HP Designjet T1100, Designjet T1100ps, Designjet T610 Service Manual

HP Designjet
T1100/T1100ps/T610
Printer Series
For HP Internal Use Only
©Copyright Hewlett-Packard Company 2007
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, April 2007
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.
WARNI NG
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 4of 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.
Content Management Department, 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.

T1100/T1100ps/T610 Table of Contents 1

1 Troubleshooting 2 System Error Codes 3 Ink Supplies Troubleshooting 4 Service Tests and Utilities 5 Service Calibrations 6 Print Quality 7 Parts and Diagrams 8 Removal and Installation 9 Preventive Maintenance
For information about Using this Manual, please refer to the next page.
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual -1
Chapter 1 T1100/T1100ps/T610 Table of Contents

Using this Manual

Purpose

This Service Manual contains information necessary to test, calibrate and service:
HP designjet T1100 Printer 24 inch (Model Q6683A)HP designjet T1100 Printer 44 inch (Model Q6687A)HP designjet T1100ps Printer 24 inch (Model Q6684A)HP designjet T1100ps Printer 44 inch (Model Q6688A)HP designjet T610 Printer 24 inch (Model Q6711A)HP designjet T610 Printer 44 inch (Model Q6712A)
For information about using these printers, refer to the corresponding User and Quick Reference Guides.

Readership

The procedures described in this Service Manual are to be performed by HP Certified service personnel only.

Part Numbers

Part Numbers for Printer options, accessories and service parts are located in Chapter 7, Parts and Diagrams.

Conventions

A small arrow indicates a link to other parts of the Service Manual where you can find information related to the topic you are consulting.
-2 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual

Troubleshooting 1

Introduction 1-2 Troubleshooting System Error Codes 1-2 Performing a Service Test on a failed Assembly 1-2 Performing the Necessary Service Calibrations 1-3 Solving Print Quality Problems 1-3 The Printer does not Power ON 1-3 The Printer Continuously Rejects Printheads 1-3 Cover Sensors are not Working 1-3 The Line Sensor has Problems Detecting Media 1-3 Banding at variable extreme environmental conditions 1-4 Worm marks on HP Coated media with light area fills 1-4 Solving Media-Handling Problems 1-5
1
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 1-1
Chapter 1 Troubleshooting

Guide to Troubleshooting the Printer

Introduction

This chapter will guide you through the relevant steps to take when troubleshooting the printer.

Troubleshooting System Error Codes

Chapter 2, System Error Codes contains a list of system error codes and their respective descriptions and recommended corrective actions. Only try one recommended action at a time and check if the error code has disappeared.
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 (See Note below). Check
firmware in Utilities / Statistics / Code rev.
The complete error number (See Note below).The Service Configuration Print.
The Current configuration sheet.
  Which software application the customer is using (name, version, etc.).
When reporting the System Error Code, make sure that you supply the full Error Code and the firmware version. Without this information, HP Support Personnel cannot help you.

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.
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.
1-2 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual
Guide to Troubleshooting the Printer - Performing the Necessary Service Calibrations

Performing the Necessary Service Calibrations

Is the printer calibrated correctly after replacing a component? For information on the Service Calibrations and how to use them see Chapter 5, Service Calibrations.
Remember that certain Calibrations are required even if an Assembly has been disassembled to gain access to another Assembly or Component.

Solving Print Quality Problems

Whenever a Print Quality problem appears, it is advisable to print the Diagnostic Print to help diagnose the problem. The Diagnostic Print will help you differentiate between possible printhead errors and other problems such as incorrect front-panel selection, driver or RIP configuration or mechanical problems. 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 Power Switch on the BACK of the Printer is in the ON
position.
3 Check to see the LED on the Front Panel Power Switch are On.
4 Check that the Front-Panel Cable is correctly connected to the Electronics
Module. Also make sure that the Front-Panel cable is not damaged.
5 Replace the Power Supply Unit
Page 8-144.

The Printer Continuously Rejects Printheads

1 Clean the flex contacts on the Printhead and in the Carriage Assembly using
the Carriage Interconnect Wiper (Refer to Page 3-20) and try again.
2 If ALL the Printheads are rejected (the status message on the Front Panel does
NOT show "OK" for ALL the Printheads) then perform the Electronic Module Test
Page 4-21.

Cover Sensors are not Working

1 Perform the Sensors Test Page 4-31.
2 Check if the cable for the faulty sensor is not damaged and is connected
correctly.
3 Replace the faulty 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
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 1-3
Chapter 1 Troubleshooting
loading white HP media in to the Printer and check if the Line sensor detects it.
2 The Line Sensor is not calibrated correctly. Perform the Line Sensor
Calibration ⇒ Page 5-15.
3 The Line Sensor is damaged or faulty. Replace the Line Sensor Page 8-
115.

Troubleshooting Media Jams/Printhead Crashes

The failure modes "media jam" and "head crash" are grouped together because in many cases a media jam causes the media to lift up into the Carriage path and cause a Printhead crash, thus causing many media jam failures to be reported as head crashes.
1 Did the media jam occur when loading media?
If the client has had media jams, it is common for pieces of media to get
When clearing a media jam, sometimes media is stuck in the paper path. To clear this, you must lift the Media Lever and insert thicker media into the paper path to push out the media that is still stuck there.
stuck in the media path. Clear the media path.
2 Is the customer using non-HP media?
The use of non-HP media can easily be the cause of media jams and
head crashes (especially head crashes because HP media is specially formulated to avoid cockle, one of the primary causes of head crashes). If the media is not HP approved, advise the customer to use HP media and check to see if the problem is now solved.

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 Media Advance 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).

Worm marks on HP Coated media with light area fills

Light bands (S-shaped) in Paper axis direction where light area fills are printed, causing unacceptable Image Quality defect.
Print the Service Configuration Print and check if the level of Humidity is
very low (below 30%). Increasing humidity may help in reducing the
1-4 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual
Guide to Troubleshooting the Printer - Solving Media-Handling Problems
severity of the problem.
The media is causing the problem and NOT the Printer. Do not attempt to try and replace Printer parts to solve this problem.

Solving Media-Handling Problems

The Front Panel indicates that media is misaligned or incorrectly positioned
Roll media
Sheet media
The roll may be loaded the wrong way. The paper should load over the
roll toward you.
Check that the paper is correctly loaded onto the spindle.The paper may be loaded at an angle. The right-hand edge must be
aligned with the blue line on the Print Platen.
With 24 inch printers, ensure that the paper is wrapped tightly on the roll. This is a very important step to remember because if this is not done, the media may be loaded at an angle, causing the media to be rejected.
Check that the Right Spindle Holder (rewinder included) is properly
attached and screwed to the printer.
For 44 inch printers, the Rewinder, located on the Right Spindle Holder (rewinder included), should maintain proper back tension. If the Right Spindle Holder (rewinder included) is misaligned or not properly attached to the printer, the Rewinder will not function properly.
A graphic of a properly installed Rewinder can be found on page 8-74, Right Spindle Holder (rewinder included). To further diagnose problems with the Rewinder, Refer to Page 4-34.
Always load sheet media using the Rear Input Tray. Do NOT load the
media as you would load roll media.
It must be loaded with the right-hand edge against the blue line on the
Print Platen.
The media may be crumpled or warped or may have irregular edges.If hand-cut media is used, the edges may not form a right-angle or they
may be rough. If possible, hand-cut media should not be used. Only purchased sheet media should be used in the Printer.
If you have problems with paper jams, check that the Overdrive is not
obstructed by bits of paper or using the Turn Drive Roller Service Utility Page 4-58.
Check that the Right Spindle Holder (rewinder included) is properly attached and screwed to the printer.
For 44 inch printers, the Rewinder, located on the Right Spindle Holder (rewinder included), should maintain proper back tension. If the Right
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 1-5
Chapter 1 Troubleshooting
Spindle Holder (rewinder included) is misaligned or not properly attached to the printer, the Rewinder will not function properly.
To further diagnose problems with the Rewinder, Refer to Page 4-34.
1-6 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual

System Error Codes 2System Error Codes 1

Introduction 2-2 Continuable and Non-Continuable Error Codes 2-2 System Error Code Brief Descriptions 2-3 System Error Codes - Full Descriptions 2-7
2
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 2-1
Chapter 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.
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 (See Note below). Check
firmware in Setup Menu / Information Menu / Show Printer Information.
The complete error number (See Note below).The Service Configuration Print.
The Current configuration sheet.
  Which software application the customer is using (name, version, etc.).
When reporting the System Error Code, make sure that you supply the full Internal Error Code and the firmware version. Without this information, HP Support Personnel cannot help you. To view the Internal Error Code, hold the UP key and press the CANCEL key at the same when the System Error.
Code is displayed on the Front Panel.
This is the code definition required when escalating a problem

Continuable and Non-Continuable Error Codes

Some of the Error Codes are continuable, which means you can press OK 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.
Even though the customer can continue working with a Continuable Error Code, an on-site visit should still be planned to troubleshoot the problem.
2-2 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual
System Error Code Brief Descriptions - Reading a System Error Code

System Error Code Brief Descriptions

Reading a System Error Code

System Error Codes explain which component/system is failing and what action should be taken to resolve the problem.
System Error Codes are displayed directly on the front panel (but can also be seen on the Information Page) and have been defined in the format XX.YZ. or XX.n:YZ.m.
XX: Can be a malfunctioning subsystem or process (2 digits).n: Subsystem or process Index (if more than one used in the product) -
Optional. – e.g. Identify the Ink Supply (color and number).
Y: Who should perform the action (1 digit) - (0 for User or1 for Service
Engineer).
Z: Action to perform (1 digit).

System Error Code Table

The following table explains the XX part of the System Error Code or Warning:
Code Component/System
01.0 Main PCA/Electronics module
01.1 Add-on Electronics module (printmech)
01.2 Print Mech PCA
02.1 Carriage PCA
02.2 Carriage PCA 03 Power supply
05.1 Fan of the Formatter 06 Formatter 08 Front panel 11 Trailing cable
12.n Carriage flex circuit n to pens 21 Service station
21.1 Service station
22.0 Bongo error BPS0 (ISS Left)
22.1 Bongo error BPS1 (ISSLeft) 24 Tube assembly (IDS)
26.n Ink Cartridge (color = n) 27 Printhead error 31 Cutter
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 2-3
Chapter 1 System Error Codes
Code Component/System
41.1 Paper-axis motor
71.19 PrintMech PCA/Formatter
74.1 Media Profile Update
75.1 Preventive Maintenance kit #1
75.2 Preventive Maintenance kit #2
75.3 Preventive Maintenance kit #3
75.4 Preventive Maintenance kit #4
78.1 Media Settings
79.1 Recoverable Firmware Error
81.1 Media advance
38 Output Tray 41 Paper-axis motor
42 Scan-axis motor 44 Aerosol fan 45 Rewinder 47 Star wh eel mo tor 48 PPS mechanism 51 Window Sensor 52 Drop detector 55 Line sensor 56 Drive roller analog encoder sensor 61 Error job 62 PC Interface 63 Input/output through LAN card 64 Input/output through USB port 65 Input/output (not known what port) 66 Input/output (not known what port) 67 Input/output through FireWire port 68 Loss of engine counters tracking 71 Memory management
72 Firmware error 73 Ser vo 74 Firmware upgrade
76 Di sk Ful l 77 Web access application 78 Borderless
79 Assertion (uncontrolled FW error)
81 Media advance
2-4 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual
System Error Code Brief Descriptions - Corrective Actions Table
Code Component/System
84 Roll Feed 85 Media-axis encoder reading 86 Carriage Movement 87 Scan-axis encoder reading 93 Ink Pumping 94 Color calibration
94.1 Profi ler 95 Printhead alignment 97 Paper advance calibration

Corrective Actions Table

The following table explains the YZ part of the System Error Code or Warning:
Code Recovery Action Response
00 Replace
01 Reseat/Reconnect/Clean/Adjust (manually)
02 Calibrate/Adjust (using Automatic Process)
03 Power OFF and Restart the Printer
04 Upgrade System Firmware
05 Upgrade Driver or Computer Software
06 Add Accessory
07 Escalate
08 Send Plot Again
09 Wrong Part Installed
Possible for customer to
perform
action
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Chapter 1 System Error Codes
Code Recovery Action Response
10 Replace
11 Reseat/Reconnect/Clean/Adjust (manually)
12 Calibrate/Adjust (using Automatic Process)
13 Power OFF
14 Upgrade System Firmware
15 Upgrade Driver or Computer Software
16 Add Accessory
17 Escalate
18 Send Plot Again
19 Wrong Part Installed
hp qualified
personnel
assistance
required
2-6 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual
System Error Codes - Full Descriptions - 01.0:YZ

