HP DesignJets 500, DesignJets 510, DesignJets 800 Service Manual
HP Large-Format Printers
DesignJets 500, 510 and 800 Series
Service Manual
For HP Internal Use Only
©Copyright Hewlett-Packard
Company 2000
This document contains
proprietary information that is
protected by copyright. All rights
are reserved. No part of this
document may be photocopied,
reproduced, or translated to
another language without the
prior written consent of HewlettPackard Company.
First Edition, August 2000
Second Edition, November 2001
Third Edition, August 2008
Fourth Edition, January 2013
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.
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 from running onto
electrical components or circuits,
or through openings in the
enclosure.
Electrostatic Discharge
Refer to the beginning of Chapter
8 of this manual, for precautions
you should take to prevent
damage to the Printer circuits
from electrostatic discharge.
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.
Technical Marketing,
Barcelona Division,
Hewlett-Packard Espanola, S.A.
Avda. Graells, 501
08190 Sant Cugat del Valles
Spain
Safety Symbols
General definitions of safety
symbols are given immediately
after the table of contents.
1
DesignJets 500, 510 and 800 SeriesHP Large-Format Printers
Service Manual
Using this Manual
Purpose
This Service Manual contains information necessary to test,
calibrate and service:
HP DesignJet 500 Printer - 24” Model (P/N C7769B)
HP DesignJet 500 Printer - 42” Model (P/N C7770B)
HP DesignJet 500PS Printer - 24” Model (P/N C7769C)
HP DesignJet 500PS Printer - 42” Model (P/N C7770C)
HP DesignJet 500Plus – 24” Model (P/N C7769F)
HP DesignJet 500Plus – 42” Model (P/N C7770F)
HP DesignJet 500Mono – 24” Model (P/N C7769E)
HP DesignJet 500Mono – 42” Model (P/N C7770E)
HP Designjet 510 – 24” Model (P/N CH336A)
HP Designjet 510 – 42” Model (P/N CH337A)
HP Designjet 510ps – 24” Model (P/N CJ996A)
HP Designjet 510ps – 42” Model (P/N CJ997A)
HP DesignJet 800 Printer - 24” Model (P/N C7779B)
HP DesignJet 800 Printer - 42” Model (P/N C7780B)
HP DesignJet 800PS Printer - 24” Model (P/N C7779C)
HP DesignJet 800PS Printer - 42” Model (P/N C7780C)
For information about using these printers, refer to the
corresponding User and Quick Reference Guides.
Readership
The procedures described in this Service Manual are to be
performed by HP Certified Service Personnel only.
Part Numbers
Part Numbers for Printer options, accessories and service parts are
2
HP DesignJets 500, 510 and 800 Series Printers Service Manual
located in Chapter 7.
Conventions
A small arrow is used to indicate other parts of the Service
Manual where you can find information related to the topic you are
consulting.
HP DesignJets 500, 510 and 800 Series Printers Service Manual
3
Table of Contents
Table of Contents 1
Troubleshooting 1-1
Introduction 1-2
Troubleshooting System Error Codes 1-2
Solving Print Quality Problems 1-3
Cover Sensors are not Working 1-3
The Line Sensor has Problems Detecting Media 1-3
Troubleshooting Paper-Axis Shutdowns 1-4
Problems with the Vacuum Fan 1-5
Vacuum suction much lower at high altitudes 1-5
HP-GL/2 color differences in different HP DesignJet Printers 1-6
Banding at variable extreme environmental conditions 1-6
The Priming Procedure Fails 1-7
Using the Power Switch LED to Troubleshoot 1-10
Using the Boot-Up Sequence to Troubleshoot 1-12
Using the Formatter/Accessory Card LEDs to Troubleshoot 1-14
System Error Codes 2-1
Introduction 2-2
Continuable and Non-Continuable Error Codes 2-2
System Error Codes - Explanation 2-2
Error Log Utility 2-5
Accessing the Error Log Utility 2-5
Ink Supplies Troubleshooting 3-1
What are the Ink Supplies? 3-2
Ink Cartridges 3-2
Printheads 3-3
