HP Designjet Z6100 Printer series Service manual
For HP Internal Use Only Warranty WARNING ©Copyright Hewlett-Packard Company 2008 The information contained in this document is subject to change without notice. The procedures described in this manual are to be performed by HP-qualified service personnel only. This document contains proprietary information that is protected by copyright. All rights are reserved.
HP Designjet Z6100 Printer series Service manual
Using this Manual Purpose This Service Manual contains information necessary to test, calibrate and service: • HP Designjet Z6100 42-inch Printer (Model Q6651A) • HP Designjet Z6100 60-inch Printer (Model Q6652A) 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.
1 Table of Contents 1 Troubleshooting Troubleshooting the printer......................................................................................................... 2 Printer Education and Training..................................................................................... 2 Firmware upgrade ..................................................................................................... 2 Troubleshooting system error codes..............................................................
Printer Usage Information.......................................................................................... Media Used Sections................................................................................................ Event Logs............................................................................................................... Calibrations Status ................................................................................................... Connectivity Configuration ...........
10. OMAS Module Test.......................................................................................... 11 EEROM Reset ................................................................................................... 12. Color Sensor Test ............................................................................................. 13. Aerosol Test .................................................................................................... 14. Primer Test ....................................
Lines appear stepped or jagged .............................................................................. Parts of lines or text are missing ............................................................................... Lines are blurred (ink bleeds from lines) .................................................................... Lines are slightly warped ........................................................................................ Dark or light horizontal lines across the image (banding) ...
Top Cover (60-inch) .............................................................................................................. Rear Door (42-inch) .............................................................................................................. Rear Door (60-inch) .............................................................................................................. Right Connector Cover .................................................................................................
9 x Left Rollfeed Module Assembly ............................................................................................... Take-Up Reel Motor .............................................................................................................. Take-Up Reel Left Hand Module.............................................................................................. Take-Up Reel Deflector Supports .............................................................................................
Troubleshooting 1 Troubleshooting • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Troubleshooting the printer ..................................................................................... 2 • Printer Education and Training.......................................................................... 2 • Firmware upgrade .......................................................................................... 2 Troubleshooting system error codes.........................................
Troubleshooting Troubleshooting the printer Refer to Section 6 for troubleshooting Image Qulaity issues. Printer Education and Training Before any attempt is made to troubleshoot the printer, it is critical that you have the relevant training on the HP Designjet Z6100 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.
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. NOTE: 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.
Troubleshooting 1. Check that the firmware is the latest available (at least 7.0.03) 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 page 145.
To resolve line sensor media detection problems, do the following: 1. Check the type of media that is being used since the Line sensor may have problems detecting transparent media or some types of Non-HP media. Try loading white HP media in to the Printer and check if the Line sensor detects it. 2. Excessive ink deposits on the Platen surface can fool the sensor by reflecting the light. Clean the Center Platen. 3. Clean the Encoder Strip ⇒ See page 454. 4.
Troubleshooting • 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 attempting any procedures to resolve the problem. Printhead 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.
Replace the Scan-Axis Motor ⇒ See page 346. Vacuum suction much lower at high altitudes At altitudes above 3,000 meters, the vacuum force holding down the media will be lower, therefore the media will not be held in place properly causing: • Ink Smearing on the Media. • Printhead crashes against the Media. • Roll Media loading problems (low probability). PRINTER LIMITATION - NO SOLUTION AVAILABLE.
Troubleshooting • 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).
Use this section to troubleshoot failures with the TakeUP Reel. Take Up Reel LED status information LED status Issue Print job interupted Possible cause Print job interrupted? Blinking quickly Take Up Reel not winding Yes Sensor beam blocked for more than 3 seconds Ensure the Take Up Reel sensors are not blocked by a strip of paper, the collection bin or other objects. Also ensure the Take Up Reel power switch is in the On position.