System Error Codes - Full Descriptions

This sections describes each of the system error codes and warnings that could be encountered while using the printer and provides the remedial action required to solve the problem detected.
Only replace one component at a time and check if the error has gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.
System Error:
Problem Description:
Corrective Action: Try the following:

01.0:YZ

HCI queue does not end after 2 seconds.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
If the System Error continues, replace the Formatter Page 8-140.If the System Error continues, replace the Main PCA Page 8-144.
System Error:
Problem Description:
Corrective Action: Try the following:

01.1:YZ

NVM backup: not found, read, write or read back error.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
If the System Error continues, replace the Main PCA Page 8-144.If the System Error continues, replace the Formatter Page 8-140.
System Error:
Problem Description:

01.2:YZ

Print Mech PCA fault or NVM backup failure.
Corrective Action: Try the following:
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
If the System Error continues, replace the PrintMech PCA ⇒ Page 8-66.
System Error:
Problem Description:
Corrective Action: Try the following:

02.1:YZ

Encoder seems to be wrong.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Trailing Cable is not damaged.Check that the Trailing Cable is correctly connected between the Main
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 2-7
Chapter 1 System Error Codes
PCA and Carriage PCA.
If the System Error continues, replace the Trailing Cable. Page 8-88.If the System Error continues, replace the Carriage PCA Page 8-125.If the System Error continues, replace the Main PCA. Page 8-141.
System Error:
Problem Description:
Corrective Action: Try the following:

02.2:YZ

Problem with the Carriage PCA.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Trailing Cable is not damaged.Check that the Trailing Cable is correctly connected between the Main
PCA and Carriage PCA.
If the System Error continues, replace the Trailing Cable.Page 8-88.If the System Error continues, replace the Carriage PCA Page 8-125..If the System Error continues, replace the Main PCA. Page 8-141.If the System Error continues, replace the Formatter Page 8-140.
System Error:
Problem Description:
Corrective Action: Try the following:

03:YZ

Problem with Power Supply Unit.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Perform the Electronics Module Test Diagnostic to troubleshoot the
problem further ⇒ Page 4-21.
If the System Error continues, replace the Power Supply Unit (PSU) ⇒ Page
8-144.
System Error:
Problem Description:
Corrective Action: Try the following:

05.1:YZ

CPU Fan is stopped or burnt.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Replace the Power Supply Unit (PSU) Page 8-144.If the System Error continues, replace the Main PCA Page 8-144.
System Error:
Problem Description:
Corrective Action: Try the following:

06:YZ

Main NVM failure - not detected, read/write failed or readback error.
Switch the Power OFF from the back of the Printer and disconnect the
2-8 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual
System Error Codes - Full Descriptions - 08:YZ
Power cord. Reconnect the power cord and power On the Printer.
If the System Error continues, replace the Formatter ⇒ Page 8-140.
System Error:
Problem Description:
Corrective Action: Try the following:

08:YZ

Problem with the Front Panel.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Front Panel interface cable is not damaged and is
correctly connected between the Main PCA and the Front Panel.
Check that the memory module in the Formatter is installed correctly.Check that the connections between the Formatter, the Formatter and the
Formatter are not damaged and are correctly connected.
Check that the Printer has the latest Firmware version. If not, update the
Firmware to the latest version.
If the System Error continues, replace the Main PCA Page 8-144.If the System Error continues, replace the Formatter Page 8-140.If the System Error continues, replace the Front Panel Page 8-43.
System Error:
Problem Description:
Corrective Action: Try the following:

11: YZ

Trailing Cable does not seem to be detected.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Trailing Cable is not damaged.Check that the Trailing Cable is correctly connected between the Main
PCA and Carriage PCA.
If the System Error continues, replace the Formatter Page 8-140.If the System Error continues, replace the Main PCA Page 8-144.If the System Error continues, replace the Carriage PCA Page 8-125.
System Error:
Problem Description:
Corrective Action: Try the following:

12.n:YZ

Carriage & PCA Main doesn’t detect pens.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Trailing Cable is not damaged.Check that the Trailing Cable is correctly connected between the Main
PCA and Carriage PCA.
Check that the Printhead has not failed and is not erroneous.Check that the Flex circuit contacts and Printhead contacts are clean.
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 2-9
Chapter 1 System Error Codes
If the System Error continues, replace the Carriage PCA Page 8-125.If the System Error continues, replace the Main PCA Page 8-144.
System Error:
Problem Description:
Corrective Action: Try the following:

21:YZ

Fail moving Service Station.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Check the Primer Tubes. Reconnect the power cord and power On the Printer.
Make sure that the Service Station path is clear. Remove any visible
obstacles (e.g. screws, plastic parts, etc...) restricting the movement of the Service Station.
Perform the Service Station diagnostic test to troubleshoot the problem
further Page 4-42.
If the System Error continues, replace the Service Station Page 8-55.If the System Error continues, replace the PrintMech PCA Page 8-66.
System Error:
Problem Description:
Corrective Action: Try the following:

21.1:YZ

Service Station servo shutdown.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Check the Primer Tubes. Reconnect the power cord and power On the Printer.
Perform the Service Station diagnostic test to troubleshoot the problem
further Page 4-42.
If the System Error continues, replace the Service Station Page 8-55.If the System Error continues, replace the PrintMech PCA Page 8-66.
System Error:
Problem Description:
Corrective Action: Try the following:

22.0:YZ

ISS Left BPS0 error.(Supplies 0, 1, 2).
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the cables between the Left Ink Supply Station and Main PCA
the are not damaged and are correctly connected.
Perform the Ink Delivery System diagnostic test to troubleshoot the
problem further ⇒ Page 4-36.
If the System Error continues, replace the Left Ink Supply Station ⇒ Page
8-130.
If the System Error continues, replace the Main PCA Page 8-144.If the System Error continues, replace the Formatter Page 8-140.
2-10 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual

System Error: 22.1:YZ

System Error Codes - Full Descriptions - 22.1:YZ
Problem Description:
Corrective Action: Try the following:
ISS Left BPS1 error.(Supplies 3, 4, 5).
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the cables between the Left Ink Supply Station and Main PCA
the are not damaged and are correctly connected.
Perform the Ink Delivery System diagnostic test to troubleshoot the
problem further Page 4-36.
If the System Error continues, replace the Left Ink Supply Station ⇒ Page
8-130.
If the System Error continues, replace the Main PCA Page 8-144.If the System Error continues, replace the Formatter Page 8-140.
System Error:
Problem Description:
Corrective Action: Try the following:

24:YZ

Ink Setup failure( Ink Delivery System (IDS) Tubes purge failed).
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Try purging the Ink Supply Tubes again once the Printer has been
restarted.
Install new Cartridges in the printer and try purging the Ink Supply Tubes
again.
System Error:
Problem Description:
Corrective Action: Try the following:

26.n:YZ (color = n)

Order of Ink Supplies incorrect.
Remove the Ink Supply Cartridges and check that they are the correct
ones for this printer and are in the proper order.
Check that the Printer has the latest firmware. If not, update the firmware
to the latest version.
System Error:
Problem Description:
Corrective Action: Try the following:

27:YZ

An error has occurred in Printhead detection.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Remove the Printheads from the Carriage Assembly and reinsert them.Replace the Printheads.Replace the Carriage Cover (Flex Circuit) Page 8-120.
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 2-11
Chapter 1 System Error Codes
Replace the Carriage PCA Page 8-125.Replace the Formatter Page 8-140.

System Error: 29.n:YZ

Problem Description:
Corrective Action: Try the following:
An error has occurred in Printhead detection.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
 Remove the Printheads from the Carriage Assembly and reinsert them.  Replace the Printheads.  Replace the Carriage Cover (Flex Circuit) Page 8-120.  Replace the Carriage PCA Page 8-125.  Replace the Formatter Page 8-140.
System Error:
Problem Description:
Corrective Action: Try the following:

31:YZ

An error has been detected with the cutter.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check the Cutter Assembly for blockage or any other obvious problems.Replace the Cutter Assembly Page 8-38.
System Error:

38:YZ

Problem Description:
Corrective Action: Try the following:
An error has been detected with the Media Output Tray.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check the Media Output Assembly for blockage or any other obvious
problems.
Replace the Media Output Assembly Page 8-13.
System Error:
Problem Description:
Corrective Action: Try the following:

41:YZ

Electrical fault or current limit in Media-Axis Motor.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Open the Window and check for any visible obstacles restricting the
movement of the Media Advance Roller. If there is a wrinkled mass of media inside the paper path, lift the Pinch wheels (using Media Lever) and clear the obstruction.
Perform the Paper Drive diagnostic test to troubleshoot the problem further
2-12 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual
System Error Codes - Full Descriptions - 41.1:YZ
Page 4-18.
If the printer has a 44 inch scan axis (and a Rewinder), perform the
Rewinder diagnostic test to troubleshoot the problem further Page 4-
34.
Check that the Media Advance Drive cable is not damaged and is
correctly connected to the Main PCA.
Replace the Media Advance Drive Page 8-155.If the System Error continues, replace the Main PCA Page 8-144.
System Error:
Problem Description:
Corrective Action: Try the following:

41.1:YZ

Electrical fault or current limit in Media-Axis Motor.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Open the Window and check for any visible obstacles restricting the
movement of the Media Advance Roller. If there is a wrinkled mass of media inside the paper path, lift the Pinch wheels (using Media Lever) and clear the obstruction.
Perform the Paper Drive diagnostic test to troubleshoot the problem further
Page 4-18.
If the printer has a 44 inch scan axis (and a Rewinder), perform the
Rewinder diagnostic test to troubleshoot the problem further Page 4-
34.
Check that the Media Advance Drive cable is not damaged and is
correctly connected to the Main PCA.
Replace the Media Advance Drive Page 8-155.If the System Error continues, replace the Main PCA Page 8-144.
System Error:
Problem Description:

42:YZ

Electrical fault or current limit in Scan-Axis Motor..
Corrective Action: Try the following:
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Open the Window and check for any visible obstacles restricting the
movement of the Media Advance Roller. If there is a wrinkled mass of media inside the paper path, lift the Pinch wheels (using Media Lever) and clear the obstruction.
Perform the Scan Axis diagnostic test to troubleshoot the problem further
Page 4-6.
Check that the Scan-Axis Motor cable is not damaged and is correctly
connected to the PrintMech PCA.
Replace the Scan-Axis Motor Page 8-109.If the System Error continues, replace the PrintMech PCA Page 8-66.
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 2-13
Chapter 1 System Error Codes
System Error:
Problem Description:
Corrective Action: Try the following:

44:YZ

Fan Electrical fault, or not connected..
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Aerosol Fan cable is not damaged and is correctly
connected to the PrintMech PCA
Replace the Aerosol Fan Assembly Page 8-60.If the System Error continues, replace the PrintMech PCA Page 8-66.
System Error: 45:YZ
Problem Description:
Corrective Action: Try the following:
An error with the Rewinder System has been detected.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Rewinder cable is not damaged and is correctly
connected to the PrintMech PCA.
Check that the Right Spindle Holder (rewinder included) is correctly
attached to and aligned with the Right Cover.
Perform the Rewinder diagnostic test to troubleshoot the problem further
Page 4-34.
Replace the Right Spindle Holder (rewinder included) Page 8-74.If the System Error continues, replace the PrintMech PCA Page 8-66.
System Error:
Problem Description:
Corrective Action: Try the following:

47:YZ

Star wheels motor error..
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Starwheel Assembly cable is not damaged and is correctly
connected to Main PCA.
Open the Window and check for any visible obstacles restricting the
movement of the Starwheel Assembly, then clear the obstruction.
Perform the Scan Axis Starwheel diagnostic test to troubleshoot the
problem further ⇒ Page 4-7.
Replace the Starwheel Motor Page 8-177.If the System Error continues, replace the Main PCA Page 8-144.
System Error:
Problem Description:
Corrective Action: Try the following:

48:YZ

PPS system failure.
2-14 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual
System Error Codes - Full Descriptions - 51:YZ
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Pen to Paper Space (PPS) Solenoid cable is not damaged
and is correctly connected to the PrintMech PCA.
Perform the Scan Axis PSS diagnostic test to troubleshoot the problem
further Page 4-9.
Replace the Pen to Paper Space (PPS) Solenoid Page 8-68.If the System Error continues, replace the PrintMech PCA Page 8-66.
System Error:
Problem Description:
Corrective Action: Try the following:

51:YZ

Window Sensor failure.
Check that the Window Position Sensor cable is not damaged and is
correctly connected to the PrintMech PCA.
Perform the Sensors Test to troubleshoot the problem further Page 4-
31.
Replace the Window Position Sensor Page 8-49.
System Error:
Problem Description:
Corrective Action: Try the following:

52:YZ

The printer has detected a problem with the Drop Detector.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Drop Detector cable is not damaged and is correctly
connected to the PrintMech PCA.
Check that the Service Station cable is not damaged and is correctly
connected to the PrintMech PCA.
Replace the Drop Detector Page 8-59.Reset the Calibration Flag of the Drop Detector Page 5-12.If the System Error continues, replace the PrintMech PCA Page 8-66.If the System Error continues, replace the Formatter Page 8-140.
System Error:
Problem Description:
Corrective Action: Try the following:

55:YZ

Problem with the Line Sensor. The printer has detected a failure to access Line Sensor EEPROM).
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Perform the Carriage Test to troubleshoot the problem further Page 4-
26
Check the Line Sensor connections to the Carriage PCA.Replace the Line Sensor Page 8-115.If the System Error continues, replace the Carriage PCA Page 8-125.
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 2-15
Chapter 1 System Error Codes
System Error:
Problem Description:
Corrective Action: Try the following:

56:YZ

Drive roller analog encoder sensor fail or calibration failed.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Perform the Media Path Test to troubleshoot the problem further ⇒ Page
4-18.
Replace the Encoder Disk and Encoder Sensor Page 8-152.If the System Error continues, replace the Main PCA Page 8-144.
System Error: 58:YZ
Problem Description:
Corrective Action: Try the following:
The Line Sensor of the printer is not functioning correctly. Either the Line Sensor shutter has failed to open, there is a failure to communicate with the Line Sensor, the Line Sensor is not calibrated correctly, or the firmware is not compatible with the Line Sensor.
Switch the Power OFF from the back of the Printer and disconnect the
power cord. Reconnect the power cord and power On the Printer.
Perform the Line Sensor calibration.Check that the Printer has the latest Firmware version. If not, update the
Firmware to the latest version.
Perform the Carriage Test to troubleshoot the problem further Page 4-
26.
If the System Error continues, replace the Line Sensor Page 8-115.
System Error:
Problem Description:
Corrective Action: Try the following:

61:YZ

The file format is incorrect and the Printer cannot process the job.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check the graphic language setting of the Printer (Refer to the User's
Guide).
Resend the file to the printer.Check that the Printer has the latest Firmware version. If not, update the
Firmware to the latest version.
The PostScript™ fonts are missing. Upgrading the Firmware will re-install
the fonts.
The file cannot be printed because it is password protected. Resend the
file without password protection.
2-16 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual

System Error: 62:YZ

System Error Codes - Full Descriptions - 62:YZ
Problem Description:
Corrective Action: Try the following:
PC Interface
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Get the latest version of the firmware.
System Error:
Problem Description:
Corrective Action: Try the following:

63:YZ

Input/Output problem through the Network Card.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Network cable is correctly connected to the Formatter.Check that the Printer has the latest Firmware version. If not, update the
Firmware to the latest version.
If the System Error continues, replace the Formatter Page 8-140.If the System Error continues, replace the Main PCA Page 8-144.
System Error:
Problem Description:

64:YZ

Input/Output problem through the USB Port.
Corrective Action: Try the following:
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the USB cable is correctly connected to the Printer.Check that the Printer has the latest Firmware version. If not, update the
Firmware to the latest version.
If the System Error continues, replace the Formatter Page 8-140.If the System Error continues, replace the Main PCA Page 8-144.
System Error:
Problem Description:
Corrective Action: Try the following:

65:YZ

Memory Driver Internal I/O error, I/O Socket Manager Internal I/O error.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the unknown port cable is correctly connected to the Printer.Check that the Printer has the latest Firmware version. If not, update the
Firmware to the latest version.
If the System Error continues, replace the Formatter Page 8-140.If the System Error continues, replace the Main PCA Page 8-144.
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 2-17
Chapter 1 System Error Codes
System Error:
Problem Description:
Corrective Action: Try the following:

66:YZ

Cannot print file on current paper type. The paper type has changed since the file was sent, so the file cannot be printed on the paper type currently loaded.
Resend the file to be printed on the current paper type.Change the paper type to the type that was loaded when the file was
originally sent.
System Error:
Problem Description:
Corrective Action: Try the following:

67:YZ

Input/Output problem through a Firewire Port.
Check that the firewire cable is correctly connected to the Printer.Check that the Printer has the latest Firmware version. If not, update the
Firmware to the latest version.
If the System Error continues, replace the Main PCA ⇒ Page 8-144.
System Error:
Problem Description:

68:YZ

Loss of engine counters tracking.
Corrective Action: Try the following:
Reboot the printer. The printer will continue to function correctly, but the
life counters will not continue counting until you restart the printer.
System Error:
Problem Description:
Corrective Action: Try the following:

71:YZ

Out of memory failure.
It is recommended that you remove any unnecessary files from the Hard
Disk Drive of the Formatter using the Web Server.
System Error:
Problem Description:
Corrective Action: Try the following:

71:19

Default Serial Number found in the main and backup NVM. It seems that both the Print Mech PCA and Hard Disk Drive have been replaced together.
Perform the “Error 71:19 Recovery” Service Utility ⇒ Page 4-51.
You MUST NEVER replace both the Formatter and the PrintMech PCA at the same time. If both parts need to be replaced, you MUST first replace one part and then power ON the Printer until it completely initializes. Then you can power OFF the Printer and replace the other part.
2-18 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual

System Error: 72:YZ

System Error Codes - Full Descriptions - 72:YZ
Problem Description:
Corrective Action: Try the following:
Generic Firmware error.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Printer has the latest Firmware version. If not, update the
Firmware to the latest version.
System Error:
Problem Description:
Corrective Action: Try the following:

73:YZ

Servo Error.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Printer has the latest Firmware version. If not, update the
Firmware to the latest version.
Perform the Scan Axis Test to troubleshoot the problem further Page 4-
6.
If the System Error continues, perform the Media Drive diagnostic test to
troubleshoot the problem further ⇒ Page 4-18.
System Error:

74:YZ

Problem Description:
Corrective Action: Try the following:
Error uploading firmware update file.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Make sure the connection between the computer and the printer is
functioning properly.
Try to update the Firmware again.
System Error:
Problem Description:
Corrective Action: Try the following:

74.1:YZ

Error uploading media profile update file.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Make sure the connection between the computer and the printer is
functioning properly.
Try to upload the media profile update file again.
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 2-19
Chapter 1 System Error Codes
System Error:
Problem Description:
Corrective Action: Try the following:

75.1:YZ

Preventive Maintenance Kit #1 counter active (Scan Axis Components ,Ink Supply Tubes, Trailing Cable, Carriage).
Switch the Power OFF from the back of the Printer and disconnect the
Power cord.
Change the Belt Assembly, the Scan-Axis Motor, the Ink Supply Tubes,
Carriage Assembly (this does not include the Carriage PCA but it does include the Trailing Cable). You should change Preventive Maintenance Kit #1. Refer to Page 7-24.
Once the parts have been changed, use the Service Menu to reset the
counters that affect PMKit #1.
Change the Trailing Cable with Preventive Maintenance Kit # 4.
Once the parts have been changed, use the Service Menu to reset the counters that affect PMKit #4.
System Error:
Problem Description:
Corrective Action: Try the following:

75.2:YZ

Preventive Maintenance Kit #2 counter active.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord.
Change the Service Station
You should change Preventive Maintenance Kit #2. Refer to Page 7-24.
Once the parts have been changed, use the Service Menu to reset the
counters that affect PMKit #2. See 4. Reset Life Counters, Page 4-63.
System Error:
Problem Description:
Corrective Action: Try the following:

75.3:YZ

Preventive Maintenance Kit #3 counter active (Cutter Assembly).
Switch the Power OFF from the back of the Printer and disconnect the
Power cord.
Change the Cutter Assembly using Preventive Maintenance Kit #3. Refer
to Page 7-24. Note that the PMkit is the same as the Cutter Assembly.
Once the parts have been changed, use the Service Menu to reset the
counters that affect PMKit #3.
System Error:
Problem Description:
Corrective Action: Try the following:

75.4:YZ

Preventive Maintenance Kit #4 counter active.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord.
Change the Trailing Cable using Preventive Maintenance Kit #4. Refer to
2-20 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual
System Error Codes - Full Descriptions - 76:YZ
Page 7-24. Note that the PMkit is the same as the Trailing Cable.
Once the parts have been changed, use the Service Menu to reset the
counters that affect PMKit #4.
System Error:
Problem Description:
Corrective Action: Try the following:

76:YZ

Hard disk drive is full.
Remove any unnecessary files from the hard disk using the web server.
System Error:
Problem Description:
Corrective Action: Try the following:

77:YZ

Web access application. The web server is not functioning correctly.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Printer has the latest Firmware version. If not, update the
Firmware to the latest version.
System Error:
Problem Description:
Corrective Action: Try the following:

78:YZ

Borderless printing not possible. Setting ignored.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Send the plot again.
System Error:
Problem Description:
Corrective Action: Try the following:

78.1:YZ

Media settings area missing in media settings file.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Printer has the latest Firmware version. If not, update the
Firmware to the latest version.
Update the OMES.
System Error:
Problem Description:
Corrective Action: Try the following:

79:YZ

Generic Firmware error.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Printer has the latest Firmware version. If not, update the
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 2-21
Chapter 1 System Error Codes
Firmware to the latest version.
System Error:
Problem Description:
Corrective Action: Try the following:

79.1:YZ

Recoverable firmware error that does not stop the printing process.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Check that the Printer has the latest Firmware version. If not, update the
Firmware to the latest version.
System Error:
Problem Description:
Corrective Action: Try the following:

81:YZ

Problem with paper advance.
Open the Window and check for any visible obstacles restricting the
movement of the Drive Roller. If there is a wrinkled mass of media inside the paper path, lift the Pinchwheels (using the Media Lever) and clear the obstruction.
Perform the Media Drive diagnostic test to troubleshoot the problem
further Page 4-18.
If the printer has a 44 inch scan axis (and a Rewinder), perform the
Rewinder diagnostic test to troubleshoot the problem further Page 4-
34.
Check the connections on the Main PCA; the Media Advance Drive is
connected to the connector labeled Paper Motor.
If the System Error continues, replace the Media Advance Driver Page
8-155.
System Error:
Problem Description:
Corrective Action: Try the following:

81.1:YZ

Problem finding the Drive Roller zero.
Open the Window and check for any visible obstacles restricting the
movement of the Drive Roller. If there is a wrinkled mass of media inside the paper path, lift the Pinchwheels (using the Media Lever) and clear the obstruction.
Perform the Media Drive diagnostic test to troubleshoot the problem
further Page 4-18.
If the printer has a 44 inch scan axis (and a Rewinder), perform the
Rewinder diagnostic test to troubleshoot the problem further Page 4-
34.
Check the connections on the Main PCA; the Media Advance Drive is
connected to the connector labeled Paper Motor.
If the System Error continues, replace the Media Advance Driver Page
8-155.
2-22 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual

System Error: 84:YZ

System Error Codes - Full Descriptions - 84:YZ
Problem Description:
Corrective Action: Try the following:
Back tension servo shutdown (roll feeding).
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
If the problem persists, contact HP support.
System Error:
Problem Description:
Corrective Action: Try the following:

85:YZ

Problem finding the Drive Roller zero.
Perform the Media Drive diagnostic test to troubleshoot the problem
further Page 4-18.
If the System Error continues, replace the Encoder Disk and Encoder
Sensor Page 8-152.
System Error:
Problem Description:
Corrective Action: Try the following:

86:YZ

Possible Paper Jam.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Open the Window and check for any visible obstacles restricting the
movement of the Drive Roller. If there is a wrinkled mass of media inside the paper path, lift the Pinch wheels (using the Media Lever) and clear the obstruction.
System Error:
Problem Description:
Corrective Action: Try the following:

87:YZ

Problem finding the Scan-axis encoder reading.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Movement jam. Possible paper jam.Mechanical Initiator scan axis measure error.Check that the Scan-Axis Motor is correctly connected.Check that the Encoder Sensor is correctly connected.Remove the Encoder Strip and clean it.Perform the Scan Axis diagnostic test to troubleshoot the problem further
Page 4-6
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 2-23
Chapter 1 System Error Codes
System Error:
Problem Description:
Corrective Action: Try the following:

93:YZ

Unable to pressurize the Ink Delivery System.
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Perform the Ink Delivery System diagnostic test to further troubleshoot the
problem. Page 4-36
If the problem persists, contact HP support.
System Error:
Problem Description:
Corrective Action: Try the following:

94:YZ

Color calibration Error.
Profiling failed due to a different error (not algorithm / data processing).Perform the Line Sensor calibration. See Troubleshooting, Line Sensor
Page 1-3
If the System Error continues, replace the Line Sensor Page 8-115If the System Error continues, replace the Carriage PCA Page 8-125.If the System Error continues, replace the Formatter Page 8-140.
System Error:
Problem Description:
Corrective Action: Try the following:

94.1:YZ

Profiling algorithm failed.
Profiling failed due to a different error (not algorithm / data processing).Perform the Line Sensor calibration. See Troubleshooting, Line Sensor Page 1-3If the System Error continues, replace the Line Sensor Page 8-115If the System Error continues, replace the Carriage PCA Page 8-125.If the System Error continues, replace the Formatter Page 8-140.
System Error:
Problem Description:
Corrective Action:

98:YZ

Automatic backup print mode enabled. Try the following:
Switch the Power OFF from the back of the Printer and disconnect the
Power cord. Reconnect the power cord and power On the Printer.
Recover the printheads.
2-24 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual

Ink Supplies Troubleshooting 3

Using the Front Panel 3-2 Introduction to Ink Supplies 3-3
Ink Cartridges 3-3 Available Ink Cartridges 3-4 Printheads 3-4 Available Printheads 3-5 General Information About the Ink Supplies 3-5 General Precautions When Handling Ink Supplies 3-5 When Should You Replace the Ink Supplies? 3-6
Ink Cartridge Levels, Information, and Replacement 3-7
Ink Cartridge Levels 3-7 Obtaining Ink Cartridge Information 3-7 Changing an Ink Cartridge 3-9
Printhead Information, Replacement and Alignment 3-11
Obtaining Printhead Information 3-11 Changing a Printhead 3-12 Aligning Printheads 3-14
Ink Cartridge and Printhead Status Messages 3-16
Ink Cartridge Status Messages 3-16 Printhead status messages 3-16
Solving Ink Supplies Problems 3-18
You Cannot Insert the Ink Cartridge Into the Printer 3-18 You Cannot Insert the Printhead Into the Printer 3-18 The front panel says to reset or replace a printhead 3-18
Maintaining and Cleaning the Printheads 3-20
Maintaining and Cleaning the Printheads 3-20 Flex Contacts Cleaning Tool 3-20
3
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 3-1
Chapter 3 Ink Supplies Troubleshooting

Using the Front Panel

Below is a diagram of the front panel.
View Loaded Paper
Unload Paper

Key Function

Arrow Keys
Use the Arrow keys to scroll through a menu or toggle between YES or NO when prompted.
Cancel
Use the Cancel key to abort or stop a procedure or reject test results.
OK
Use the OK key to select a menu option.
Power
Use the Power key to turn the printer ON and OFF.
Menu
Use the Menu key to enter the main menu.
Back
Use the Back key to go back to the previous menu or reject test results.
View Ink Levels
Form Feed and Cut
Arrow Keys
Cancel
OK
Power
Menu
Back

Service Key Combinations

Diagnostic mode
With the printer OFF, press and hold the UP and OK keys. While holding the Up and OK keys down, press and hold the Power key to turn on the printer. Hold all three keys until the Power key stops flashing, usually about 5 seconds.
Service Menu (Service Engineers Only)
From the main menu, press and hold the Up and Cancel keys.
Service Menu (For users)
From the main menu, press and hold the Down and Cancel keys.
3-2 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual

Introduction to Ink Supplies

What are Ink Supplies?

For each of the ink colors used in the printer, there are two components, the Printhead and Ink Cartridge. These components are called Ink Supplies.
Introduction to Ink Supplies - What are Ink Supplies?

Ink Cartridges

Printheads
Ink Cartridges
The printer's six Ink Cartridges provide matte black, magenta, yeloow, cyan, gray and photo black ink to the Printheads. The color Ink Cartridges supplied with the printer have a capacity of 69ml but optional 130 ml are
also available
.l
All these Ink cartridges are physically the same size. Only the internal capacity varies.
The Ink Cartridges for the T1100/T1100ps/T610 printer series require no maintenance or cleaning. As long as each Ink Cartridge is inserted correctly into its slot, the ink will flow to the Printheads. Because the Printheads control the amount of ink transferred to the page, you will continue to see high­quality printing results even when the ink levels are getting low.
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 3-3
Chapter 3 Ink Supplies Troubleshooting
The front panel displays the status of the Ink Cartridge. Using the front panel, detailed information can be checked on the Ink Cartridges.

Available Ink Cartridges

T1100/T1100ps /T610 Cartri dges Part
number
HP 72 69 ml Photo Black Ink Cartridge
HP 72 69 ml Cyan Ink Cartridge Ink Cartridge C9398A HP 72 69 ml Magenta Ink
Cartridge HP 72 69 ml Yellow Ink
Cartridge HP 72 69 ml Gray Ink Cartridge Ink Cartridge C9401A HP 72 130 ml Matte Black Ink
Cartridge HP 72 130 ml Photo Black Ink
Cartridge HP 72 130 ml Cyan Ink
Cartridge HP 72 130 ml Magenta Ink
Cartridge HP 72 130 ml Yellow Ink
Cartridge HP 72 130 ml Gray Ink
Cartridge
Ink Cartridge C9397A
Ink Cartridge C9399A
Ink Cartridge C9400A
Ink Cartridge C9403A
Ink Cartridge C9370A
Ink Cartridge C9371A
Ink Cartridge C9372A
Ink Cartridge C9373A
Ink Cartridge C9374A

Printheads

The Printheads are extremely durable and do not need to be replaced every time an Ink Cartridge is replaced. They are independent of the Ink Cartridges and will continue giving excellent image quality results even if the
Ink Cartridges are low on ink.
If you notice a decline in print quality such as lines or dots missing from text/ graphics, go to Page 6-22, Troubleshooting Print Quality Problems .
3-4 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual
Introduction to Ink Supplies - Available Printheads

Available Printheads

Printhead Type Printer Model Part
number
HP 72 Gray & Photo Black Printhead
HP 72 Magenta & Cyan Printhead C9383A
HP 72 Matte Black & Yellow Printhead
T1100/T1100ps/ T610
C9380A
C9384A

General Information About the Ink Supplies

For optimum results from the printer and modular ink delivery system always follow these guidelines when handling the ink supplies:
Always install the Ink Cartridges and Printheads before the expiration
date, which is on the packaging.
Install Ink Cartridges and Printheads in their color-coded slots.Follow the instructions on the front panel of the Printer during installation.Avoid unnecessary removal of the Ink Cartridges and Printheads.When turning off the Printer always use the power Off button on the front
panel. The Printheads are then stored correctly which prevents them from drying out.
The Ink Cartridges should never be removed while the printer is printing.
They should only be removed when the printer is ready for you to replace them. The front panel will guide you through the removal and installation procedure.

General Precautions When Handling Ink Supplies

Use the following precautions when handling Ink Supplies:
Do not touch, wipe or attempt to clean the printhead nozzles. This can damage the printhead.
Handle the ink supplies with care. In particular the Printhead, which is a
high precision device and must be handled carefully.
Do not touch the Printhead nozzles.Do not put the Printhead down on the nozzles.Do not be rough when handling the Printheads. Always set them down
gently.
Do not drop the Printheads.Proper handling will assure optimum performance throughout the
Printhead life.
Do not touch the end of the Ink Cartridge which is inserted into the printer
as there may be a small amount of ink on the connection.
Avoid storing partially used Ink Cartridges on their ends.
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 3-5
Chapter 3 Ink Supplies Troubleshooting

When Should You Replace the Ink Supplies?

When to change the ink supplies is mostly determined by you with guidance from the front panel. In conjunction with the messages displayed in the front panel and the message explanations in this chapter, you will be able to choose for yourself when is the right time to change the ink supplies.
The Printer will also display the ink level and will tell you when the ink supply is low on ink. This means you have constantly updated information about the ink supplies.
3-6 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual
Ink Cartridge Levels, Information, and Replacement - Ink Cartridge Levels

Ink Cartridge Levels, Information, and Replacement

Ink Cartridge Levels

The front panel displays Ink Levels shown as level bars. These bars represent how much ink is remaining in the Ink Cartridges: as ink is used up the bars get shorter in length.
There are two methods for checking the ink levels of your Ink Cartridges.
“View Ink Levels” Direct Access Key
Pressing the “View ink levels” direct access key on the Front Panel will
immediately show you the ink levels. For more information about direct access keys, See Using the Front Panel, Page 3-2.
“View Ink Levels” from the ink menu
Choosing the View ink levels option from the Ink menu will
immediately show you the ink levels:

Obtaining Ink Cartridge Information

1 Scroll to the Ink Menu icon and press OK.
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Chapter 3 Ink Supplies Troubleshooting
2 In the Ink Menu submenu, scroll to Ink cartridge information and press
OK.
3 In the Ink Cartridge Information submenu, scroll to the Ink Cartridge that you
want information on and press OK.
4 The front panel displays information on the selected Ink Cartridge. Use the
Arrow keys to scroll through the information.
The information supplied is:
The color of the Ink CartridgeThe make of the Ink Cartridge (hp no.72 is recommended).The product number of the Ink Cartridge.The serial number of the Ink Cartridge.The current status of the Ink Cartridge.The current ink level of the ink cartridge in milliliters.Original capacity of the ink cartridge in milliliters.The Expiration Date of the ink cartridge.The manufacturer of the Ink Cartridge (hp is recommended).The current warranty status of the Ink Cartridge.
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Ink Cartridge Levels, Information, and Replacement - Changing an Ink Cartridge

Changing an Ink Cartridge

There are two occasions when you need to remove an ink cartridge:
The ink cartridge is very low and you want to replace it with a full
cartridge for unattended printing (you can use up the remaining ink in the first cartridge at a more convenient time).
The ink cartridge is empty or faulty, and you must replace it to continue
printing.
Do not try to remove an ink cartridge while printing. Remove an ink cartridge only if you are ready to insert another one. Make sure the printer wheels are locked (the brake lever is pressed down) to prevent the printer from moving.
Change an ink cartridge using the following procedure:
1 Scroll to the Ink Menu icon and press OK.
2 In the Ink Menu submenu, scroll to Replace ink cartridges and press
OK.
3 The front panel displays the status of the Ink Cartridges.
4 Press OK to continue.
5 Open the relevant Ink Cartridge cover for the Ink Cartridge you want to
replace.
6 Pull the required Ink Cartridge straight up to remove it from the printer.
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Chapter 3 Ink Supplies Troubleshooting
7 The front panel indicates the missing Ink Cartridge.
8 Before removing the cartridge from its wrapping, shake it vigorously.
9 Unwrap the new ink cartridge, find the label identifying the ink color. Check
that the letter or letters marking the empty slot, matches the letter or letters on the cartridge label.
10 Insert the ink cartridge into its slot.
11 Push the cartridge into the slot until it snaps into position. You should hear a
beep and see confirmation that the cartridge has been inserted.
12 When all cartridges have been inserted, close the cover.
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Printhead Information, Replacement and Alignment - Obtaining Printhead Information

Printhead Information, Replacement and Alignment

Obtaining Printhead Information

1 Scroll to the Ink Menu icon and press OK.
2 In the Ink Menu submenu, scroll to Printhead information and press
OK.
3 In the Printhead Information submenu, scroll to the Printhead that you want
information on and press OK.
4 The front panel displays information on the selected Printhead.
The information supplied is:
The make of the printhead (hp no.72 is recommended).The product number of the Printhead.The serial number of the Printhead.The current status of the printhead.How much ink has been fired (consumed) by the printhead. Note: It is
possible for a printhead to consume more than one Ink Cartridge.
The current warranty status of the Printhead.
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Chapter 3 Ink Supplies Troubleshooting

Changing a Printhead

1 Scroll to the Ink Menu icon and press OK.
2 In the Ink Menu submenu, scroll to Replace printheads and press OK.
3 The printer moves the Carriage to the correct position to replace Printheads.
If the carriage is left in the removal position for more than three minutes without inserting or removing any printheads, it will try to move back to its normal position at the right-hand end.
4 When the carriage has stopped moving, the front panel display will prompt
you to open the window and lift the carriage cover.
5 Open the window.
6 Lift the Carriage cover to access the printheads.
7 Lift the blue handle and pull the Printhead straight up out of the Carriage.
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Printhead Information, Replacement and Alignment - Changing a Printhead
8 To insert a new printhead first remove the orange protective caps.
9 The printhead is designed to prevent you from accidentally inserting it into
the wrong slot. Check that the colored label on the printhead matches the colored label of the carriage slot into which the printhead is to be inserted. Insert the printhead slowly and vertically, straight down. It may be damaged if you insert it too fast, or at an angle, or if you rotate it as you insert it.
10 Insert all other printheads that need to be installed, and close the carriage
cover.
11 Close the Window.
12 When all the printheads have been inserted correctly and accepted by the
printer, the printer will beep. If the printer does not beep when you insert the printhead and the Replace message appears on the front panel display, the printhead may need to be reinserted. The front panel display confirms that all printheads are correctly inserted. The printer will start checking and preparing the printheads. The default
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Chapter 3 Ink Supplies Troubleshooting
routine process, when all printheads are changed, takes 25 minutes. If the printer finds problems in preparing the printheads, it will take longer, up to 55 minutes. For a single printhead insertion, the times vary between 15 and 35 minutes. After all printheads are checked and prepared, for the printhead realignment.

