HP DesignJet T7200 Service Manual

Designjet T7200 Production Printer

Service Manual

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Company, L.P.	This document contains proprietary
1st edition	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.

Notices

Warranty

The information contained in this document is subject to change without notice.

Hewlett-Packard makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose.

Hewlett-Packard shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material.

WARNING

The procedures described in this manual are to be performed by HP-qualified service personnel only.

Electrical shock hazard

Serious shock hazard leading to death or injury may result if you do not take the following precautions:

●Ensure that the AC power outlet (mains) has a protective earth (ground) terminal.

●Disconnect the printer from the power source prior to performing any maintenance.

●Prevent water or any other liquids from running onto electrical components or circuits, or through openings in the enclosure.

Electrostatic discharge

Refer to the beginning of Service tests and utilities on page 81 in this manual for precautions you should take to prevent damage to the printer circuits from electrostatic discharge.

Safety symbols

General definitions of safety symbols are given immediately after the table of contents.

WARNING

The Warning symbol calls attention to a procedure, practice, or the like, which, if not correctly performed or adhered to, could result in personal injury. Do not proceed beyond a Warning symbol until the indicated conditions are fully understood and met.

CAUTION

The Caution symbol calls attention to an operating procedure, practice, or the like, which, if not correctly performed or adhered to, could result in damage to or destruction of part or all of the product. Do not proceed beyond a Caution symbol until the indicated conditions are fully understood and met.

Customer Assurance

Customer Experience Section

Large Format Printing Division

Hewlett-Packard Española, S.L.

Cami de Can Graells, 1-21

08174 Sant Cugat del Vallès

Spain

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Notices

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Using this manual

Purpose

This service manual contains information necessary to test, calibrate, and service:

●HP Designjet T7200 printer (Models CQ105A, CQ105B, CQ106A)

For information about using these printers, refer to the Using your printer manual.

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 Parts and diagrams on page 175.

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Using this manual

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Table of contents

1 Printing tips and tricks ..................................................................................................................................	1
Paper loading .........................................................................................................................................................	2
Paper-advance calibration ....................................................................................................................................	2
Printhead alignment ..............................................................................................................................................	2
Use of multiple rolls ..............................................................................................................................................	3
2 Troubleshooting ...........................................................................................................................................	5
Printer education and training ..............................................................................................................................	7
Firmware update ....................................................................................................................................................	7
Print-quality troubleshooting ...............................................................................................................................	7
Troubleshooting system error codes ....................................................................................................................	8
Performing a service test on a failed assembly ....................................................................................................	8
Performing the necessary service calibrations .....................................................................................................	8
The printer does not power on ..............................................................................................................................	8
The printer hangs during printing and displays ‘processing’ ...............................................................................	9
The printer continuously rejects printheads .........................................................................................................	9
A new maintenance cartridge is incorrectly detected as ‘used’ ...........................................................................	9
Cover sensors are not working ..............................................................................................................................	9
The Line Sensor has problems detecting paper .................................................................................................	10
How to remove the Left Hub when the actuator is broken ................................................................................	10
Troubleshooting paper jams and printhead crashes ..........................................................................................	11
Troubleshooting shutdowns ...............................................................................................................................	11
Vacuum suction much lower at high altitudes ....................................................................................................	12
Banding at variable extreme environmental conditions ....................................................................................	13
Printhead crashes/smears on high-density prints using coated paper .............................................................	13
Banding due to ink cartridge replacement while printing ..................................................................................	13
34" Rice Paper not supported .............................................................................................................................	13
Worm marks on HP Coated Paper with light area fills ........................................................................................	14
Solving paper-handling problems ......................................................................................................................	14
Difficult to load paper: “Too much skew” ...........................................................................................................	14
How to read the power switch LEDs ....................................................................................................................	14
How to read the Formatter LEDs .........................................................................................................................	15
If the front panel turns on and then stops ..........................................................................................................	17
How to interpret the Service Information Pages ................................................................................................	17
When the main window is open and the printer is printing (safety compliance) ...............................................	24

