 15 Repeat the process from step 2 but this time selecting Detail Normal instead MEDIA ADV PRINT DETAIL NORMAL UJ invent Manufacturing Print 1 Cap Position This option allows you to correct the value of the capping position In the Printer Adjustment submenu scroll to Cap Position and press the OK key CAP POSITION gt 40 0 mm 2 Use the and keys to change the digit
86. ard are abnormal Try the following Check whether 36V is supplied to the Main PCA If not then Make sure that the Rear Cover is closed Replace Power Supply Unit Page 8 45 Preset the Head Relay Board Voltage from the Diagnostic Menu Use a circuit tester to check the voltages of the channels that have an error B If the voltage is supplied it means that the voltage check circuit is defective Replace the Main PCA Page 8 36 f the voltage is not supplied replace the Head Relay Board Page 8 42 B There is a possibility of a short circuit off the Head Relay Board output line Perform a short circuit test on the Main PCA B Make sure the Carriage Trailing Cable is connected correctly and is not damaged System Error 11Ax NVRAM Error The data in the NVRAM is incorrect Try the following Switch the Printer OFF and ON again and check if the error still appears f the error continues skip the Power ON SelF Diagnostic by keeping the Cancel Key pressed and powering ON the Printer Perform NVRAM Initialization Page 4 47 and then perform Restore Calibs Page 4 48 Switch the Printer OFF and ON again and check if the error still appears B f the error continues restore the Printer to defaults settings Switch the Printer OFF and ON again and check if the error still appears Check whether the NVRAM is mounted on the Main PCA correctly If necessary replace Page 8 41
87. are Access Cover These parts are contained in boxes that measure at least 3 meters so should be dispatched directly from the parts stock to the customer invent Figure 3 Center Covers invent Electronics Module Electronics Module Reference HP Part Number Quantity Description Comments on Drawing Q6693 60010 Power Supply Unit Q6665 60017 NVRAM Head Relay Board Heater Relay Assembly U3 invent Parts and Diagrams Figure 4 Electronics Module HP Designjet 10000s Series Printer Service Manual 7 9 invent Control Panels Control Panels Reference HP Part Number Quantity Description Comments on Drawing Parts and Diagrams Figure 5 Control Panels HP Designjet 10000s Series Printer Service Manual 7 11 invent Carriage Assembly Carriage Assembly Reference HP Part Number Quantity Description Comments on Drawing Q6665 60052 Printhead Cooling Fan Q6665 60048 Carriage PCA Q6665 60001 Printhead does not include the Printhead Connector Assembly Printhead Connector Assembly comes in a kit of 3 Cables one for the left hand Printhead one for the Center Printhead and one for the right hand Printhead Line Sensor Air Damper Kit Carriage Home Position Sensor Discharge Brush Q6665 60047 invent Figure 6 Carriage Assembly invent Scan Axis Assemblies S
88. at secure the Scan Axis Motor Bracket to the Chassis 7 Move the Scan Axis Motor Bracket to the right to release the tension on the Scan Axis Belt 8 Release the Scan Axis Belt and remove the Drive Pulley from the Printer Removal and Installation invent 9 Remove one screw that secures the Belt to the right side of the Carriage Assembly Carefully slide the Belt out of the Carriage Assembly and remove from the Printer Tl Remove the Tension Pulley from the Printer HP Designjet 10000s Series Printer Service Manual 8 77 Encoder Strip Removal 1 Remove the Rear Cover Page 8 3 2 Remove the Upper Side Cover Left and Right Page 8 4 3 Remove the Top Side Cover Left and Right Page 8 5 4 Remove the Top Cover Page 8 5 Remove the screws that secure the Encoder Strip to the Chassis 6 Slide the Encoder Strip out of the Printer Rr a son Trailing Cable Removal 1 Remove the Rear Cover Page 8 3 2 Remove the Upper Side Cover Right gt Page 8 4 3 Remove the Top Side Cover Right Page 8 5 4 Remove the Top Cover Page 8 5 Remove the Capping Door Page 8 13 6 Remove the Electronics Module Cover Page 8 2 7 Remove the Front Heater Page 8 29 8 Remove two screws that secure the Carriage Cover to the Carriage Assembly 9 Remove the Carriage Cover from the Carriage Assembly
89. at the Wiper Blade moves to upper position 3 Remove four screws that secure the Wiper Blade to the Wiper Belts Rr a son 4 Remove the Wiper Blade from the Wiper Belts Wiper Belts Remove the Upper Side Cover Left Page 8 4 Remove the Top Side Cover Left Page 8 5 Remove the Lower Side Cover Left Page 8 8 Remove the Lower Wiping Cover Page 8 15 Remove the Wiping Door Page 8 17 Remove the Wiping Station Assembly Page 8 145 Remove the C ring that secures the Gears 8 Remove the Gears from the Wiping Station 9 Remove the screw and spring from each side of the Wiping Station 10 Remove one screw that secures the metal plate Tl Lift up the Wiping System invent 12 Remove the metal plate from the Wiping Station 13 Remove the Wiper Blade and belts from the Wiping Station 14 Remove four screws that secure the Wiper Blade to the Wiper Belts UD Rr a son 15 Remove the Wiper Blade from the Wiper Belts Pinchwheel Assembly Removal 1 Remove the Rear Cover Page 8 3 2 Remove the Upper Side Cover Left and Right Page 8 4 3 Remove the Top Side Cover left and Right Page 8 5 Remove the Top Cover Page 8 Remove the Front Heater Page 8 29 Remove the Paper Axis Motor Page 8 68 Uncap the Carriage and
90. bmenu scroll to PH Cooling Fan and press the OK key PH COOLING FAN gt OFF In the PH Cooling Fan submenu select to start the PH Cooling Fans and then press the OK key PH COOLING FAN ON You will need to confirm that you want to start the PH Cooling Fans by pressing the OK key PH COOLING FAN ON OK CP Hitec ade 4 To stop the Printhead Cooling Fans select Off in the PH Cooling Fan submenu and then press the OK key PH COOLING FAN OFF MSR Motor This option allows you to control the Media Supply Reel Motor In the Motors submenu scroll to MSR Motor and press the OK key MSR MOTOR gt OFF In the MSR Motor submenu select On to start the MSR Motor and then press the OK key MSR MOTOR ON You will need to confirm that you want to start the MSR Motor by pressing the OK key MSR MOTOR ON OK To stop the MSR Motor select Off in the MSR Motor submenu and then press the OK key MSR MOTOR OFF TUR Motor This option allows you to control the Take up reel Motor In the Motors submenu scroll to TUR Motor and press the OK key TUR MOTOR gt OFF In the TUR Motor submenu select On to start the TUR Motor and then press the OK key TUR MOTOR ON 3 You will need to confirm that you want to start TUR Motor by pressing the OK key TUR MOTOR ON OK To stop the TUR Motor select O
91. by any foreign object Enter the Sensors Menu in Maintenance Mode and select Sub Tank Sensor Then execute the XX Ink Pump option for each color and check invent System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action Sate Error Codes if the Ink Supply Sensor is functioning correctly Manually move the gear and if the Sensor responds it means that it is working correctly E f any of the Ink Supply Sensors fail to respond then replace the corresponding Ink Supply Station Page 8 110 Replace the Main PCA Page 8 36 System Error 126x Trailing Cable Connection Error The Trailing Cable connected to the one of the following connectors is faulty B x 0 Connector 9 B 1 Connector 10 B x 2 Connector 11 B x 3 Connector 12 Try the following E Reconnect the Trailing Cable to the Carriage and the Main PCA Make sure that the Trailing Cable is not damaged E Replace the Carriage PCA Page 8 96 f the error continues replace the Main PCA Page 8 36 System Error 1270 Feed Motor Error Over current problem in the Feed Motor Drive Circuit Try the following Check the short circuit of the internal cable of the Feed Rewind Motor and Feed Motor Relay Cable Check the s
92. can Axis Assemblies Reference HP Part Number Quantity Description Comments on Drawing Q6693 60020 Trailing Cable Assembly eon ile Sre riley Scan Axis Motor Assembly Figure 7 Scan Axis Assemblies invent Paper Path Assemblies Paper Path Assemblies Reference HP Part Number Quantity Description Comments on Drawing i Fenn ar o 26693 60016 rer cud beara Media Edge Guard Pinch Roller Kit Pinch Roller Blade Media Sensor Front and Rear Media Lever Sensor Front and Rear Net Kit Media Drive Roller When ordering the Center Platen or the Media Drive Roller you MUST also order the Platen Flatness Adjustment Tools Part Number Q6693 60037 Also due to the size and weight of the Center Platen and the Media Drive Roller two Customer Engineers are required when installing these parts These parts are contained in boxes that measure at least 3 meters so should be dispatched directly from the parts stock to the customer Figure 8 Paper Path Assemblies mes M Media Entry Assemblies Media Entry Assemblies Reference HP Part Number Quantity Description Comments on Drawing Figure 9 Media Entry Assemblies invent Take Up Reel Assemblies Take Up Reel Assemblies Reference HP Part Number Quantity Description Comments on Drawing Q6693 60027 Take Up Reel Drive Unit Assembly Q6693 60029 Let
93. cement If the Printer must be switched Off for a long period of time the customer must use either an Ink System Storage Kit to store and protect the Printheads or an Ink System Cleaning kit to recover the Printheads Tips and Tricks B f the Printer will not be maintained for a couple of days i e weekends make sure that the customer performs the daily maintenance before switching Off the Printer f a customer has not been able to perform the daily maintenance for more than one week ask them to fill up the Wiper Sponge with Wiper Liquid using a full syringe for each day the Printer has not been used Also advise the customer to perform a Printhead Recovery using a Strong level Daily Inspection and Maintenance The following procedures should be performed on a daily basis in order to ensure acceptable print quality Wiper Blade Cleaning Moistening the Wiper Sponge Capping Unit Cleaning Waste Ink Bottle Disposal Test Print Normal Printhead Recovery Only if Printheads require cleaning Wiper Blade Cleaning When the Printer Ready message appears on the Front Panel press the Online key to take the Printer offline PRINTER READY ROLL 64 PAPER When the following screen is displayed on the Front Panel press the Shift key once AINK MEDIA REGW MEDIA M ADV gt When the following screen is displayed on the Front Panel press key to enter into the PH Main Menu APH MAIN
94. cription Corrective Action Boot Up Error Problem Description Corrective Action Boot Up Error Problem Description Corrective Action Boot Up Error Problem Description Corrective Action Boot Up Error Problem Description Corrective Action invent Internal RAM 0001 The read write of the RAM on the Main PCA was diagnosed and an error was detected Try the following Replace the Main PCA Page 8 36 SRAM 0002 The read write of the SRAM on the Main PCA was diagnosed and an error was detected Try the following Replace the Main Page 8 36 Flash ROM 0004 The program area in the Flash ROM is sum checked and it could not be read causing an error Try the following E Reinstall the Firmware Printer and Boot Firmware f the Error continues replace the Main Page 8 36 PIO 0008 The read write of a specific Parallel O PIO was tested and an error was detected Try the following E Replace the Main Page 8 36 NVRAM 0010 Problems with the NVRAM detected Try the following f multiple errors have occurred that include the NVRAM error try to resolve the other errors first After resolving the other errors except NVRAM switch the Printer Off Switch the Printer On again and only the error recovery will be performed f System Error Code appears when the Printer is turned On then
95. d as necessary 1 Inthe Sensors submenu scroll to Printer Sensors and press P key PRINTER SENSORS LINE SENSOR 2 Inthe Printer Sensors submenu select the Sensor that you would like to test and press the OK key If you would like to exit the Printer Sensors submenu press the key PRINTER SENSORS LINE SENSOR gt The Front Panel will show the status of the selected Sensor By activating and deactivating the selected Sensor the status will change and a buzzer will make a sound PRINTER SENSORS LINE SENSOR 0 invent The Sensors that can be tested in this menu are as follows E ine Sensor Displays the status of the Line Sensor located in the Carriage Assembly 0 No media 1 Media present Front Media Displays the status of the Front Media Sensor located under the Front Heater O Not blocked 1 blocked Rear Media Displays the status of the Rear Media Sensor located under the Rear Heater 0 Not blocked 1 blocked Home Position Displays the status of the Home Position Sensor 0 Home position not detected 1 Home position detected B Wiper Blade Displays the status of the Wiper Sensor 0 blocked 1 Not blocked Media Lever Displays the status of the Media Lever Sensor located 0 Lowered 1 Raised Rear Cover Displays the status of the Capping Door Sensor 0 Closed 1 Open Rear Cover Displays the statu
96. d to confirm that you want to test the by pressing the OK key PIO OK While the PIO is being tested the following message will be displayed on the Front Panel EXECUTING If the PIO test passes the Front Panel will display the following message PIO PASS invent If the PIO test fails the Front Panel will display the following message PIO PIO ERR If the PIO test fails try the following B Replace the Main PCA Page 8 36 NVRAM This option allows you to test the NVRAM contained in the Main PCA In the Elect submenu scroll to and press the OK key NVRAM You will need to confirm that you want to test the NVRAM by pressing the OK key NVRAM OK While the NVRAM is being tested the following message will be displayed on the Front Panel NVRAM EXECUTING If the test passes the Front Panel will display the following message NVRAM If the test fails the Front Panel will display the following message NVRAM NVRAM ERR If the NVRAM test fails try the following B Replace the Page 8 41 E f the test fails again after replacing the replace the Main PCA Page 8 36 CP Hitec ade Ink EEPROM This option allows you to test the Ink EEPROM contained in the Ink Cartridge 1 In the Elect submenu scroll to Ink EEPROM and press the OK key INK EEPROM gt
97. ded to perform routine maintenance This Chapter explains the necessary procedures to be performed on a daily weekly or monthly basis Printheads Maintenance In order to ensure Image Quality the Printheads in the Printer must be maintained on a frequent basis If the Printheads are not looked after correctly it is possible to get clogged or misdirected nozzles due to dried ink which can cause banding If the Printhead cannot be recovered it means the replacement of the Printhead which can be very expensive In order to prevent the Printhead from malfunctioning the customer has the responsibility to 1 Perform daily maintenance of the Printheads The daily maintenance is necessary to Clean any dried ink that remains on the Capping or Wiping systems E Keep the Wiping system wet so that it can efficiently clean the Printhead s nozzle plate 2 Don t switch Off the Printer The Printer has an internal clock which allows to automatically perform a fill cap operation flushing some ink through the Printhead which keeps the Printheads in good condition This is done after the first 20 hours without printing and every 3 days If the Printer is switched Off for a long period this process does not happen If the ink does not flow through the Printheads from time to time the ink will dry inside the nozzles reaching a point where it is impossible to recover them and the Printhead will fail This will mean an expensive Printhead repla
98. der to adjust the Printhead you must first print the Check Printhead pattern as follows Enter in to the Maintenance Mode Page 4 7 Press the key to enter in to the Printhead Adjustment menu In the Printhead Adjustment submenu scroll to PH Adj Prints and press the OK key PH PRINTS NOZZLE CHECK In the Printhead Adjustment Prints submenu scroll to Check Printhead and press the OK key PH ADJ PRINTS CHECK PRINTHEAD You will need to confirm that you want to print the Check Printhead pattern by pressing the OK key PH PRINTS CHECK PRINTHEAD OK The Printer will start printing the Check Printhead pattern and the following message will appear on the Front Panel PH ADJ PRINTS EXECUTING O shes Adjust the Printhead Once you have printed the Check Printhead pattern you can use it to adjust the Printhead as follows 1 Locate the mechanical adjustment pattern in the Check Printhead pattern BEN 2 Using a Measuring Loupe you must first measure the deviation of the Printhead in the vertical position HIIS RD Deviation Pinhood ademen J 4 Using the measurement obtained in step 2 calculate how many scales you will need to turn the Vertical Adjustment Screw to adjust the vertical position of the Printhead 1 Scale 10 micromillimeters 1 Turn 100 micromillimeters Vertical Adjustment Screw 5
99. disposal The level in the HP Waste Ink Bottle should be checked by visual inspection to prevent overflow If the waste ink level is above the indication line the bottle must be replaced with an empty HP Waste Ink Bottle The use of safety glasses and gloves is recommended when performing cleaning and maintenance operations Table of Contents Troubleshooting 1 1 System Error Codes 2 1 Head Adjustment 3 1 Maintenance Mode 4 1 Adjustments and Calibrations 5 1 Print Quality 6 1 Parts and Diagrams 7 1 Removal and Installation 8 1 Preventive Maintenance 9 1 invent Troubleshooting Introduction 1 2 Troubleshooting System Error Codes 1 2 Performing a Service Test on a Failed Assembly 1 2 Performing the Necessary Service Calibrations or Adjustments 1 3 Solving Print Quality Problems 1 3 The Printer does not Power ON 1 3 Cover Sensors are not Working 1 3 The File Sent is Not Processed Immediately 1 3 Troubleshooting Media Jam Messages 1 4 Media Jams Occur Frequently 1 5 Print Speed is Very Slow 1 5 No Ink Message when there is Enough Ink 1 5 Abnormal Sound Coming from the Printer 1 5 Front Panel is Not Working 1 5 Heater Panel is Not Working 1 5 Solving Heater Problems 1 6 Power ON Heater Power Switch appears on Heater Panel 1 6 Heater Does NOT become Hot 1 6 Abnormal Temperature is Displayed 1 6 The Heater Temperature Becomes Extremely High 1 6 Initializing Continuously Appears on th
100. e if the needle moves counter clockwise to 85 this should be read as a value of 15 negative value This should then be multiplied by 10 which will give you a final value of 150 um This is an example of how to note down the values on a piece of paper EAE 14 Once all the screw positions have been measured you will need to verify that they are within the range of the accepted tolerance 300 pm You will need to check the difference between the row with the highest value and the row with the lowest value to ensure that the difference is less than 300 um For example using the Front Values row 9 has the lowest value 180 and row 5 has the highest value 110 so the difference between the two is 290 um this is within the tolerance range of 300 um To give you an example of a Platen that is out of the accepted range take a look at the Back Values in the above table Row 2 has the lowest value 250 and row 5 has the highest value 140 so the difference between the two is 390 um this is out of the tolerance range of 300 um To resolve this problem you would need to add a large Shim 0 2 mm 200 um at the back part of the Center Platen at row 2 15 Ifall of the positions of the Platen are within the accepted range then you can remove the Flatness Measurement Gauge and reinstall the Carriage Shield s 16 Turn Off the printer CA Aisi ard iratos Platen Flatness Adjustment Perfor
101. e 4 80 W Error Log Print Page 4 81 History Print Page 4 81 To enter in to the System Information menu enter in to the Maintenance Mode and press the Shift key three times and then the key Press the Up Arrow System Print This option allows you to turn print information relating to the system settings mechanical parameters and ink In the System Inf submenu scroll to System Print and press the OK key SYSTEM PRINT gt You will need to confirm that you want to print the System Print by pressing the OK key SYSTEM PRINT OK While the System Print is being printed the following message will be displayed on the Front Panel SYSTEM PRINT EXECUTING To cancel the print press the Cancel key invent Error Log Print This option allows you to turn print error log information stored in the Printer 1 In the System Inf submenu scroll to Error Log Print and press the OK key ERROR LOG PRINT gt 2 You will need to confirm that you want to print the Error Log Print by pressing the OK key ERROR LOG PRINT OK 3 While the Error Log Print is being printed the following message will be displayed on the Front Panel ERROR LOG PRINT EXECUTING 4 To cancel the print press the Cancel key History Print This option allows you to turn print information relating to the ink system cleaning condition which is stored in the Printer