Identifying the Components 3-3
General Information About the Ink Supplies 3-4
Some General Precautions When Handling the Ink Supplies 3-5
When Should You Replace the Ink Cartridges? 3-6
When Should You Replace the Printheads? 3-7
Obtaining Ink Cartridge Information 3-9
4
HP DesignJets 500, 510 and 800 Series Printers Service Manual
Table of Contents
Obtaining Printhead Information 3-10
Ink Cartridge Status Messages 3-12
Ink Cartridge Status While Replacing 3-12
Printhead Status Messages 3-13
Printhead History Utility 3-14
Accessing the Printhead History Utility 3-14
Is the Printer Causing Repetitive Printhead Problems? 3-16
Is the User Replacing the Printheads too Early? 3-18
Troubleshooting Repetitive Ink Cartridge Messages 3-20
Troubleshooting Repetitive Printhead Error Messages 3-21
Printhead Error Codes 3-22
Summary of Solving Ink Supplies Problems 3-23
Service Tests and Utilities 4-1
Introduction 4-2
Phone Support 4-2
Diagnostics - Self Test 4-2
Service Tests (Diagnostics) 4-3
Entering the Service Tests Menu 4-4
Ink Supply Station 4-6
Carriage Movement 4-8
Paper Advance Test 4-10
Service Utilities 4-13
Entering the Service Utilities Menu 4-14
EEROM Setup 4-16
Turn Drive Roller 4-21
Unlock Carriage 4-22
Prime Tubes 4-23
Change Cutter 4-24
Change Ink Tubes 4-25
Printer Information 4-26
Service Calibrations 5-1
Entering the Service Calibrations Menu 5-3
Printhead Alignment (includes PPS Calibration) 5-5
Color Calibration 5-7
Advance Calibration 5-9
Factory Advance Calibration 5-11
HP DesignJets 500, 510 and 800 Series Printers Service Manual
5
Table of Contents
Print Quality 6-1
Print Quality 6-2
Print Quality Troubleshooting Checklist 6-2
How to Use the Troubleshooting Procedure 6-4
What is the Troubleshooting Procedure? 6-4
Considerations for Using the Troubleshooting Procedure. 6-4
Performing the Troubleshooting Procedure 6-4
Troubleshooting Procedure Flowchart 6-7
No Printing Defects Found Using the Troubleshooting Procedure 6-8
Solving Color Accuracy problems 6-9
Color Consistency problems 6-9
Long Term Color Bleeding (Glossy Papers) 6-9
Media 6-10
There are Smears or Scratching on the Printed Media 6-10
Parts and Diagrams 7-1
Printer Support 7-2
Right Hand Cover 7-4
Left Hand Cover 7-6
Top Cover and Deflectors 7-8
Rollfeed Module 7-10
Back Platen Assembly 7-12
Electronics Module 7-14
Power Supply 7-16
Cutter Assemblies 7-18
Ink Delivery System 7-20
Service Station and Spittoon 7-22
Service Station Holder 7-24
Pinch-Wheel Assemblies 7-26
Scan-Axis Motor 7-28
Drive Roller Encoder Sensor 7-30
Print Platen Assembly 7-32
Carriage Assembly 7-34
Vacuum Fan 7-36
Interconnect Cable 7-38
Paper-Axis Motor 7-40
Drive Roller 7-42
Miscellaneous Items 7-44
6
HP DesignJets 500, 510 and 800 Series Printers Service Manual
Removal and Installation 8-1
Introduction 8-2
Safety Precautions 8-2
Electrostatic Discharge (ESD) Precautions 8-3
Required Tools 8-3
Screw Types 8-4
Left Hand Cover 8-5
Right Hand Cover 8-7
Front Panel 8-9
Window and Top Cover 8-10
Media Deflectors 8-11
Left End Roll-Feed 8-13
Right End Roll-Feed 8-15
Back Platen 8-17
Media Sensor 8-19
Formatter 8-20
LAN Card 8-21
Spittoon 8-23
Electronics Module 8-24
Power Supply 8-27
Scan-Axis Motor Assembly 8-29
Cutter Assembly 8-32
Left Encoder Holder 8-33
Cutter Bushing 8-35
Cutter Guide Bracket 8-36
Drive Roller Encoder Sensor 8-38
Trailing Cable 8-40
Ink Supply Station 8-48
Interconnect PCA 8-50
Service Station and Aerosol Fan 8-52
Cutter Guide 8-55
Print Platen 8-56
Service Station Holder 8-57
Interconnect Cable 8-59
Ink Supply Tubes 8-60
Vacuum Fan 8-64
Pinch-Arm 8-66
Pinch-Arm Mechanism 8-67
Pinch-Arm Lever 8-69
Table of Contents
HP DesignJets 500, 510 and 800 Series Printers Service Manual
7
Table of Contents
