HP DesignJet 500 & 800 Series Service Manual Plotter
Service Manual

HP DesignJet Large Format Printer Plotters

HP DesignJet 500 & 800 Series Service Manual Plotter
This Service Manual contains information necessary to test,

Calibrate & Service:

HP DesignJet 500 Printer - 24 Model (P/N C7769B)

HP DesignJet 500 Printer - 42 Model (P/N C7770B)

HP DesignJet 500PS Printer - 24 Model (P/N C7769C)

HP DesignJet 500PS Printer - 42 Model (P/N C7770C)

HP DesignJet 800 Printer - 24 Model (P/N C7779B)

HP DesignJet 800 Printer - 42 Model (P/N C7780B)

HP DesignJet 800PS Printer - 24 Model (P/N C7779C)

HP DesignJet 800PS Printer - 42 Model (P/N C7780C)

PDF form at 286 Pages

TROUBLESHOOTING 1-1
INTRODUCTION 1-2
TROUBLESHOOTING SYSTEM ERROR CODES 1-2 SOLVING PRINT QUALITY PROBLEMS 1-3 COVER SENSORS ARE NOT WORKING 1-3
THE LINE SENSOR HAS PROBLEMS DETECTING MEDIA 1-3 TROUBLESHOOTING PAPER-AXIS SHUTDOWNS 1-4 PROBLEMS WITH THE VACUUM FAN 1-5
VACUUM SUCTION MUCH LOWER AT HIGH ALTITUDES 1-5
HP-GLL2 COLOR DIFFERENCES IN DIFFERENT HP DESIGNJET PRINTERS 1-6 BANDING AT VARIABLE EXTREME ENVIRONMENTAL CONDITIONS 1-6
THE PRIMING PROCEDURE FAILS 1-7
USING THE POWER SWITCH LED TO TROUBLESHOOT 1-10 USING THE BOOT-UP SEQUENCE TO TROUBLESHOOT 1-12
USING THE FORMATTER! ACCESSORY CARD LEDS TO TROUBLESHOOT 1-14
SYSTEM ERROR CODES 2-1
INTRODUCTION 2-2
CONTINUABLE AND NON-CONTINUABLE ERROR CODES 2-2 SYSTEM ERROR CODES - EXPLANATION 2-2
ERROR LOG UTILITY 2-5
ACCESSING THE ERROR LOG UTILITY 2-5
INK SUPPLIES TROUBLESHOOTING 3-1
WHAT ARE THE INK SUPPLIES? 3-2 INK CARTRIDGES 3- 2
PRINTHEADS 3-3
IDENTIFYING THE COMPONENTS 3-3
GENERAL INFORMATION ABOUT THE INK SUPPLIES 3-4
SOME GENERAL PRECAUTIONS WHEN HANDLING THE INK SUPPLIES 3-5 WHEN SHOULD YOU REPLACE THE INK CARTRIDGES? 3-6
WHEN SHOULD YOU REPLACE THE PRINTHEADS? 3-7
OBTAINING INK CARTRIDGE INFORMATION 3-9
HP DESIGNJETS 500 AND 800 SERIES PRINTERS SERVICE MANUAL
OBTAINING PRINTHEAD INFORMATION 3-10 INK CARTRIDGE STATUS MESSAGES 3-12
INK CARTRIDGE STATUS WHILE REPLACING 3-12 PRINTHEAD STATUS MESSAGES 3-13
PRINTHEAD HISTORY UTILITY 3-14
ACCESSING THE PRINTHEAD HISTORY UTILITY 3-14
IS THE PRINTER CAUSING REPETITIVE PRINTHEAD PROBLEMS? 3-16 IS THE USER REPLACING THE PRINTHEADS TOO EARLY? 3-18 TROUBLESHOOTING REPETITIVE INK CARTRIDGE MESSAGES 3-20 TROUBLESHOOTING REPETITIVE PRINTHEAD ERROR MESSAGES 3-21 PRINTHEAD ERROR CODES 3-22
SUMMARY OF SOLVING INK SUPPLIES PROBLEMS 3-23
SERVICE TESTS AND UTILITIES 4-1
INTRODUCTION 4-2
PHONE SUPPORT 4-2
DIAGNOSTICS - SELF TEST 4-2
SERVICE TESTS (DIAGNOSTICS) 4-3 ENTERING THE SERVICE TESTS MENU 4-4 INK SUPPLY STATION 4-6
CARRIAGE MOVEMENT 4-8
PAPER ADVANCE TEST 4-10
SERVICE UTILITIES 4-13
ENTERING THE SERVICE UTILITIES MENU 4-14 EEROM SETUP 4-16
TURN DRIVE ROLLER 4-21
UNLOCK CARRIAGE 4-22
PRIME TUBES 4-23
CHANGE CUTTER 4-24
CHANGE INK TUBES 4-25
PRINTER INFORMATION 4-26
SERVICE CALIBRATIONS 5-1