102. e Heater Panel 1 6 Power Save Mode Continuously Appears on the Heater Panel 1 7 Special Power On Procedure 1 7 Both NVRAM and Main PCA are Replaced Together 1 8 HP Designjet 10000s Series Printer Service Manual 1 1 invent 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 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 Model and Serial Number of the printer Which firmware revision the printer is using B The complete error number B The System and History Prints B Which software application the customer is using name version etc 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 actual component assembly that has failed For information on the Service Tests and how to use them see Chapter 4 Mainten
103. e Idle Unit until it is the same as the height on the Capping side Loosen these SCIews Turn this Bolt to adjust the height 6 Tighten the screws loosened in the previous step 7 Apply red paint to the bottom of the Bolt so it does not accidently loosen invent Media End Sensor Adjustment This adjustment is necessary to adjust the direction of the light emitted from the light emission unit of the Media End Sensor located on the Media Feed side in the upper location This adjustment must be performed whenever Media End Sensor is disassembled or replaced Perform the Media End Sensor Adjustment as follows 1 Remove the Main Scroller and Sub Scroller from the Media Feed side 2 Remove two screws that secure the Sensor Cover on the Media Feed Unit Sensor Cover 3 Remove the Sensor Cover from the light emission units on the Media Feed Unit 4 Disconnect the connector labelled K Slack of the light emission unit of the Media Slack Sensor lower sensor on the Media feed Unit Media End Sensor Media Slack Sensor Disconnect this connector UJ invent 5 Turn the top adjusting screw counter clockwise to adjust the light emission unit to a position where both the upper and lower light receiving units receive the light the red LEDs are ON Adjusting Screw 6 Turn the top adjusting screw clockwise gradually until the Media Slack Sensor lower sensor no longer receives th
104. e Printer the Printer will follow the internal initialization process turning on the different systems and making the necessary system checks In order to troubleshoot the Printer the following Power On options are available Press the Cancel key and Power On button This will allow you to skip the system check of the Printer Press the Cancel and Shift keys and Power On button This will allow you to skip the error recovery check of the Printer You will be given the option to enter the Maintenance Mode in order to troubleshoot the Printer by entering a password b Shift ond OK MAINTENANCE MODE PASSWORD This option is useful if you want to perform the following Ink purging without installing media In a normal power On situation the Printer cannot function without the media loaded Recovery of a damaged NVRAM By powering in the special power On situation the NVRAM can be recovered by entering the Maintenance Mode and by performing the necessary steps to recover the NVRAM ue RN 10 n 12 13 invent Both NVRAM and Main PCA are Replaced Together When both the NVRAM and the Main PCA are replaced at the same time mechanical correction value parameters counters calibrations etc are lost Whenever possible this most be prevented by just replacing either the NVRAM or the Main PCA If for whatever reason both the NVRAM and the Main PCA are replaced together you need t
105. e before removing the Belt 5 Remove one screw that secures the Belt to the left side of the Carriage Assembly and then release the Belt from the Carriage Assembly 6 Loosen three screws that secure the Scan Axis Motor Bracket to the Chassis 7 Move the Scan Axis Motor Bracket to the right to release the tension on the Scan Axis Belt 8 Release the Scan Axis Belt and remove the Drive Pulley from the Printer Removal and Installation LA invent 9 Remove two screws that secure the Scan Axis Motor to the Bracket 10 Release the Scan Axis Belt and remove the Scan Axis Motor from the Printer 11 Remove the Scan Axis Belt from the Printer 8 74 HP Designjet 100005 Series Printer Service Manual DU Removal and Installation invent Carriage Drive Assembly Includes Carriage Belt Removal 1 Remove the Upper Side Cover Left and Right Page 8 4 2 Remove the Top Side Cover Left and Right Page 8 5 3 Loosen two screws that secure the Tension Pulley on the right hand side of the Printer Loosening these two screws will release the tension on the Carriage Belt which must always be done before removing the Belt 4 Remove one screw that secures the Belt to the left side of the Carriage Assembly 5 Release the Belt from the Carriage Assembly HP Designjet 10000s Series Printer Service Manual 8 75 invent 6 Loosen three screws th
106. e light the red LED light goes OFF a Bottom LED should go OFF Adjusting Screw 7 Turn the top adjusting screw clockwise a further 1 25 times 8 Check that the Media End Sensor upper sensor receives light the red LED light is ON and connect the connector of the light emission unit of the Media Slack Sensor lower sensor Connect this connector 9 Install the Sensor Cover and secure with two screws Sensor Cover UJ invent Media Slack Sensor Adjustment This adjustment is necessary to adjust the direction of the light emitted from the light emission unit of the Media Slack Sensor located on the Media Feed side in the lower location This adjustment must be performed whenever B Media Slack Sensor is disassembled or replaced Perform the Media Slack Sensor Adjustment as follows 1 Remove the Main Scroller and Sub Scroller from the Media Feed side 2 Remove two screws that secure the Sensor Cover on the Media Feed Unit Sensor Cover 3 Remove the Sensor Cover from the light emission units on the Media Feed Unit 4 Disconnect the connector labelled K End of the light emission unit of the Media End Sensor upper sensor on the Media feed Unit Media End Sensor Media Slack Sensor Disconnect this connector 5 Turn the bottom adjusting screw counter clockwise to adjust the light emission unit to a position where both the upper and lower
107. e of the following messages will be displayed on the Front Panel You will need to make sure that a valid Purging Cartridge has been installed correctly before you can continue OPEN INKCOVER LOAD PURGING CAR LOAD XX SLOT LOAD XX SLOT The Storage Liquid purge process will start and you will need to recheck whether the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked START PURGING BOTTLE OK The Printer will purge the Storage Liquid which could take at least 10 minutes and the following message will be displayed on the Front Panel PURGING XXX Once the Storage Liquid has been purged from the system the following message will be displayed on the Front Panel Open the Left Ink Cartridge Door and remove ALL 3 Purging Cartridges OPEN L INKCOVER LOAD CL CART CP rites ade 13 14 15 16 17 Once the Purging Cartridges have been removed install a NEW Cleaning Liquid Cartridge in to each slot and close the Left Ink Cartridge Door LOAD CL CART CLOSE L INKCOVER If the Printer detects that a Cleaning Liquid Cartridge has been installed incorrectly or if any of the Cleaning Liquid Cartridges contain less than 500cc of liquid or if an invalid Cleaning Liquid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Cleaning Liquid Cartridge has been installed
108. e problem it is recommended to use the Offset Media Loading option to reload the media reter to the User s Guide for further information ti Troubleshooting Printhead Problems If a Print Quality problem occurs it could be due to a problem with the actual Printheads Use this checklist to try and resolve any problems with the Printheads 1 Print the Nozzle Check Pattern Page 4 17 to verify if any Printhead Nozzle are missing If any missing nozzles cannot be recovered the failing Printhead may need to be replaced 2 ls the problem caused by an electrical issue or by the Ink System B f ALL the Printheads are faulty then this definitely points to an electrical problem Check all cables connected to the Printheads and from the Carriage PCA to the Main PCA to make sure that they are connected correctly and not damaged B f only one Printhead is faulty then this points to a Printhead Ink System or electrical system problem To check if it is an electrical problem swap the connector on the faulty Printhead with a connector from a working Printhead If the Printhead continues to be faulty then this definitely points to a Printhead Problem 3 How to check if the Ink System is defective Verify that the ink is being absorbed If not then you will need to check the Capping Station Capping Unit or Ink Tubes Verity if there is air in the Ink Tube If there is air in the Ink Tube then you will need to refill th
109. e sub tank replace the Capping Unit tighten the Tube joints or replace the Printhead 4 Ifa Printhead is actually defective Perform the Printhead Recovery procedure Perform the Fill Cap procedure Purge the Ink System Page 4 25 Charge the Ink System with new ink Page 4 23 5 f a problem occurs due to a Printhead rubbing or a Media crash Check the Printhead Nozzle plate for any damage Check the carriage Height and adjust it if necessary Page 5 5 Make sure that the Media is loaded correctly and that the Media Edge Guards are correctly positioned Check the flatness of the Center Platen and adjust if necessary gt Page 5 45 6 Ifthe amount of missing nozzles increases while printing Check the voltage of the Printhead and if necessary adjust it Page 4 22 B Clean any dust that is on the media passing through the Media Feed side Check for jagged edges on the Media that could cause friction against the Printheads Clean the Capping Units and the Wiper Blade Change the settings for the Printhead Cleaning cycle gt Media Reg Menu PH Cleaning During Print or During Print2 7 Make sure that there is no ink on the Printhead Connector Cable or the Carriage Cable invent Parts and Diagrams Right Hand Covers 7 2 Left Hand Covers 7 4 Center Covers 7 6 Electronics Module 7 8 Control Panels 7 10 Carriage Assembly 7 12 Scan Axis Assemblies 7 14 Pape
110. e sure that the Heater Relay Assembly is connected correctly to the Center Platen Replace the Heater Relay Assembly Page 8 52 Replace the Center Platen Heater Page 8 34 Heater Error HO9 Operation Panel Switch Error The specified switch is not pressed for 30 seconds or more when the diagnostics that verifies the switch action is executed Try the following Replace the Heater Relay Assembly Page 8 52 Heater Error H10 Zero Cross Error This error occurs when the diagnostics for the AC Relay is executed Try the following Make sure that the Heater Board is connected correctly to the relays on the Heater Block Assembly Make sure that the Heater Board is connected correctly to the Relay Board via the Relay Cable Replace the Heater Relay Assembly Page 8 52 System Error Codes A System Error Code appears on the Front Panel when an unrecoverable system exception interrupt occurs in the Printer nnnn System Error Code The System Error Codes are listed in the following table Error Description F es 0001 Operation Code Exception F es 0002 Slot Illegal Exception F es 0003 Address Exception F es 0004 DMA Error F es 0005 NMI Occurrence WatchDog Error Corrective Action 1 Replace the Main PCA Page 8 36 2 Upgrade the Printer Firmware invent Printhead Adjustment Introduction 3 2 Tools Required 3 2 Calibrate the Printhead Adjustment Jig 3
111. ead used when installing a new Printhead Check Printhead Prints a Printhead adjustment check pattern PH Row Prints a Printhead alignment pattern invent PH to PH Prints a Printhead to Printhead alignment pattern Bidirection Def Prints a Bi directional adjustment pattern Bidirection F D Prints a Bi directional adjustment pattern for the Fine Draft print mode Check PH to PH Prints a Printhead to Printhead check pattern Check Bidir Def Prints a Bi directional check pattern Check Bidir F D Prints a Bi directional check pattern for the Fine Draft print mode You will need to confirm that you want to print the selected printhead Adjustment Pattern by pressing the OK key PH PRINTS OK The Printer will start printing the selected Printhead Adjustment Pattern and the following message will appear on the Front Panel PH ADJ PRINTS EXECUTING Move Carriage This option allows you to move the Carriage when adjusting the Printhead In the Printhead Adjustment submenu scroll to Move Carriage and press the OK key MOVE CARRIAGE gt HOME In the Move Carriage submenu scroll to the position that you would like the Carriage to move to and press the OK key MOVE CARRIAGE HOME The positions that the Carriage can move to are as follows B Home Moves the Carriage to the home position Cap Moves the Carriage to the capping positi
112. emove the Upper Side Cover Right Page 8 4 Remove the Top Side Cover Right Page 8 5 Remove the Lower Side Cover Right gt Page 8 8 Remove the Lower Capping Cover Page 8 Remove Capping Door Page 8 13 Remove two screws that secure the metal bracket to the chassis on the Capping Side Remove the metal bracket from the Printer 9 Release ALL the cables from the cable clips 10 Remove four screws that secure the metal plate to the chassis 11 Remove the metal plate from the chassis invent 12 Disconnect the Solenoid Assembly cable 13 Release the Solenoid Assembly cable connector from the chassis UD Rr a son 15 Remove the Solenoid Cover from the Capping Station 16 Cut ALL cable ties that secure the Solenoid Assembly cable 17 Remove two screws that secure the Solenoid Assembly to the Capping Station 18 Remove Solenoid Assembly from the Capping Station Rr a son Waste Bottle Holder and Sensor Assembly Removal 1 Remove the Upper Side Cover Right gt Page 8 4 2 Remove the Top Side Cover Right Page 8 5 3 Remove the Lower Side Cover Right Page 8 8 4 Remove the Lower Capping Cover Page 8 5 Remove Capping Door Page 8 13 6 Remove two screws that secure the metal bracket to the chassis on the Capping Side 7 Remove the metal brac
113. emoved install a Purging Cartridge in to each slot and close the Left Ink Cartridge Door LOAD PURGING CAR CLOSE L INKCOVER 6 10 n 12 If the Printer detects that a Purging Cartridge has been installed incorrectly or if an invalid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Purging Cartridge has been installed correctly before you can continue OPEN L INKCOVER LOAD PURGING CAR LOAD XX SLOT LOAD XX SLOT When the following message is displayed on the Front Panel open the Right Ink Cartridge Door and remove ALL 3 Ink Cartridges OPEN INKCOVER REMOVE CARTRIDGE Once the Ink Cartridges have been removed install a Priming Cartridge in to each slot and close the Right Ink Cartridge Door LOAD PURGING CAR CLOSE R INKCOVER If the Printer detects that a Purging Cartridge has been installed incorrectly or if an invalid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Purging Cartridge has been installed correctly before you can continue OPEN INKCOVER LOAD PURGING CAR LOAD XX SLOT LOAD XX SLOT The Ink Purging process will start and you will need to recheck whether the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked START PURGING BOTTLE OK
114. ent and Adjustment 5 44 Calibrations 5 55 Wiping Position Calibration 5 55 Capping Position Calibration 5 57 Line Sensor Calibration Side Margin 5 59 Line Sensor Calibration Top Margin 5 60 HP Designjet 10000s Series Printer Service Manual 3e invent Adjustments and Calibrations The Printer requires certain adjustments and calibration procedures that must be performed under certain conditions Adjustments refer to procedures that require physical mechanical fine tuning of the different components in the Printer Calibrations refer to procedures that require entering values through the Front Panel in order to fine tune the components in the Printer Adjustments Belt Tension Adjustment Page 5 3 Carriage Height Adjustment Page 5 5 Scan Axis Belt Tension Adjustment Page 5 12 Paper Axis Belt Tension Adjustment Page 5 14 Timing Belt for Feed TUR Unit Tension Adjustment Page 5 16 Wiping Station Height Adjustment Page 5 18 Wiper Belt Tension Adjustment gt Page 5 21 Wiper Blade Height Adjustment Page 5 22 Capping Station Height Adjustment Page 5 25 OQ 0 BOND o Printhead Capping Limit Adjustment Page 5 27 Carriage Shield Height Adjustment Page 5 28 Media Feed and Take Up Reel Unit Adjustment Page 5 29 Media End Sensor Adjustment Page 5 32 Media Slack Sensor Adjustment Page 5 35 Take Up Reel Sensor Adjustment g
115. enta Sub Tank Full Sensor Full Displays the status of the Light Cyan Sub Tank Full Sensor invent Y Full Displays the status of the Yellow Sub Tank Full Sensor M Full Displays the status of the Magenta Sub Tank Full Sensor C Full Displays the status of the Cyan Sub Tank Full Sensor K Half Displays the status of the Black Sub Tank Half Sensor Lm Half Displays the status of the Light Magenta Sub Tank Half Sensor Lc Half Displays the status of the Light Cyan Sub Tank Half Sensor Y Half Displays the status of the Yellow Sub Tank Half Sensor M Half Displays the status of the Magenta Sub Tank Half Sensor C Half Displays the status of the Cyan Sub Tank Half Sensor K Ink Pump Displays the status of the Black Ink Pump Sensor Lm Ink Pump Displays the status of the Light Magenta Ink Pump Sensor Lc Ink Pump Displays the status of the Light Cyan Ink Pump Sensor Y Ink Pump Displays the status of the Yellow Ink Pump Sensor M Ink Pump Displays the status of the Magenta Ink Pump Sensor C Ink Pump Displays the status of the Cyan Ink Pump Sensor 4 If you would like to exit the Sub Tank Sensor submenu first press the Cancel key and then press the key Bottle Sensor This option allows you to check the status of the Waste Bottle Sensor in real time so that if it is faulty it can be replaced as necessary 1 In the Sensors submenu scroll to Bottle Sensor and press
116. er Blade to the Wiper Belts 6 Move the Carriage to the Wiping Station and position the top edge of the Wiper Blade at least 0 5 mm above the top edge of the Printhead Nozzle Plate black part Wiper Blade Printhead Nozzle Plate gt 7 While holding the Wiper Blade in position tighten the two screws that you loosened in a previous step invent 8 Manually rotate the Wiper Blade using the Wiping Station Gear and check that the Wiper Blade touches the Printheads evenly Capping Station Height Adjustment This adjustment must be performed whenever Capping Station is disassembled or replaced For this adjustment you will need the Capping Height Tools Perform the Capping Station Height Adjustment as follows Make sure that the Capping Station is correctly installed and that the Carriage is moved to the Capping Station Make sure that the Printhead Height Lever is in the upper position so that Printhead height is actually in the lower position Make sure you loosen the two Printhead Height Adjustment screws before trying to change the position of the Printhead Height Lever 5 Before continuing with the Capping Station Height Adjustment make sure that the Capping Station is at it s lowest position by rotating the Capping Belt Capping Gears Capping Belt 6 Install the four Capping Height screws into the Carriage in the positions sh
117. er to make sure it is not damaged and is connected correctly Check the data file that was sent to print Make sure that the media type selected in the Front Panel is the same as the media type loaded into the Printer Check that the room temperature is higher than 20 C and make sure that you leave the Printer to warm up sufficiently a Quali invent Output Only Contains a Partial Print Corrective Action 1 There might be a problem between the Printer and Computer Check the cable between the computer and the Printer to make sure it is not damaged and is connected correctly 2 There might be foreign objects attached to the Printhead Perform the Printhead Recovery procedure and reprint the image 3 If cleaning the Printheads does NOT solve the problem then the nozzles might be blocked Perform the Wash Printheads procedure refer to the User s Guide and reprint image The Printer Area is Stained Corrective Action 1 Check if the Carriage Shields are covered in ink If the Carriage Shields are covered in ink then try to clean them with a cloth 2 Check if the Carriage Shields are correctly positioned because they could be installed too low If necessary adjust the Carriage Shields Page 5 28 3 Check if the leading edge of the media is curled If it is curled cut off the leading edge before printing 4 Check if the media is wrinkled If it is wrinkled advance the media and cut off the part of the med