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How to troubleshoot the 79:04 system error .....................................................................................................	25
3 System error codes ......................................................................................................................................	37
What to do if the front panel is blank .................................................................................................................	38
System error codes ..............................................................................................................................................	38
Explanation of system error codes and warnings ..............................................................................................	38
Continuable and non-continuable error codes ...................................................................................................	41
4 Ink supplies ................................................................................................................................................	69
What are ink supplies? .........................................................................................................................................	70
General information about the ink supplies .......................................................................................................	72
General precautions when handling ink supplies ...............................................................................................	72
Priming the ink system ........................................................................................................................................	73
When should you replace the ink supplies? ........................................................................................................	73
Obtaining Ink Cartridge information ...................................................................................................................	73
Obtaining Printhead information ........................................................................................................................	74
Summary of solving ink supplies problems ........................................................................................................	77
Troubleshooting Printhead error codes ..............................................................................................................	78
Carriage Interconnect Wiper ................................................................................................................................	79
Warranty information for ink supplies ................................................................................................................	79
5 Service tests and utilities .............................................................................................................................	81
Introduction .........................................................................................................................................................	82
Diagnostics—self test .........................................................................................................................................	82
Phone support .....................................................................................................................................................	82
Service tests (diagnostics) ..................................................................................................................................	82
Entering the Service Tests menu ........................................................................................................................	83
Service utilities ....................................................................................................................................................	98
6 Service calibrations ...................................................................................................................................	113
Service calibrations ...........................................................................................................................................	114
Entering the Service Calibrations menu ............................................................................................................	115
7 Print quality ..............................................................................................................................................	137
Initial print-quality troubleshooting actions ....................................................................................................	138
Troubleshooting tools .......................................................................................................................................	139
How to use the Image Quality Service Diagnostic Print ...................................................................................	142
Print-quality issues by symptom ......................................................................................................................	157
Working with other commercially available papers .........................................................................................	170
8 Parts and diagrams ....................................................................................................................................	175
Printer ................................................................................................................................................................	176
Stacker ...............................................................................................................................................................	194

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9 Printer part removal and installation ..........................................................................................................	205
Service part order ..............................................................................................................................................	206
Disassembly order .............................................................................................................................................	209
10 Stacker part removal and installation .......................................................................................................	401
Right Cover ........................................................................................................................................................	402
Left Cover ..........................................................................................................................................................	403
Top Cover ...........................................................................................................................................................	405
Lower Front Cover .............................................................................................................................................	408
Pinchwheels .......................................................................................................................................................	412
Drive Motor ........................................................................................................................................................	414
Front Cover Sensor ............................................................................................................................................	416
Safety Temperature Sensor ..............................................................................................................................	418
Temperature Sensor PCA ..................................................................................................................................	419
Media Sensor .....................................................................................................................................................	421
Extension Tray ...................................................................................................................................................	423
Receiving Tray ...................................................................................................................................................	425
Printer Interlocks ...............................................................................................................................................	426
Paper Infeed Platen ...........................................................................................................................................	428
Electronics PCA ..................................................................................................................................................	429
Power Supply Unit .............................................................................................................................................	431
Heating Lamp ....................................................................................................................................................	436
Heat Roller .........................................................................................................................................................	439
Transport Belt ....................................................................................................................................................	441
11 Preventive maintenance ...........................................................................................................................	449
Moisture on the printer .....................................................................................................................................	450
Noisy Carriage Bushing ......................................................................................................................................	450
Belt swelling ......................................................................................................................................................	450
General cleaning ................................................................................................................................................	450
Clean the Drive Roller and Overdrive ................................................................................................................	450
Clean the Platen ................................................................................................................................................	450
Clean the Encoder Strip .....................................................................................................................................	452
Clean the Paper-advance Sensor window ........................................................................................................	454
Apply oil to the Overdrive ..................................................................................................................................	454
Lubricate the Carriage Assembly ......................................................................................................................	455
Scheduled maintenance ....................................................................................................................................	455
Preventive Maintenance Kits .............................................................................................................................	456

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1 Printing tips and tricks

●Paper loading

●Paper-advance calibration

●Printhead alignment

●Use of multiple rolls

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Paper loading

Rolls with 3-inch cores cause fewer ink smears and paper jams, and the finished prints stack better, in the bin or the HP stacker.

To avoid selecting the wrong paper name when loading, we recommend hiding paper types that you never use, which can be done from the HP Utility.

Paper-advance calibration

The printer will automatically start paper-advance calibration in the following situations.

●A new type of plain or coated paper is loaded for the first time. Each type is calibrated separately: for instance, there is one calibration for plain paper and another for HP Universal Inkjet Paper.

●A new matte-black printhead is installed.

●The firmware is updated.

Calibration adjusts the paper advance to reduce banding and line continuity issues for each paper type (including all different roll sizes). It is important to use a different front-panel name for each paper type. For example, if a third-party plain paper A is loaded as “plain” in the front panel, and a third-party paper B is also loaded as “plain”, the printer may not be optimized for paper B. We recommend in this case using a different name for B, for instance “HP Universal Inkjet Paper”.