Aligning Printheads

Precise alignment between printheads is essential for accurate colors, smooth color transitions, and sharp edges in graphical elements. Your printer has an automatic printhead alignment process which runs whenever a printhead has been accessed or replaced.
In cases where the paper has jammed, you have used a custom paper, or are experiencing problems with color accuracy you may need to align the printheads. If the paper has jammed, it is recommended that you reinsert the printheads and initiate the realignment procedure with the Image Quality
Maintenance menu.
Do not use transparent and semi-transparent paper to align the printheads. Photo paper is recommended for the best quality.
Reinsert Printheads Procedure
1 If the realignment process is running and the wrong paper is loaded, press
the cancel key on the front panel. Do not print if the realignment process has been canceled. You can restart the alignment with the Image Quality Maintenance menu procedure.
2 Load the paper you wish to use,. You can use a roll or cut sheet, however, it
must be A3 landscape or larger.
3 Remove and re-insert all the printheads, see Remove a printhead and Insert
a printhead. This will start the printhead alignment procedure.
4 Ensure the transparent window closed, as a strong light source near the
printer during printhead realignment can affect alignment.
5 The process will take about six minutes. Wait until the front panel display
shows the process complete before using the printer.
Image Quality Maintenance Procedure
1 Load the paper you wish to use. You can use a roll or cut sheet, however, it
must be A3 landscape or larger (420 by 297 mm). Do not use transparent and semi-transparent paper to align the printheads. Photo paper is recommended for the best results; plain, bond and thin coated papers provide acceptable but marginal results.
2 Press the Menu key to return to the main menu and select the Image Quality
Maintenance menu icon.
3 Select Align printheads. The printer will check to see if it has enough paper
to run the realignment.
4 If the loaded paper is satisfactory, the printer will run the realignment and
print a realignment pattern. Ensure the transparent window is closed, as a
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Printhead Information, Replacement and Alignment - Aligning Printheads
strong light source near the printer during printhead realignment can affect alignment.
T1100/T1100ps/T610 Plot:
5 The process will take about five minutes. Wait until the front panel display
shows the process complete before using the printer.
Scanning errors during alignment
If the alignment process FAILs, a Scanning problems message appears on the front panel. This means that the alignment has not completed successfully. Therefore the printer is not aligned and the alignment should be repeated before printing with good image quality. The problem may be due to:
The paper used was not valid, repeat the alignment with valid paper.Printhead health problems, clean printheads.The alignment was done with the transparent window open, repeat the
alignment with the window closed.
If the problem persists after using valid paper, cleaning the printheads, and keeping the window closed, there may be a Failure in the scanning system needing reparation or the printheads, although clean, may not work and need to be replaced.
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Chapter 3 Ink Supplies Troubleshooting

Ink Cartridge and Printhead Status Messages

Ink Cartridge Status Messages

OK The Ink Cartridge is operating correctly and no action is required.
Missing There is no Ink Cartridge present, or it is not properly connected to the
printer
Low The Low message is an early warning sign and it is advisable that new
supplies should be obtained of that particular color. The amount of ink remaining in the Ink Cartridge depends on it’s capacity, but there is approximately 14% of ink available for the user.
Very Low When the Very Low message is displayed, overnight printing should not
be attempted. Changing the Ink Cartridge is strongly recommended to prevent the printer from stopping halfway through a print. There is approximately 8% of ink available for the user.
Empty The printer will stop and will not be able to continue printing until a new Ink
Cartridge has been installed. If this occurs halfway through printing an image, you should check the quality of this image, as stopping mid-plot can affect the print. It would be recommended to reprint the image once a new Ink Cartridge has been installed.
Reseat You are recommended to remove the Ink Cartridge and then reinsert it.
Replace You are recommended to replace the Ink Cartridge with a new Ink
Cartridge.
Altered There is something unexpected about the Ink Cartridge's status.
Expired The Ink Cartridge has passed the expiration date.

Printhead status messages

OK The Printhead is operating correctly and no action is required.
Missing There is no Printhead present, or it is not properly connected to the printer.
Test printhead separately
Reseat You are recommended to start the printhead removal process from the front
You are recommended to test the printheads individually to find the failing printhead. Remove all the printheads and insert them alone one by one, Closing the latch and the carriage cover after every insertion. The front panel display will indicate the failing one showing the reseat or replace message.
panel, but instead of removing the printhead, simply press the OK key on the front panel.
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Ink Cartridge and Printhead Status Messages - Printhead status messages
Replace You are recommended to remove the printhead and then reinsert it; if that
fails, clean the electrical connections; if that fails, replace the printhead with a new printhead.
Replacement incomplete
Remove The printhead is not a suitable type for use in printing (for instance, a setup
A printhead replacement process has not completed successfully, relaunch the replacement process and let it finish completely (it is not needed to change the printheads).
printhead).
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Chapter 3 Ink Supplies Troubleshooting

Solving Ink Supplies Problems

Most of the problems that you could encounter when working with the ink supplies are solved with guidance from the front panel. A full list of front panel messages are supplied in the User’s Guide.

You Cannot Insert the Ink Cartridge Into the Printer

1 Ensure that you have the correct hp no.72 Ink Cartridge.
2 Ensure that the Ink Cartridge is the correct color for that slot.
3 Ensure that the Ink Cartridge is the correct orientation, with the color coded
label at the top.
Never clean inside the Ink Cartridge slots as this can cause damage to the Printer.

You Cannot Insert the Printhead Into the Printer

1 Ensure that you have the correct hp no.72 Printhead.
2 Ensure that the printhead is the correct color for that slot.
3 Ensure that the printhead is in the correct orientation.
4 Ensure that the protective cap is removed from the Printhead.

The front panel says to reset or replace a printhead

1 From the front panel, turn the power off then on.
2 Check the front panel display message, if it shows the ready message, the
printer is ready to print. If the problem remains continue with the next step.
3 Remove the printhead.
4 Clean the electrical connections on the backside of the printhead with a lint
free cloth. You can carefully use a mild rubbing alcohol if moisture is needed to remove residue. Do not use water. You can use the Flex Contacts Cleaning Tool.
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Solving Ink Supplies Problems - The front panel says to reset or replace a printhead
This is a delicate process and may damage the printhead. Do not touch the nozzles on the bottom side of the printhead, especially not with any alcohol.
5 Reinsert the printhead.
6 Check the front panel display message. If the problem remains, try a new
printhead.
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Chapter 3 Ink Supplies Troubleshooting

Maintaining and Cleaning the Printheads

Clean the printheads

As long as the printer is kept turned on, an automatic cleaning is performed periodically. This ensures there is fresh ink in the nozzles and prevents nozzle clogs, which ensures color accuracy.
If you have not already done so, please refer to Horizontal lines across the image (banding) and The Image Diagnostics Print before proceeding.
To clean the printheads, press the Menu key to return to the main menu and select the Image Quality Maintenance menu icon, then Clean printheads. If you have gone through the Image Quality Diagnostic print process, you know which colors are failing. Select to the pair of printheads which contain the failing colors. If you are not sure which colors to clean, you can also select to clean all printheads.
Cleaning all printheads takes about nine minutes. Cleaning a single pair of printheads takes about six minutes. Cleaning all printheads uses more ink than cleaning a single pair.
If you have cleaned the printheads using the Clean printheads procedure from the front panel and are still experiencing image quality problems, you can try cleaning the printhead nozzles manually using the following
procedure.
This is a delicate process and may damage the printhead. Do not touch the electrical connections on the backside of the printhead.
You must remove the printhead (see Remove a printhead) and using a cotton swab and a little de-ionized, distilled water, or Carriage Interconnect Wiper clean the bottom of the printhead until the residue is removed.

Flex Contacts Cleaning Tool

The Flex Contacts Cleaning Tool is part of the Maintenance Tool Kit which can be ordered using Part Number Q5669-
60690. All the instructions needed to use the Flex Contacts Cleaning Tool will be packaged with the kit.
Whenever you replace the Printhead, check the empty slots to see if they need cleaning. In extreme circumstances, when a Printhead is inserted, it is possible that the Printer will not recognize it due to the build-up of ink on the electrical connection between the Printhead and the Carriage Assembly.
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Maintaining and Cleaning the Printheads - Flex Contacts Cleaning Tool
Included with the T1100/T1100ps/T610 Printer is a Flex Contacts Cleaning Tool. This tool is provided in a separate package. It also contains replacement sponges and an instruction sheet. This tool should be used for cleaning the electrical interconnects of both the Carriage Assembly and the Printhead.
If the front panel displays the message “Reseat” or “Replace” next to the offending printhead, try cleaning the flex circuits of the Carriage and the
Printheads using the Carriage Interconnect Wiper.
Do not touch, wipe or attempt to clean the printhead nozzles. This can damage the printhead and reduce print quality.
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Chapter 3 Ink Supplies Troubleshooting
3-22 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual

Service Tests and Utilities 4

Introduction 4-2
Diagnostics - Self Test 4-2
Service Tests (Diagnostics) 4-3
Using the Front Panel 4-5 Entering the Service Tests Menu 4-6
1. Scan Axis 4-6
2. Paper Drive 4-18
3. Electronics Module 4-21
4. Carriage Assembly 4-26
5. Sensors 4-31
6. Rewinder 4-34
7. I n k D e l i v e r y S y s t e m ( I D S ) 4 - 36
8. Service Station 4-42
9. I/O Information 4-48
10. Unit Information 4-48
11. EEROM Reset 4-49
12. Set Unit Configuration 4-51
13. Error 71:19 Recovery 4-51
14. Others 4-55
Service Utilities 4-56
Entering the Service Utilities Menu 4-56
1. Turn Drive Roller 4-58
2. Purge Tubes 4-60
3. Set SN 4-62
4. Reset Life Counters 4-63
5. Diagnostic Print 4-64
6. Set Date and Time 4-65
7. Enable/Disable Firewall 4-66
8. Reset User Life Counters 4-67
9. Disk Wipe DoD 5220.22OM 4-67
4
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Chapter 4 Service Tests and Utilities

Introduction

This chapter explains how to use the built-in Service Tests and Service Utilities and what to do if any of the Service Tests FAIL.
If possible, always perform a Service Test on the component that you are about to replace, just to make sure that is the component that has FAILed. If the test on that component passes, there is no need to replace it.

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 2, System Error Codes.