118. ether ink charge has been completed 1 In the Printhead Maintenance submenu scroll to Ink Charge Done and press the OK key INK CHARGE DONE gt 2 Inthe Ink Charge Done submenu select Yes if ink charge has been completed or No if ink charge has not been completed yet and then press the OK key INK CHARGE DONE YES Printhead Recovery This option allows you to activate the Printhead Recovery process 1 In the Printhead Maintenance submenu scroll to PH Recovery and press the OK key PH RECOVERY gt NORMAL ALL 2 Inthe PH Recovery submenu select the level of Printhead recovery you would like to activate and then press the OK key PH RECOVERY NORMAL ALL The different options in this submenu are as follows B Normal All Activates a normal recovery for all Printheads Strong All Activates a strong recovery for all colors Strong Lm Activates a strong recovery for the Black Light Magenta and Light Cyan Printheads Strong Y M C Activates a strong recovery for the Yellow Magenta and Cyan Printheads 3 The Carriage will begin to perform the printhead recovery process which can take a few minutes CP Hitec de Uncap Carriage This option allows you to uncap the Carriage from the Capping Station 1 In the Printhead Maintenance submenu scroll to Uncap Carriage and press the OK key The Capping Station will move downwards uncapping the
119. every 0 25 in the 99 0 to 101 1 range Triple Density 12 pass printmode Rough H Qual2 Prints the media advance adjustment pattern every 0 25 in the 99 0 to 101 1 range High Quality2 16 pass printmode Rough H Dens2 Prints the media advance adjustment pattern every 0 25 in the 99 0 to 101 1 range High Density2 16 pass printmode Rough Draft Prints the media advance adjustment pattern every 0 25 in the 99 0 to 101 1 range Draft 2 pass printmode Detail Normal Prints the media advance adjustment pattern every 0 06 in the current setting value 0 12 range Standard 4 pass printmode Detail H Qual Prints the media advance adjustment pattern every 0 06 in the current setting value 0 12 range High Quality 8 pass printmode Detail H Dens Prints the media advance adjustment pattern every 0 06 in the current setting value 0 12 range High Density 8 pass printmode Detail 3 Times Prints the media advance adjustment pattern every 0 06 in the current setting value 0 12 range Triple Density 12 pass printmode Detail H Qual2 Prints the media advance adjustment pattern every 0 06 in the current setting value 0 12 range High Quality2 16 pass printmode Detail H Dens2 Prints the media advance adjustment pattern every 0 06 in the current setting value 0 12 range High Density2 16 pass printmode Detail Draft Prints the media adv
120. f for example the deviation measured in step 2 was 240 micro millimeters you would turn the Vertical Adjustment Screw 2 full turns and 4 scales 7 Reprint the Check Printhead pattern and measure again the deviation of the Printhead in the vertical position If there is still deviation repeat the instructions from step 3 CP sein 8 Ifthe deviation measured is you will now measure the deviation of the Printhead in the slant position m sm Deviation 10 Using the measurement obtained in step 8 calculate how many scales you will need to turn the Slant Adjustment Screw to adjust the slant position of the Printhead 1 Scale 10 micromillimeters 1 Turn 100 micromillimeters Slant Adjustment Screw n If for example the deviation measured in step 8 was 120 micro millimeters you would turn the Slant Adjustment Screw 1 full turn and 2 scales 13 14 15 16 Reprint the Check Printhead pattern and measure again the deviation of the Printhead in the slant position If there is still deviation repeat the instructions from step 9 If the deviation measured is O you can remove Printhead Adjustment Jig 2 from the Carriage Tighten the rear Printhead mounting screw Remove Printhead Adjustment Jig 1 from the Carriage CP sein Tip to Speed Up the Printhead Adjustment An alternative and faster way to adjust a new Printhead is as follows 1 Before removing the
121. ff in the TUR Motor submenu and then press the OK key TUR MOTOR OFF Pump Motors This option allows you to control the Ink Pump Motors In the Motors submenu scroll to XX Pump Motor and press the OK key XX PUMP MOTOR gt STOP The ink colors that correspond to each Ink Pump Motor are as follows K Pump Motor Black Ink Pump Motor Lm Pump Motor Light Magenta Ink Pump Motor Pump Motor Light Cyan Ink Pump Motor Y Pump Motor Yellow Ink Pump Motor M Pump Motor Magenta Ink Pump Motor C Pump Motor Cyan Ink Pump Motor In the Pump Motor submenu select the direction that you would like the selected Ink Pump Motor to run and then press the OK key XX PUMP MOTOR NORMAL The different directions that you can run the Ink Pump Motor are as follows Stop Stops the Motor running B Normal Runs the Motor in the normal direction E Reverse Turns the Motor in the reverse direction CP Hitec ade 3 You will need to confirm that you want to run the selected Ink Pump Motor in the selected direction by pressing the OK key XX PUMP MOTOR NORMAL OK 4 To stop the Ink Pump Motor turning select Stop in the Pump Motor submenu and then press the OK key XX PUMP MOTOR STOP invent SYSTEM INF This menu can be used to print various information pages The different options available in this menu are as follows E System Print Pag
122. ft 18 Remove the Roller from the Roller Shaft Drive Unit Timing Belt Removal 1 Remove the Media Feed Drive Unit Assembly Page 8 165 or the TUR Drive Unit Assembly Page 8 169 2 Remove four screws that secure the side cover to the Drive Unit Assembly 3 Remove the side cover from the Drive Unit Assembly Rr a son 4 Remove four screws that secure the top cover to the Drive Unit Assembly 5 Remove the top cover from the Drive Unit Assembly 6 Remove four screws that secure the Top Drive Motor Cover to the Drive Unit Assembly invent 7 Remove the Top Drive Motor Cover from the Drive Unit Assembly 8 Remove four screws that secure the Bottom Drive Motor Cover to the Drive Unit Assembly 9 Remove the Bottom Drive Motor Cover from the Drive Unit Assembly A Rr a son 10 Remove the three Bearings from the shatts 11 Loosen four screws that secure the Drive Motor Bracket to the Drive Unit Assembly 12 Remove the Timing Belt that needs to be replaced from the Drive Unit Assembly Media Sensors Media End Media Slack and Take Up Reel Removal Media End Slack Light Emission Units 1 Remove two screws that secure the Sensor Cover to the Drive Unit Assembly 2 Remove the Sensor Cover from the Drive Unit Assembly UD Rr ni son 3 Disconnect the two connectors for the Media End Slack
123. ft Ink Cartridge Door and remove ALL 3 Cleaning Liquid Cartridges OPEN L INKCOVER REMOVE CARTRIDGE Once the Cleaning Liquid Cartridges have been removed install a Purging Cartridge in to each slot and close the Left Ink Cartridge Door LOAD PURGING CAR CLOSE L INKCOVER If the Printer detects that a Purging Cartridge has been installed incorrectly or if an invalid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Purging Cartridge has been installed correctly before you can continue OPEN L INKCOVER LOAD PURGING CAR LOAD XX SLOT LOAD XX SLOT When the following message is displayed on the Front Panel open the Right Ink Cartridge Door and remove ALL 3 Cleaning Liquid Cartridges OPEN INKCOVER REMOVE CARTRIDGE Once the Cleaning Liquid Cartridges have been removed install a Purging Cartridge in to each slot and close the Right Ink Cartridge Door LOAD PURGING CAR CLOSE R INKCOVER If the Printer detects that a Purging Cartridge has been installed incorrectly or if an invalid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Purging Cartridge has been installed correctly before you can continue OPEN INKCOVER LOAD PURGING CAR LOAD XX SLOT LOAD XX SLOT The Cleaning Liquid purge process will start and you will need to recheck whethe
124. g Cartridges have been removed install a used Cleaning Liquid Cartridge in to each slot and close the Right Ink Cartridge Door LOAD CL CART CLOSE R INKCOVER CP Hitec ade 50 Ifthe Printer detects that a Cleaning Liquid Cartridge has been installed incorrectly or if any of the Cleaning Liquid Cartridges contain less than 500cc of liquid or if an invalid Cleaning Liquid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Cleaning Liquid Cartridge has been installed correctly before you can continue OPEN INKCOVER LOAD CL CART LOAD XX SLOT LOAD XX SLOT LOAD USED CL CART LOAD XX SLOT 51 The Sub Tank priming process will start and you will need to recheck whether the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked PRIME SUBTANK BOTTLE OK 52 The Printer will extract the Sub Tank and the following message will be displayed on the Front Panel PURCING XXX 53 Once the Clean Ink System process has been completed the Front Panel will return to the Ink System Opt submenu INK SYSTEM OPT gt CLEAN INK SYS 54 Remove the Cleaning Liquid Cartridges from the Printer 55 Install normal Ink Cartridges into the Printer and perform the Charge Ink System procedure Page 4 23 Ink Charge Done This option allows you to check or indicate wh
125. g Units and the Printheads O 2 P 7 Enter the deviation measured using the and W keys to change the digits and the and P keys to select the digits If the Printheads are on the right side of the Capping Units then enter a value and if the Printheads are on the left side of the Capping then enter a value CAP POSITION 0 3 mm Value Value pP ug 8 Press the OK key once you have entered the deviation value 9 Open the Rear Cover and close it again so that the Carriage adjusts itself in relation to the Capping Station 10 Check again that the center of the Capping Units are aligned with the center of the Printheads If they are still not aligned then repeat the procedure from step 6 11 Once the Capping position is aligned move the Carriage Assembly to the Home Position Page 4 18 or power Off and On the Printer Line Sensor Calibration Side Margin This calibration allows you to correct the value for the side margin position This calibration must be performed whenever ine Sensor is disassembled or replaced Black Printhead is disassembled or replaced Perform the Side Margin Position Calibration as follows Enter into the Maintenance Mode Page 4 7 Print the Adjust Pattern Page 4 10 Measure the side margin using a ruler If the distance measured is more or less than 5 mm then the side marg
126. g side you will need to adjust the position of the Idle Unit as explained in step 5 5 Loosen four screws that secure the Idle Unit on the wiping side and adjust Idle Unit until the distance from the Printer Stand to the center of the Main Scroller is the same as the distance measured in step 2 6 Tighten the screws loosened in the previous step Vertical Adjustment Perform the Vertical Adjustment on the Media Feed or Take Up Reel Unit as follows 1 Tie a piece of string around the Main Scroller on the Capping Side and pass it through the paper entry path 2 Pull the string tight and mark the point where it crosses the Cutter Groove on the Center Platen CA Asia ard rons 3 Slide the string across to the Wiping Side and check that the point marked in step 2 is aligned with the Cutter Groove in the Center Platen III LII a a eee ee wee ene s a es T m T oe ee EAE eee es E Uam LA NL NL h Nr 1 B A T m aom Cam Le oc nt x Te Se ot 0 Lo wA 4 Ifthe point marked in step 2 is either above or below the Cutter Groove you will need to adjust the position of the Idle Unit as explained in step 5 5 Loosen one screw on each side of the Idle Unit and turn the Bolt to adjust the height of th
127. g the OK key NVRAM INIT OK 5 In the Setup submenu scroll to Restore and press OK key RESTORE NVRAM gt 6 You will need to confirm that you want to restore the NVRAM contents by pressing the OK key RESTORE NVRAM OK 7 Power Off the Printer wait a few seconds and then power the Printer On again invent Head Relay Board Removal 1 Remove the Electronics Module Cover gt Page 8 2 2 Remove five screws that secure the Main PCA Tray to the Printer from the rear 3 Remove three screws that secure the Main PCA Tray to the front of the Printer 4 Disconnect ALL the cables connected to the Main PCA Rr a son 5 Disconnect ALL the cables connected to the Add On Control PCA no need to disconnect cables connected between the Add On Control PCA and the Switching Power Supply Unit 6 Remove one screw that secures the Grounding Strip and disconnect the cable from the Switching Power Supply Unit 7 Remove the Main PCA Tray from the Printer invent 8 Remove four screws that secure the Head Relay Board to the Main PCA 9 Remove the Head Relay Board from the Main PCA Rr a son Add On HEB2 Control PCA Removal 1 Remove the Electronics Module Cover gt Page 8 2 2 Remove five screws that secure the Main PCA Tray to the Printer from the rear 3 Remove three scre
128. ge Door LOAD PURGING CAR CLOSE L INKCOVER 6 10 n 12 If the Printer detects that a Purging Cartridge has been installed incorrectly or if an invalid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Purging Cartridge has been installed correctly before you can continue OPEN L INKCOVER LOAD PURGING CAR LOAD XX SLOT LOAD XX SLOT When the following message is displayed on the Front Panel open the Right Ink Cartridge Door and remove ALL 3 Ink Cartridges OPEN INKCOVER REMOVE CARTRIDGE Once the Ink Cartridges have been removed install a Purging Cartridge in to each slot and close the Right Ink Cartridge Door LOAD PURGING CAR CLOSE R INKCOVER If the Printer detects that a Purging Cartridge has been installed incorrectly or if an invalid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Purging Cartridge has been installed correctly before you can continue OPEN INKCOVER LOAD PURGING CAR LOAD XX SLOT LOAD XX SLOT The Ink extraction process will start and you will need to recheck whether the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked START PURGING BOTTLE OK The Printer will purge the ink which could take at least 10 minutes a
129. hange the digits and the and P keys to select the digits If the Printheads are on the right side of the Wiper Blades then enter a value and if the Printheads are on the left side of the Wiper Blades then enter a value WIPE POSITION 0 5 mm alue 9 Press the OK key once you have entered the deviation value 10 Check again that the center of the Wiper Blades are aligned with the center of the Printheads If they are still not aligned then repeat the procedure from step 4 11 Once the Wiping position is aligned clean the edges of the Wiper Blades with a swab dipped in Wiping Liquid CA Aisi ard iratos Capping Position Calibration This calibration must be performed whenever Capping Station is disassembled or replaced Capping Unit is disassembled or replaced Perform the Capping Position Calibration as follows 1 Enter into the Maintenance Mode Page 4 7 2 Move the Carriage Assembly to the Capping Station if not already at the Capping Station Page 4 18 3 If the Printheads are capped uncap them Page 4 43 4 Enter into the Cap Position Menu Page 4 13 CAP POSITION gt 0 0 mm 5 Visually check that the center of the Capping Units are aligned with the center of the Printheads Printhead Capping Unit 6 If the center of the Capping Units are not aligned with the center of the Printheads you will need to visually estimate the deviation between the Cappin
130. he error continues replace the Paper Axis or Scan Axis Motors invent Heater Error Problem Description Corrective Action Heater Error Problem Description Corrective Action Heater Error Problem Description Corrective Action Heater Error Problem Description Corrective Action Syste Error Codes Heater Error Codes A Heater Error Code appears on the Heater Panel when a component of the Heater has failed during normal usage Each Heater Error Code and it s appropriate corrective actions are explained on the following pages Heater Error System Error Abnormal operation of the Heater Relay Assembly Try the following Replace the Heater Relay Assembly Page 8 52 Heater Error HO2 Relay Board Error The Heater Board and the Relay Board are not connected together Try the following B Make sure that the Heater Board is connected correctly to the Relay Board via the Relay Cable Replace the Heater Relay Assembly Page 8 52 Heater Error HO3 Front Heater Temperature Error Temperature read by the Front Heater is abnormal lower than 10 C or higher than 70 C Try the following Make sure that the Heater Relay Assembly is connected correctly to the Front Heater Replace the Heater Relay Assembly Page 8 52 Replace the Front Heater Page 8 29 Heater Error H04 Rear Heater Temperature Error Temperature read by the Rear Heater is abnorma
131. hort circuit of the Feed Motor Replace the Add On HEB2 Control PCA Page 8 45 System Error 1280 Take Up Reel Motor Error Over current problem in the Take Up Reel Motor Drive Circuit Try the following Check the short circuit of the internal cable of the Feed Take Up Reel Motor and Take Up Reel Motor Relay Cable Check the short circuit of the Take Up Reel Motor Replace the Add On HEB2 Control Page 8 45 System Error 1290 End of Life of Part Reached The end of life of the Prime Assembly has been reached since it has been working for more than 58 hours Try the following E Replace the Prime Assembly Page 8 121 System Error Problem Description Corrective Action invent System Error 170X Servo Motor Error x 0 Feed System x Carriage System x 2 Servo Unit The Paper Axis or the Scan Axis Motor moves the Carriage but the input from the Linear Encoder Sensor does not change Try the following Make sure that there is no paper jam blocking the Carriage path Make sure that the corresponding cables are connected correctly to Connectors CN14 and CN17 on the Main PCA Make sure that the Linear Encoder Sensor Cable is connected correctly to the Carriage PCA Make sure that the Encoder Strip is not damaged or scratched Make sure that the pinchwheels rotate correctly Make sure that the Carriage gears work correctly Replace the Main PCA Page 8 36 If t
132. ia that is wrinkled 5 Make sure that the media type selected in the Front Panel is the same as the media type loaded into the Printer 6 Make sure that the Center Platen is not stained with ink since this could be transferred to the printed image Part of Image is Missing at the Start of the Print Corrective Action 1 There might be a problem between the Printer and Computer Check the cable between the computer and the Printer to make sure it is not damaged and is connected correctly 2 Make sure 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 invent Print Quality is not Improved After Printhead Recovery Corrective Action Perform the Daily Maintenance procedure Page 9 3 Repeat the Printhead Recovery procedure Page 9 11 and reprint the image Print the Nozzle Check pattern and check if there any nozzles missing If there are several nozzles missing and the Printhead Recovery procedure has not improved the print quality then it might be necessary to replace the failing Printhead Color Density Irregularities at the Edges of the Media Corrective Action Check the temperature of the Heaters to make sure that they are not set too low If necessary raise the temperature of the Heaters and reprint the image If raising the temperature of the heaters does not solve th