Factory paper-advance	OMAS calibration	Automatic paper-advance	Manual paper-advance
		calibration	calibration
calibration
Paper-advance settings	This is a dynamic correction	This is an offset applied to the	This is an offset applied to the
specific to each paper category.	applied to every advance	paper advance that takes into	other paper-advance
This is a baseline for the	depending on the OMAS	account the printheads and the	calibrations.
printer, to which the other	readings. It is applied to the	specific paper loaded.
calibrations add a correction.	specific paper loaded.
Hard-coded in printer		Automatically triggered by	Triggered by user only
		printer or by user
Used with paper types, such as	Used with paper types that are	Mandatory for fiber-based	May be used by customers to
films, with which OMAS cannot	compatible with OMAS.	papers printing with relatively	fine-tune the paper advance.
be used.		few passes. Does not work with	Also useful for natural tracing
		natural tracing paper. Optional	paper, with which automatic
		for other papers, such as	calibration does not work.
		heavyweight or glossy.

The paper advance is normally managed by a combination of automatic paper-advance calibration and OMAS tracking of the paper movement.

Printhead alignment

For printhead alignment to work best with all kinds of plain paper, it is recommended to perform the alignment using HP Coated or HP Bright White papers. Vertical line straightness with other plain papers (such as non-HP plain papers and recycled papers) will improve.

The printheads must be aligned whenever a new printhead is installed, and should be aligned after any paper jam that may have moved the printhead slightly.

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Use of multiple rolls

There are various ways to set up the printer for multi-roll printing, using the roll-switch and paper-mismatch policies. Here are some examples.

1.Same paper type and different sizes loaded: this is typical when printing line drawings in standard sizes. For instance, two rolls with A0 size plain paper and one roll with A1 size plain paper. Driver settings: paper type to Any and roll to Any.

●Roll switching policy:

◦Minimize paper waste: Recommended setting for this workflow. With this setting, roll switch takes precedence over autorotate. This setting minimizes the paper wasted. For instance, if an A2 portrait is sent, the printer autorotates the A2 to fit it onto the A1 roll in landscape. But, if a A1 portrait is sent and the active roll is A0, the printer switches to an A1 roll to save paper.

◦Minimize roll changes: Not recommended except for very specific situations, when the customer wants to consume a roll faster. Autorotate takes precedence over roll switch, which reduces overall printing speed.

◦Use roll with less paper: Not recommended in this workflow. This setting ensures that the roll with least paper is used up before changing to another.

●Paper mismatch policy:

◦Print anyway: In this case, for instance, if a A0 page is sent and no A0 roll is available, the printer uses an A1 roll and clips the image. Recommended for a workgroup environment in which users share one printer.

◦Put job on hold: The printer saves the A0 page on hold in the queue and prints the next pages in the queue that can be printed. To reprint the A0 page, the customer needs to access the queue from the front panel or the Embedded Web Server. This setting is confusing in a workgroup enviornment because distributed customers may not know how to access the queue, but it can be useful in a centralized print environment to avoid clipping.

◦Pause printer to load paper: The printer stops printing completely. This could be useful for a centralized printing environment where project print order must be maintained—for instance, when a project is a mix of A0, A1 and A2 in a given order. For a workgroup environment this would not be recommended. Can be useful in a centralized print environemnt to will avoid clipping and preserve the printing order.

2.The same setup as example 1. This time, the customer does not want to waste paper, but he does not want the printer to stop if the document size does not match the paper size.

●Roll switching policy: Match exact size

●Paper mismatch policy: Put job on hold

3.Three rolls loaded, two with plain and one with glossy paper: this is typical when printing line drawings of standard sizes and where some high-density printing is requested. Roll 1 with A0 plain, Roll 2 with A1 plain and Roll 3 with glossy. Driver settings: paper type to Any and roll to Any. To print on glossy paper, set paper type to Glossy paper or roll to Roll 3.

●Roll switching policy: Minimize paper waste

●Paper mismatch policy: Print anyway for workgroups and Put job on hold or Pause printer to load paper for centralized printing

●Protect roll 3, to avoid printing with glossy paper unless the roll or paper type has been explicitly selected.

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4.The same setup as example 3. This time, the customer does not want to waste paper, but he does not want the printer to stop if the document size does not match the paper size.

●Roll switching policy: Match exact size

●Paper mismatch policy: Put job on hold

5.The same setup as example 3. This time, the customer is not concerned about wasting paper, and he does not want the printer to stop.

●Roll switching policy: Minimize paper waste

●Paper mismatch policy: Print anyway

6.Working with HP IP Pro. This is a solution specifically designed for centralized environments managed by an operator. With HP IP, the jobs to be printed are selected one by one, previewed and assigned to a specific roll to print. So no automatic roll selection is used in this case. When a roll is out of paper, the queue stops, waiting for the operator to load paper, to ensure correct page order.