Phone Support

In certain circumstances, a Call Agent can try and troubleshoot the Printer by requesting the Customer to perform a Service Test via the phone. Using this process, it can be determined whether the Printer requires any on-site maintenance. Remember that the Key combination for the Customer to Enter the Service Tests and Utilities is different from the one that the Customer Engineer will use.
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Service Tests (Diagnostics)

The following is a list of all internal Service Tests available in the Printer. Instructions for entering the Service Tests menu are given on Page 4-6.
1 Scan Axis Test ⇒ Page 4-6
The purpose of this test is to verify the operation of components related to the Scan Axis. The tests verify the operation of the:
PRSScan AxisStar Wheel LifterCutter
2 Paper Drive Test ⇒ Page 4-18
The purpose of this test is to verify the operation of components related to the Media Axis.
3 Electronics Module ⇒ Page 4-21
The purpose of this test is to verify the operation of the:
Main PCA (Formatter).Printer Configuration.Power Supply Unit.PrintMech.Carriage Communication.
Service Tests (Diagnostics) - Phone Support
4 Carriage Assembly Test ⇒ Page 4-26
The purpose of this test is to verify the operation of the Carriage Assembly.
5 Sensors Test ⇒ Page 4-31
The purpose of this test is to verify the operation of the following Sensors:
Window Sensor.Media Lever Sensor.Media Sensor.
6 Rewinder Test ⇒ Page 4-34
The purpose of this test is to verify the operation of the Rewinder.
7 Ink Delivery Test ⇒ Page 4-36
The purpose of this test is to verify the operation of the Ink Delivery System.
8 Service Station Test ⇒ Page 4-42
The purpose of this test is to verify the operation of the Service Station.
9 I/O Information ⇒ Page 4-48
The purpose of this test is to verify the TCP/IP configuration.
10 Unit Information ⇒ Page 4-48
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Chapter 4 Service Tests and Utilities
This option allows you to view the Firmware Version, Part Number, and Serial Number of the Printer.
11 EEROM Reset ⇒ Page 4-49
The purpose of this test is to reset the EEROM values.
12 Set Unit Configuration ⇒ Page 4-51
Not implemented.
13 Error 71:19 Recovery ⇒ Page 4-51
The purpose of this utility is to set the Serial Number and Part Number in case both the Formatter and the PrintMech PCA are replaced at the same time or select the correct Serial Number and Part Number if only one of the components has been replaced.
14 I/O Tests ⇒ Page 4-55
Not implemented.
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Service Tests (Diagnostics) - Phone Support

Using the Front Panel

Below is a diagram of the front panel.
View Loaded Paper
Unload Paper
Key Function
Arrow Keys
Use the Arrow keys to scroll through a menu or toggle between YES or NO when prompted.
Cancel
Use the Cancel key to abort or stop a procedure or reject test results.
OK
Use the OK key to select a menu option.
Power
Use the Power key to turn the printer ON and OFF.
Menu
Use the Menu key to enter the main menu.
Back
Use the Back key to go back to the previous menu or reject test results.
View Ink Levels
Form Feed and Cut
Arrow keys
Cancel
OK
Power
Menu
Back
Service Key Combinations
Diagnostic mode
With the printer OFF, press and hold the UP and OK keys. While holding the Up and OK keys down, press and hold the Power key to turn on the printer. Hold all three keys until the Power key stops flashing, usually about 5 seconds.
Service Menu (Service Engineers Only)
From the main menu, press and hold the Up and Cancel keys.
Service Menu (For users)
From the main menu, press and hold the Down and Cancel keys.
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Chapter 4 Service Tests and Utilities

Entering the Service Tests Menu

In order to enter the Service Utility Menu, please refer to the instructions on Page
1 Make sure the printer is switched OFF from the power switch on the front of
the printer and NOT from the power switch on the back of the printer.
2 For On-Site Engineers, hold the Up arrow key and the OK key down and
switch the printer ON using the front power switch. Wait until the LED of the power switch stops flashing (usually after 5 seconds) before releasing ALL three keys.
3 Once inside the Service Tests Menu use the Arrow keys to scroll through the
“Service Tests” selections. Press the OK key to begin a specific test when the required Service Test is highlighted.
T
R
PO
SUP
P
HO
O
N
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E
UP
S
E
T
I
S
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PO
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4-56
.
The Service Tests work in a special Mode which does NOT require the full Initialization of the Printer. Therefore it is important that once you have finished with the Service Tests, you MUST power OFF the Printer and Power ON again before trying to print or before executing another Service Test.
In some cases a quick press of a button may not be recognized by the Printer. When pressing a button, be sure to press it deliberately and all the way to the bottom of its travel.
If the Printer hangs up during a test, switch the Printer OFF and restart from step 1.

1. Scan Axis

The complete Scan Axis test consists of individual tests for the different components related to the Scan Axis. The subsystem that are included in this assembly are:
Star Wheel LifterAutomatic PPS Adjustment. Scan Axis ServosystemCutter
You must perform the Scan-Axis Test after:
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Service Tests (Diagnostics) - 1. Scan Axis
System Error Code 87:XZ.System Error Code 42:XZ.System Error Code 47:XZ.System Error Code 73:XZ.System Error Codes related to Scan-Axis shutdown or Carriage jam.
Diagnostic tests also need to be performed after removing or replacing certain printer components. If you have removed or replaced printer components, check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform. Refer to Page 8-4.
ALL THE COVER SENSORS ARE DISABLED WHEN IN THE SERVICE TESTS MENU. IF THE CARRIAGE IS MOVING IT WILL NOT STOP IF THE WINDOW IS OPENED, SO BE VERY CAREFUL NOT TO PUT YOUR HANDS INSIDE.
IF POSSIBLE, ALWAYS PERFORM THIS TEST BEFORE REPLACING ANY COMPONENT OF THE SCAN-AXIS.
Star Wheel Lifter test
The Star Wheel Lifter subassembly is designed to move the Start Wheel support to the up and down positions. This is used to load roll or sheet media and avoid damage to the Star Wheel caused by paper jams etc.
Perform the Scan Axis - Starwheel lifter test as follows:
Perform this test with the Printheads and the Tubes System installed in order to get values that can be compared correctly.
1 In the Diagnostics menu, scroll to 1. Scan Axis and press OK.
2 The Front Panel will show the 1. Scan Axis submenu.
3 In the Scan Axis submenu, scroll to Star Wheel Lifter and press OK to
start the test.
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Chapter 4 Service Tests and Utilities
If there is a Failure at any point during the tests, the Front Panel will display the relevant System Error Code. To trouble shoot any displayed error codes, refer to page 2-7, System Error Codes - Full Descriptions.
4 The printer then starts the Star wheel lifter PWM control test to verify the
subsystem. As the test executes the Front Panel displays the following messages:
Starting Horsburgh & Mips.Starting nvmStarting Tests PWM.Starting Tests GPIO.Booting up the Carriage.Starting SVS MotorStarting Carriage Motor.Starting Service Station.Starting Scan Axis.Moving SVS out of Scan.Homing Scan Axis.Move Carriage out of SVS path.Homing Service StationStarting Servicing Services.Capping Service Station.Uncapping Service Station.Starting Star Wheels Motor.Doing Dummy CyclesGetting SWL path length.Checking SWL length.
5 The printer displays the test results and prompts you to continue.
6 Press OK to continue. Once you continue the test, the Front Panel displays
the following messages:
Checking SWL PWM Forward.Moving & Getting traces.Moving SWL MotorDumping motor traces.Analyzing motor traces.Checking PWM results.Checking SWL PWM Backward.Moving & Getting traces.Moving SWL Motor
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Service Tests (Diagnostics) - 1. Scan Axis
Dumping motor traces.Analyzing motor traces.Checking PWM results.
If there is a Failure at any point during the test, the Front Panel will display the relevant System Error Code. To trouble shoot any displayed error codes, refer to page 2-7, System Error Codes - Full Descriptions.
7 Once the test has been completed the Front Panel displays the test results.
8 Press any key to finish.
9 The Front Panel shows the test complete display for a few seconds.
10 The Front Panel prompts you to shutdown the printer to complete the test.
11 Press any key to shutdown the printer.
PRS Test
The PRS subsystem is designed to move the carriage assembly between two predetermined vertical positions with respect to print platen plane. This allows different media of different thicknesses to be used without losing print quality.
Perform the Scan Axis - PRS test as follows:
Perform this test with the Printheads and the Tubes System installed in order to get values that can be compared correctly.
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Chapter 4 Service Tests and Utilities
1 In the Diagnostics menu, scroll to 1. Scan Axis and press OK.
2 The Front Panel will show the 1. Scan Axis submenu.
3 In the Scan Axis submenu, scroll to PRS and press OK to start the test.
The Printer will start the Scan Axis subsystem Common Initialization and PRS test initialization. If there is a Failure at any point during the tests, the Front Panel will display the relevant System Error Code. To trouble shoot any displayed error codes, refer to page 2-7, System Error Codes - Full Descriptions.
4 The printer then starts the PRS test to verify the subsystem. As the test executes
the Front Panel displays the following messages:
Starting Horsburgh and Mips.Starting Nvm.Starting Tests PWM.Starting Tests GPIO.Booting up the Carriage.Starting SVS Motor.Starting Carriage Motor.Starting PpsMotor.Starting Service Station.Starting Scan Axis.Moving SVS out of Scan.Homing Scan Axis.Move Carriage out of SVS.Starting Servicing Services.Reading PRS Position.Moving PRS position to HIGH.Moving PRS position to LOW.Moving PRS position to HIGH.Moving PRS position to HIGH.Moving PRS position to LOW.Moving PRS position to LOW.
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Service Tests (Diagnostics) - 1. Scan Axis
Moving PRS position to HIGH.
5 Once the test has completed, the Front Panel prompts you to confirm that the
PRS moved.
6 If the PRS moved, press OK to accept the results. If the PRS did not move,
press Back or Cancel to reject the results and exit the test.
7 The Front Panel shows the test complete display for a few seconds.
8 The Front Panel prompts you to shutdown the printer to complete the test.
9 Press any key to shutdown the printer.
Scan Axis Test
The Scan Axis subsystem is designed to move the carriage assembly between two predetermined horizontal positions with respect to the print platen plane. This allows media of different widths to be used without losing print quality.
Perform the Scan Axis - Scan Axis test as follows:
Perform this test with the Printheads and the Tubes System installed in order to get values that can be compared correctly.
1 In the Diagnostics menu, scroll to 1. Scan Axis and press OK.
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Chapter 4 Service Tests and Utilities
2 The Front Panel will show the 1. Scan Axis submenu.
3 In the Scan Axis submenu, scroll to Scan Axis and press OK to start the
test. The Printer will start the Scan Axis subsystem Common Initialization. If there
is a Failure at any point during the tests, the Front Panel will display the relevant System Error Code. To trouble shoot any displayed error codes, refer to page 2-7, System Error Codes - Full Descriptions.
4 The printer then starts the Scan Axis test initialization. As the test executes the
Front Panel displays the following messages:
Starting Horsburgh and Mips.Starting Nvm.Starting PWMManagerDelSol.Starting Tests PWM.Starting Tests GPIO.Moving StarWheelLifter to lower bump.
5 The Front Panel then asks if the Starwheel Lifter moved to the lower position.
6 If the PRS moved to the LOW position, press OK to accept the result. If the
result is not correct use the Arrow keys to select NO and press OK. If there is a Failure at any point during the test, the Front Panel will display
the relevant System Error Code. To trouble shoot any displayed error codes, refer to page 2-7, System Error Codes - Full Descriptions.
7 The printer then starts the PSU check. As the test executes the Front Panel
displays the following messages:
Clear GPIO psu_sleep.Clear GPIO psu_Carr.Clear GPIO psu_Fan.Checking Voltage.Set GPIO psu_sleep.Set GPIO psu_Carr.Checking Voltage.
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Service Tests (Diagnostics) - 1. Scan Axis
8 The Front Panel prompts you to confirm that the carriage supply LED is
switched on.
9 Open the Window and verify that the LED is on. The LED can be seen
through the slots in the carriage cover.
10 Press OK if the LED is on. If the LED is not on or use the Arrow keys to
select NO and press OK..
11 The printer then continues the Scan Axis test. As the test executes the Front
Panel displays the following messages:
Booting Up Carriage.Starting SVS Motor.Getting Part Number.Getting Scan Axis SizePreparing SVS.Prog slow PWM scan.Moving Carriage middle.
12 The Front Panel prompts you to confirm that the Carriage has moved.
13 Use the Arrow keys to select whether or not the motor moved the carriage.
14 Press OK to continue.
15 The Front Panel prompts you to confirm that the Carriage has moved to the
middle position.
16 Use the Arrow keys to select whether or not the carriage has moved to the
middle.
17 Press OK to continue.
18 The printer then continues the Scan Axis test. As the test executes the Front
Panel displays the following messages:
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Preparing SVS.Prog slow PWM scan.Moving Carriage middle.Starting Carriage Encoder.Prog fast PWM scan
19 The Front Panel prompts you to move the carriage to check the encoder
readings.
20 Use the Arrow keys to move the Carriage left or right as prompted to by the
Front Panel.
21 Repeat step 20 to complete the ten Carriage movements used to check the
encoder.
22 The Front Panel displays the encoder check results.
23 Press any key to continue.
24 The printer then continues the Scan Axis test. As the test executes the Front
Panel displays the following messages:
Starting Carriage Motor.On/Off Carriage Motor.Doing a right side bump.Doing a left side bump.Exit bump position.Checking scan axis length.
25 The Printer checks the complete length of the Scan-Axis and displays the
result on the Front Panel. The length must be between 1073586 and
1076610.
26 Press any key to continue.
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Service Tests (Diagnostics) - 1. Scan Axis
27 The printer then continues with the PWM test. As the test executes the Front
Panel displays the following messages:
Starting PpsMotor.Starting Scan Axis.Doing PWM test.
28 The Front Panel displays the PWM check results and prompts you to confirm
or reject the test results.
The PWM Average should be between 0 and 18750.The PWM min diff limit should be greater than or equal to 40.
29 If the results are correct, press OK to accept the results. If the results are not
correct, press Back/Cancel to reject the results and FAIL the test.
30 The printer then continues the Scan Axis test. As the test executes the Front
Panel displays the following messages:
Moving PRS to High.
31 The Front Panel displays the PRS position check results.
32 Press any key finish.
33 The Front Panel shows the test complete display for a few seconds.
34 The Front Panel prompts you to shutdown the printer to complete the test.
35 Press any key to shutdown the printer.
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Chapter 4 Service Tests and Utilities
Cutter test
The Cutter is designed to cut roll media after printing for the size of sheet defined. Before executing this test you should run the Scan Axis, Media Drive and Carriage tests to ensure that each of these subsystems is operating correctly.
Perform the Scan Axis - Cutter test as follows:
1 In the Diagnostics menu, scroll to 1. Scan Axis and press OK.
2 The Front Panel will show the 1. Scan Axis submenu.
3 In the Scan Axis submenu, scroll to Cutter and press OK to start the test.
The Printer will start the Scan Axis subsystem Common Initialization and Cutter test initialization. If there is a Failure at any point during the tests, the Front Panel will display the relevant System Error Code. To trouble shoot any displayed error codes, refer to page 2-7, System Error Codes - Full Descriptions.
4 The printer then starts the Cutter test to verify the subsystem. As the test
executes the Front Panel displays the following messages:
Starting Horsburgh and Mips.Starting Nvm.Starting TestsGpio.Getting Part Number.Starting SvsMotor.Starting CarriageMotor.Starting ServiceStation.Starting ScanAxisMoving SVS to rear bump.Homing Scan Axis.Move Carriage out of SVS path.Homing Service Station.Starting ServicingServices.Capping Service Station.Uncapping Service Station.
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Service Tests (Diagnostics) - 1. Scan Axis
Starting Cutter.Starting PaperMotor.Starting Media Sensor.Reading Media Presence.
5 If paper is already loaded, the printer detects the paper and continues the
test. If paper is NOT loaded, the Front Panel prompts you to load roll media.
6 Raise the Media Lever, load roll media, lower the Media Lever, and press
any key to continue.
7 The printer then starts an actual test cut of the media. As the test executes the
Front Panel displays the following messages:
Advance paper.Engaging cutter.Cutting paper.Disengaging cutter.
8 Once the test has completed the Front Panel displays the test result and
prompts you to confirm that the cutter worked.
9 Press OK if the cutter worked or BACK/CANCEL if the cutter did NOT work.
.
10 The Front Panel shows the test complete display for a few seconds.
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11 The Front Panel prompts you to shutdown the printer to complete the test.
12 Press any key to shutdown the printer.