133. ics Module Cover Page 8 2 2 Remove four screws that secure the Power Supply Unit to the Printer from the rear 3 Remove three screws that secure the Power Supply Unit to the Printer from the front 4 Disconnect ALL the cables connected to the Power Supply Unit 5 Remove the Power Supply Unit from the Printer invent Heater Relay Assembly Removal 1 Remove the Electronics Module Cover gt Page 8 2 2 Remove three screws that secure the Heater Relay Assembly Tray to the Printer from the rear 3 Disconnect ALL the cables from the Heater Relay Assembly except for the long black and white cable 4 Remove two screws that secure the Heater Relay Assembly to the Printer UD Rr a son 5 Pull out slightly the Heater Relay Assembly from the Printer 6 Remove two screws that secure the black and white cable with the red sleeves to the relay 7 Release the black and white cable from the relay and remove the Heater Relay Assembly from the Printer invent Waste Bottle Sensor Removal 1 Remove the Waste Ink Bottle from the Printer 2 Remove two screws that secure the Waste Bottle Locking Bracket 3 Disconnect the Waste Bottle Sensor Cable Rr a son 4 Turn the Waste Bottle Bracket 180 degrees and remove two screws that secure the Waste Bottle Sensor to the Bracket 5 Remove the Waste Bottle Sensor f
134. ile is sent when the Printer is in the Offline state invent Troubleshooting Media Jam Messages There are three different messages that appear on the Front Panel if a media Jam occurs in the Printer B Warning 0 Clear Media Jam B Warning 1 Clear Media Jam B Warning 2 Clear Media Jam Warning 0 Clear Media Jam Over current has been detected in the use of the Paper Axis Motor Try the following 1 Open the Rear Cover and check for any visible obstacles in the paper path If there is a wrinkled mass of paper inside the paper path lift the Pinchwheels using the Media Lever and clear the obstruction 2 Check the Tension Bar to make sure that it is not applying too much weight on the Media check the User s Guide for information on the correct usage of the Tension Bars 3 If sticky media is being used then either use different media or use it with the Liner 4 Clean the Drive Roller and make sure that there is no paper dust or other dirt trapped around the Drive Roller 5 Check the tension of the Paper Axis Belt and adjust it if necessary gt Page 5 14 If this problem continues replace the Paper Axis Motor Page 8 68 Warning 1 Clear Media Jam Over current has been detected in the use of the Scan Axis Motor Try the following 1 Open the Rear Cover and check for any visible obstacles in the paper path If there is a wrinkled mass of paper inside the paper path lift the Pinchwheels usi
135. in value will need to be changed Measure this distance Printing Direction Enter into the LS Adj Side Val Menu Page 4 14 LS ADJ SIDE VAL gt 0 0 mm Determine the side margin value to be entered by subtracting the distance measured from the specitied side margin value of 5 mm For example if the distance measured was 7 mm then you subtract 7 mm from 5 mm and you get a result of 2 mm If the distance measured was 2 mm then you subtract 2 mm from 5 mm and you get a result of 3 mm Enter the side margin value using the and keys to change the digits and lt and P keys to select the digits LS ADJ SIDE VAL 3 0 mm Press the OK key once you have entered the side margin value invent Line Sensor Calibration Top Margin This calibration allows you to correct the value for the top margin position This calibration must be performed whenever ine Sensor is disassembled or replaced Black Printhead is disassembled or replaced Perform the Top Margin Position Calibration as follows Enter into the Maintenance Mode Page 4 7 Print the Adjust Pattern Page 4 10 Measure the top margin using a ruler If the distance measured is more or less than 5 mm then the top margin value will need to be changed Printing Enter into the LS Adj Top Val Menu Page 4 14 Measure this distance LS ADJ TOP VAL gt 0 0 mm Determine the t
136. justment must be performed whenever Carriage Assembly is disassembled or replaced Center Platen is disassembled or replaced For this adjustment you will need the Carriage Height Adjustment Tools You must first check the Carriage height and only if it is out of the accepted limits you must adjust the Carriage height Before you check the Carriage Height you must do the following Make sure that the Media Load Lever is in the lower position and that the Media Pressure Lever is set in the Normal position Enter the Heater Panel Maintenance Mode and the activate the Heater Test Page 4 90 Set the temperature of the Heaters at 45 C Front 40 C Center and 45 C Rear Check the Carriage Height Check the Carriage height as follows Move the Carriage Assembly to the middle of the Center Platen so that it is positioned between the 6th and 7th screw position on the center Platen 2 Remove the Carriage Shields from both sides of the Carriage Assembly the Printhead height is actually in the lower position Make sure you loosen the two Printhead Height Adjustment screws before trying to change the position of the Printhead Height Lever 4 Identify the four positions that will be used to measure the Carriage height the image below shows the Carriage viewed from underneath CA Aisi libros 5 Before starting to measure the Carriage height you should become familiar with the Ca
137. ket from the Printer Removal and Installation QJ invent 8 Release ALL the cables from the cable clips 9 Remove four screws that secure the metal plate to the chassis 10 Remove the metal plate from the chassis Rr a non 11 Remove two screws that secure the metal cover to the side of the Printer 12 Remove two screws that secure the metal cover to the front of the Printer 13 Pull the metal cover down slightly so that the Priming Tubes are exposed 14 Carefully cut Waste Tube at the point indicated 15 Disconnect or unscrew and discard the cut part of the Waste Tube including Tube Joint and the O Ring from the Capping Tubes Bracket 16 Remove the Waste Ink Bottle from the Printer invent 17 Disconnect the Waste Bottle Sensor Cable 18 Remove three screws that secure the Waste Bottle Holder to the Drive Unit 19 Remove the Waste Bottle Holder and Assembly from the Drive Unit Installation 1 Connect screw the Tube Joint and the O Ring into the Capping Tubes Bracket 2 Pass the Waste Tube through the hole in the metal cover containing the foam 3 Connect the Waste Tube to the Tube Joint Rr a son Wiping Station Assembly Removal 1 Remove the Upper Side Cover Left Page 8 4 2 Remove the Top Side Cover Left Page 8 5 3 Remove the Lower Side Cover Left
138. l lower than 10 C or higher than 709C Try the following B Make sure that the Heater Relay Assembly is connected correctly to the Rear Heater Replace the Heater Relay Assembly Page 8 52 Replace the Rear Heater Page 8 32 Heater Error Problem Description Corrective Action Heater Error Problem Description Corrective Action Heater Error Problem Description Corrective Action invent Heater Error HO5 Center Heater Temperature Error Temperature read by the Center Heater is abnormal lower than 10 C or higher than 709C Try the following Make sure that the Heater Relay Assembly is connected correctly to the Center Platen Replace the Heater Relay Assembly Page 8 52 Replace the Center Platen gt Page 8 34 Heater Error HO6 Front Heater Time out Error The temperature of the Front Heater does not reach the preset temperature even after 15 minutes Try the following Make sure that the Voltage alternation switch located at the back of the Printer is set correctly to the AC voltage being used Make sure that the Fuse F2 on the Heater Relay Assembly has not blown If the fuse has blown replace it B Make sure that the Heater Board is connected correctly to the Relay Board via the Relay Cable Make sure that the Heater Relay Assembly is connected correctly to the Front Heater Replace the Heater Relay Assembly Page 8 52 Re
139. lated to the Pump Tube YY relates to the ink color YY PUMP TUBE gt 000125000sec 2 Use the and keys to change the digits and use the and P keys to select the digits YY PUMP TUBE gt 000153000sec 3 Press the OK key once you have entered the new usage amount 4 If the Pump Tube counter needs to be reset return to the Counter submenu scroll to Reset YY Pump and press the OK key RESET YY PUMP gt 5 You will need to confirm that you want to reset the counter by pressing the OK key RESET YY PUMP OK Wiper Cleaning This option allows you to view and change the date of when the Wiper Cleaning Assembly was last replaced 1 In the Counter submenu scroll to Wiper Cleaning and press the OK key to view the date of when the Wiper Cleaning Assembly was last replaced WIPER CLEANING gt 05 05 08 Use the and keys to change the digits and use the and P keys to select the digits WIPER CLEANING Format Year Month Day gt 05 06 06 Press the OK key once you have entered the new date If the Wiper Cleaning date needs to be reset to today s date return to the Counter submenu scroll to Reset Wipe Clean and press the OK key RESET WIPE CLEAN gt You will need to confirm that you want to reset the date by pressing the OK key RESET WIPE CLEAN OK Wiper Belt This option allows you to view and change the date of when the Wiper Belt was
140. le below If the correct voltages are not supplied then replace the Power Supply Unit Page 8 45 t is possible that this error occurred because of a faulty Main PCA Replace the Main PCA Page 8 36 Check whether the motors have been short circuited by testing 24 V If 24 V is not supplied then replace both Scan Axis Paper Axis Motors If error continues replace the Main PCA Page 8 36 Measuring Position on the Main PCA TP93 TP33 35 00 V to 37 00 V Sistem ror codes Boot Up Error Problem Description Corrective Action Boot Up Error Problem Description Corrective Action Add On HEB2 Control PCA 2000 Problems with the Add On HEB2 Control PCA detected Try the following Make sure the HEB2 Board Interface Cable is connected correctly and is not damaged E Replace the Add On HEB2 Control PCA Page 8 45 f the error continues replace the Main Page 8 36 Cap Position Adjustment Value 4000 This error appears when the Cap Position Adjustment Value is set to zero Try the following To clear this error Turn the Printer ON in error skip mode by holding down the Cancel and Shift keys and pressing the ON button Enter the Password to enter the Maintenance Mode menu P Shift and OK Set the correct Cap Position value so that it is not set at 0 0 mm Page 4 13 System Error Problem Description Corrective
141. llows you to view and change the usage counter related to the Capping Units 1 In the Counter submenu scroll to Capping Unit and press the OK key to view the usage counter related to the Capping Units CAPPING UNIT gt 0057800 2 Use the and keys to change the digits and use the and P keys to select the digits CAPPING UNIT gt 0045400 3 Press the OK key once you have entered the new usage amount 4 Ifthe Capping Unit counter needs to be reset return to the Counter submenu scroll to Reset Cap Unit and press the OK key RESET CAP UNIT gt 5 You will need to confirm that you want to reset the counter by pressing the OK key RESET CAP UNIT OK Scan Axis Belt This option allows you to view and change the usage counter related to the Scan Axis Belt 1 In the Counter submenu scroll to Scan Axis Belt and press the OK key to view the usage counter related to the Scan Axis Belt SCAN AXIS BELT gt 0057800 2 Use and W keys to change digits and use the and P keys to select the digits SCAN AXIS BELT 0045400 Press the OK key once you have entered the new usage amount If the Scan Axis Belt counter needs to be reset return to the Counter submenu scroll to Reset Scan Belt and press the OK key RESET SCAN BELT gt You will need to confirm that you want to reset the counter by pressing the OK key RESET
142. m running onto electrical components or circuits or through openings in the enclosure Electrostatic Discharge Refer to the beginning of Chapter 4of 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 Service Manual HP Designjet 100005 Series Printers invent invent Using this Manual Purpose This Service Manual contains information necessary to test calibrate and service HP Designjet 100005 Series Printers Model Q6693A For information about using these printers refer to the corresponding User Guide Readership The procedures described in this Service Manual are to be performed by HP Certified service personnel only Part Nu
143. m the Platen Flatness Adjustment as follows 1 Move the Carriage to the Capping Station turn Off the Printer from the switch at the rear of the Printer if not already done so 2 Remove the Rear Heater Page 8 32 3 Remove the sponges from both ends of the Printer 4 Remove two screws that secure the Sponge Plate from both ends of the Printer invent 6 Remove one screw that secures the Grounding Strip and Bracket at the wiping end of the Printer Remove the Bracket from the Printer 8 Disconnect the connectors from ALL the Vacuum Fans and from the Media Sensor DU invent and Calibrations 9 Remove the screws securing the 5 Mounting Brackets Mounting Bracket 10 11 Disconnect the connectors of the Heater Power Supply and the Temperature Sensor for the Center Platen 12 Remove ALL the screws that secure the Vacuum Fan Mounting Plate invent 13 Remove the Vacuum Fan Mounting Plate from the Printer Vacuum Fan Mounting Plate p 14 Connect the connectors of the Heater Power Supply and the Temperature Sensor for the Center Platen Also connect a Dummy Sensor to the connector of the Temperature Sensor for the Rear Heater 15 Turn On the Printer 16 Enter the Heater Panel Maintenance Mode and the activate the Heater Test gt Page 4 90 Set the temperature of the Heaters at 45 C Front 40 C Center and 45 C Rear invent
144. mbers 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 Safety Precautions The following Warnings and Cautions are presented in this Service Manual and must be observed Follow the instructions marked with these symbols Failure to follow the guidelines marked TAD with this symbol could result in severe WAHNING personal injury or death Failure to follow the guidelines marked CAUTION with this symbol could result in minor TI personal injury or product and or peripheral damage U3 invent WARNING ejeje Inks used in the printer and liquids in the HP Cleaning and Maintenance kits contain an organic solvent ethylene glycol monobutyl ether acetate CAS No 112 072 Observe all local state and federal regulations related to the handling use storage and disposal of organic solvents Avoid contact between ink and skin eyes and clothing Immediately wash skin with soapy water Remove clothing soaked with ink from contact with skin Use an approved eye wash station if ink is splashed into eyes and consult a doctor if necessary If an approved eye wash station is unavailable flush eyes with cold water and consult a doctor if necessary Be sure the printer is well grounded Failure to g
145. move the Carriage to the Wiping Station making sure that the Carriage does not hit the Wiping Station There should be a slight gap between the Carriage and the Wiping Station invent Wiper Belt Tension Adjustment This adjustment must be performed whenever B Wiper Blade is disassembled or replaced B Wiper Belts are disassembled or replaced Perform the Wiper Belt Height Adjustment as follows 1 Make sure that the Wiper Belts are correctly installed 2 Tighten or loosen the Tension screw on both sides of the Wiping Station for each Wiper Belt until the remaining length of the screw is 13 mm invent Wiper Blade Height Adjustment This adjustment must be performed whenever Wiping Station is disassembled or replaced B Wiper Blade is disassembled or replaced B Wiper Belts are disassembled or replaced Perform the Wiper Blade Height Adjustment as follows 1 Make sure that the Wiping Station and the Wiper Belts are correctly installed and adjusted 2 Make sure that the Wiper Blade is correctly installed 4 Make sure that the Printhead Height Lever is in the upper position so that Printhead height is actually in the lower position Make sure you loosen the two Printhead Height Adjustment screws before trying to change the position of the Printhead Height Lever j j fes te 2 p D iia ard iratos 5 Loosen four screws that secure the Wip
146. n one screw from each side of the Subtank Station 7 Remove one screw from each side of the Subtank Station 8 Carefully pull out the Subtank Station slightly 9 Remove eight screws that secure the metal plate to the Subtank Station 10 Remove the metal plate from the Subtank Station 11 Remove the Sensor Plate from the Subtank Station 12 Disconnect Subtank Sensor cables 13 Remove two screws that secure the Subtank Sensors Assembly to the Subtank Station 14 Remove the Subtank Sensors Assembly from the Subtank Station invent 15 Unclip the Sensors from the Subtank Sensors Assembly Capping Station Assembly Removal 1 Uncap the Carriage and move it to the Wiping Station 2 Remove the Upper Side Cover Right gt Page 8 4 3 Remove the Upper Side Cover Right Page 8 4 4 Remove the Top Side Cover Right Page 8 5 5 Remove the Lower Side Cover Right gt Page 8 8 6 Remove the Lower Capping Cover Page 8 7 Remove Capping Door Page 8 13 8 Remove two screws that secure the metal bracket to the chassis on the Capping Side 9 Remove the metal bracket from the Printer Rr a son 10 Release ALL the cables from the cable clips 11 Remove four screws that secure the metal plate to the chassis 12 Remove the metal plate from the chassis invent
147. n press the OK key CAP STAT MOTOR STOP invent Wiping Station Motor This option allows you to control the Wiping Station Motor In the Motors submenu scroll to Wipe Stat Motor and press the OK key WIPE STAT MOTOR gt STOP In the Wipe Stat Motor submenu select the direction that you would like the Wiping Station Motor to run and then press the OK key WIPE STAT MOTOR NORMAL The different directions that you can run the Wiping Station Motor are as follows Stop Stops the Motor running B Normal Runs the Motor in the normal direction E Reverse Turns the Motor in the reverse direction You will need to confirm that you want to run the Wiping Station Motor in the selected direction by pressing the OK key WIPE STAT MOTOR NORMAL OK To stop the Wiping Station Motor turning select Stop in the Wipe Stat Motor submenu and then press the OK key WIPE STAT MOTOR STOP Solenoid Left or Right This option allows you to control the Solenoid left or right In the Motors submenu scroll to Solenoid L or Solenoid R and press the OK key SOLENOID L gt CLOSED In the Solenoid submenu select Open to start the selected Solenoid and then press the OK key SOLENOID L OPEN CP Hitec ade 3 You will need to confirm that you want to start the selected Solenoid by pressing the OK key SOLENOID L OPEN OK 4 To s
148. nd remove ALL 3 Purging Cartridges OPEN R INKCOVER LOAD CL CART Once the Purging Cartridges have been removed install a used Cleaning Liquid Cartridge in to each slot and close the Right Ink Cartridge Door LOAD CL CART CLOSE R INKCOVER If the Printer detects that a Cleaning Liquid Cartridge has been installed incorrectly or if any of the Cleaning Liquid Cartridges contain less than 500cc of liquid or if an invalid Cleaning Liquid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Cleaning Liquid Cartridge has been installed correctly before you can continue OPEN INKCOVER LOAD CL CART LOAD XX SLOT LOAD XX SLOT LOAD NEW CL CART LOAD XX SLOT The Cleaning Liquid charge process will start and you will need to recheck whether the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked START FILLING CL BOTTLE OK The Printer will charge the Cleaning Liquid and the following message will be displayed on the Front Panel FILLING CL XXX Once the Cleaning Liquid has been charged the Printheads and the Sub Tank will be flushed and the following message will be displayed FLUSHING XXX CP Hitec ade 37 38 39 40 41 42 43 Once the printheads and the Sub Tank have been flushed the following message will be displayed on the Front Panel Open the Le
149. nd the following message will be displayed on the Front Panel PURGING XXX Once the ink has been purged from the system the following message will be displayed on the Front Panel Open the Left Ink Cartridge Door and remove ALL 3 Purging Cartridges OPEN L INKCOVER LOAD SL CART CP rites ade 13 14 15 16 17 Once the Purging Cartridges have been removed install a NEW Storage Liquid Cartridge in to each slot and close the Left Ink Cartridge Door LOAD SL CART CLOSE L INKCOVER If the Printer detects that a Storage Liquid Cartridge has been installed incorrectly or if any of the Storage Liquid Cartridges contain less than 500cc of liquid or if an invalid Storage Liquid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Storage Liquid Cartridge has been installed correctly before you can continue OPEN L INKCOVER LOAD SL CART LOAD XX SLOT LOAD XX SLOT LOAD NEW SL CART LOAD XX SLOT When the following message is displayed on the Front Panel open the Right Ink Cartridge Door and remove ALL 3 Purging Cartridges OPEN INKCOVER LOAD SL CART Once the Purging Cartridges have been removed install a NEW Storage Liquid Cartridge in to each slot and close the Right Ink Cartridge Door LOAD SL CART CLOSE R INKCOVER If the Printer detects that a Storage Liquid Cartridge has been installed incorrectly or if a