Pinch-Arm Sensor 8-71
Fork Idler, Tensioner and Idler Pulley 8-74
Encoder Strip 8-76
Carriage Assembly (Including Belt) 8-78
Paper-Axis Motor 8-84
Drive Roller 8-86
Gear Assemblies 8-92
Preventive Maintenance 9-1
Moisture on the Printer 9-2
Noisy Carriage Bushing 9-2
Belt Swelling 9-2
Cleaning the Printer 9-2
General Cleaning 9-2
Cleaning the Drive Roller/Print Platen 9-3
Scheduled Maintenance 9-3
Level of Printer Usage 9-3
Scan-Axis Maintenance 9-4
Functional Overview 10-1
Introduction 10-2
SKU Overview 10-2
Electrical System 10-3
Introduction 10-3
Hardware Description 10-3
Power Supply Unit (PSU) 10-5
Front Panel 10-6
Ink Delivery System (IDS) 10-7
Ink Supply Station (ISS) 10-7
Tubes Assembly 10-9
Service Station 10-10
Glossary
Index
8
HP DesignJets 500, 510 and 800 Series Printers Service Manual
Troubleshooting 1
Introduction 1-2
Troubleshooting System Error Codes 1-3
Performing a Service Test on a Failed Assembly 1-3
Performing the Necessary Service Calibrations 1-3
Solving Print Quality Problems 1-4
The Printer does not Power ON 1-4
Cover Sensors are not Working 1-4
The Line Sensor has Problems Detecting Media 1-4
Troubleshooting Paper-Axis Shutdowns 1-5
Problems with the Vacuum Fan 1-6
Vacuum suction much lower at high altitudes 1-6
HP-GL/2 color differences in different HP DesignJet Printers 1-7
Banding at variable extreme environmental conditions 1-7
The Priming Procedure Fails 1-8
Using the Power Switch LED to Troubleshoot 1-11
Using the Boot-Up Sequence to Troubleshoot 1-13
How to Detect Problems Related to the Encoder Disk 1-17
1
HP DesignJets 500, 510 and 800 Series Printers Service Manual
1-1
Troubleshooting
Menu
Back
Enter
Cancel
Form Feed
and cut
Guide to Troubleshooting the Printer
Introduction
This chapter will guide you through the relevant steps to take when
troubleshooting the printer.
Front Panel Difference for the HP DesignJet 500, 510 and 800 Series Printers
Front Panel for the HP DesignJet 500 and 800 Series
Front Panel for the HP DesignJet 510 Series
1-2
HP DesignJets 500, 510 and 800 Series Printers Service Manual
Troubleshooting
NOTE The layout shown below will be used to refer to both types of
front panels
Troubleshooting System Error Codes
Chapter 2 - System Error Codes contains a list of system error
codes and their respective descriptions and recommended corrective
actions. Only try one recommended action at a time and check if the
error code has disappeared.
Performing a Service Test on a Failed Assembly
If possible, always perform a Service Test on the component/
assembly that you are about to replace, just to make sure that is the
component/assembly that has failed.
NOTE If the test on that component/assembly passes, you should NOT
replace it.
For information on the Service Tests and how to use them see
Chapter 4 - Service Tests and Utilities.
Performing the Necessary Service Calibrations
Is the printer calibrated correctly after replacing a component?
NOTE Remember that certain Calibrations are required even if an
Assembly has been disassembled to gain access to another
Assembly or Component.
For information on the Service Calibrations and how to use them
see Chapter 5 - Service Calibrations.
HP DesignJets 500, 510 and 800 Series Printers Service Manual
1-3
Troubleshooting
Solving Print Quality Problems
The Printer contains an internal Troubleshooting procedure which
helps you to diagnose and resolve the possible source of any Image
Quality or Line Quality defects. If Print Quality is poor before the
minimum life expectancy of the Printhead has been reached, the
Troubleshooting procedure should be performed which will
determine whether the Printhead needs replacing or not after
performing various levels of recovery actions.