Roll switching policy	Paper mismatch policy	Result
Match exact size	Print anyway	Prints always. If the loaded paper is narrower than the document
		to be printed, the document is clipped.
	Put job on hold	Puts the job on hold if the document width does not match any of
		the loaded rolls.
	Pause printer to load paper	Stops printing if the document width does not match any of the
		loaded rolls.
Minimize paper waste	Print anyway	Prints always. If the loaded paper is narrower than the document
		to be printed, the document is clipped.
	Put job on hold	Puts the job on hold if the document is wider than any of the
		loaded rolls.
	Pause printer to load paper	Stops printing if the document is wider than any of the loaded
		rolls.

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2 Troubleshooting

●Printer education and training

●Firmware update

●Print-quality troubleshooting

●Troubleshooting system error codes

●Performing a service test on a failed assembly

●Performing the necessary service calibrations

●The printer does not power on

●The printer hangs during printing and displays ‘processing’

●The printer continuously rejects printheads

●A new maintenance cartridge is incorrectly detected as ‘used’

●Cover sensors are not working

●The Line Sensor has problems detecting paper

●How to remove the Left Hub when the actuator is broken

●Troubleshooting paper jams and printhead crashes

●Troubleshooting shutdowns

●Vacuum suction much lower at high altitudes

●Banding at variable extreme environmental conditions

●Printhead crashes/smears on high-density prints using coated paper

●Banding due to ink cartridge replacement while printing

●34" Rice Paper not supported

●Worm marks on HP Coated Paper with light area fills

●Solving paper-handling problems

●Difficult to load paper: “Too much skew”

●How to read the power switch LEDs

●How to read the Formatter LEDs

●If the front panel turns on and then stops

●How to interpret the Service Information Pages

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●When the main window is open and the printer is printing (safety compliance)

●How to troubleshoot the 79:04 system error

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Printer education and training

Before any attempt is made to troubleshoot the printer, you must have the relevant training on the HP Designjet T7200 printer series. If you are not trained on this printer, please contact HP Education or HP Training to enquire about becoming ‘HP Service Qualified’ for this printer.

Firmware update

The first step to take when trying to clear an error with the printer is to check that the firmware installed in the printer is the latest available. Firmware updates often include fixes for common problems, and simply updating the firmware can often resolve the problem. New firmware can be downloaded here: http://www.hp.com/go/designjet/downloads

USB firmware update

If it is not possible to perform a firmware update using the Embedded Web Server (for instance, if the printer has a System Error and the Embedded Web Server is inaccessible), it is still possible to do it using a USB flash drive.

1.Turn off the printer.

2.Ensure that your USB flash drive contains a valid FMW firmware file and no other files.

3.Connect the USB flash drive to the USB host port on the Formatter.

4.Turn on the printer and follow the instructions on the front panel.

Forced firmware update

When the printer is started for the first time, it may automatically request a firmware update in order to fix some known issues. You can respond in one of the following ways.

●Use the USB flash drive provided in the box with the printer.

When a firmware update is requested, you should find a USB flash drive in the box, containing the new FMW firmware file. Follow the instructions in the flier accompanying the USB flash drive.

NOTE: The USB flash drive is provided only to update the printer's firmware. No other uses of the USB flash drive are supported.

NOTE: If the USB flash drive is not in the printer box, or fails to work properly, then download the firmware instead.

●Download the FWM firmware file from the HP Web site.

Store the file in a standard USB flash drive with no other files. Connect the flash drive to the formatter's USB host port to perform the firmware update, following the instructions on the front panel.

●Skip the firmware update.

If you cannot find the USB flash drive and you have no Internet connection, you can skip the forced firmware update temporarily by pressing the OK key on the front panel three times, and the printer will continue with the initialization sequence. Make sure that the firmware update is performed later. The printer will request the firmware update every time that it starts, until the update is performed.

Print-quality troubleshooting

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

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problems such as incorrect front-panel selection, driver or RIP configuration or mechanical problems. For more information on solving print-quality problems, see Print quality on page 137.

Troubleshooting system error codes

System error codes on page 37 contains a list of system error codes and their respective descriptions and recommended corrective actions. Try only one recommended action at a time and check whether 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.

NOTE: 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.

●The service configuration print.

●The current configuration sheet.

●Which software application the customer is using (name, version, and so on).

Performing a service test on a failed assembly

If possible, always perform a Service Test on the component/assembly that you are about to replace, just to make sure that is the component/assembly that has failed.

NOTE: If the test on that component/assembly passes, you should NOT replace it.

For information on the Service Tests and how to use them, see Service tests and utilities on page 81.

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 Service calibrations on page 113.