150. nding direction 1 Outer winding direction ME Sensor Displays the status of the Media End Sensor 0 Sensor blocked 1 Sensor not blocked B loose Displays the status of the Media Slack Sensor 1 Sensor blocked O 2 Sensor not blocked B Feeder SW Displays the status of the Black Media Feed Switch on the Media Feed Drive Unit 1 Switch not pressed O Switch pressed Winder SW Displays the status of White Media Rewind Switch on the Media Feed Drive Unit 1 Switch not pressed O Switch pressed 4 If you would like to exit the Media Supply Reel Sensors submenu first press the Cancel key and then press key TUR Sensors This option allows you to check the status of the sensors related to the Take Up Reel in real time so that faulty sensors can be replaced as necessary In the Sensors submenu scroll to TUR Sensors and press P key TUR SENSORS BACKWARDS In the TUR Sensors submenu select the Sensor that you would like to test and press the OK key If you would like to exit the TUR Sensors submenu press the lt key TUR SENSORS UPPER gt The Front Panel will show the status of the selected Sensor By activating and deactivating the selected Sensor the status will change and a buzzer will make a sound TUR SENSORS UPPER O The Sensors that can be tested in this menu are as follows ma cv Wb Forwards Switch Backward
151. nel to the Printer 7 Remove the Heater Panel from the Printer Rr a son Front Heater Removal 1 Remove the Upper Side Cover Left Page 8 4 2 Remove the Lower Side Cover Left Page 8 8 3 Remove the Subtank Side Cover Left Page 8 9 4 Carefully pull out the Left Subtank Station slightly Page 8 115 5 Remove three screws that secure the Sub Scroller Holder to the Printer 6 Remove the Sub Scroller Holder from the Printer cA Remove one screw from either side of the Printer Remove seven screws that secure the bottom of the Front Heater to the Printer 9 Pull out the Front Heater slightly 7 8 UD Rr a son 10 Disconnect the Front Heater Cables from the Front Heater Tl Remove the Front Heater including the white net from the Printer Rear Heater Removal invent 1 Loosen the screw that secures each Tension Bar Holder and remove the five Holders from the Printer 2 Loosen nine screws that secure the bottom of the Rear Heater to the Printer 3 Remove 11 screws that secure the top of the Rear Heater to the Printer Rr a son 4 Pull out the Rear Heater slightly 5 Disconnect the Rear Heater Cables from the Rear Heater 6 Remove the Rear Heater including the white net from the Printer invent Center Platen Removal 1 Remove the Rear Heater Page 8 32
152. ng the Media Lever and clear the obstruction N Check the Ink Supply Tubes Rail to make sure that it is correctly positioned if not correctly positioned it could cause extra friction on the Carriage Check the tension of the Carriage Belt and adjust it if necessary Check the Encoder Strip to make sure that it is not dirty or damaged Check the Slider Rod to make sure that it not dirty Check the tension of the Scan Axis Belt and adjust it if necessary Page 5 12 XO UO A W If this problem continues replace the Scan Axis Motor gt Page 8 72 Warning 2 Clear Media Jam This problem could be caused by a firmware error Try the following 1 Switch the Printer OFF and ON again and check if the message still appears rubles ting Media Jams Occur Frequently Make sure that the paper type setting matches the type of paper loaded into the Printer Open the Rear Cover and check for any visible obstacles in the paper path If there is a wrinkled mass of paper inside the paper path lift the Pinchwheels using the Media Lever and clear the obstruction Make sure that the Vacuum Fans are working correctly Print Speed is Very Slow Make sure that the Printer is being used at temperatures of 20 C or higher No Ink Message when there is Enough Ink Make sure that the Ink Cartridge is installed correctly Check that the connector in the Ink Cartridge is NOT damaged Make sure that the Ink Cartridge Sensors are
153. nit of the Take Up reel Sensor and install it on the third hole from the top of the Mounting Bracket Light Emission Unit 23 Install the Sensor Cover and secure with two screws Sensor Cover invent Platen Flatness Measurement and Adjustment This measurement and adjustment is necessary to ensure that the center Platen is completely flat within given tolerances The flatness of the Center Platen should first be measured to check if it is out of the given tolerances and only then should it be adjusted This adjustment must be performed whenever Center Platen or Media Drive Roller is disassembled or replaced B There is a higher level of ink spray due to Center Platen not being flat Using the Carriage Height Tools to Measure Platen Flatness Before ordering the Platen Flatness Adjustment Tools to measure the Platen Flatness it is possible to use the Carriage Height Adjustment Tools to measure the Platen Flatness along the Printer You should refer to Page 5 5 for more detailed information on how to perform the Carriage Height Adjustment 1 Check the Carriage height along the complete Center Platen in every screw position 11 positions in total starting from the Capping side 2 You should only measure one side of the Carriage positions 1 and 3 so there is no need to measure positions 2 and 4 Include the values measured in a table as shown below 3 For each row take the minimum and maximum value
154. nnot 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 Model and Serial Number of the printer Which firmware revision the printer is using The complete error number E The Service Configuration Print The Current configuration sheet Which software application the customer is using name version Sistem ror codes Self Diagnostic Errors at Power On When the Printer is powered up it performs the Boot Up sequence which initializes the major components of the Printer If for some reason the Boot Up sequence fails because a component has failed to initialize an error code will appear on the Front Panel INITIALIZING E Ennnn The Boot Up error codes are hexa decimal based numbers and correspond to bits which are explained in the following table emdEM _ 3 9 MEM 99 m 8 900 NMCON mme KA _ 95 m es HN When multiple errors occur during the Boot Up sequence the error codes are added together and only one hexa decimal figure is displayed on the Front Panel For example if the NVRAM and the Power Supply foil during the Boot Up sequence the error code E0810 will be displayed NVRAM 0010 Power Supply 0800 0810 Each error code and it s appropriate corrective actions are explained on the following pages Boot Up Error Problem Des
155. nstalled B M Ink Cart Displays the status of the Magenta Ink Cartridge Sensor 0 Ink Cartridge installed 1 Ink Cartridge not installed B C Ink Cart Displays the status of the Cyan Ink Cartridge Sensor 0 Ink Cartridge installed 1 Ink Cartridge not installed B Inkcover L Displays the status of the Left Ink Cartridge Door Sensor 0 Closed 1 Open B Inkcover R Displays the status of the Right Ink Cartridge Door Sensor 0 Closed 1 Open If you would like to exit the Ink Sensor submenu first press the Cancel key and then press key Sub Tank Sensor This option allows you to check the status of the sensors related to the Sub Tank system in real time so that faulty sensors can be replaced as necessary In the Sensors submenu scroll to Sub Tank Sensor and press P key SUB TANK SENSOR K FULL In the Sub Tank Sensor submenu select the Sensor that you would like to test and press the OK key If you would like to exit the Sub Tank Sensor submenu press the key SUB TANK SENSOR K FULL gt The Front Panel will show the status of the selected Sensor By activating and deactivating the selected Sensor the status will change and a buzzer will make a sound SUB TANK SENSOR K FULL O The Sensors that can be tested in this menu are as follows B K Full Displays the status of the Black Sub Tank Full Sensor m Full Displays the status of the Light Mag
156. nter 3 Remove the Top Side Cover from the Printer Cover Removal 1 Remove the Rear Cover Page 8 3 2 Remove the Upper Side Cover Left and Right Page 8 4 3 Remove the Top Side Cover left and Right Page 8 5 4 Remove seven screws that secure the Top Cover to the left hand side of the Printer 5 Remove nine screws that secure the Top Cover to the right hand side of the Printer 6 Remove the Top Cover from the Printer invent Lower Side Cover Left or Right Removal 1 Open the Ink Cartridge Door and remove two screws that secure the metal cover to the Ink Supply Station Remove the metal cover from the Ink Supply Station 2 Remove two screws that secure the Lower Side Cover to the Printer 3 Remove the Lower Side Cover from the Printer invent Subtank Cover Left or Right Removal 1 Remove the Upper Side Cover Left or Right Page 8 4 2 Remove the Lower Side Cover Left or Right Page 8 8 3 Remove two screws that secure the Electronics Module Side Trim to the Printer 4 Remove the Electronics Module Side Trim from the Printer 5 Remove two screws that secure the Subtank Cover to the Printer invent 6 Remove two screws that secure the Subtank Cover to the Printer 7 Remove the Subtank Cover from the Printer 0000000000000 0smednivslaon L
157. ny of the Storage Liquid Cartridges contain less than 500cc of liquid or if an invalid Storage Liquid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Storage Liquid Cartridge has been installed correctly before you can continue OPEN R INKCOVER LOAD SL CART LOAD XX SLOT LOAD XX SLOT LOAD NEW SL CART LOAD XX SLOT 18 19 20 21 22 23 24 invent The Storage Liquid charge process will start and you will need to recheck whether the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked START FILLING SL BOTTLE OK The Printer will charge the Storage Liquid and the following message will be displayed on the Front Panel FILLING SL Once the Storage Liquid has been charged the following message will be displayed on the Front Panel Open the Left Ink Cartridge Door and remove ALL 3 Storage Liquid Cartridges OPEN L INKCOVER REMOVE CARTRIDGE Once the Storage Liquid Cartridges have been removed install a Purging Cartridge in to each slot and close the Left Ink Cartridge Door LOAD PURGING CAR CLOSE L INKCOVER If the Printer detects that a Purging Cartridge has been installed incorrectly or if an invalid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Purging Car
158. o perform the following Make sure that the NVRAM and the Main PCA have been installed correctly Press the Cancel key and Power On button in order to skip the system check Enter into the Maintenance Mode Page 4 7 Press the Shift key once and then lt key to enter in to the Setup menu In the Setup submenu scroll to NVRAM Init and press the OK key NVRAM INIT gt You will need to confirm that you want to initialize the NVRAM by pressing the OK key NVRAM INIT OK In the Setup submenu scroll to Language and press the OK key LANGUAGE gt ENGLISH In the Language submenu select English or Japanese and press the OK key LANGUAGE ENGLISH Power Off the Printer Press the Cancel and Shift keys and Power On button in order to skip the error recovery check of the Printer Perform the Line Sensor Test Page 4 53 to register the platen s maximum value read by the Line Sensor to the NVRAM automatically Power Off the Printer wait a few seconds and power On the Printer again You will need to check and if necessary perform the following Wiping Position Calibration Page 5 55 Capping Position Calibration Page 5 57 Printhead Voltage Page 4 22 Printhead Row Value Page 4 19 Printhead to Printhead Value Page 4 19 Bidirection Definitions Page 4 27 Media Advance Print Page 4 17 sees 14 15 16 17 18 19 20 Side Margin
159. o switch between the parameters and to change the value of the digits Use the 4 and P keys to move between the digits when entering a parameter Use the OK key to confirm the parameter Use the Cancel key to cancel the parameter without changing it and return to the menu selection level Exiting Maintenance Mode Use the Online key at anytime to immediately exit the Maintenance Mode invent P ADJ Printer Adjustment This menu contains the necessary options to set the adjustment parameters of the Printer so that it functions correctly The different options available in this menu are as follows Adjust Print Page 4 10 Media Advance Print Page 4 17 Manufacturing Print 1 Page 4 13 Cap Position gt Page 4 13 Wipe Position Page 4 13 Line Sensor Adjust Top Value Page 4 14 Line Sensor Adjust Side Value Page 4 14 Media Advance Value Page 4 15 Back Adjust Print gt Page 4 15 Back Adjust Value Page 4 16 To enter in to the Printer Adjustment menu enter in to the Maintenance Mode and press the amp key lt gt _ e SA 60 sm Press the Up Arrow Key to select Adjust Print This option allows you to print an adjustment print that is then used to calibrate the Line Sensor 1 In the Printer Adjustment submenu scroll to Adjust Print and press the OK key ADJUST PRINT LS ADJ PRINT 2 Inthe Adjust Print submenu scroll to LS Adj
160. o the Printer after more than 2 weeks When returning to the Printer a Printhead recovery procedure will need to be done using the Ink System Cleaning Kit together with the Printhead Wash option to clean the Ink System from the maintenance liquid Once the Ink System is cleaned the Ink Charge option is used to refill the Ink System with regular ink After returning to the Printer after leaving it switched Off for more than 2 weeks perform the following Daily Maintenance Page 9 3 B Clean Ink System gt Page 4 33 Charge Ink Page 4 23 In order to perform the Clean Ink System procedure you will need the HP 790 Ink System Cleaning Kit part number CB296A This kit includes Six Ink System Purging Cartridges Six Ink System Cleaning Liquid Cartridges invent If the Printer is Switched Off for less than 2 weeks If a customer accidently leaves the Printer switched Off for less than 2 weeks they will be able to recover the Printheads if the nozzles have been blocked with dried ink The success of recovering the Printheads will depend on how long the Printer has been left switched Off If the Printer has been switched Off for longer than 2 weeks it could mean the replacement of some or ALL of the Printheads After returning to the Printer after leaving it switched Off for less than 2 weeks perform the following Daily Maintenance gt Page 9 3 B Clean Ink System Page 4 33 Charge
161. o the results obtained from the Printhead Adjustment Print 1 In the Printhead Adjustment submenu scroll to Bi Def L xxxxxx and press the gt key BI DEF L xxxxxx K 2 Inthe Bi Def L submenu select the color of the Printhead that you would like to adjust and press the OK key If you would like to exit the Bi Det L submenu press the key K 400 Set Bidir Media The different colors of the Printheads are as follows B K Black B Lm Light Magenta B Light Cyan B Y Yellow B M Magenta B C Cyan 3 Use the and keys to change the digits and use the lt and P keys to select the digits The numerical value can be changed in a range of 32 to 31 1 unit 1 dofl BI DEF L xxxxxx gt K gt 02 4 Press the OK key once you have entered the new value invent Printhead Voltage This option allows you to enter the drive voltage value for each Printhead 1 In the Printhead Adjustment submenu scroll to PH Voltage and press the P key PH VOLTAGE K L 2 In the PH Voltage submenu select the color of the Printhead either left or right for which you would like to set the Printhead Voltage and press the OK key If you would like to exit the PH Voltage submenu press the key PH VOLTAGE 1 gt 16 0V The different colors of the Printheads are as follows B K Black B Lm Light Magenta B Light Cyan B Y Yellow B M M
162. om the Printer UJ invent Drive Unit Rollers Removal 1 Remove the Media Feed Drive Unit Assembly Page 8 165 or the TUR Drive Unit Assembly Page 8 169 2 Remove two screws that secure the Sensor Cover to the Drive Unit Assembly 3 Remove the Sensor Cover from the Drive Unit Assembly 4 Disconnect the cables from the Sensors UJ invent 5 Remove one screw that secures the Sensor Bracket to the Drive Unit Assembly 6 Remove the Sensor Bracket including the Sensors from the Drive Unit Assembly 7 Remove two screws that secure the left Roller Cover to the Drive Unit Assembly invent 8 Remove the left Roller Cover from the Drive Unit Assembly 9 Remove two screws that secure the right Roller Cover to the Drive Unit Assembly 10 Remove the right Roller Cover from the Drive Unit Assembly UJ invent Tl Remove three screws that secure the top Roller Cover to the Drive Unit Assembly 12 Remove the top Roller Cover from the Drive Unit Assembly 13 Remove five screws that secure the side Roller Cover to the Drive Unit Assembly invent 14 Remove the side Roller Cover from the Drive Unit Assembly 15 Remove the Bearing from the Roller Shaft 16 Remove the Black Ring from the Roller Shaft invent 17 Using an Allen Key loosen the two screws that secure the Roller to the Roller Sha
163. on Center Moves the Carriage to the center of the Printer Wipe Moves the Carriage to the wiping position You will need to confirm that you want to move the Carriage to the selected position by pressing the OK key MOVE CARRIAGE WIPE OK CP Hitec ade Printhead Row Value This option allows you to adjust the left and right position of each Printhead by entering the correction values according to the results obtained from the Printhead Adjustment Print 1 In the Printhead Adjustment submenu scroll to PH Row Val and press the P key PH ROW VAL 2 In the PH Row Val submenu select the color of the Printhead that you would like to adjust and press the OK key If you would like to exit the PH Row Val submenu press the key PH ROW VAL K gt 00 The different colors of the Printheads are as follows K Black Lm Light Magenta Le Light Cyan Y Yellow M Magenta C Cyan 3 Use the and keys to change the digits and use the and P keys to select the digits The numerical value can be changed in a range of 32 to 31 1 unit 1 del PH ROW VAL le gt 04 4 Press the OK key once you have entered the new value Printhead to Printhead Value This option allows you to adjust the Printhead position in the main scanning direction of each head by entering the correction values according to the results obtained from the Printhead Adjustment P
164. ons 5 While tensioning the Timing Belts tighten the bottom two screws in order to secure the Drive Unit Motor Make sure that these covers are installed before tensioning the Timing Belts 6 Remove the Top Drive Motor Cover and tighten the top two screws that secure the Drive Unit Motor 7 Re install all the covers invent Wiping Station Height Adjustment This adjustment must be performed whenever Wiping Station is disassembled or replaced Perform the Wiping Station Height Adjustment as follows 1 Make sure that the Wiping Station is correctly installed 2 Remove the Carriage Shields from both sides of the Carriage Assembly 5 K 3 Make sure that the Printhead Height Lever is in the upper position so that Printhead height is actually in the lower position Make sure you loosen the two Printhead Height Adjustment screws before trying to change the position of the Printhead Height Lever CA Aisa ard iratos 5 Remove the Black Cover that is stuck over the hole in the Wiping Station Se We La 2 7 Adjust the Wiping Station so that it is level with the aluminum frame piece on the left rear of the Wiping Station Make sure that the Wiping Station is as level as possible before tightening the screws in the next step 8 Tighten the five screws that you loosened in the previous steps and insert black cover removed in step 5 9 Gently