For information on solving Print Quality problems see Chapter 6 -
Print Quality.
The Printer does not Power ON
1 Check that the power cord is connected correctly to the Printer and
to the Power Socket.
2 Check that the Front-Panel Cable is correctly connected to the
Interconnect PCA. Also make sure that the Front-Panel cable is not
damaged.
3 Check that the Interconnect Cable is properly connected at the both
ends of the Printer.
Cover Sensors are not Working
1 Check if the faulty sensor is installed correctly.
2 Check if the cable for the faulty sensor is connected correctly.
3 Replace the faulty Sensor (or the assembly that contains the Sensor).
The Line Sensor has Problems Detecting Media
1 Check the type of media that is being used since the Line Sensor
may have problems detecting transparent media or some types of
Non-HP media. Try loading white HP media in to the Printer and
check if the Line Sensor detects it.
2 Excessive ink deposits on the Print Platen surface can fool the
sensor by reflecting the light. Clean the Print Platen.
1-4
3 The Line Sensor is damaged or faulty. Replace the Carriage
Assembly Page 8-78.
HP DesignJets 500, 510 and 800 Series Printers Service Manual
Troubleshooting
Troubleshooting Paper-Axis Shutdowns
A Paper-Axis shutdown can happen when the Printer detects that
the Drive Roller is not moving but at the same time power is being
supplied to the Paper-Axis Motor (which should be turning the
Drive Roller).
The reasons for the Paper-Axis shutdown, and their solutions, are
explained as follows:
1 The Paper-Axis Motor does not respond to the electrical simulation.
It is possible to determine whether the Paper-Axis is faulty by
performing the Paper Advance Test (Refer to Page 4-11). The
Printer will move the Motor backwards and forwards and
measure directly from the Motor Encoder whether the Paper-Axis
Motor responded to the force. If the Paper-Axis Motor did not
respond, the solution would be to replace the Paper-Axis Motor
Page 8-84.
2 The Transmission Gears, which transmit the moveme nt to the Drive
Roller, are not turning. This problem could be caused either by
blockage of the gears (caused by an obstacle) or by one of the gears
being damaged. To solve the problem, try the following:
Remove the Back Platen Page 8-67 and check if there are any
obstacles blocking the Gears. Remove the obstacles if necessary.
Remove the Back Platen Page 8-67 and check if the
Transmission Gears are damaged. If the Gears are damaged,
replace the Gear Assemblies Page 8-92.
3 The Drive Roller cannot move because of an obstacle or because it
is damaged. To solve the problem, try the following:
Remove the Back Platen Page 8-67 and check if there are any
obstacles blocking the Drive Roller. Remove the obstacles if
necessary.
Remove the Back Platen Page 8-67 and check if the Drive
Roller is damaged. If the Drive Roller is damaged, replace the
Drive Roller Page 8-86.
4 The Drive Roller Encoder Sensor is faulty
It is possible to determine whether the Encoder Sensor is faulty
by loading a sheet of paper from the front of the Printer. If the
Drive Roller is working, the sheet will be loaded correctly, and
the Printer will detect that media has been loaded (using the
Media Sensor). Therefore the problem must be the Encoder
Sensor and the solution would be to replace the Encoder Sensor
Page 8-38.
HP DesignJets 500, 510 and 800 Series Printers Service Manual
1-5
Troubleshooting
Problems with the Vacuum Fan
If you have problems loading either Roll or Sheet Media, then there
could be a problem with the Vacuum Fan. T o verify if there really is
a problem with the Vacuum Fan, try the following:
1 With the Printer ON, open the Window of the Printer and place a
sheet of HP High Gloss Photo Paper (must be D-Size), aligned with
the blue lines on the Center Platen. If the Vacuum Fan holds the
sheet in place, and then loads it correctly, then the Vacuum Fan
functions correctly. If the Vacuum Fan does not hold the sheet in
place (no suction), then try the following:
Check that the holes in the Center Platen are NOT blocked.
Check that the Vacuum Fan is installed correctly.