NOTE: Remember that certain Calibrations are required even if an Assembly has been disassembled to gain access to another Assembly or Component.

The printer does not power on

To resolve printer power up problems, do the following.

1.Check that the power cord is connected correctly to the printer and to the power socket.

2.Check that the power switch at the rear of the printer is in the on position.

3.Check that the front-panel cable is correctly connected to the Electronics Module. Also make sure that the front-panel cable is not damaged.

4.Check to see if any of the LEDs on the power switch are on. If any of the LEDs are on, then see How to read the power switch LEDs on page 14 for more information.

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The printer hangs during printing and displays ‘processing’

It has been seen under certain circumstances that the printer hangs whilst printing, this may happen immediately after printing, or only a partial print. In some cases when this occurs if the machine is restarted a system error 79:04 is displayed, although restarting again appears to clear this error. After this point, although the printer displays that it is in the “Ready” state, attempting to print anymore plots will once again hang the printer, including internal demo plots.

79:04

Cause

Solution

The reason for this error is that a large spooled file (11 GB for example) has been sent to the printer and has been placed in the disk partition which is related to the print queue. The file completely fills up all the disk space, because of this it will never successfully print, and so the file remains in the disk partition. Even after restarting the printer the file remains, subsequent print requests also fail as there is not sufficient space available in the partition to process anything else.

Perform the following few steps to clear the error.

1.Check that the firmware is the latest available

2.Turn Off and ON the printer.

3.Set Queue to OFF.

4.Set ‘When Start Printing’ to ‘Immediately’.

Please guide the customer through the front panel of the printer to set up the “Queue” to “OFF” and “When Start Printing” to “Immediately”.

Wipe disk solution

If the above procedure does not clear the error, use the wipe the hard disk procedure (Unsecure mode) See Disk Wipe DoD

5330.22’M on page 106. This will delete all previous jobs, ICC profiles and paper presets that were present on the hard disk. This procedure has an advantage for the customer in that it solves the issue without the need to wait for an onsite engineer to come to their premises and remove and replace the HDD (which would also have the same affect of deleting all the previous jobs, ICC profiles and paper presets). The whole procedure should not take more than 30-35 minutes.

Important step is that you need to select the Unsecure mode.

The printer continuously rejects printheads

To resolve printhead rejection problems, do the following.

1.Clean the flex contacts on the Printhead and in the Carriage Assembly using the Carriage Interconnect Wiper (see Carriage Interconnect Wiper on page 79) and try again.

2.If all the Printheads are rejected (for each Printhead, the status message on the Front Panel does not show 'OK') then perform the Carriage Assembly Test Carriage Assembly test on page 87..

A new maintenance cartridge is incorrectly detected as ‘used’

This can occur if the printer has detected the previous Maintenance Cartridge was nearly full, and when a new Maintenance Cartridge is installed the Front Panel displays an error that the cartridge is ‘used’. To resolve the problem, manually reset the counter of the Maintenance Cartridge Reset Life Counters on page 103.

Cover sensors are not working

To resolve cover sensor problems, do the following.

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The printer hangs during printing and displays ‘processing’

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1.Check that the cable for the faulty sensor is not damaged and is connected correctly.

2.Replace the faulty sensor.

NOTE: Covers sensors are disabled in sleep mode, don't expect them to work in this situation.

The Line Sensor has problems detecting paper

To resolve Line Sensor paper detection problems, do the following.

1.Check the type of paper that is being used: the Line sensor may have problems detecting transparent paper or some types of Non-HP paper. Try loading white HP paper into the printer and check whether the Line Sensor detects it.

2.Excessive ink deposits on the Platen surface can fool the sensor by reflecting the light. Clean the Center Platen.

3.Clean the Encoder Strip See Clean the Encoder Strip on page 452.

4.The Line Sensor is not calibrated correctly. Perform the Line Sensor Calibration See Line Sensor calibration on page 120.

5.The Line Sensor is damaged or faulty. Replace the Line Sensor See Line Sensor Assembly on page 285.

How to remove the Left Hub when the actuator is broken

You need a standard 90º Torx/Allen key(Torx T10 or Allen 2.5).

1.Insert the key about 20 mm between the sheet-metal and plastic parts.

2.Pull the key to the left to release the brake.

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Troubleshooting paper jams and printhead crashes

NOTE: If you were using HP Coated Paper when the problem occurred, see also Printhead crashes/smears on high-density prints using coated paper on page 13.

Paper jams and printhead crashes are grouped together because in many cases a paper jam causes the paper to lift up into the Carriage path and cause a printhead crash, which means that many paper jams are reported as printhead crashes.