2. Paper Drive

The Paper Drive test diagnoses Failures of components of the Media-Axis. You must perform the Paper Drive Test after:
System Error Code 81:XZ.System Error Code 41:XZ.System Error Code 73:XZ.
Diagnostic tests also need to be performed after removing or replacing certain printer components. If you have removed or replaced printer components, check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform. Refer to Page 8-4.
ALL THE COVER SENSORS ARE DISABLED WHEN IN THE SERVICE TESTS MENU. IF THE CARRIAGE IS MOVING IT WILL NOT STOP IF THE WINDOW IS OPENED, SO BE VERY CAREFUL NOT TO PUT YOUR HANDS INSIDE.
IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE REPLACING ANY COMPONENT OF THE MEDIA-AXIS.
Perform the Paper Drive test as follows:
Perform this test with the Printheads and the Tubes System installed in order to get values that can be compared correctly.
1 In the Diagnostics menu, scroll to 2. Paper Drive and press OK.
2 The printer starts the Paper Drive test to verify the subsystem. As the test
executes the Front Panel displays the following messages:
Starting Horsburgh and Mips.
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Service Tests (Diagnostics) - 2. Paper Drive
Starting NvmStarting Tests PWM.Starting Tests GPIO.Booting up the Carriage.Starting DelSol1.Starting Carriage.Getting Part Number.Par t NumberChecking PCA Rev
3 The Front Panel then displays the Main PCA Revision and prompts you to
press any key to continue. The Main PCA Revision should be greater than
.15.
4 Press any key to continue.
5 The Front Panel displays the following messages:
Prog slow PWM paper.
6 The Front Panel then prompts you to remove the media.
7 Remove the media.
8 Press any key to continue.
9 The Front Panel then displays the Open Loop ROLL test result.
10 Press any key to continue.
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11 The Front Panel then displays the Open Loop UNROLL test result.
12 Press any key to continue.
13 The Front Panel then displays:
Starting Paper Motor.Starting Paper Axis.Calib. Analog Decoder.
14 The Front Panel then displays the Analog Decoder calibration results.
 The GAIN for channel A must be between 0 and 3.5.  The GAIN for channel B must be between 0 and 4.5.  The OFFSET for channel A must be between -63.5 and 63.5.  The OFFSET for channel B must be between 63.5 and 63.5.
15 If the results are correct, press OK to accept the results. If the results are not
correct, press Back/Cancel to reject the results and FAIL the test.
16 If you accept the results, the Front Panel then displays:
Starting Media Path.Homing and repeatability test.
17 The Front Panel then prompts you to remove the media.
18 Remove the media.
19 Press any key to continue.
20 The Front Panel then displays:
PWM test without paper.
21 The Front Panel then displays the test results.
 The PWM avg results must be between 16000 and 14000.  The Speed error results must be less than 50.
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Service Tests (Diagnostics) - 3. Electronics Module
The PWM StDev results must be between 0 and 500.The PWM max results must be between 15000 and 20000.
22 If the results are correct, press OK to accept the results. If the results are not
correct, press Back/Cancel to reject the results and FAIL the test.
23 If you accept the results, the Front Panel shows the test complete display for a
few seconds:
24 The Front Panel prompts you to shutdown the printer to complete the test.
25 Press any key to shutdown the printer.

3. Electronics Module

The Electronics Module test diagnoses Failures of the following components:
Main PCA componentsElectronics Module to Carriage interfacing.Print Mech PCA components.Power Supply Unit voltages.
Diagnostic tests also need to be performed after removing or replacing certain printer components. If you have removed or replaced printer components, check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform. Refer to Page 8-4.
Perform the Electronics Module test as follows:
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1 In the Diagnostics menu, scroll to 2. Electronics Module and press OK.
2 The printer starts the Electronics Module test and displays the following
messages:
Starting Horsburgh and Mips.Starting Nvm.Accessing Nvm.
3 The printer starts the Electronics Module test to verify the subsystem and
prompts you to test the Power Supply:
4 Press OK to the test the Power Supply. If you do not wish to test the power
supply use the Arrow keys to select NO and press OK.
5 The Power supply test starts and the Front Panel displays the following
messages:
Starting DelSol7.Starting Carriage.Getting PSU voltages.
6 The Front Panel then displays the Power Supply test results.
7 Press any key to continue.
8 The Fan Speed test starts and the Front Panel displays:
Getting PSU Fan Rotation
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Service Tests (Diagnostics) - 3. Electronics Module
9 The Front Panel then displays the Fan Speed test result and prompts you to
press any key to continue.
10 Press any key to continue.
11 The Front Panel then prompts you to test the Formatter.
12 Press OK to the test the Formatter. If you do not wish to test the Formatter use
the Arrow keys to select NO and press OK.
13 The Formatter voltage test starts and the front Panel displays the following
messages:
Starting DelSol1.Getting PCA revision.
14 The Front Panel then displays PCA Rev. Voltage test result and prompts you to
press any key to continue.
15 Press any key to continue.
16 The Formatter memory size test starts and the Front Panel displays the
following messages:
Getting Memory Size.
17 The Front Panel then displays Formatter Memory Size and prompts you to
press any key to continue.
18 Press any key to continue.
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19 The Formatter hard disk test starts and the Front Panel displays the following
messages:
Getting HDA info.
20 The Front Panel then displays Formatter Hard Disk information test results and
prompts you to press any key to continue.
21 Press any key to continue.
22 The Formatter hard disk file information test starts and the Front Panel
displays the following messages:
Getting File System Info.
23 The Front Panel then displays Formatter Hard Disk File information test results
and prompts you to press any key to continue.
24 Press any key to continue.
25 The MainBoard Revision Voltage test starts and the Front Panel displays the
following messages:
Getting MainBoard Rev.
26 The Front Panel then displays MainBoard Voltage test results and prompts
you to press any key to continue.
27 Press any key to continue.
28 The Main Memory Size test starts and the Front Panel displays the following
messages:
Getting Main Memory Size.
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Service Tests (Diagnostics) - 3. Electronics Module
29 The Front Panel then displays Main Memory size test results and prompts you
to press any key to continue.
30 Press any key to continue.
31 The Front Panel then prompts you to test the Formatter Communications.
32 Press OK to the test the Formatter. If you do not wish to test the Formatter use
the Arrow keys to select NO and press OK.
33 The Formatter Communications test starts and the front Panel displays the
following messages:
Starting Micci2Bus.Starting Micci2BusProxy.Checking Communications.
34 The Front Panel then displays Formatter Communications test results and
prompts you to press any key to continue.
35 Press any key to continue.
36 The Front Panel then prompts you to check the Plotter Information.
37 Press OK to the check the Plotter Information. If you do not wish to test the
Plotter Information use the Arrow keys to select NO and press OK.
38 The Plotter information test starts and the Front Panel displays the following
messages:
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Getting Plotter info.
39 The Front Panel then displays the Plotter Information results and prompts you
to press any key to finish.
40 Press any key to finish.
41 The Front Panel shows the test complete display for a few seconds.
42 The Front Panel prompts you to shutdown the printer to complete the test.
43 Press any key to shutdown the printer.

4. Carriage Assembly

The Carriage assembly test diagnoses Failures of any components of the Carriage. Always run this test before replacing the Carriage Assembly.
Diagnostic tests also need to be performed after removing or replacing certain printer components. If you have removed or replaced printer components, check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform. Refer to Page 8-4.
1 In the Diagnostics menu, scroll to 4. Carriage Assembly and press OK.
2 The Power supply test starts and the Front Panel displays the following
messages:
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Service Tests (Diagnostics) - 4. Carriage Assembly
Starting Horsburgh.Starting Nvm.Accessing Nvm.Starting AdcManagerHorus.Starting Carriage.Getting Carriage PCA Rev.
3 The Front Panel prompts you to verify the Carriage Assembly PCA revision.
The PCA Rev must be between 0.949 and 1.161.
4 If the results are correct, press OK to accept the results. If the results are not
correct, press Back/Cancel to reject the results and FAIL the test.
5 The Carriage Assembly test starts and the Front Panel displays the following
messages followed by their results:
Getting Num of pens.Getting Scan Access size.Getting Vs Carriage Voltage.
6 The Front Panel then displays the Carriage Voltage (+Vs) test results. The +vs
Voltage should be between 43.6 and 46.3.
7 If the results are correct, press OK to accept the results. If the results are not
correct, press Back/Cancel to reject the results and FAIL the test.
8 The Carriage Assembly Vaux test starts and the Front Panel displays:
Getting Vaux Carriage Volt.
9 The Front Panel then displays the Carriage Voltage (+Vaux) test results.
10 Press any key to continue.
11 The Carriage Assembly Pens Voltage test starts and the Front Panel displays:
Getting Vpp.
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12 The Front Panel then displays the Pens Voltage test results. The result must be
between 26.5 and 33 Volts.
13 If the results are correct, press OK to accept the results. If the results are not
correct, press Back/Cancel to reject the results and FAIL the test.
14 The Carriage Assembly test continues and the Front Panel displays:
Starting Line Sensor Leds.Starting LightSensor.Starting LineSensing.Starting SVS Motor.Starting Carriage Motor.Moving SVS out of Sax.Moving Carriage middle.Initializing LineSensor.
15 The Front Panel then prompts you to load roll media.
16 Load roll media.
For the LED test to work properly, the paper must be loaded completely through the carriage path.
17 Press any key to continue.
18 The Carriage Assembly test continues and the Front Panel displays the result
of each phase of the test:
Setting LS low intensity.
For each color LED: Blue, Green, Red, and Amber
Setting LS max intensity.
For each color LED: Blue, Green, Red, and Amber
Checking Tolerance.Deactivating LS.Starting NvmLineSensor.Initializing NvmLineSensor.Getting LS Serial Number.Reading LS Nvm.
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Service Tests (Diagnostics) - 4. Carriage Assembly
Writing new LS Nvm.Checking LS Serial Number.Restoring LS Serial Number.Starting Service Station.Starting Scan Axis.Moving SVS out of sax.Homing Scan Axis.Moving Carriage out of SVS.Homing Service Station.Starting Servicing Services.Capping Service StationUncapping ServiceMoving to Pen postion.Reading Pen presence.
19 The Carriage moves into the print path and the front Panel then prompts you
to remove all pens.
20 Open the Window.
21 Open the Carriage cover.
22 Remove all the Printheads from the Carriage.
23 Press any key to continue.
24 The Carriage Assembly pens test executes and checks the pens status.
25 The Front Panel then prompts you to replace all the Printheads.
26 Replace all the Printheads.
27 Close the Carriage Cover.
28 Close the Window.
29 Press any key to continue.
30 The Carriage Assembly pens test continues and checks the pens status.
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31 The Front Panel then displays the test result.
32 Press any key to continue.
33 The printer continues the test, and the Front Panel displays:
Preparing Pen initialization.Checking Pen status
34 The Front Panel then displays the test result.
35 The Encoder Manager test starts and the Front Panel displays:
Starting EncoderManager.Moving Carriage center.Setting Encoder.Reading Encoder position.Moving Carriage to left.Reading Encoder position.Checking Encoder readings.Moving Carriage rightwardsReading Encoder positionsChecking Encoder readings
36 The Front Panel then displays Encoder Difference (Left/Right) test result and
prompts you to press any key to finish.
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Service Tests (Diagnostics) - 5. Sensors
37 Press any key to finish.
38 The Front Panel shows the test complete display for a few seconds.
39 The Front Panel prompts you to shutdown the printer to complete the test.
40 Press any key to shutdown the printer.