Replace the Vacuum Fan Page 8-64.
2 If the Vacuum Fan held the sheet in place, but couldn’t correctly
load it, then there could be a problem with the Drive Roller. In this
case, replace the Drive Roller Page 8-86.
Vacuum suction much lower at high altitudes
Sometimes, at high altitudes, the vacuum force holding down the
media will be lower, therefore the media will not be held in place
properly causing:
Ink Smearing on the Media.
Printhead crashes against the Media.
Cut Sheet loading problems (high probability).
Roll Media loading problems (low probability).
The solution to this would be to change the Vacuum force by
changing the Altitude setting. This can be done via the front panel
Set-up Menu / Altitude.
1-6
HP DesignJets 500, 510 and 800 Series Printers Service Manual
Troubleshooting
HP-GL/2 color differences in different HP DesignJet Printers
Color differences between one image printed on the HP DesignJet
500/510/800 Series and the rest of the DesignJet platforms are due
to the different chemistry of the 500/510/800 series inks compared
with the rest of the inks for other printers. This color variability
among different HP DesignJet Series Printers has always been
present. To solve the problem, try the following:
Perform the color calibration from the driver at the time of
printing. However, that calibration is not very accurate but it may
help in the most severe cases.
Some applications have color controls for the user to modify the
image in order to obtain the desired colors.
Printing with PostScript reduces the problem significantly.
Avoid very long exposures to extreme environmental conditions
after printing with glossy media (more than 12 hours at 80%
humidity may result in severe changes in color).
Banding at variable extreme environmental conditions
Since the Accuracy Calibration has been done at normal
environmental conditions, printing in extreme environmental
conditions will cause banding because the advance of the Drive
Roller does not correspond to the same conditions that the
calibration was done in. To solve the problem, try the following:
Perform the Accuracy Calibration in the new environmental
conditions (Refer to the User’s Guide).
HP DesignJets 500, 510 and 800 Series Printers Service Manual
1-7
Troubleshooting
The Priming Procedure Fails
When the customer first receives the Printer, it is supplied with a set
of four Start-up Printheads pre-installed in the Printhead Carriage.
These Start-up Printheads are used for the priming of the tubes in
the Ink Delivery System.
When the Printer is powered ON for the first time, the Printer will
automatically perform the priming process. Without the priming
process, the customer will NOT be able to use the Printer.
The initial startup assumes that the Start-up Printheads are installed,
but the Printer cannot detect them because the Printer can only
detect normal Printheads. If normal Printheads are installed during
the initial startup, the Printer will request the User to remove them
and check if they really have been removed. It will then request the
User to install the Start-up Printheads.
Also the Printer will request the User to install the Ink Cartridges if
they have not been installed already . If the Ink Cartridges contain less
than 20cc of ink (the Ink Cartridges are encoded with the quantity of
ink remaining) they will be rejected. Normally with a new Printer this
should not be a problem since the Printer comes with Ink Cartridges
that are full, but there maybe cases when the Ink Supply Tubes need
to be replaced, in which case half empty Ink Cartridges may be used.
Once the Printer assumes that the
Start-up
Printheads and Ink Cartridges
with enough ink are installed, the priming process will begin.
If the priming process is completed successfully, the Printer will
directly proceed to the Printhead replacement procedure in order to
replace the used Start-up Printheads with normal Printheads.
Once the priming process has started, it can fail due to 2 different
problems:
The Ink Supply Tubes were not completely empty - This is the
most common cause especially if the Printer has been powered
ON and OFF several times with the Ink Cartridges installed since
the initialization process performs at least one pumping cycle.
The Printer detects that one or more of the tubes cannot be
detected as filled with ink - The most likely cause for this
problem is Ink Cartridges with a faulty valve.
Even if the priming process fails, the Printer will try to verify
whether the priming process has been completed by moving the
Carriage to the access position and you will see the following
1-8
HP DesignJets 500, 510 and 800 Series Printers Service Manual
Troubleshooting
Unable to prepare
ink system.
Open window to check
SETUP printheads
1. Lift printhead cover
Menu
Back
Enter
2. Check if there is ink
inside printhead windows
3. Press ENTER to continue
Check for ink
Menu
Back
Enter
Are all printhead windows
filled with ink?