Troubleshooting Checking the Take Up Reel is correctly installed Many system error codes are displayed as a result of the Take UP Reel not being installed correctly or because parts have moved or become dislodged from their correct positions. This troubleshooting procedure checks the machnical installation of the Take Up Reel. 1. Check that the Take UP Reel sensor unit is correctly installed on the right foot. 2. To correctly install the foot, the wheel has to be positioned as shown. 3.
There are two different setups: 1. The Take Up Reel has been installed via the front panel from the media menu – how to check it: If the words 'Take Up Reel installed' is blanked out, this means that the Take Up Reel is not installed in the front panel. 2. The Take UP Reel has not been install via the front panel – how to check it: When selecting the media menu, there is no line ‘Take Up Reel installed’.
Troubleshooting Number of Beeps Problem Description Corrective Action 4 Faulty Video Card (not used) • Replace the Main PCA ⇒ See page 375. 5 Faulty PCI Card • Replace the Main PCA ⇒ See page 375 6 BIOS Damaged • Replace the Main PCA ⇒ See page 375 7 Motherboard damaged • Replace the Main PCA ⇒ See page 375 • Remove the Main PCA Cover and (with the Printer switch On) check that the HDD is spinning (you should feel it spinning when you touch it or at least hear it spinning).
Troubleshooting Step Initialization Process 25 Load system font. 24 Start up swapping. 23 • • Set the hostname. Initialize USB controller and HID devices 22 • • • Set variables for options to be later used for filesystem check Turn Off DMA on CD-ROMs Turn On Hard Disk optimization 21 Perform file system check on root volume. 20 Update quotas if fsck was run on root 19 Setup pnp 18 • • • • • • • Remount the root filesystem read-write. LVM initialization. Clear mtab.
Troubleshooting Step Initialization Process 5 Printer IO startup. 4 Front Panel application startup (but wait for engine launching, i.e. Front Panel is not cleared yet). 3 Engine startup, start EE and Mechanical initialization. 2 HPGL/PS parsers startup. 1 All subsystems launched. Wait for Front Panel application to clear the Front Panel and start signaling the initialization sequence.
Check the other end of the CAN cable is also correctly connected 3. Check the LEDs under the OMAS board. This LED only comes on for the first 20 seconds after the printer is turned On. When the firmware has succesfully loaded into the memory the LED will switch OFF. Troubleshooting 2. These LEDs come On and stay lit. From right to left: 1st LED=24 volts 2nd LED=5 volts 3rd LED=3.
Troubleshooting 1. When only the Amber LED is On: • 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/Main PCA will initiate the Printer to start). 2. When the Blue LED is On: Deliver standard “ATX” power for the Electronics Module PCAs (+12V, +5V, -5V, -12V, etc...).
VPOWER2 - Comes from the PSU (42V) after a fuse on the Interconnect PCA. Used to power the Carriage PCA. Should be ON at the same time as Green Power Switch LED. PrintMech PCA The following illustration shows the locations of the LEDs on the PrintMech PCA. DS7: 5Vsb DS5: VAUX=12V DS4: 24V DS3: VPOWER2 PrintMech PCA DS2: 5V DS1: 3V3 5Vsb - Comes from the PSU after the fuse on PrintMech PCA. 3V3 - Comes from the Power Supply Unit. 5V - Comes from the Power Supply Unit.
Troubleshooting Signal LED on Interconnect PCA LED on PrintMech PCA Power Switch LED Corrective Action • 5Vsb OFF OFF Amber or no LED • • 2. If the Printer starts (after having pressed the ON button on the Front Panel) but the front Panel remains black: Signal LED on Interconnect PCA LED on PrintMech PCA Power Switch LED Corrective Action • 5V OFF ON Blue • • 5V 3. Check the connection between the PSU and the PrintMech PCA and Interconnect PCA.