5. Sensors

The Sensors test diagnoses Failures of any sensors of the printer. Always run this test before replacing any of the following sensors:
Window sensor.Media Lever position sensor.Media sensor
Diagnostic tests also need to be performed after removing or replacing certain printer components. If you have removed or replaced printer components, check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform. Refer to Page 8-4.
1 In the Diagnostics menu, scroll to 5. Sensors and press OK.
2 The Sensors test starts and the Front Panel then displays the following
messages:
Starting Horsburgh and MipsStarting NvmStarting Tests GPIOGetting part number
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3 The Sensors test starts and the Front Panel prompts you to verify default
sensor positions:
4 Verify that the sensors are in the default positions and any key to continue.
5 The Window sensor test starts and the Front Panel prompts you to open the
Window:
6 Open the Window.
7 Press any key to continue.
8 The Window sensor test continues and the Front Panel prompts you to close
the Window:
9 Close the Window.
10 Press any key to continue.
11 The Media Lever sensor test starts and the Front Panel prompts you to raise
the Media Lever:
12 Raise the Media Lever.
13 Press any key to continue.
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14 The Media Lever sensor test continues and the Front Panel prompts you to
lower the Media Lever:
15 Lower the Media Lever.
16 Press any key to continue.
17 The Media sensor test starts and the Front Panel prompts you load media:
18 Raise the Media Lever.
19 Load media.
20 Lower the Media Lever.
21 Press any key to continue.
22 The Media sensor test continues and the Front Panel prompts to remove
media:
23 Raise the Media Lever.
24 Unload the media.
25 Lower the Media Lever.
26 Press any key to continue.
27 The Front Panel shows the test complete display for a few seconds.
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28 The Front Panel prompts you to shutdown the printer to complete the test.
29 Press any key to shutdown the printer.

6. Rewinder

The Rewinder test diagnoses failures of the Rewinder located in the Paper Path Assemblies (Rear). Always run this test before replacing the Right Spindle Holder (rewinder included).
The Rewinder is only available on the 44 inch T1100/ T1100ps/T610 printer. The 24 inch T1100/T1100ps/T610 printer does NOT have a Rewinder
.
Perform this test after:
System Error Code 41:YZSystem Error Code 45:YZSystem Error Code 81:YZ
Diagnostic tests also need to be performed after removing or replacing certain printer components. If you have removed or replaced printer components, check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform. Refer to Page 8-4.
Perform this test with the Printheads and the Tubes System installed in order to get values that can be compared correctly.
ALL THE COVER SENSORS ARE DISABLED WHEN IN THE SERVICE TESTS MENU. IF THE CARRIAGE IS MOVING IT WILL NOT STOP IF THE WINDOW IS OPENED, SO BE VERY CAREFUL NOT TO PUT YOUR HANDS INSIDE.
1 In the Diagnostics menu, scroll to 6. Rewinder and press OK.
The printer will start the Open Loop, Rewinder Servo System, and Media Driver PWM tests.
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Service Tests (Diagnostics) - 6. Rewinder
If there is a Failure at any point during the tests, the Front Panel will display the relevant System Error Code. To trouble shoot any displayed error codes, refer to page 2-7, System Error Codes - Full Descriptions.
2 The Rewinder test starts and the front Panel displays the following messages:
Starting Horsburgh.Starting NvmAccessing NvmStarting PWM ManagerLunaStarting ENC ManagerLunaSetting encoder position
3 The Front Panel prompts you to make sure the media is unloaded and the
spindle is removed.
4 Remove the media from the printer.
5 Remove the spindle from the spindle holders.
6 Press any key to continue.
7 The Front Panel displays the following messages and results:
Moving Rewinder ForwardMoving Rewinder Backward
8 The Front Panel shows the test complete display for a few seconds.
9 The Front Panel prompts you to shutdown the printer to complete the test.
10 Press any key to shutdown the printer.
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Once you have completed the Rewinder diagnostic test, you must perform a Paper Advance Calibration. Refer to Page
6
.

7. Ink Delivery System (IDS)

The complete Ink Delivery System test consists of individual tests for the different components related to this subsystem. These tests are:
Ink Delivery SystemCheck Ink Supplies Check Leakage
Diagnostic tests also need to be performed after removing or replacing certain printer components. If you have removed or replaced printer components, check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform. Refer to Page 8-4.
Ink Delivery System
1 In the Diagnostics menu, scroll to 7. I D S and press OK.
5-
2 The Front Panel will show the 7. ID S submenu.
3 In the IDS submenu, scroll to Ink Delivery System and press OK to start
the test.
4 The Ink Delivery System test starts and the front Panel prompts you to remove
all the Ink Supplies.
5 Remove all the Ink Cartridges.
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Service Tests (Diagnostics) - 7. Ink Delivery System (IDS)
6 Press OK to continue.
7 The test continues and the front Panel displays the following messages:
Starting Horsburgh0.Starting Mips.Starting Nvm.Getting Part Number.Starting ISS Motors.Moving Bongos down.Reading Bongos down.Moving Bongos up.Reading Bongos up.Starting OutOfInk sensors.Reading OutOfInk.
8 The Front Panel then prompts you push down Bongo0.
9 Press and hold down Bongo0 which is located at the furthest left Ink
Cartridge position.
10 Press any key.
11 Release Bongo0.
12 Press any key.
13 The Front Panel then displays the Bongo0 test results.
14 Press any key to continue.
15 Repeat steps 8 through 14 for the remaining Out of Ink sensors for each of
the Ink Cartridges.
16 The front Panel prompts you to insert all the Ink Supplies.
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17 Install all the Ink Cartridges.
18 Press OK to continue.
19 The Acumen Supplies test and the front Panel displays the following
messages:
Starting AcumenSupplies.Reading AcumenSupplies.
20 The Front Panel then displays Acumen Supplies test results.
21 The Front Panel shows the test complete display for a few seconds.
22 The Front Panel prompts you to shutdown the printer to complete the test.
23 Press any key to shutdown the printer.
Check Ink Supplies
1 In the Diagnostics menu, scroll to 7. I D S and press OK.
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Service Tests (Diagnostics) - 7. Ink Delivery System (IDS)
2 The Front Panel will show the 7. ID S submenu.
3 In the IDS submenu, scroll to Check Ink Supplies and press OK to start
the test.
4 The Check Ink Supplies test starts and the front Panel displays the following
messages:
Starting Horburgh & Mips.Starting Nvm.Getting Part Number.Starting Supplies.Starting AcumenSupplies.Reading Ink Supplies.
5 The Front Panel then displays Check Ink Supplies test results Use the Arrow
keys to view the second results screen.
6 Press OK to exit.
7 The Front Panel shows the test complete display for a few seconds.
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8 The Front Panel prompts you to shutdown the printer to complete the test.
9 Press any key to shutdown the printer.
Check Leakage
1 In the Diagnostics menu, scroll to 7. I D S and press OK.
2 The Front Panel will show the 7. ID S submenu.
3 In the IDS submenu, scroll to Check Leakage and press OK to start the
test.
4 The Ink Delivery System test starts and the front Panel prompts you to remove
all the Ink Supplies.
5 The Check Leakage test starts and the Front Panel displays the following
messages:
Starting Horsburgh and MipsStarting NvmStarting TubesReading Tubes statusGetting Part NumberStarting ISS MotorsStarting DDI SensorsMoving Bongos down
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6 While the printer moves the Bongos down, the Front Panel displays the
following message:
7 If a Bongo remains in the UP position, use your finger to help push it down.
The test continues and displays the following messages:
Reading DDI SensorsMoving Bongos upReading DDI SensorsMoving Bongos down
8 The front Panel prompts you to insert all the Ink Supplies.
9 Install all the Ink Cartridges.
10 Press OK to continue.
11 The test continues and displays the following messages:
Moving Bongos upChecking DDI condition
12 The Front Panel then displays Check Leakage test results.
13 The Front Panel shows the test complete display for a few seconds.
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14 The Front Panel prompts you to shutdown the printer to complete the test.
15 Press any key to shutdown the printer.

8. Service Station

The complete Service Station test consists of individual tests for the different components related to this subsystem.
These tests are:
Service StationPrimer MotorAerosol Fan
Diagnostic tests also need to be performed after removing or replacing certain printer components. If you have removed or replaced printer components, check the Service Calibration Guide to Removal and Installation to see which tests and calibrations you need to perform. Refer to Page 8-4.
Service Station
1 In the Diagnostics menu, scroll to 8. Service Station and press OK.
2 The Front Panel will show the 8. Service Station submenu.
3 In the 8. Service Station submenu, scroll to Service Station and press
OK to start the test.
4 The Service Station test starts and the front Panel displays the following
messages:
Starting Horsburgh and MipsStarting NvmBooting up Carriage.
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Service Tests (Diagnostics) - 8. Service Station
Starting SVS Motor.Starting Carriage MotorGetting Part Number.Starting Service Station.Starting Scan Axis.Moving SVS out of Sax.Homing Scan Axis.Moving Carriage out of SVS.Homing Service Station.Moving to Spit Rear pos.Moving to Spit Front pos.Moving to Wipe forward pos.Moving to Wipe reverse pos.Moving to Cleaner pos.Moving to SOL pos.Moving to PEG pos.Homing Scan Axis.Starting ServicingServices.Capping Service Station.Uncapping Service Station.Starting Mechanical Init.
5 The Front Panel then prompts you to check the status of the printer.
6 Check that:
The Window is closed.The Media Lever is lowered.All Printheads are inserted.Valid Cartridges are inserted.
7 Press OK to continue.
8 The test continues and the Front Panel displays the following messages:
Moving SVS to Wiping bider position.Moving SVS to Scrape position.Moving SVS to Snout Wipe position.
HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual 4-43
Chapter 4 Service Tests and Utilities
9 The Front Panel then asks if you want to cap the Service Station.
10 Select YES to cap the Service Station or NO to skip this test.
11 The test continues and displays the following messages:
Capping Service Station.
12 The Front Panel displays the Service Station test results.
13 Press any key to finish the test.
14 The Front Panel shows the test complete display for a few seconds.
15 The Front Panel prompts you to shutdown the printer to complete the test.
16 Press any key to shutdown the printer.
Primer Motor
1 In the Diagnostics menu, scroll to 8. Service Station and press OK.
4-44 HP Designjet T1100/T1100ps/T610 Printer Series — Service Manual
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