ALL with some ink
NOT all with ink
message on the Front Panel:
Open the Window and you will see the following message on the
Front Panel:
HP DesignJets 500, 510 and 800 Series Printers Service Manual
Open the Carriage Cover and check if there is ink inside the Start-up
Printheads. On the Front Panel you will see the following question
and you will need to select the answer depending on whether the
Start-up Printheads were filled with ink or not:
If there is ink in all of the Start-up printheads, the Printer considers
that the priming procedure has been completed successfully and will
proceed to the Printhead replacement process.
If you select NOT all with ink the Printer will react differently
depending on the source of the problem:
1-9
Troubleshooting
NOTE If you need to reseat the Start-up Printheads, make sure you re-
insert them in the same color slot in the Carriage.
The Printer will request you to reseat the Start-up Printheads (or
in the case of missing Start-up Printheads you should install them
or order new ones) and then retry the priming process (if the
priming process fails 3 times because of the same problem, it will
display a System Error). In this situation, the problem could be
the following:
1 The Start-up Printheads were not installed co rrectly or they are
missing (one or all of them).
2 The Start-up Printheads do not work properly and do not allow
air to flow (one or all of them).
3 The Ink Supply Station fails to pressurize the Ink Cartridges.
To check this, perform the Ink Supply Station test Page 4-6.
4 The Ink Supply Tubes are blocked, preventing the ink from
flowing correctly.
If a System Error is displayed, try the following:
1 The Ink Cartridge valve is broken so the Ink Cartridge should
be replaced.
2 The Start-up Printhead is not working properly and allows ink
to flow outside.
3 The Ink Supply Tube is leaking.
NOTE The last 2 cases will be more obvious because there will be a lot
of ink in the Printer (around 20 cc of ink). Remove the Ink
Cartridges and release the Tubes Bracket from the Ink Supply
Station and check if there is ink in this area.
For more information on this problem, refer to System Error 93:10
on Page 2-19.
1-10
HP DesignJets 500, 510 and 800 Series Printers Service Manual
Troubleshooting
LED OFF
LED ON
Using the Power Switch LED to Troubleshoot
In certain circumstances the LED located in the power switch
(located on the left hand side of the Printer) can help to troubleshoot
the Printer. The LED can be OFF, ON or flashing and using different
combinations can indicate different problems.
NOTE You should only use the LED to troubleshoot when the Printer
does not Power up completely. The LED may flash in other
circumstances which are completely normal and this does not
mean that there is a problem with the Printer.
HP DesignJets 500, 510 and 800 Series Printers Service Manual
1 Check that power cord is connected correctly to the Printer and to
2 Replace the Power Supply Unit Page 8-27.
LED is OFF - This indicates that the Power Supply Unit is
completely dead. Try the following:
the Power Socket. Also make sure that you firmly press the Power
Switch to the ON position.
LED is ON (all the time) - This indicates that the Main PCA is
completely dead. Replace the Electronics Module Page 8-24.
LED is Flashing continuously
- A problem has been detected with the
previous firmware upgrade. Try resending the firmware upgrade file.
LED Flashes twice every few seconds - The Printer cannot detect
1-11
Troubleshooting
the Interconnect Cable. Try the following:
1 Check that the Interconnect Cable is connected correctly to the
Electronics Module and to the Interconnect PCA.
2
If the Interconnect cable is connected correctly and the LED continues
to flash twice then replace the Interconnect Cable Page
8-59
.
LED Flashes 3 times every few seconds - The Printer cannot
detect the Front Panel. Try the following:
1 Check that the Front Panel is connected correctly to the Interconnect
PCA.
2 Check that the Interconnect Cable is properly connected at the both
ends of the Printer.
3 If the Front Panel is connected correctly and the LED continues to
flash 3 times then replace the Front Panel Page 8-9.
4 R
eplace the Interconnect Cable Page
5
Replace the Electronics Module Page
8-59
8-24
.
.
LED Flashes 4 times every few seconds
- This indicates that the
Main PCA has failed. Replace the Electronics Module Page
LED Flashes 5 times every few seconds
- This indicates that the
Main PCA has failed. Replace the Electronics Module Page
8-24
8-24
.
.