LED on Interconnect PCA LED on PrintMech PCA Power Switch LED Corrective Action • 24V 24V 4. 5. OFF ON ON Blue and Green OFF Blue and Green Troubleshooting Signal • • • Check the connection between the PSU and the Interconnect PCA. If connection OK, run the Electronics Module Test to further diagnose the problem. Check the connection between the PSU and the PrintMech PCA. If connection OK, run the Electronics Module Test to further diagnose the problem.
Troubleshooting • Embedded Web Server: Support tab ⇒ Service Support ⇒ Printer Information. 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.
Troubleshooting Current Configuration This page contains full details of the current configuration of the Printer.
Troubleshooting Current Media, Printhead and Ink Information This page contains the following information: • Current Printer Configuration. • Paper Loaded Information. • Current Printhead Kit Information. • 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).
Troubleshooting Printer Usage Information This page contains the following information: • Printer Usage. • Usage per Printhead Slot. • Usage per Cartridge Slot. • Media Usage per Media Type. • Component Usage. • Spittoon Usage. • Preventive Maintenance Usage.
Troubleshooting Media Used Sections • Total media used in the Printer. • Media used for each media type. It is possible that the sum of the media used for each media type is lower that the total amount of media used in the Printer. This is because only the total media used in the Printer is saved in the backup EEROM which is located in the ISS PCA. When the Hard Disk Drive is replaced, the total media used per media type is reset to zero (0), but the total media used is recovered from the backup EEROM.
One cycle is counted when the Carriage makes one movement to the left of the Printer and then returns to the right. To find the total of Monochrome ink consumed in cc use the the formula ^0.61. Example: For a value marked as 11504, use the formula ^0.61 to convert it to cc=300cc (11504 0.61=300). Spittoon Section This section contains information on the different Spittoons located in the Printer.
Troubleshooting System/Warning Error • The Line and Internal Code do not provide much information, but are useful in the case of escalating a problem to the division (different internal error codes can point to the same error code (e.g. 01.10:10)). • Media Usage (in square meters) and Date (from the Printer’s Internal Clock (RTC)) help you to understand if the Printer has been used (media usage) and how much time has passed since the last error.
Media Specific Calibrations (performed by the User). Troubleshooting • General Calibrations • Printhead Alignment relates to the Printhead Alignment which changes to ‘pending’ when a Printhead is replaced and the Printhead Alignment has not been performed. NOTE: When a component is replaced, the corresponding calibration is NOT automatically set to ‘NOT DONE‘. This is because the Printer does not know that there is a new part installed.
Troubleshooting Connectivity Configuration This page contains full details of the current configuration of the Printer.
We describe the details of the behavior of the printer when the window is opened while the carriage is moving If the main window is opened while the printer is doing something, be it a swath of a print job or a system task, the printer will: 1. Before the carriage stops, it will finish whatever it was doing when the window was opened. It will not finish an image it was printing, but it will finish the current swath, so as to avoid any impact on image quality.
Troubleshooting • Network connection : Ensure that a Gigabit Ethernet connection is used between the PC and the printer to provide sufficient network throughput. To ensure that the traffic between the RIP and the printer do not disrupt your other network traffic, please use a Gigabit network switch (not a hub).
Question: When printing from the ONYX RIP, my PC becomes too slow and/or the carriage stops between each swath, how can I troubleshoot this problem Answer: A number of different factors can cause this to happen. Here is a troubleshoot checklist which should solve the majority of issues: 1. Uninstall the HP Easy Printer Care, the Color Center and/or the HP Printer Utility. If you need to use this tool, you might be able to install them on another PC. 2.
Troubleshooting Since this is a generic error, there can be multiple causes behind it. This document will cover the most probable causes behind a system error 79:04 and will recommend the most efficient troubleshooting steps to resolve customer issues. One important point to mention is that, although 79:04 system errors can be caused by a hardware malfunction, the vast majority of 79:04 system errors are pure software or firmware issues.