165. op margin value to be entered by subtracting the distance measured from the specified side margin value of 5 mm For example if the distance measured was 8 mm then you subtract 8 mm from 5 mm and you get a result of 3 mm If the distance measured was 3 mm then you subtract 3 mm from 5 mm and you get a result of 2 mm Enter the top margin value using the and keys to change the digits and the lt and P keys to select the digits LS ADJ TOP VAL 2 0 mm Press the OK key once you have entered the top margin value invent Print Quality Print Quality 6 2 Print Quality Troubleshooting Actions 6 2 Print Quality General Advice 6 2 Troubleshooting Print Quality Problems 6 5 Horizontal Lines Across the Image Banding 6 5 Images are Blurred 6 6 Bleeding Repelling or Mottling Problems 6 6 Image is Completely Blank or Faded 6 6 Output Only Contains a Partial Print 6 7 The Printer Area is Stained 6 7 Part of Image is Missing at the Start of the Print 6 7 Print Quality is not Improved After Printhead Recovery 6 8 Troubleshooting Printhead Problems 6 9 HP Designjet 100005 Series Printer Service Manual 6 1 Print Quality invent Print Quality Troubleshooting Actions When faced with a Print Quality problem perform the following actions in order to resolve the problem Printer Configuration Check that the media type selected in the Front Panel is the same as the media type loaded into the P
166. ower Capping Cover Removal 1 Remove the Upper Side Cover Right gt Page 8 4 2 Remove the Lower Side Cover Right Page 8 8 3 Open the Capping Door 4 Remove three screws that secure the Lower Capping Cover to the Printer 5 Remove one screw that secures the Lower Capping Cover to the Printer _ 6 Remove the Lower Capping Cover from the Printer 0smednivslaon Capping Door Removal 1 Remove the Upper Side Cover Right Page 8 4 2 Remove the Lower Side Cover Right Page 8 8 3 Open the Window 4 Open the Capping Door 5 Remove one screw that secures the Capping Door hinge to the Printer invent 6 Remove the Hinge from the Printer 7 Slide the Capping Door to the left and remove from the Printer Rr a son Lower Wiping Cover Removal 1 Remove the Upper Side Cover Left Page 8 4 2 Remove the Lower Side Cover Left Page 8 8 3 Open the Wiping Door 4 Remove three screws that secure the Lower Wiping Cover to the Printer B5 Remove one screw that secures the Lower Wiping Cover to the Printer 6 Remove the Lower Wiping Cover from the Printer Rr a son Wiping Door Removal 1 Remove the Upper Side Cover Left Page 8 4 2 Remove the Lower Side Cover Left Page 8 8 3 Open the Window 4 Open the Wiping Door 5 Remove one
167. own below Capping Height Screws Pp 7 Adjust the height of the Capping Station so that at least three Capping Height screws are touching the top part of the capping Station 8 While holding the Capping Station in position tighten the screws that you loosened in the previous steps 9 Remove the four Capping Height Screws from the Carriage DU aii ard lios Printhead Capping Limit Adjustment This adjustment is necessary in order to stop the Capping Units from pushing against the Printheads too much This adjustment must be performed whenever Capping Station is disassembled or replaced Perform the Printhead Capping Limit Adjustment as follows 1 Make sure that the Capping Station is correctly installed 2 Uncap the Carriage Assembly Page 4 18 3 Make sure that the Printhead Height Lever is in the lower position so that Printhead height is actually in the upper position Make sure you loosen the two Printhead Height Adjustment screws before trying to change the position of the Printhead Height Lever Bon JJ GM 5 Lower each Limit Plate until the bearing attached to the Plate almost touches the Limit Brackets on the Capping Station The space between the Bearing and the Limit Brackets should be between 0 3 and 0 5 mm ML Ji 6 Tighten the screws that secure the Plates Limit Bracket invent Carriage Shield Height Adjustment This adjustment must be performed
168. ping Cover Page 8 15 7 Remove the Wiping Door Page 8 17 8 Remove two screws that secure the metal bracket to the chassis on the Capping Side 9 Remove the metal bracket from the Printer 10 Remove one screw from each side of Solenoid Assembly 11 Rotate the Solenoid Assembly so that the Right Rear Cover Sensor can be accessed 12 Disconnect the Cable from the Right Rear Cover Sensor UD Rr a son 13 Loosen two screws that secure the Sensor Plate and the Right Rear Cover Sensor to the Chassis 14 Remove the Sensor Plate from the Printer 15 Remove two screws that secure the Right Rear Cover Sensor to the Chassis Remove the Right Rear Cover Sensor 16 Loosen two screws that secure the Sensor Plate and the Left Rear Cover Sensor to the Chassis 17 Remove the Sensor Plate from the Printer 18 Remove two screws that secure the Left Rear Cover Sensor to the Chassis 19 Disconnect the Sensor Cable from the Right Rear Cover Sensor and remove from the Printer Home Position Sensor Removal 1 Remove the Upper Side Cover Right gt Page 8 4 2 Remove the Top Side Cover Right Page 8 5 3 locate the Home Position Sensor 4 Remove two screws that secure the Home Position Sensor to the Printer 5 Remove the Home Position Sensor from the Printer 6 Disconnect the Cable from
169. place the Front Heater Page 8 29 Heater Error HOZ Rear Heater Time out Error The temperature of the Rear Heater does not reach the preset temperature even after 15 minutes Try the following Make sure that the Voltage alternation switch located at the back of the Printer is set correctly to the AC voltage being used Make sure that the Fuse F2 on the Heater Relay Assembly has not blown If the fuse has blown replace it Make sure that the Heater Board is connected correctly to the Relay Board via the Relay Cable Make sure that the Heater Relay Assembly is connected correctly to the Rear Heater Replace the Heater Relay Assembly Page 8 52 Replace the Rear Heater Page 8 32 Sistem ror codes Heater Error Problem Description Corrective Action Heater Error Problem Description Corrective Action Heater Error Problem Description Corrective Action Heater Error HO8 Center Heater Time out Error The temperature of the Center Heater does not reach the preset temperature even alter 15 minutes Try the following Make sure that the Voltage alternation switch located at the back of the Printer is set correctly to the AC voltage being used Make sure that the Fuse F2 on the Heater Relay Assembly has not blown If the fuse has blown replace it B Make sure that the Heater Board is connected correctly to the Relay Board via the Relay Cable Mak
170. r Path Assemblies 7 16 Media Entry Assemblies 7 18 Take Up Reel Assemblies 7 20 Capping Assemblies 7 22 Wiping Assemblies 7 24 Ink Supply and Subtank Assemblies 7 26 Printer Stand and Waste Bottle 7 28 Media Feed and TUR Sensors 7 30 Accessories 7 32 Service Tools 7 34 HP Designjet 100005 Series Printer Service Manual invent Right Hand Covers Right Hand Covers Reference HP Part Number Quantity Description Comments on Drawing Q6665 60011 Top Side Cover Q6693 60003 Upper Side Cover Q6665 60008 Lower Side Cover Q6665 60005 Capping Door Q6665 60006 Lower Capping Cover Q6693 60004 Right Subtank Cover Q6665 60014 Right Ink Cartridge Door Q6665 60016 Side Ink Cartridge Cover Q6693 60007 Right Rear Ink Cartridge Cover invent Figure 1 Right Hand Covers invent Left Hand Covers Left Hand Covers Reference HP Part Number Quantity Description Comments on Drawing Q6665 60011 Top Side Cover Q6665 60007 Upper Side Cover Q6665 60008 Lower Side Cover Q6693 60001 Wiping Door Q6665 60003 Lower Wiping Cover Q6693 60005 Left Subtank Cover Q6665 60015 Lett Ink Cartridge Door Q6665 60016 Side Ink Cartridge Cover Q6665 60081 Left Rear Ink Cartridge Cover Figure 2 Left Hand Covers mese M Center Covers Center Covers Reference HP Part Number Quantity Description Comments on Drawing Top Cover Electronics Module Cover Firmw
171. r the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked START PURGING BOTTLE OK 44 45 46 47 48 49 The Printer will extract the Cleaning Liquid which could take at least 10 minutes and the following message will be displayed on the Front Panel PURGING XXX Once the Cleaning Liquid has been purged from the system the following message will be displayed on the Front Panel Open the Left Ink Cartridge Door and remove ALL 3 Purging Cartridges OPEN L INKCOVER LOAD CL CART Once the Purging Cartridges have been removed install a used Cleaning Liquid Cartridge in to each slot and close the Left Ink Cartridge Door LOAD CL CART CLOSE L INKCOVER If the Printer detects that a Cleaning Liquid Cartridge has been installed incorrectly or if any of the Cleaning Liquid Cartridges contain less than 500cc of liquid or if an invalid Cleaning Liquid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Cleaning Liquid Cartridge has been installed correctly before you can continue OPEN L INKCOVER LOAD XX SLOT LOAD CL CART LOAD XX SLOT LOAD USED CL CART LOAD XX SLOT When the following message is displayed on the Front Panel open the Right Ink Cartridge Door and remove ALL 3 Purging Cartridges OPEN R INKCOVER LOAD CL CART Once the Purgin
172. re version of the Heater 1 In the Setup submenu scroll to Heater FW Ver and press the OK key Version Number XX Add On HEB2 Control PCA Version This option allows you to view the version of the Add On HEB2 Control PCA 1 In the Setup submenu scroll to HEB Ver and press the OK key Version Number Heater Upgrade This option allows you to update the firmware version of the Heater 1 In the Setup submenu scroll to Heater Upgrade and press the OK key HEATER UPGRADE gt 2 You will need to confirm that you want to upgrade the firmware version of the Heater by pressing the OK key HEATER UPGRADE OK CP rites ade 3 You will need to insert the IC Card containing the latest version of the firmware into the Main PCA Press the OK key once the IC Card has been inserted INSERT IC CARD OK 4 The Printer will start upgrading the Heater firmware and the following message will appear on the Front Panel Flashes while the firmware is being updated UPGRADING PLEASE WAIT 5 Once the upgrade has been completed the following message will appear on the Front Panel UPGRADE FINISHED POWER OFF ON 6 Power Off the Printer and power it On again and check the Heater firmware version once the Printer has initialized Page 4 50 The following messages could appear during the Heater firmware upgrade procedure The Printer does
173. respond then replace the corresponding Ink Supply Station Page 8 110 Enter the Motors Menu in Maintenance Mode and set the X Pump Motor option to Normal to drive the Ink Supply Motor When the Sub Tank is already full it will not be checked and therefore ink should be discharged Once the motor drive has been checked set it Stop immediately Repeat the process with the other colors If any Ink Supply Motor fails then replace the corresponding Ink Supply Station gt Page 8 110 Replace the Main Page 8 36 System Error System Error 125x Sub Tank Supply Error Problem The Sub Tank Sensor does not switch to less than half even though ink has been Description consumed B x 0 Printhead Number 1 Black B x 1 Printhead Number 2 Light Magenta B x 2 Printhead Number Light Cyan B x 3 Printhead Number 4 Yellow E x 4 Printhead Number 5 Magenta B x 5 Printhead Number 6 Cyan Corrective Action Try the following Enter the Motors Menu in Maintenance Mode and set the Solenoid L and Solenoid R options to Closed to cut the outside air Now set the Cap Stat Motor to Prime to discharge the ink from the Sub Tank and check if the Ink Supply Motor drives by turning the power ON again when there is a little bit of ink left If the Motor is not driven replace the corresponding Cable or Ink Supply Station Check whether the Sub Tank Sensor Plate works correctly and is not blocked
174. rform the recovery process by pumping ink through the Printheads and performing the wiping procedure in order to unblock any nozzles that could be blocked During the recovery process the following message will be displayed on the Front Panel PH RECOVERY EXECUTING XXX Once the recovery process has finished the Front Panel will return to the following screen PH RECOVERY gt NORMAL ALL When Leaving the Printer Off for more than 2 weeks It is important to remember that the Printer should not be switched Off so that the Printer can automatically trigger the internal Printhead maintenance procedures to prevent the Printheads from failing But there might be certain circumstances where the Printer needs to be switched Off for a long period of time In order to do this the customer must follow the storage procedure using the HP 790 Ink System Storage Kit together with the internal storage option This procedure replaces the ink from the Ink System with a lower solvent liquid which will maintain the health of the Printheads preventing them from failing Before leaving the printer switched Off for more than 2 weeks perform the Store Ink System procedure Page 4 27 In order to perform the Service Clean procedure you will need the HP 790 Ink System Storage Kit part number CB297A This kit includes Six Ink System Purging Cartridges Six Ink System Storage Liquid Cartridges When Returning t
175. rint 1 In the Printhead Adjustment submenu scroll to PH to PH Val and press the P key PH TO PH VAL Maintenance Mode invent 2 Inthe PH to PH Val submenu select the color of the Printhead that you would like to adjust and press the OK key If you would like to exit the PH to PH Val submenu press the key PH TO PH VAL Zim gt 00 The different colors of the Printheads are as follows B Lm Light Magenta B Light Cyan B Y Yellow B Magenta B C Cyan 3 Use the and keys to change the digits and use the and P keys to select the digits The numerical value can be changed in a range of 32 to 31 1 unit 1 dot PH TO PH VAL gt 03 4 Press OK key once you have entered the new value Set Bidirection Media This option allows you to select the target media that will be used to adjust the Bidirectional values media selected here will be used in the Bidirection Definition 1 In the Printhead Adjustment submenu scroll to Set Bidir Media and press the OK key SET BIDIR MEDIA MNFG 2 Inthe Set Bidir Media submenu scroll to the media that you would like to use for Bidirection adjustment and press the OK key SET BIDIR MEDIA PAPER CE Bites ade Bidirection Definition This option allows you to adjust the lett Bidirection position of each head for the selected media by entering the correction values according t
176. rinter B Make sure that the correct adjustments have been made for each media Perform the Printhead Recovery procedure Media Select the correct media type through the front panel when loading it Make sure that HP or HP approved media is being used Check that original HP Ink Cartridges are being used in the Printer Check if the latest version of the firmware is installed If not install the latest firmware revision For further information refer directly to the Troubleshooting section that covers the different Print Quality problems Print Quality General Advice Performing the Daily Maintenance ensures that the Printheads stay in a good condition and the nozzles don t get blocked Make sure that the media type selected in the Front Panel is the same as the media type loaded into the Printer Roll media usually gives better Print Quality than a single sheet of the same type of media The most appropriate print quality settings must be used for the current purpose 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 Remember that certain print quality problems can be solved by E Performing the Printhead Recovery procedure Adjusting the Media Advance invent Using the IQ Print to Troubleshoot The IQ Print can be used to check for Print Quality problem
177. rom the Carriage PCA Remove two screws that secure the Encoder Sensor UD Rr a son 7 Remove the Encoder Sensor from the Printer Removal and Installation DU invent Line Sensor Removal 1 Open the Rear Cover 2 Remove one screw that secures the Line Sensor Cable clip 3 Disconnect the Line Sensor Cable from the Carriage PCA 4 Release the Line Sensor Cable from the cable clips 8 106 HP Designjet 100005 Series Printer Service Manual Rr a son 5 Remove one screw that secures the Line Sensor to the Carriage PCA 6 Remove the Line Sensor from the Printer invent Ink Pump Assembly Removal 1 Purge the Ink from the Printer Page 4 25 Once the ink has been purged switch Off the Printer 2 Remove the Rear Ink Cartridge Cover Left or Right Page 8 20 3 Cut the cable tie that secures the Ink Pump Tube 4 Disconnect the Ink Pump Assembly cables 5 Carefully disconnect the Ink Pump Tube as shown Rr a son 6 Remove two screws that secure the Ink Pump Tube Bracket 7 Remove three screws that secure the Ink Pump Assembly to the Printer 8 Remove the Ink Pump Assembly from the Printer invent Ink Supply Station Left or Right Removal 1 Purge the Ink from the Printer Page 4 25 Once the ink has been purged switch Off the Printer 2 Remove the Lower Side
178. rom the Bracket Front Media Sensor Removal 1 Remove the Front Heater Page 8 29 2 Disconnect the Front Media Sensor Cable 3 Remove one screw that secure the Cable Holder to the Printer 4 Remove one screw that secures the Front Media Sensor to the Bracket Rr a son 5 Remove the Front Media Sensor from the Printer Rear Media Sensor Removal 1 Remove the Rear Heater Page 8 32 loi LX CU mm 2 Disconnect the Rear Media Sensor Cable 3 Remove one screw that secures the Rear Media Sensor to the Bracket 4 Remove the Rear Media Sensor from the Printer Removal and Installation invent Media Lever Sensor Removal 1 Remove the Front Heater Page 8 29 2 Disconnect the Media Lever Sensor Cable 3 Remove one screw that secures the Media Lever Sensor to the Bracket 4 Remove the Media Lever Sensor from the Printer HP Designjet 10000s Series Printer Service Manual 9 59 5 Remove the Media Lever Sensor from the Bracket E Rr a son Rear Cover Sensor Removal 1 Remove the Upper Side Cover Left and Right Page 8 4 2 Remove the Top Side Cover Left and Right Page 8 5 3 Remove the Lower Side Cover Left and Right Page 8 8 4 Remove the Lower Capping Cover Page 8 5 Remove Capping Door Page 8 13 6 Remove the Lower Wi
179. round the printer may result in electrical shock fire and susceptibility to electromagnetic interference Ink and fluids used in the Cleaning and Maintenance Kits are combustible Do not use or store within 8 meters 25 feet of open flames sparks or other sources of ignition Switch power OFF remove the power cords from the electric outlets and allow the printer to cool before attempting to remove any panels or covers The printer contains high voltage and hot components Removal of panels or covers may result in exposure to electric shock and burns Do not allow metal or liquids except those used in HP Cleaning and Maintenance Kits to touch the internal parts of the printer Doing so may cause fire electric shock or other serious hazards When shutting down the entire system always turn OFF the printer switch as well as the heater switch breaker Use only an HP Waste Ink Bottle The bottle must be installed according to instructions or waste ink may overflow An HP Waste Ink Bottle must always be installed before turning the printer ON Automatic and manual service cycles produce waste ink that must be contained in an HP Waste Ink Bottle Always use both hands to remove and carry an HP Waste Ink Bottle Keep the HP Waste Ink Bottle upright Do not place on tables or shelves where it could fall invent Waste ink is combustible Keep an HP Waste Ink Bottle containing waste ink away from open flames sparks
180. rrect for the media currently loaded In this situation it is recommended to perform the Media Advance adjustment on the media that is currently being used Refer to the User s Guide iy Troubleshooting Print Quality Problems 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 Check that the appropriate print quality settings are being used and reprint the image 2 If not already done so perform the Printhead Recovery procedure and reprint the image with the same settings as before 3 Perform the Media Advance adjustment on the media that is currently being used Refer to the User s Guide 4 Check the temperature of the Heaters to make sure that they are not set too high high temperatures could cause the media to become sticky If necessary lower the temperature of the Heaters and reprint the image 5 Print the Nozzle Check Pattern Page 4 17 to verify if any Printhead Nozzle are missing If any missing nozzles cannot be recovered the failing Printhead may need to be replaced 6 f banding occurs unevenly across the printed image this could be caused by the misalignment between the Drive Unit and the Idle Unit either on the TUR side or the Media Feed side To correct this problem perform