Question	Answer
Did the paper jam occur when loading paper?	If paper jams have occurred previously, some pieces of paper may
	still be stuck in the paper path. Clear the paper path.
	NOTE: Customers often store used rolls without protecting
	them from office environmental conditions; when exposed to
	high humidity, the paper edges tend to curl. This curling can
	cause paper jams when paper is loaded by feeding paper in.
Did the paper jam occur when loading 30 inch wide media?	Media may jam due to excessive friction in the opposite edge of
	the media loading reference edge. Check that there is no damage
	due to the paper feed brake providing more tension than needed
	to the media. In this case, replace the paper feed brake. If the
	problem persists; escalate to HP Support.

Is the customer using non-HP paper?

The use of non-HP paper can easily be the cause of paper jams and printhead crashes—especially printhead crashes, because HP paper is specially formulated to avoid cockle, one of the primary causes of head crashes. If the paper is not HP-approved, advise the customer to use HP paper and check to see if the problem is now solved.

TIP: When clearing a paper jam, sometimes paper is stuck in the paper path. To clear this, you must open the Rear Door and insert thicker paper into the paper path to push out the paper that is still stuck there.

Troubleshooting shutdowns

If a shutdown occurs, you will get the message “Switch Power Off” followed by one of these messages:

●Check Maintenance Cartridge Path

●Check Paper Path

●Check Printhead Path

NOTE: A shutdown in each path will require different steps to resolve the problem as explained below. In each case, make sure that you power off the printer before trying to resolve the problem.

Also check that the Rewinder Motor moves easily (without friction) with the printer turned off.

Maintenance cartridge path

Open the right door of the printer and check for any visible obstacles restricting the movement of the Service Station. Manually move the Service Station, checking for smooth and free movement.

Paper path

To resolve paper path problems, do the following.

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1.Open the Window and check for any visible obstacles restricting the movement of the Drive Roller. Make sure that the mylar is not damaged. If there is a wrinkled mass of paper inside the paper path, lift the Pinchwheels (opening the Rear Door) and clear the obstruction.

2.If this shutdown happens at the end of a Roll of Paper, it could be because the paper is stuck firmly to the Roll. Lift the Pinchwheels (opening the Rear Door) and pull the paper clear.

3.Replace the spindle if broken.

4.Perform the Paper Drive Test to obtain further information on the problem Paper Drive test on page 84.

Printhead path

When a shutdown occurs in the Printhead path, you will get the message “Switch Power Off / Check Printhead Path (*). The (*) will be a number, which will give an indication on where the failure occurred.

PWM shutdown

To resolve a PWM shutdown, do the following.

1.Clean Slider Rods and Apply Oil along the complete axis of the Slider Rods. After applying the Oil,

perform the Scan-Axis Test See Scan Axis test on page 83 and check that the values are within the given limits.

2.Clean the Encoder Strip See Clean the Encoder Strip on page 452.

3.Perform the Scan-Axis Test to obtain further information on the problem Scan Axis test on page 83.

Velocity shutdown

To resolve a velocity shutdown, do the following.

1.Open the Window and check for any visible obstacles restricting the movement of the Carriage Assembly. Try and move the Carriage Assembly manually, checking for smooth and free movement.

2.Check that the Encoder Strip is clean. If necessary, clean Encoder Strip using a damp cloth.

Energy shutdown

To resolve an energy shutdown, do the following.

1.Clean Slider Rods and Apply Oil along the complete axis of the Slide Rods. After applying the Oil,

perform the Scan-Axis Test See Scan Axis test on page 83 and check that the values are within the given limits.

2.Clean the Encoder Strip See Clean the Encoder Strip on page 452.

3.Perform the Scan-Axis Test to obtain further information on the problem Scan Axis test on page 83.

Vacuum suction much lower at high altitudes

At altitudes above 3,000 meters, the vacuum force holding down the paper will be lower, therefore the paper will not be held in place properly causing:

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●Ink Smearing on the Paper.

●Printhead crashes against the Paper.

●Roll Paper loading problems (low probability).

Banding at variable extreme environmental conditions

NOTE: This problem is only applicable if the OMAS is disabled.

Since the Accuracy Calibration has been done at normal environmental conditions, printing in extreme environmental conditions will cause banding because the advance of the Drive Roller does not correspond to the same conditions that the calibration was done in. To solve the problem, perform the Accuracy Calibration in the new environmental conditions (see Using your printer).

Printhead crashes/smears on high-density prints using coated paper

High density prints can cause cockle mainly on HP Coated Paper. This causes two main problems:

1.Cockling in the borders - Because the printer places too much ink on the Coated Paper, the borders of the print become raised, causing the Printhead to crash against the paper. To solve the problem, try the following.