1. Send the job using a variety of different settings. Many times, the issue is caused by a combination of the job contents combined with some specific setting(s). 2. If the customer is sending the file directly to the printer, try using the HP driver instead 3.
Troubleshooting c. 2. 3. Delete any non standard paper preset in the printer (both the ones that have been created by the user and the ones that have been installed as OMES profiles through the EWS or the HP Printer Utility) If step 1 did not resolve the issue, you can use Service Tools to clear additional information that could be causing the issue: a. Start the printer in Diagnostics Boot Mode b.
Disconnect the network cable to be able to boot the printer and change network settings 2. In the Network configuration menu in the Front Panel, disable any protocols that you are not using, including IPv6, SNMP and WebServices. 3. If step “2” does not work, try setting a manual configuration of the device: 4. a. Enter the correct subnet mask and an IP in the valid range b. In the GateWay field, set the same value as in the IP address field c.
Troubleshooting When a program with a memory leak is executed a lot, the memory becomes progressively full (since it is not properly freed). When the leak becomes too big, the printer is left ‘out of memory’ to execute new processes and a 79:04 is triggered • Concurrence issues: there are certain resources that can be accessed by multiple programs or by multiple executions of the same program (what is known as multiple threads).
Application that is being used; RIP or driver that is being used • Application/RIP/Driver settings • Type of output files this application, RIP or driver is generating • Some sample files that are representative of what the customer is using • Operating System • Method of connection to the printer • A description of the normal flow when the issue occurs and the typical frequency of occurrence (i.e.
Troubleshooting 2. Replace the memory 3. Replace the HDD 4. Escalate the issue before replacing any additional parts. Troubleshooting based on symptoms This section will describe which troubleshooting steps to perform for a 79:04 system error based on the symptoms of the issue. Perform each step as it appears in the list and only move on to the next step once you are sure the 79:04 error has not been cleared: Front panel displays 79:04 at Start-up • Reboot the printer twice.
In order to narrow the scope of the issue, try the following: a. Disable the queue b. Disable any unused network protocols c. Disable SNMP and WebServices (if they are available in the printer) d. Disable “Sleep mode” from the Service Utilities menu e. Delete any Paper Presets that you may have uploaded or created using the printer Spectrophotometer. 5. Restart the printer in Diagnostics Boot Mode and perform the “Electronics test”. If an electronic component is identified as faulty, replace it.
Troubleshooting 4. 5. d. If you are using the PS driver, try using the HP-GL/2 driver instead e. If you are using the PS driver from an Adobe application (or any other application that can handle PS), try changing the application’s print settings so that the PS is generated as Raster. Try the following Front Panel settings: a. Change the Print Language option in the Front Panel from “Automatic” (which is the default setting) to the language that is being printed (PS, HP-GL/2, …) b. Queue = OFF c.
Reboot the printer twice (after the first reboot, the printer will show the 79:04 system error again, since the printer will attempt to reprint the last job in the queue. If the issue continues occurring randomly, continue troubleshooting 2. If you are using an HP driver, update the driver to the latest version 3. Upgrade the printer’s firmware. Even if the currently installed firmware version is the latest one, reinstall it. 4. Try the following changes in the workflow: 5. 6. a.
Troubleshooting 42 Chapter 1 Troubleshooting
System Error Codes • • • Introduction..................................................................................................................... 44 System Error Codes and Warnings - Explanation ................................................................. 44 Continuable and Non-Continuable 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.
Code Component/System 01.0 01.1 01.2 02 02.1 03 05 05.1 05.3 06 07 08 11 21 23 24 26.n 27.n 31 32 38 39 41 42 43 44 50 51 51.1 52 53 54 55 56 58 61 61.1 61.