181. rriage Height Adjustment Tools l 5 a Two Tools contain Hole Steps 1 thru 6 of the Tool will be used to measure the Carriage Height at positions 1 and 2 Steps A thru D of the Tool will be used to measure the Carriage Height at positions 3 and 4 There are two types of Carriage Height Adjustment Tools one with a hole and the other without a hole As the height measured may differ at positions 3 and 4 use a corresponding step of the Tool depending on the position that you would like to measure The thickness of each step is shown below 6 Insert the Carriage Height Adjustment Tool under Carriage at positions 3 and 4 as shown below lm ail i Ux 7 AA Position tool between 7 the two grooves EIR RM the Center Platen 7 Make a mark on the side of the Tool to indicate where Tool stops going under the Carriage From this mark measure 23 8 mm to locate the step that indicates the Carriage Height at that position Make a note of this step marking on tool and 2 as shown below As a guide use the 3rd screw on the Center Platen to find the correct position 9 Once the Tool stops going in make sure that it has reached the correct measuring point by moving it in the directions shown until it hits the right and left walls Once in the correct position check the Carriage height The Carri
182. rriage and move it to the Wiping Station 2 Remove the Capping Door Page 8 13 3 Remove six screws that secure the Capping Plates to the Capping Station 4 Remove the Capping Plates from the Capping Station 5 Release the Capping Unit and remove from the Capping Station Prime Assembly Remove the Upper Side Cover Right Page 8 4 Remove the Top Side Cover Right Page 8 5 Remove the Lower Side Cover Right Page 8 8 Remove the Lower Capping Cover Page 8 Remove Capping Door Page 8 13 Remove two screws that secure the metal bracket to the chassis on the Capping Side Remove the metal bracket from the Printer 8 Release ALL the cables from the cable clips 9 Remove four screws that secure the metal plate to the chassis 10 Remove the metal plate from the chassis invent 11 Remove two screws that secure the metal cover to the side of the Printer 12 Remove two screws that secure the metal cover to the front of the Printer 13 Pull the metal cover down slightly so that the Priming Tubes are exposed Rr a son 14 Disconnect the Priming Tube from both ends 15 Remove two screws that secure the Prime Assembly to the Capping Station 16 Remove the Prime Assembly from the Capping Station Solenoid Assembly Uncap the Carriage and move it to the Wiping Station R
183. rtain parameters CE Bites ade Entering the Maintenance Mode Enter in to the Maintenance Mode as follows 1 When the Printer Ready message appears on the Front Panel press the Online key to take the Printer offline PRINTER READY ROLL 64 PAPER 2 When the following screen is displayed on the Front Panel press the following keys in this order Cancel Shift Cancel Cancel AINK MEDIA REGW MEDIA M ADV gt 3 When the following screen is displayed on the Front Panel you will be requested to enter a password Press the following keys in this order amp P Shift and OK MAINTENANCE MODE PASSWORD 4 Once the password has been entered correctly you will enter in to the Maintenance Mode PH MAIN V Basic Menu Operation Menu Group Selection You can select a menu group directly with the V and P keys In order to switch between the different Maintenance Mode menus the Shift key has to be used The order of the different menus is as follows MNIFG PRN FEEDW SETUP SENSORS vom WV ELECT MOTORS SYSTEM INF COUNTER CP Bites ade Menu Selection Use and keys to change between the menus at the same level Use key to move to a higher level menu and use the P key to move to a lower level menu Use the OK key to select a menu Parameter Setting Use the and keys t
184. rts of the Printer Secure with tape E a 13 Enter into the Ink System Options submenu and select Wash Printheads in order to charge the replaced Printhead with ink 14 Print a Nozzle Check pattern in order to verify that ink has been charged correctly into the Printhead If any of the nozzles are not firing correctly then perform a Normal Printhead Recovery and then retry the nozzle Check pattern O Rd ean Set Printhead Voltage Before the Printhead can be used to print correctly you must set the Printhead Voltage as follows You can find the Printhead Voltage values on each Printhead as shown 1 Power On the Printer and enter in to the Maintenance Mode Page 4 7 2 Press the key to enter in to the Printhead Adjustment menu In the Printhead Adjustment submenu scroll to PH Voltage and press the key PH VOLTAGE Lm L 4 n the PH Voltage submenu select the color of the Printhead either left or right for which you would like to set the Printhead Voltage and press the OK key If you would like to exit the PH Voltage submenu press the key PH VOLTAGE gt Lm L 16 0 V 5 Use the and V keys to change the digits and use the and P keys to select the digits The value can be changed in a range of 12 0 to 20 0 V in increments of V Press the OK key once you have entered the new value PH VOLTAGE gt Lm L gt 17 6 V in
185. s HP Designjet 100005 Series Printer Service Manual 7 27 Printer Stand and Waste Bottle Printer Stand and Waste Bottle Reference HP Part Number Quantity Description Comments on Drawing Figure 14 Printer Stand and Waste Bottle Media Feed TUR Sensors Media Feed and TUR Sensors Reference HP Part Number Quantity Description Comments on Drawing Media Sensor Kit Includes 2 Receiving Units and 2 Emitting Units Parts and Diagrams Figure 15 Media Feed and TUR Sensors HP Designjet 10000s Series Printer Service Manual 31 invent Accessories Accessories Reference HP Part Number Quantity Description Comments on Drawing Q6693 60047 Main Scroller Q6693 60048 Sub Scroller Q6693 60049 Tension Bar Kit Q6693 60054 Foot Switch Q6693 60057 Sub Scroller Holder Assembly Q6693 60055 Flange Spacer Q6693 60056 Flange Stopper 8 0669360041 Subscroller Flange ee Q6693 60040 Edge Guard Kit when using a Liner x Q6693 60042 Edge Guard Kit for Dual Roll Printing Q6693 60046 Liner Separator Bar Set p 0669360052 Paper Tube Flanges Kit x Q6693 60053 Paper Set Gauge p Q6693 60058 Flange Joint C7790 60425 USB Cable 5 m These parts are contained in boxes that measure at least 3 meters so should be dispatched directly from the parts stock to the customer Figure 16 Accessories
186. s like banding and can be used to isolate the root cause of the problem 1 When the Printer Ready message appears on the Front Panel press the Online key to take the Printer offline PRINTER READY ROLL 64 PAPER 2 When the following screen is displayed on the Front Panel press the Shift key twice AINK MEDIA REG W MEDIA M ADV gt 3 When the following screen is displayed on the Front Panel press the key to enter into the Adjust Menu A PRINTER SETUP V ADJUST 4 In the Adjust submenu scroll to Test Prints and press the OK key TEST PRINTS gt IQ PRINT 5 n the Test Prints submenu scroll to IQ Print and press the OK key TEST PRINTS IQ PRINT 6 You will need to confirm that you want to print the IQ Print by pressing the OK key TEST PRINTS IQ PRINT OK 7 The Printer will start to print the IQ Print and the following message will appear on the Front Panel TEST PRINTS EXECUTING If problems are found in the Test print try the following Banding in One or Several Colors If the problem detected is banding in one or several colors it is more than likely that the nozzles are either blocked or misfiring In this situation it is recommended to perform the Printhead Recovery procedure Refer to the User s Guide Banding in ALL the Colors If the problem detected is banding across ALL the colors it is more than likely that the feed adjust is not co
187. s Switch B Backwards Displays the status of the Backwards Direction Switch on the TUR Drive Unit O 2 Switch activated 1 2 Switch deactivated Forwards Displays the status of the Forwards Direction Switch on the TUR Drive Unit O 2 Switch activated 1 Switch deactivated B Upper Displays the status of the Upper TUR Sensor Sensor blocked 1 Sensor not blocked lower Displays the status of the Lower TUR Sensor 1 Sensor blocked O Sensor not blocked B Feeder SW Displays the status of the White TUR Feed Switch on the TUR Drive Unit 1 Switch not pressed O Switch pressed Winder SW Displays the status of Black TUR Rewind Switch on the TUR Drive Unit 1 Switch not pressed O Switch pressed It you would like to exit the TUR Sensors submenu first press the Cancel key and then press key CP Hitec ade Temperature Sensors This option allows you to check the status of the temperature sensors located in the Printer in real time so that faulty sensors can be replaced as necessary 1 Inthe Sensors submenu scroll to Temp Sensors and press P key TEMP SENSORS AMBIENT 2 In the Temp Sensors submenu select the Sensor that you would like to test and press the OK key If you would like to exit the Temp Sensors submenu press the key TEMP SENSORS AMBIENT gt 3 The Front Panel will show the temperature read by the selected Sensor TEMP SE
188. s and use the lt and P keys to select the digits The value can be changed in a range of 5 0 to 5 0 mm CAP POSITION 0 3 mm 3 Press the OK key once you have entered the new value Wipe Position This option allows you to correct the value of the wiping position In the Printer Adjustment submenu scroll to Wipe Position and press the OK key WIPE POSITION gt 40 0 mm 2 Use the and keys to change the digits and use the and P keys to select the digits The value can be changed in a range of 5 0 to 5 0 mm WIPE POSITION 0 5 mm 3 Press the OK key once you have entered the new value invent Line Sensor Adjust Top Value This option allows you to correct the value for the Line Sensor top margin position according to the print results of the Adjust Print 1 In the Printer Adjustment submenu scroll to LS Adj Top Val and press the OK key LS ADJ TOP VAL gt 0 0 mm 2 Use the and keys to change digits and use the lt and P keys to select the digits The value can be changed in a range of 5 0 to 5 0 mm LS ADJ TOP VAL 0 8 mm 3 Press the OK key once you have entered the new value Line Sensor Adjust Side Value This option allows you to correct the value for the Line Sensor side margin position according to the print results of the Adjust Print 1 In the Printer Adjustment submenu scroll to LS Adj Side
189. s in the Printer The different options available in this menu are as follows Flash ROM Page 4 60 PIO Page 4 01 NVRAM Page 4 62 Ink EEPROM Page 4 63 AIG Page 4 63 DRAM Page 4 64 RSM Page 4 65 PTC Page 4 65 PDD Page 4 66 HEB Page 4 66 ALL Page 4 68 VDD Page 4 68 Front Panel Page 4 69 To enter in to the Electronics menu enter in to the Maintenance Mode and press the Shift key twice and then the key Press the Left Arrow Key to select Flash ROM This option allows you to test the Flash ROM contained in the Main PCA 1 In the Elect submenu scroll to Flash ROM and press the OK key 2 You will need to confirm that you want to test the Flash ROM by pressing the OK key FLASH ROM OK FLASH ROM gt CP Hitec ade 3 While the Flash ROM is being tested the following message will be displayed on the Front Panel FLASH ROM EXECUTING If the Flash ROM test passes the Front Panel will display the following message FLASH ROM If the Flash ROM test fails the Front Panel will display the following message FLASH ROM FLASH ERR If the Flash ROM test fails try the following E Replace the Main Page 8 36 PIO Parallel Input Output This option allows you to test the Parallel Input Output contained in the Main PCA In the Elect submenu scroll to PIO and press the OK key PIO You will nee
190. s of the Wiping Door Sensor 0 Closed 1 Open If you would like to exit the Printer Sensors submenu first press the Cancel key and then press the key Ink Sensor This option allows you to check the status of the sensors related to the Ink Cartridges in real time so that faulty sensors can be replaced as necessary In the Sensors submenu scroll to Ink Sensor and press gt key INK SENSOR K INK CART In the Ink Sensor submenu select the Sensor that you would like to test and press the OK key If you would like to exit the Ink Sensor submenu press the key INK SENSOR KINK CART gt The Front Panel will show the status of the selected Sensor By activating and deactivating the selected Sensor the status will change and a buzzer will make a sound INK SENSOR K INK CART O igen Mode The Sensors that can be tested in this menu are as follows B K Ink Cart Displays the status of the Black Ink Cartridge Sensor 0 Ink Cartridge installed 1 Ink Cartridge not installed B m Ink Cart Displays the status of the Light Magenta Ink Cartridge Sensor Ink Cartridge installed 1 Ink Cartridge not installed Lc Ink Cart Displays the status of the Light Cyan Ink Cartridge Sensor Ink Cartridge installed 1 Ink Cartridge not installed Y Ink Cart Displays the status of the Yellow Ink Cartridge Sensor 0 Ink Cartridge installed 1 Ink Cartridge not i
191. screw that secures the Wiping Door hinge to the Printer invent 6 Remove the Hinge from the Printer 7 Slide the Wiping Door to the right and remove from the Printer D Removal and Installation invent Ink Cartridge Door Left or Right Removal Switch off the product and remove the power cable 1 Remove one screw that secures the Ink Cartridge Door Hinge to the Printer 2 Remove the Hinge from the Printer 3 Open the Ink Cartridge Door and remove from the Printer HP Designjet 10000s Series Printer Service Manual 8 19 Removal and Installation D invent Rear Ink Cartridge Cover Left or Right Removal Switch off the product and remove the power cable 1 Remove three screws that secure the Rear Ink Cartridge Cover to the Printer 2 Loosen one screw that secures the Rear Ink Cartridge Cover to the Printer 3 Remove the Rear Ink Cartridge Cover trom the Printer 8 20 HP Designjet 100005 Series Printer Service Manual UJ invent Removal and Installation Electronics Module Cover Removal 1 Remove two screws that secure the Left Electronics Module Side Trim to the Printer 2 Remove the Left Electronics Module Side Trim from the Printer 3 Remove two screws that secure the Right Electronics Module Side Trim to the Printer HP Designjet 100005 Series Printer Service Manual 9 21 invent 4
192. ssage will be displayed on the Front Panel Open the Left Ink Cartridge Door and remove ALL 3 Cleaning Liquid Cartridges OPEN L INKCOVER REMOVE CARTRIDGE Once the Cleaning Liquid Cartridges have been removed install a Purging Cartridge in to each slot and close the Left Ink Cartridge Door LOAD PURGING CAR CLOSE L INKCOVER If the Printer detects that a Purging Cartridge has been installed incorrectly or if an invalid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Purging Cartridge has been installed correctly before you can continue OPEN L INKCOVER LOAD PURGING CAR LOAD XX SLOT LOAD XX SLOT When the following message is displayed on the Front Panel open the Right Ink Cartridge Door and remove ALL 3 Cleaning Liquid Cartridges OPEN INKCOVER REMOVE CARTRIDGE Once the Cleaning Liquid Cartridges have been removed install a Purging Cartridge in to each slot and close the Right Ink Cartridge Door LOAD PURGING CAR CLOSE R INKCOVER CP Hitec ade 25 Ifthe Printer detects that a Purging Cartridge has been installed incorrectly or if an invalid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Purging Cartridge has been installed correctly before you can continue OPEN INKCOVER LOAD PURGING CAR LOAD XX SLOT LOAD XX SLOT 2
193. t 2 You will need to confirm that you want to restore the contents by pressing the OK key RESTORE NVRAM OK Boot Version This option allows you to view the version of the Boot ROM 1 In the Setup submenu scroll to Boot Version and press the OK key Version Number XXX Printer Firmware Version This option allows you to view the version of the Printer Firmware 1 In the Setup submenu scroll to Printer FW Ver and press the OK key PRINTER FW VER X XX Version Number Control Code Main PCA Version This option allows you to view the version of the Main PCA 1 In the Setup submenu scroll to Main PCA Ver and press the OK key Version Number XX Carriage PCA Version This option allows you to view the version of the Carriage PCA 1 In the System submenu scroll to Carriage PCA Version and press the OK key NA XX X Version Number ASIC Version This option allows you to view the version of the ASIC 1 In the Setup submenu scroll to ASIC and press the OK key XX X Version Number Heater Hardware Version This option allows you to view the hardware version of the Heater 1 In the System submenu scroll to Heater HW and press the OK key ES Ne VERS X X Version Number Heater Firmware Version This option allows you to view the firmwa
194. t Page 5 38 o mun Cou Nx Platen Flatness Measurement and Adjustment Page 5 44 Calibrations Wiping Position Calibration Page 5 55 Capping Position Calibration Page 5 57 Side Margin Position Calibration Page 5 59 Top Margin Position Calibration Page 5 60 1 2 3 4 CA Wed iratos Belt Tension Adjustment This adjustment must be performed whenever Carriage Assembly is disassembled or replaced Carriage Belt is disassembled or replaced Perform the Belt Tension Adjustment as follows 1 Make sure that the Carriage Belt is correctly installed 2 Move the Carriage to the Wiping Station and Capping Station several times to make sure that the Carriage Belt does not move vertically on the Tension Pulley If necessary adjust the slant of the Tension Pulley by tightening or loosening the screws Make sure the Belt stays in the center of the Tension Pulley 4 Using the Push Pull Gauge measure the tension in middle of the Carriage Belt The tension measured should be between 3 2 N 0 3 N between 0 300 and 0 330 kgf am n Carriage Belt Protection Block Se Push Pull Gauge 5 If the tension is below 2 9 N 0 300 kgf then you must tighten the Tension Pulley screws If the tension is above 3 5 N 0 330 kgf then you must loosen the Tension Pulley screws Tension Pulley Screws Carriage Height Adjustment This ad
195. t tighten the three screws that you loosened in step 2 Paper Axis Belt Tension Adjustment This adjustment must be performed whenever E Paper Axis Motor is disassembled or replaced E Paper Axis Belt is disassembled or replaced Pertorm the Paper Axis Belt Tension Adjustment as follows 1 Make sure that the Paper Axis Motor and Belt are correctly installed 3 LEAN 3 Hook the Push Pull Gauge onto the Paper Axis Motor Bracket and tension the Paper Axis Belt to a force of 49 0 N 2 0 N 5 0 kgf 0 2 kgf 8 Hook the Push Pull gt Gauge onto this hole CA Aisi ard iratos 4 While tensioning the Paper Axis Belt tighten the three screws that you loosened in step 2 Timing Belt for Feed TUR Unit Tension Adjustment This adjustment must be performed whenever Timing Belt for Feed TUR Unit is disassembled or replaced Perform the Timing Belt for Feed TUR Unit Tension Adjustment as follows 1 Make sure that the Timing Belts for Feed TUR Unit are correctly installed 3 Reinstall the three Bearings onto the shafts and re install the Top Drive Motor Cover and secure with four screws 4 Position a screwdriver on top of the Drive Unit Motor by passing it through a hole and then Push the Push Pull Gauge onto the Screwdriver and tension the Timing Belts to a force of 19 6 to 24 5 N 2 0 kgf to 2 5 kgf Push Pull Gauge CD Wed Calibrati
196. t Bottom Leg Covers Front and Rear Media Scroller Support Roller for Feed TUR Unit Timing Belt for Feed TUR Unit Right Tension Bar Guide Left Tension Bar Guide Discharge Brush invent Figure 10 Take Up Reel Assemblies mese M Capping Assemblies Capping Assemblies Reference HP Part Number Quantity Description Comments on Drawing Q6693 60022 Capping Station Assembly Q6665 60061 06 Capping Unit Q6665 60062 Solenoid Assembly Q6665 60063 es Prime Assembly Q6665 60024 Rear Cover Sensor d invent Figure 11 Capping Assemblies Wiping Assemblies Wiping Assemblies Reference HP Part Number Quantity Description Comments on Drawing Q6665 60064 Wiping Station Assembly Wiper Wier Bh Wiper Cleaning Assembly Rear Cover Sensor Parts and Diagrams Figure 12 Wiping Assemblies HP Designjet 100005 Series Printer Service Manual 25 Ink Supply and Subtank Assemblies Ink Supply and Subtank Assemblies Reference HP Part Number Quantity Description Comments on Drawing Q6665 60055 Right Ink Supply Station Q6665 60056 Left Ink Supply Station Q6665 60053 Ink Pump Assembly includes Ink Pump Tube Q6665 60054 es Ink Pump Tube Q6665 60057 Ink Cartridge Door Sensor Q6665 60059 6 Subtank Assembly Q6665 60058 oe Subtank Sensors Parts and Diagrams Figure 13 Ink Supply and Subtank Assemblie