●Change the paper margins to 15mm, either in the Front Panel or in the Driver. If the customer is printing PostScript images, send them a PPD file containing the extended margins of 15mm.

2.Cockling within the print - If the printer places too much ink within the print, the paper starts to ripple, causing the Printhead to smear against the paper. To solve the problem, try the following.

●Check in the Front Panel if Ink Limiting is ON or OFF. If Ink Limiting is OFF, turn it ON.

●Never use HP Coated Paper for High Density prints. As a substitute use HP Heavy Coated Paper.

Banding due to ink cartridge replacement while printing

A user has removed the Ink Cartridge while the printer was printing, which has caused the printer to stop. If the user does not replace the Ink Cartridge immediately, when the printer starts to print again, a band will appear in the position where the printing restarted. This is because the wet ink interacts with the dried ink on the paper causing the band to appear. To solve the problem, try the following.

●Do NOT remove the Ink Cartridge while the printer is Printing. Only replace/remove Ink Cartridges in between Prints.

●If the Ink Cartridge was replaced due to the “Empty” status on the Front Panel, then advise the customer to replace the Ink Cartridge when the “Very Low” status is showing on the Front Panel.

●Reprint the file (without remove the Ink Cartridge).

34" Rice Paper not supported

Roll width is 34" (non-standard), and the pinch wheels can't control the edge of the paper, causing ink smears and printhead crashes.

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Worm marks on HP Coated Paper with light area fills

Light bands (S-shaped) in the direction of the media axis when light area fills are printed, causing an unacceptable print-quality defect.

●Print the Service Configuration Print and check whether the ambient humidity is very low (below 30%). Increasing humidity may help to reduce the severity of the problem.

NOTE: The paper is causing the problem and not the printer. Do not attempt to replace printer parts to solve this problem.

Solving paper-handling problems

The front panel keeps indicating that paper Is misaligned or incorrectly positioned.

●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.

NOTE: 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 paper may be loaded at an angle, causing the paper to be rejected.

●The Line Sensor may be malfunctioning. See The Line Sensor has problems detecting paper on page 10.

Difficult to load paper: “Too much skew”

If you encounter a high failure rate when loading paper and the front panel reports “Too much skew” it is likely that:

●The encoder strip must be cleaned (this can be carried out by the customer using the User Maintenance Kit).

●The Line Sensor must be cleaned.

●The Blue Line calibration must be performed. See Platen blue line calibration on page 129.

How to read the power switch LEDs

In certain circumstances, the LEDs located on top of the power switch (located at the rear of the printer) indicate the status of power supply to the printer.

1.When only the Amber LED is On:

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●The printer has been switched Off from the Front Panel (after having pressed the On/Off button).

●The Power Supply Unit only delivers a 5 V “Standby”; power that is needed to restart the printer after the Front Panel On/Off button is pressed (the Formatter will start the printer).

2.When the Blue LED is On: Deliver standard “ATX” power for the Electronics Module PCAs (+12V, +5V, -5V, -12V and so on). All the functions of the Electronics Module are fully operational (Embedded Web Server and so on).

3.When the Green LED is On: Deliver “analog” 24V and 36V to enable printing.

If you turn on the printer at the front panel, and the Blue LED does not come on, there is a problem. Turn off the printer using the switch at the rear, then turn it on again using the same switch. If the Blue LED still does not come on, replace the Power Supply Unit.

If the Blue LED comes on this time, you will probably see an error reported on the front panel as the printer starts up. If no error is reported, but you continue to have problems when turning on the printer from the front panel, see How to read the Formatter LEDs on page 15.

How to read the Formatter LEDs

The LEDs located on the Formatter can help to troubleshoot the printer. The LEDs can either be on or off; different combinations can indicate different problems.

The following image shows the three Formatter LEDs, which are numbered from the top down: number I at the top, number II in the middle, number III at the bottom.

Use the following table to interpret the LEDs and find the source of the problem. Remember that you should read these LEDs when you push the Power button.

Some combinations may require you to replace two or more components. In this case, always replace one component at a time. Test the printer to see if the problem has disappeared (check the LEDs again). If the same LED sequence continues, replace the next component indicated in the table.