1-12
HP DesignJets 500, 510 and 800 Series Printers Service Manual
Troubleshooting
Using the Boot-Up Sequence to Troubleshoot
When you Power On the Printer, the Printer 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, the following explanations will help you to
locate the failing component:
During the first phase of the Boot-up sequence (all the squares turn
grey) the Printer is initializing the Operating System. If for some
reason this sequence fails, try the following:
1 Switch the Printer Off and wait a few minutes. Switch the Printer
On again and check if the initialization sequence is successful.
2 If the initialization sequence fails again, replace the Electronics
Module Page 8-24.
During the second phase of the Boot-up sequence (all the squares
turn black) the Printer is initializing various components (too
numerous to mention). In normal circumstances, if a component fails
during this sequence a System Error will appear and you should refer
to Chapter 2 -
System Error Codes
. The following information
explains what is being initialized as each square turns black:
Initializing various components of the Main PCA.
Initializing various components of the Main PCA.
Initializing a portion of the Firmware.
Initializing various components of the Main PCA.
HP DesignJets 500, 510 and 800 Series Printers Service Manual
1-13
Troubleshooting
Initializing various components of the Main PCA.
Initializing a portion of the Firmware.
Initializing the I/O.
Initializing the User Interface (Front Panel menus).
Initializing a portion of the Firmware.
Initializing the Formatter.
Initializing the communication between Main PCA and Formatter.
End of initialization sequence.
Entering Service Menu at Power Up - Only for Onsite Repair
If the Printer fails to initialize completely because of a System Error
and you need to use the Service Menu (Service Tests and Utilities),
the Printer can be powered up in Service Mode by pressing the Up
and Enter keys while switching the Printer ON. This will give you
access to some of the Service Tests and Utilities without having to
complete the System Initialization (if you perform some of the tests,
they will need to initialize the relevant part of the System).
1-14
HP DesignJets 500, 510 and 800 Series Printers Service Manual
Troubleshooting
LED’s on the HP-GL/2
The LED’s on the Formatter
can be seen without having to
remove the Left Hand Cover.
LED’s on the Formatter
Accessory Card
Using the Formatter/Accessory Card LEDs to Troubleshoot
In certain circumstances the LEDs located in the Formatter or HPGL/2 Accessory Card can help to highlight certain failures. There
are 3 LEDs, Red, Yellow and Green and using different
combinations can indicate different problems.
HP DesignJets 500, 510 and 800 Series Printers Service Manual
The yellow LED (normally flashing) indicates that the Formatter/
Accessory Card is alive. If it stops flashing, it means that the
Formatter/Accessory Card has failed and should be replaced.
The green LED indicates that there is power being supplied to the
1-15
Troubleshooting
Formatter/Accessory Card. If the green LED is NOT lit and the
LED in the Power Switch is ON, then it could mean that the
Formatter/Accessory Card is badly connected or that the Printer if
switched OFF . If after reseating the Formatter/Accessory Card, the
problem persists, try the following:
1 Switch the Printer OFF and remove the Formatter/Accessory Card
BUT leaving the LAN Card installed (if available). Switch the
Printer ON. If the Printer powers up correctly and the LAN Card
works properly , then try step 2. If the LAN Card doesn’ t work, then
try step 3.
2 Switch the Printer OFF and remove the LAN Card from the current
slot and install the Formatter/Accessory Card in the same slot (that
was previously used by the LAN Card). Switch the Printer ON and
check if the green LED in the Formatter/Accessory Card is lit. If the
green LED is NOT lit, it means that the Formatter/Accessory Card
is faulty and should be replaced.
If the green LED is lit, then switch the Printer OFF and install the
LAN Card in the vacant slot. Switch ON the Printer and check if the
LAN Card works properly. If the LAN Card does NOT work, then
there is a problem with the Electronics Module and should be
replaced Page 8-24.
3 Switch the Printer OFF and remove the LAN Card. Switch ON the
Printer and check if it initializes completely . If it initializes correctly
without any problems, then the problem could be with the
Electronics Module and should be replaced Page 8-24.
4 If the Printer does not even start to power up (i.e. nothing seen on
the Front Panel and the LED in the Power Switch is NOT flashing)
without the LAN Card nor the Formatter/Accessory Card, but the
power switch LED is ON (all the time) the problem could be with
the Electronics Module or the Power Supply Unit.