System Error Codes Code Component/System 76 77 78 79 81 85 86 87 91 93 94 98 Disk Full WebAccess Application Borderless Assertion (Uncontrollable Firmware Error) Media Advance Media-Axis Encoder Reading Carriage Movement Scan-axis encoder reading Printhead Firing Ink Pumping Color Calibration Automatic Backup Print Mode Enabled The following table explains the YZ part of the System Error Code or Warning: Code Recovery Action 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 Replace Reseat/
Continuable and Non-Continuable Error Codes Some of the Error Codes are continuable, which means you can press Enter on the front-panel and continue working with the Printer. Non-Continuable Error Codes do not allow you to continue working with the Printer, in this case power the Printer OFF and ON again and see if the System Error disappears. If the Error Code reappears, then the Printer requires an on-site visit in order to resolve the problem.
• Replace the PrintMech PCA ⇒ Page 384. • If the System Error continues, replace the Sausalito PCI PCA ⇒ Page 369. System Error: 01.2:10 Problem Description: System Error Codes ISS PCA problem. 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. • Low humidity in the customer’s environment can be a cause of this system errror. You can check the humidity by using the EWS.
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. • Perform the Electronics Modules Test (⇒ Page 105) to troubleshoot the problem further. • If the System Error continues, replace the Power Supply Unit ⇒ Page 379. System Error: System Error Codes 05.1:10 Problem Description: CPU Fan is stopped or burnt.
• If the System Error continues, replace the Hard Disk Drive ⇒ Page 377. System Error: 06:10 Problem Description: Main NVM failure - not detected, read/write failed or readback error. System Error Codes 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 Hard Disk Drive ⇒ Page 377.
Check that the Printer has the latest Firmware version. If not, update the Firmware to the latest version. • Replace the Hard Disk Drive ⇒ Page 377. • Replace the Main PCA ⇒ Page 375. • Replace the Memory Module ⇒ Page 373. • Replace the Interconnect PCA ⇒ Page 357. • Replace the Front Panel ⇒ Page 292. • Replace the Sausalito PCI PCA⇒ Page 369. System Error Codes • System Error: 11:10 Problem Description: Trailing Cable does not seem to be connected.
System Error: 21:10 Problem Description: Fault has been detect in the area of the Service Station. Corrective Action: System Error Codes 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. • Make sure that the Service Station path is clear. Remove any visible obstacles (e.g. foam from the printer’s packaging, screws, plastic parts, etc...) restricting the movement of the Service Station.
System Error: 24:03 Problem Description: Ink Setup failure (Ink Supply Tubes purge failed). Corrective Action: • 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 rebooted. • Install new Ink Cartridges in to the Printer and try purging the Printer again.
System Error Codes • Remove the Magenta Ink Cartridge and reinstall it in to the Printer. • Replace the Magenta Ink Cartridge. • Check that the ISS to Cartridge cable (Magenta Ink Cartridge) is not damaged and is correctly connected to the Ink Supply Tubes PCA. • Replace the ISS to Cartridge cable (Magenta Ink Cartridge) ⇒ Page 318. • Replace the Ink Supply Tubes and Trailing Cable ⇒ Page 312.
• Replace the Ink Supply Tubes and Trailing Cable ⇒ Page 312. NOTE: If the Ink Supply Tubes are to be replaced, the Ink Cartridges need to be checked beforehand to see if they are capable of purging the new tubes, if they are not, new Ink Cartridges must also be sent with the parts to be replaced. To check the Ink Cartridges go to ⇒ Page 129. System Error: Problem Description: Bad contact detected in ISS slot 3 floater.
System Error: 26.5:01 Problem Description: Bad contact detected in ISS slot 5 floater. Corrective Action: System Error Codes Try the following: • Remove the Light Cyan Ink Cartridge and reinstall it in to the Printer. • Replace the Light Cyan Ink Cartridge. • Check that the ISS to Cartridge cable (Light Cyan Ink Cartridge) is not damaged and is correctly connected to the Ink Supply Tubes PCA. • Replace the ISS to Cartridge cable (Light Cyan Ink Cartridge) ⇒ Page 318.