ENTERING THE SERVICE CALIBRATIONS MENU 5-3 PRINTHEAD ALIGNMENT (INCLUDES PPS CALIBRATION) 5-5 COLOR CALIBRATION 5-7
ADVANCE CALIBRATION 5-9
FACTORY ADVANCE CALIBRATION 5-LL
PRINT QUALITY 6-1 PRINT QUALITY 6-2
PRINT QUALITY TROUBLESHOOTING CHECKLIST 6-2 HOW TO USE THE TROUBLESHOOTING PROCEDURE 6-4 WHAT IS THE TROUBLESHOOTING PROCEDURE? 6-4
CONSIDERATIONS FOR USING THE TROUBLESHOOTING PROCEDURE. 6-4 PERFORMING THE TROUBLESHOOTING PROCEDURE 6-4 TROUBLESHOOTING PROCEDURE FLOWCHART 6- 7
NO PRINTING DEFECTS FOUND USING THE TROUBLESHOOTING PROCEDURE 6-8 SOLVING COLOR ACCURACY PROBLEMS 6-9
COLOR CONSISTENCY PROBLEMS 6-9
LONG TERM COLOR BLEEDING (GLOSSY PAPERS) 6-9 MEDIA 6-10
THERE ARE SMEARS OR SCRATCHING ON THE PRINTED MEDIA 6-10
PARTS AND DIAGRAMS 7-1 PRINTER SUPPORT 7-2
RIGHT HAND COVER 7-4
LEFT HAND COVER 7-6
TOP COVER AND DEFLECTORS 7-8 ROLLFEED MODULE 7-10
BACK PLATEN ASSEMBLY 7-12 ELECTRONICS MODULE 7-14
POWER SUPPLY 7-16
CUTTER ASSEMBLIES 7-18
INK DELIVERY SYSTEM 7-20 SERVICE STATION AND SPITTOON 7-22 SERVICE STATION HOLDER 7-24 PINCH-WHEEL ASSEMBLIES 7-26 SCAN-AXIS MOTOR 7-28
DRIVE ROLLER ENCODER SENSOR 7-30 PRINT PLATEN ASSEMBLY 7-32 CARRIAGE ASSEMBLY 7-34
VACUUM FAN 7-36
INTERCONNECT CABLE 7-38 PAPER-AXIS MOTOR 7-40
DRIVE ROLLER 7-42
MISCELLANEOUS ITEMS 7-44
REMOVAL AND INSTALLATION 8-1
INTRODUCTION 8-2 SAFETY PRECAUTIONS 8-2
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 8-3 REQUIRED TOOLS 8-3
SCREW TYPES 8-4
LEFT HAND COVER 8-5
RIGHT HAND COVER 8-7
FRONT PANEL 8-9
WINDOW AND TOP COVER 8-10 MEDIA DEFLECTORS 8-11
LEFT END ROLL-FEED 8-13 RIGHT END ROLL-FEED 8-15 BACK PLATEN 8-17
MEDIA SENSOR 8-19 FORMATTER 8-20
LAN CARD 8- 21
SPITTOON 8-23
ELECTRONICS MODULE 8-24 POWER SUPPLY 8-27
SCAN-AXIS MOTOR ASSEMBLY 8-29 CUTTER ASSEMBLY 8-32
LEFT ENCODER HOLDER 8-33
CUTTER BUSHING 8-35
CUTTER GUIDE BRACKET 8-36
DRIVE ROLLER ENCODER SENSOR 8-38 TRAILING CABLE 8-40
INK SUPPLY STATION 8-48 INTERCONNECT PCA 8-50
SERVICE STATION AND AEROSOL FAN 8-52 CUTTER GUIDE 8-55
PRINT PLATEN 8-56
SERVICE STATION HOLDER 8-57 INTERCONNECT CABLE 8-59 INK SUPPLY TUBES 8-60 VACUUM FAN 8-64 PINCH-ARM 8-66
PINCH-ARM MECHANISM 8-67 PINCH-ARM LEVER 8-69
PINCH-ANN SENSOR 8-71
FORK IDLER, TENSIONER AND IDLER PULLEY 8-74 ENCODER STRIP 8- 76
CARRIAGE ASSEMBLY (INCLUDING BELT) 8-78 PAPER-AXIS MOTOR 8-84
DRIVE ROLLER 8-86
GEAR ASSEMBLIES 8-92
PREVENTIVE MAINTENANCE 9-1
MOISTURE ON THE PRINTER 9-2 NOISY CARRIAGE BUSHING 9-2 BELT SWELLING 9-2
CLEANING THE PRINTER 9-2 GENERAL CLEANING 9-2
CLEANING THE DRIVE ROLLER/PRINT PLATEN 9-3 SCHEDULED MAINTENANCE 9-3
LEVEL OF PRINTER USAGE 9-3
SCAN-AXIS MAINTENANCE 9-4
FUNCTIONAL OVERVIEW 10-1
INTRODUCTION 10-2
SKU OVERVIEW 10-2
ELECTRICAL SYSTEM 10-3 INTRODUCTION 10-3
HARDWARE DESCRIPTION 10-3 POWER SUPPLY UNIT (PSU) 10-5 FRONT PANEL 10-6
INK DELIVERY SYSTEM (IDS) 10-7 INK SUPPLY STATION (ISS) 10-7 TUBES ASSEMBLY 10-9
SERVICE STATION 10-10














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