The red LED will flash a few times when the Printer is started up
but if it stays lit (all the time) or flashes continuously, then this
indicates that the Formatter/Accessory Card is faulty and should
be replaced.
HP Designjet 510 Series printers will only include “HPGL/2
Accessory Card (Processor Card)” installed in the Left Slot of the
Electronics Module.
1-16
HP DesignJets 500, 510 and 800 Series Printers Service Manual
Troubleshooting
Encoder Disk
Paper Advance test
System error 56:10
Roller encoder sensor
failed
How to Detect Problems Related to the Encoder Disk
The following information will help you detect any problems
related to the Encoder Disk:
Horizontal and periodic white lines, all of them with the same
width depending on the failure mode. This is a clear indication
that the Encoder Disk is damaged.
System Error 56:10 - This means that you have to replace the
Drive Roller Encoder Sensor Page 8-38. But, if the problem
persists, replace the Encoder Disk Assembly.
System Error 81:01 - This means a Paper-Axis shutdown. If this
error code appeared but was NOT caused by a paper jam, then
perform the Paper Advance Test Page
Advance Test fails during the third test, the Front Panel will
display the following message:
4-11
. If the Paper
NOTE In order to remove the Encoder Disk, you must first remove t he Driv e
HP DesignJets 500, 510 and 800 Series Printers Service Manual
In this case, you should replace the Drive Roller Encoder Sensor
Page 8-38. But, if the problem persists, replace the Encoder Disk
Assembly.
Roller
Be very careful when assembling the Axle Spring because you could
damage the Encoder Disk.
Check that no air bubbles are trapped between the Encoder Disk and the
hub once it is installed.
Page 8-86.
1-17
Troubleshooting
1-18
HP DesignJets 500, 510 and 800 Series Printers Service Manual
System Error Codes 2
System Error Codes 1
Introduction 2-2
Continuable and Non-Continuable Error Codes 2-2
System Error Codes - Explanation 2-2
Accessing the Error Log Utility 2-5
01:10 2-7
01:11 2-7
01:12 2-7
01:13 2-8
02:10 2-8
02:13 2-8
03:10 2-9
04:11 2-9
05:10 Warning (Only applicable to HP DesignJet 800 Series) 2-9
05:11 2-10
08:11 2-10
11:11 2-10
11:13 2-10
12:11 2-11
21:10 2-11
21:11 2-11
22:10 2-11
41:10 2-12
41:13 2-12
42:10 2-12
43:10 2-12
43:11 2-12
56:10 2-13
56:13 2-13
61:04 2-13
61:05 2-14
64:04 2-14
71:04 2-15
71:06 2-15
72:04 2-16
73:04 2-16
79:04 2-17
81:01 2-17
81:11 2-17
85:10 2-18
86:01 2-18
86:11 2-18
86:13 2-19
87:13 2-19
93:10 2-19
2
HP DesignJets 500, 510 and 800 Series Printers Service Manual
2-1
System Error Codes
Introduction
System error codes are hexa-decimal based numbers generally
caused by internal system errors. The following pages contain 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.
Continuable and Non-Continuable Error Codes
Some of the Error Codes are continuable, which means you can
press Enter on the front-panel and continue working with the
Printer. Non-Continuable Error Codes do not allow you to continue
working with the Printer, in this case power the Printer OFF and ON
again and see if the System Error disappears. If the Error Code
reappears, then the Printer requires an on-site visit in order to
resolve the problem.
NOTE Even though the customer can continue working with a
Continuable Error Code, an on-site visit should still be planned
to troubleshoot the problem.
System Error Codes - Explanation
System Error Codes consist of 4 digits which explain which
component/system is failing and what action should be taken to
resolve the problem.
The following table explains the
Code Component/System
01 Main PCA/Electronics Module
02 Carriage/Carriage PCA
03 Power Supply Unit
04 Network Card
05 Formatter
06 Hard Disk Drive
first
2 digits of the System Error Code:
2-2
07 Interconnect PCA
08 Front Panel
11 Trailing Cable
12 Carriage Flex Circuit
HP DesignJets 500, 510 and 800 Series Printers Service Manual
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