Corrective Action: • Remove the Cyan Ink Cartridge and reinstall it in to the Printer. • Replace the Cyan Ink Cartridge. • Check that the ISS to Cartridge cable (Cyan Ink Cartridge) is not damaged and is correctly connected to the Ink Supply Tubes PCA. • Replace the ISS to Cartridge cable (Cyan Ink Cartridge) ⇒ Page 318.
Corrective Action: Try the following: • Remove the Printheads and check that they are the correct ones for this Printer. • Check that the Printer has the latest Firmware version. If not, update the Firmware to the latest version. • Replace the Printheads. System Error Codes System Error: 29:02 Problem Description: The maintenance cartridge absorber is almost full. It will have to be replaced soon. Corrective Action: Try the following: • Replace the Maintenece Cartridge.
The most probable cause of this error is the user has forgotten to set the switch direction or tape the paper to the spindle core, when the paper reaches the floor and blocks the TUR IR sensors. Corrective action • Check that there is no interference around the Take-up-reel optical sensors. • Check the paper is attached to the TUR spindle. • Check the TUR switch is in the correct position.
• 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. • Replace the Media-Axis Motor ⇒ Page 349. • If the System Error continues, replace the PrintMech PCA ⇒ Page 384. System Error: System Error Codes 41:10 Problem Description: Electrical fault in paper 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. • Check that the Scan-Axis Motor cable is not damaged and is correctly connected to the PrintMech PCA. • Clean the Encoder Strip using a lint free cloth dampened with tap water, then reset the counter (Setup > Resets > Encoder cleaning) ⇒ See the instructions provided in the User Maintenance Kit and ⇒Page 454 • Replace the Scan-Axis Motor ⇒ Page 346.
Problem Description: Aerosol Fan not connected. Corrective Action: System Error Codes Try the following: • Check that the Aerosol Fan cable is not damaged and is correctly connected to the Interconnect PCA. • Replace the Aerosol Fan ⇒ Page 300. System Error: 46:03 Problem Description: Primer servo shutdown. 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.
• Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. • Clean the Encoder Strip ⇒ Page 454 • Replace the Primer Assembly ⇒ Page 294. System Error: 50:01 Problem Description: System Error Codes OMAS Navigation 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.
System Error Codes • 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. • Check that the OMAS Module cable is not damaged and is correctly connected to the OMAS Controller PCA. • Replace the OMAS Controller Card ⇒ Page 362 • Replace the OMAS Module ⇒ Page 351.
• 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. • Check that the OMAS Module cable is not damaged and is correctly connected to the OMAS Controller PCA. • Replace the OMAS Controller Card ⇒ Page 362 • Replace the OMAS Module ⇒ Page 351. System Error Codes System Error: 50.
Corrective Action: Try the following: • Check that the Maintenance Cartridge Door Sensor cable is not damaged and is correctly connected to the Interconnect PCA. • Replace the Maintenance Cartridge Door Sensor. System Error: System Error Codes 52:01 Problem Description: Drop Detector fiber detected. 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.
• Replace the Media Sensor ⇒ Page 415. System Error: 54:10 Problem Description: Pinch Lever sensor error detected. Corrective Action: • Check that the Media Lever Sensor cable is not damaged and is connected correctly to the Interconnect PCA. • Replace the Media Lever Sensor ⇒ Page 423. System Error Codes Try the following: System Error: 55:10 Problem Description: Problem with the Line Sensor.
• Replace the Encoder Disc and Sensor ⇒ Page 417. System Error: 58:10 Problem Description: An error detected with the Color Sensor. System Error Codes 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 Printer has the latest firmware version. If not, update the Firmware to the latest version. • Perform the Color Sensor test.
Problem Description: The Postscript fonts are missing. Upgrading the Firmware will re-install the fonts. Corrective Action: Perform a full firmware upgrade that includes package ’B’. System Error: System Error Codes 61:08.1 Problem Description: The file cannot be printed because it is password protected. Corrective Action: Resend the file without password protection. System Error: 63:04 Problem Description: Input/Output problem through the Network Card.