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Power	Power	Power	Formatter I	Formatter II	Formatter	Front	Problem and recommendations
amber	blue	green	LED	LED	III LED	panel
LED	LED	LED				status
Off	Off	Off	Off	Off	Off	Off	The printer is not receiving electrical
							power.
							1.	Ensure that the printer is connected
								to the power outlet.
							2.	Ensure that the outlet delivers the
								expected power.
							3.	Replace the Power Supply Unit.
On	Off	Off	Off	Off	Off	Off	The Power key fails to turn on the printer.
							1.	Turn the printer off using the switch
								at the rear, and disconnect the
								power cord. Reconnect the power
								cord and turn on the printer using
								the switch at the rear.
							2.	If the problem persists, replace the
								Front Panel.
Off	On	Off	Off	Off	Off	Off	There is a power failure in the Formatter.
							1.	Reseat the power connector in the
								Formatter.
							2.	Replace the Main PCA.
							3.	If the problem persists, replace the
								Formatter.
							4.	If the problem persists, replace the
								Power Supply Unit.
Off	On	Off	On	Off	Off	Off	The Formatter BIOS is unable to start.
							If an external Memory Module is installed:
							1.	Reseat the Memory Module.
							2.	Remove the Memory Module and
								restart the printer.
							3.	If the printer is able to start
								normally, replace the Memory
								Module. If not, replace the
								Formatter.
							If an external Memory Module is not
							installed, replace the Formatter.
Off	On	Off	Flashing	Off	Off	Off	The Formatter BIOS cannot detect the
							Hard Disk Drive.
							1.	Reseat the Hard Disk Drive
								connectors.
							2.	Replace the Hard Disk Drive.
Off	On	Off	On	Flashing	Off	Off	The operating system has experienced a
							fatal error. Replace the Hard Disk Drive.

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Power	Power	Power	Formatter I	Formatter II	Formatter	Front	Problem and recommendations
amber	blue	green	LED	LED	III LED	panel
LED	LED	LED				status
Off	On	Off	On	On	Off	Off	There is a communication failure with the
							Main PCA.
							1.	Reseat the Main PCA.
							2.	Replace the Main PCA.
Off	On	Off	On	On	Flashing	Off	There is an initialization failure in the
							Formatter. Replace the Formatter.
Off	On	Off	On	On	On	Off	There is an initialization failure in the
							Front Panel.
							1.	Reseat the Front Panel cable.
							2.	Replace the Front Panel.

If the front panel turns on and then stops

If the power-up process stops while the front panel is displaying a number, respond as follows.

1.If the printer's Power-Up process stops when the front panel is displaying the number 17, this indicates that there is a problem with the file system on the printer's Hard Disk Drive, so the printer is checking the whole file system and making any necessary corrections. This problem can arise when there has been a power cut while the printer was switched On, or if there is a physical problem with the Hard Disk Drive.

Checking the whole file system normally takes about half an hour (but could take much longer). There is nothing that can be done to speed up the file checking process. If you turn Off the printer during the checking process, the file system check will restart whenever you turn it On again

If you experience this problem repeatedly when there has been no power cut, then this could mean that

the Hard Disk Drive is faulty. In this case, replace the Hard Disk Drive See Hard Disk Drive (HDD) on page 363.

2.If the printer's start-up process stops when the front panel is displaying any other number between 1 and 30, then try the following.

●Turn the power off at the rear of the printer and disconnect the power cord. Reconnect the power cord and turn on the printer.

●If the printer continues to stop during the power-up process, replace the Hard Disk Drive See Hard Disk Drive (HDD) on page 363.

How to interpret the Service Information Pages

The Service Information Pages contain the following information:

●Current Configuration

●Current Information

●Usage Information

●Event Logs

●Calibration Status

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●Connectivity Configuration

●All Pages

It is possible to print the Service Information Pages either through the Front Panel or through the Embedded Web Server:

●Front Panel: icon > Service information prints.

●Embedded Web Server: Support tab > Service support > Printer information.

Even if the printer cannot print, the Information Pages are still accessible through the Embedded Web Server.

Main characteristics

●Only available in English (except the current information page).

●From the Front Panel, you can choose to print all pages or just select the specific pages that are needed. If all pages are printed:

◦Nesting is turned on automatically (and turned off once all the pages have been printed).

◦Nesting cannot be mixed with other jobs in the queue.

●Each page can be printed from the Web browser when using the Embedded Web Server.

●Each page can be sent by e-mail from the Web Browser when using the Embedded Web Server (File Send Page by E-mail).

●You can see the same information through the Front Panel or the Embedded Web Server.

Current configuration

This page contains full details of the current configuration of the printer.

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Current media, printhead and ink information

This page contains the following information:

●Current Printer Configuration.

●Paper Loaded Information.

●Current Printhead Kit Information.

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●Current Ink cartridge Information I and II.

The first two lines are available at the beginning of each Service Information Page and contains standard information (like Service ID, firmware version).

Printer usage information

This page contains the following information:

●Printer Usage

●Usage per Printhead Slot

●Usage per Cartridge Slot

●Media Usage per Paper Type

●Component Usage

●Spittoon Usage

●Preventive Maintenance Usage

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