197. t screws before trying to change the position of the Printhead Height Lever 6 Loosen the two screws and remove the Carriage Shields from the Carriage Assembly from the right hand side 7 Install the Flatness Measurement Gauge onto Carriage Assembly reusing the two screws used for the Carriage Shield Make sure you tighten the two screws so that the Gauge is securely positioned tomm m m E 9 umm omm e zna m Page 4 90 Set the temperature of the Heaters at 45 Front 40 Center and 45 C Rear 9 Uncap the Carriage and move it to the 6th screw position on the center Platen While moving the Carriage make sure you press down both handles of the Flatness Measurement Gauge so that the measurement pins are raised o Press down both 4 Ns handles when moving the Carriage At the 6th screw position adjust the dials of the Flatness Measurement Gauge so that the scale is set at zero CD Wed lios 11 Measure the Center Platen in every screw position 11 positions in total starting from the Capping side Measure the Platen flatness at every screw position 11 in total 12 When measuring each screw position note the value of the Back and Front positions on a piece of paper Sa Front Position 13 Before noting the values make sure you multiply read values by 10 For exampl
198. ted Description Corrective Action Try the following B When the ambient temperature is very low the Pump Motor Tube becomes hard and the load on the Capping Motor is increased Make sure that the Printer is an environment where the temperature is not below 10 C or higher than 85 C The Capping Station has a Torque Limiter for up and down operation so that the Capping Station does not experience any over current Apply grease on the shaft of the Capping Station Gear so that it helps with rotation Enter the Motors Menu in Maintenance Mode and open Solenoids L and R Access the Pump Motors and check whether the Motor Drive Circuit and Motor work correctly by manually rotating the Motor When the home position is set to O it is clear that the home position has not been adjusted and that capping is not available Make sure that the Capping Station cables are connected correctly and are not damaged B f the Capping Motor cannot be rotated replace the Capping Station gt Page 8 120 Make sure the Cap Sensor Cable is connected correctly and is not damaged E Replace the Main Page 8 36 Sistem ror codes System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error 119x Head Relay Variable Supply Error Output voltages of the Head Relay Bo
199. the Media Feed and Take Up Reel Unit Adjustment Page 5 29 invent Images are Blurred Description of problem This problem is often caused by incorrect adjustment of the Bi directional print position causing the image or text to look blurred Corrective Action Use the Printer in an environment that is less humid Make sure that the media type selected in the Front Panel is the same as the media type loaded into the Printer Check the temperature of the Heaters to make sure that they are not set too high If necessary lower the temperature of the Heaters and reprint the image Perform the Bi Directional Print Position Correction Bleeding Repelling or Mottling Problems Description of problem The problems can be described as follows Ink Bleeding can spoil the sharpness of the image and cause the text to be blurred Ink Repelling can cause the lines to be dotty or uneven Ink Mottling can cause dark lines in high density prints Corrective Action Try printing using a higher quality print mode Check the temperature of the Heaters to make sure that they are not set too high If necessary lower the temperature of the Heaters and reprint the image if you see mottling when using lower temperatures it is best fo raise the temperature Image is Completely Blank or Faded Corrective Action There might be a problem between the Printer and Computer Check the cable between the computer and the Print
200. the Printer Ready message appears on the Front Panel press the Online key to take the Printer offline PRINTER READY ROLL 64 PAPER 2 When the following screen is displayed on the Front Panel press the Shift key once AINK MEDIA REG W MEDIA 3 When the following screen is displayed the Front Panel press the 4 key to enter into the PH Recovery Menu APH MAIN PH RECOVERY 4 n the PH Recovery submenu press the OK key PH RECOVERY NORMAL ALL invent In the PH Recovery submenu select the level of recovery you would like and then press the OK key PH RECOVERY Recommended cleaning NORMAL ALL level is NORMAL The different levels of Printhead Recovery are as follows B Normal All Activates a normal recovery for all Printheads Strong All Activates a strong recovery for all colors Strong Lm Activates a strong recovery for the Black Light Magenta and Light Cyan Printheads Strong Y M C Activates a strong recovery for the Yellow Magenta and Cyan Printheads You will need to confirm that you want to perform the selected Printhead Recovery procedure by pressing the OK key PH RECOVERY OK When the following message appears on the Front Panel check whether the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked PH RECOVERY BOTTLE OK The Carriage will begin to pe
201. the Take Up Reel side Sensor Cover invent 5 Remove the Sensor Cover from the light receiving units on the Take Up Reel Unit 6 Remove the two screws that secure the upper and lower light receiving units to the Take Up Reel Unit 7 Remove the upper and lower light receiving units from the Take Up Reel Unit there is no need to disconnect them invent 8 Loosen the adjusting screw turn it counter clockwise Adjusting Screw 9 Tighten the adjusting screw clockwise gradually and then give it one full turn when the Mounting Plate for the Sensors begins to move starts to bend Mounting Plate for Sensors Adjusting Screw Re install the upper and lower light receiving units onto the Take Up Reel Unit and secure with the two screws invent 11 Remove the screw that secures the Light Emission Unit to the Mounting Bracket 12 Install the Light Emission Unit on the bottom hole of the Mounting Bracket Bottom Mounting Position 13 Enter into the Maintenance Mode Page 4 7 or with the Printer power Off press the Cancel and Shift keys and Power On button this is useful if you cannot enter the Maintenance Mode because no media is loaded Enter the password when requested gt Shift and OK 14 Enter into the TUR Sensors Menu Page 4 58 and check that both the upper and lower limit sensors receive the light the red LED lights
202. the digits and use the and P keys to select the digits MEDIA USED 0000200m Press the OK key once you have entered the new usage length CP Hitec ade 4 If the Media Used counter needs to be reset return to the Counter submenu scroll to Reset Media Used and press the OK key RESET MEDIA USED gt You will need to confirm that you want to reset the counter by pressing the OK key RESET MEDIA USED OK Prime Assembly This option allows you to view and change the usage counter related to the Prime Assemblies In the Counter submenu scroll to Prime Assy and press the OK key to view the usage counter related to the Prime Assemblies PRIME ASSY gt 000045000sec Use the and keys to change the digits and use the and P keys to select the digits PRIME ASSY gt 000053000sec Press the OK key once you have entered the new usage amount If the Prime Assembly counter needs to be reset return to the Counter submeny scroll to Reset Prime Assy and press the OK key RESET PRIME ASSY gt You will need to confirm that you want to reset the counter by pressing the OK key RESET PRIME ASSY OK invent Pump Tube This option allows you to view and change the usage counter related to the different Pump Tubes 1 In the Counter submenu scroll to YY Pump Tube and press the OK key to view the usage counter re
203. top the Pump Solenoid select Off in the Pump Solenoid submenu and then press the OK key SOLENOID L CLOSED Vacuum Fans This option allows you to control the five Vacuum Fans left left center center right or right center 1 In the Motors submenu scroll to Vacuum Fan L Vacuum Fan LC Vacuum Fan C or Vacuum Fan R C or Vacuum Fan R and press the OK key VACUUM FAN L gt OFF 2 Inthe Vacuum Fan submenu select to start the selected Vacuum Fan and then press the OK key VACUUM FAN L ON 3 You will need to confirm that you want to start the selected Vacuum Fan by pressing the OK key VACUUM FAN L ON OK 4 To stop the Vacuum Fan select Off in the Vacuum Fan submenu and then press the OK key VACUUM FAN L OFF invent Exhaust Fans This option allows you to control the Exhaust Fans In the Motors submenu scroll to Exhaust Fans and press the OK key EXHAUST FANS gt OFF In the Exhaust Fans submenu select On to start the Exhaust Fans and then press the OK key EXHAUST FANS ON You will need to confirm that you want to start the Exhaust Fans by pressing the OK key EXHAUST FANS ON OK To stop the Exhaust Fans select Off in the Exhaust Fans submenu and then press the OK key EXHAUST FANS OFF PH Cooling Fans This option allows you to control the Printhead Cooling Fans In the Motors su
204. tridge has been installed correctly before you can continue OPEN L INKCOVER LOAD PURGING CAR LOAD XX SLOT LOAD XX SLOT When the following message is displayed on the Front Panel open the Right Ink Cartridge Door and remove ALL 3 Storage Liquid Cartridges OPEN INKCOVER REMOVE CARTRIDGE Once the Storage Liquid Cartridges have been removed install a Purging Cartridge in to each slot and close the Right Ink Cartridge Door LOAD PURGING CAR CLOSE R INKCOVER CP Hitec ade 25 Ifthe Printer detects that a Purging Cartridge has been installed incorrectly or if an invalid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Purging Cartridge has been installed correctly before you can continue OPEN INKCOVER LOAD PURGING CAR LOAD XX SLOT LOAD XX SLOT 26 The Storage Liquid purge process will start and you will need to recheck whether the Waste Ink Bottle is present and is NOT full Press the OK key once the Waste Ink Bottle has been checked START PURGING BOTTLE OK 27 The Printer will extract the Storage Liquid which could take at least 10 minutes and the following message will be displayed on the Front Panel PURGING XXX 28 Once the Storage Liquid has been extracted from the system the following message will be displayed on the Front Panel Open the Left Ink Cartridge Door and remove ALL 3 Purging Car
205. tridges OPEN L INKCOVER LOAD SL CART 29 Once the Purging Cartridges have been removed install a used Storage Liquid Cartridge in to each slot and close the Left Ink Cartridge Door LOAD SL CART CLOSE L INKCOVER 30 Ifthe Printer detects that a Maintenance Liquid Cartridge has been installed incorrectly or if any of the Maintenance Liquid Cartridges contain less than 250cc of liquid or if an invalid Maintenance Liquid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to make sure that a valid Maintenance Liquid Cartridge has been installed correctly before you can continue OPEN L INKCOVER LOAD SL CART LOAD XX SLOT LOAD XX SLOT LOAD NEW SL CART LOAD XX SLOT 31 32 33 34 35 36 37 When the following message is displayed on the Front Panel open the Right Ink Cartridge Door and remove ALL 3 Purging Cartridges OPEN R INKCOVER LOAD SL CART Once the Purging Cartridges have been removed install a used Storage Liquid Cartridge in to each slot and close the Right Ink Cartridge Door LOAD SL CART CLOSE R INKCOVER If the Printer detects that a Maintenance Liquid Cartridge has been installed incorrectly or if any of the Maintenance liquid Cartridges contain less than 250cc of liquid or if an invalid Maintenance Liquid Cartridge has been installed one of the following messages will be displayed on the Front Panel You will need to
206. u scroll to DRAM and press the OK key DRAM gt You will need to confirm that you want to test the DRAM by pressing the OK key DRAM OK While the DRAM is being tested the following messages will be displayed on the Front Panel WRITE OO DRAM READ If the DRAM test passes the Front Panel will display the following message DRAM PASS CP rites ade 5 If the DRAM test fails the Front Panel will display the following message DRAM DRAM ERR If the DRAM test fails try the following E Replace the Main Page 8 36 RSM This option allows you to test the RSM contained in the Main PCA In the Elect submenu scroll to RSM and press the OK key RSM You will need to confirm that you want to test the RSM by pressing OK key RSM OK While the RSM is being tested the following message will be displayed on the Front Panel EXECUTING If the RSM test passes the Front Panel will display the following message RSM PASS If the RSM test fails the Front Panel will display the following message RSM ERR If the RSM test fails try the following E Replace the Main PCA Page 8 36 PTC This option allows you to test the PTC contained in the Carriage PCA In the Elect submenu scroll to PTC and press the OK key PIC 2 You will need to confirm that you want to test the by pressing OK
207. uid on to the Wiper Sponge using the Dropper Wiper Sponge invent Capping Unit Cleaning When the Printer Ready message appears on the Front Panel press the Online key to take the Printer offline PRINTER READY ROLL 64 PAPER When the following screen is displayed on the Front Panel press the Shift key once AINK MEDIA REG W MEDIA M ADV gt When the following screen is displayed on the Front Panel press key to enter into the PH Main Menu APH MAIN PH RECOVERY In the PH Main submenu scroll to Cap Cleaning and press the OK key CAP CLEANING gt You will need to confirm that you want to perform the Cap Cleaning procedure by pressing the OK key CAP CLEANING OK The Carriage will automatically move to the wiping side of the Printer so that the Capping Unit can easily be accessed during which the following message will be displayed on the Front Panel CARRIAGE MOVING PLEASE WAIT Reve Msinonnce 7 When the following message is displayed on the Front Panel open the Rear Cover and the Capping Door Rear Cover OPEN COVER CAP CLEANING Capping Door 9 Use the cleaning swab to clean the edges and the upper surfaces of ALL six Capping Units Capping Unit 10 After the Capping Unit has been thoroughly cleaned close the Capping Door and the Rear Cover to automatically return the Carriage to it s home position
208. vent Print the Printhead Adjustment Pattern In order to correct the Printhead position you must first print the Printhead Adjustment pattern as follows Enter in to the Maintenance Mode Page 4 7 Press the key to enter in to the Printhead Adjustment menu In the Printhead Adjustment submenu scroll to PH Adj Print and press the OK key In the Printhead Adjustment Prints submenu scroll to Printhead Adj and press the OK key PH ADJ PRINTS PRINTHEAD You will need to confirm that you want to print the Printhead Adjustment pattern by pressing the OK key PH ADJ PRINTS PRINTHEAD ADJ OK The Printer will start printing the Printhead Adjustment pattern and the following message will appear on the Front Panel PH ADJ PRINTS EXECUTING Perform Printhead Position Correction Once you have printed the Printhead Adjustment pattern you can use it to correct the position of the Printhead as follows AAA E EP EE E EI P LA E OOOI NAAN WHERE EP EE E E E E E EE EAE LT HERE EHE E E EHE E EE E E EAE Printhead Row Pattern 2 Select the pattern that looks the best aligned and note down the value either a value or a value TH 3 Lines not vel aligned Lines well aligned n Il 3 In the Printhead Adjustment submenu scroll to PH Row Val and press key
209. whenever Carriage Shields are disassembled or replaced Perform the Carriage Shield Height Adjustment as follows 1 Make sure that the Carriage Shields are correctly installed 2 Loosen 2 screws that secure the Carriage Shield to the Carriage 3 Adjust the Carriage Shield so that there is a 2 3 mm clearance between the Carriage Shield and the Center Platen 4 While holding the Carriage Shield in position tighten the two screws that you loosened in a previous step stmt and Calibrations invent Media Feed and Take Up Reel Unit Adjustment Whenever the Media Feed or Take Up Reel Unit has been disassembled or replaced you must adjust them horizontally and vertically Horizontal Adjustment Perform the Horizontal Adjustment on the Media Feed or Take Up Reel Unit as follows 1 Make sure that the Media Feed or the Take Up Reel Unit is correctly installed and that the Main Scrollers are in position 2 Measure the distance from the side of the Printer Stand to the center of the Main Scroller on the Capping Side The distance should be approximately 239 5 mm for the Media Feed Unit and 159 5 mm for the Take Up Reel Unit 3 Measure the distance from the side of the Printer Stand to the center of the Main Scroller on the Wiping Side The distance should be approximately the same as measured in the previous step 4 If the distance measured on the wiping side is different to the distance measured on the cappin
210. ws should not be tightened too much just enough so that the Printhead does not move loosely 2 Install the Printhead Adjustment Jig 1 in to position against the Carriage Base Plate Make sure that the 2 datum pins touch the Printhead as shown Datum Pins Printhead Adjustment Jig 1 Printhead _ r Printhead Positioning Pins invent 4 Tighten the two fixing screws so that the Printhead Adjustment Jig 1 is securely attached to the Carriage Base Plate Plate Make sure the Printhead Adjustment Jig 2 is located against this pin This corner of the Printhead should Printhead Adjustment Jig 2 6 Stretch the spring and hook the key over the top screw of the Printhead Adjustment Jig 1 as shown 7 Thefollowing drawing shows the overall position of the Printhead Adjustment Jigs in relation to the Printhead the tubes have been removed for clarity invent Printhead Adjustment Jig 1 8 Once the Printhead Adjustment Jigs are in place tighten the front screw that secures the Printhead to the Carriage Base Plate invent 10 Attach the Ink Tube to the Printhead and secure it tightly 11 Attach the Printhead Connector Assembly to the Printhead and secure it with 2 screws 12 Before moving to the next stage of the Printhead Adjustment procedure make sure that the Printhead Connector cables are safely secured with tape so that they don t hit other pa
211. ws that secure the Main PCA Tray to the front of the Printer 4 Disconnect ALL the cables connected to the Add On Control PCA 5 Pull out slightly the Main PCA Tray from the Printer and remove five screws that secure the Add On Control PCA to the Main PCA Tray 6 Remove the Add On Control PCA from the Main PCA Tray Rr a son Switching Power Supply Unit Removal Remove the Electronics Module Cover gt Page 8 21 Remove five screws that secure the Main PCA Tray to the Printer from the rear Remove three screws that secure the Main PCA Tray to the front of the Printer Disconnect ALL the cables connected to the Main PCA invent 5 Disconnect ALL the cables connected to the Add On Control PCA no need to disconnect cables connected between the Add On Control PCA and the Switching Power Supply Unit 050 Y x ee LI i I X ese P 6 Remove one screw that secures the Grounding Strip and disconnect the cable from the Switching Power Supply Unit 7 Remove the Main PCA Tray from the Printer Rr a slaton 8 Disconnect ALL the cables connected to the Switching Power Supply Unit 9 Remove three screws that secure the Switching Power Supply Unit to the Main PCA Tray 10 Remove the Switching Power Supply Unit from the Main PCA Tray Power Supply Unit Removal 1 Remove the Electron
212. y the following This error can be avoided if the Store Ink System procedure is performed before turning the Printer OFF for long periods To clear this error Turn the Printer ON in error skip mode by holding down the Cancel and Shift keys and pressing the ON button Enter the Password to clear the internal error flag b Shift ond OK Switch the Printer OFF and then ON again System Error 12Ax End of Life of Part Reached The end of life of the Pump Tube has been reached since it has been working for more than 73 hours Try the following E Replace the Ink Pump Assembly Page 8 99 System Error 120x Printhead Drive IC Error The Piezo Drive IC on a Printhead is too hot 85 C or higher or too low 10 C or lower Try the following Check whether the temperature of the Printhead voltage circuit on the Carriage PCA is extremely hot If it is extremely high check the short circuit of the Printhead and the Printhead Cable using a tester The Short circuit may have been caused by the incorrect insertion of the Printhead Cable internal failure of the Printhead or by a foreign object attached to the Carriage PCA E Replace the Printhead Page 8 36 E Replace the Carriage PCA Page 8 96 Sistem ror codes System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action

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