Problem Description: Input/Output problem through an unknown port. Corrective Action: System Error Codes Try the following: • 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. System Error: 66:08 Problem Description: Cannot print file on current paper type.
Problem Description: Generic Firmware error. 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 Printer has the latest Firmware version. If not, update the Firmware to the latest version. System Error Codes • System Error: 73:03 Problem Description: Carriage encoder reading error.
• Check that the Printer has the latest Firmware version. If not, update the Firmware to the latest version. System Error: 76:03 Problem Description: System Error Codes Disk out of space. 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. • Resend the file to the Printer.
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 Printer has the latest Firmware version. If not, update the Firmware to the latest version. System Error: System Error Codes 79:04 Problem Description: Generic Firmware error. Corrective Action: Try the following: • Switch the Power OFF from the back of the Printer and disconnect the Power cord.
• 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 (⇒ Page 101) to further troubleshoot the error code. • If the System Error continues, replace the Media-Axis Motor ⇒ Page 349. System Error: System Error Codes 85:03 Problem Description: Problem finding the Drive Roller zero.
System Error: 87:01 Problem Description:. Corrective Action: Try the following: • Clean the Encoder Strip using a lint free cloth dampened with tap water, then reset the counter. (Setup > Resets > Encoder cleaning) ⇒ See the instructions provided in the User Maintenance Kit (P/N Q6715A). Refer to ⇒page 454 NOTE: This operation is a standard maintenance procedure for the customer. It is fully documented in the User Maintenance Kit.
System Error: 94:08 Problem Description: Color Calibration failed: This errror message is briefly displayed after failing to calibrate. Corrective Action: System Error Codes Try the following: • There are a few types of media which will cause the calibration to fail if used: • Semi-translucent and transparent media (film). • Media that is not completly flat with a Satin finish will cause the light to reflect in different directions.
• Use HP Media to perform the calibration. • Perform the manual advance calibration (Ink -> image quality maintenance -> Paper advance calibration -> Adjust Paper advance), moving from 0 to 100% represent to an advance of the media by 1.5mm per meter. • Check cable connections between the densitophotometer/line sensor and the Carriage PCA.
System Error Codes 78 Chapter 2 System Error Codes
Ink Supplies • • • • • • • • • • • What are Ink Supplies?........................................................................................ 80 General Information About the Ink Supplies ............................................................ 82 General Precautions When Handling Ink Supplies ................................................... 82 Priming the Ink System .........................................................................................
What are Ink Supplies? For each of the eight ink colors used in the printer, there are three separate components, the Printhead, the Maintenance Cartridge, and the Ink Cartridge. All of these components are called Ink Supplies. Printheads Maintenance Cartridge Ink Supplies Ink Cartridges Ink Cartridges The printer's eight Ink Cartridges provide yellow, magenta, light magenta, photo black, matte black, yellow, light cyan, cyan, and light gray ink to the Printheads.
The following table lists the Ink Cartridges for the HP Designjet Z6100 Printer series.
Maintenance Cartridge Use the Maintenance Cartridge to clean and maintain the Printheads, ensure the best possible print quality, and seal the Printheads when they are not in use to prevent them from drying out. The Maintenance Cartridge for the HP Designjet Z6100 Printer series is the HP 91 Maintenance Cartridge P/N C9518. General Information About the Ink Supplies Ink Supplies NOTE: When reporting the System Error Code, make sure that you supply the full Error Code and the firmware version.
• Do not drop the Printheads. • Proper handling will assure optimum performance throughout the Printhead life. • The Maintenance Cartridge should always be handled and stored upright to avoid a potential spillage of ink. • 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.
1. Scroll to the Ink Menu icon and press Enter. Press Enter to confirm selection Use UP and DOWN keys to select 2. In the Ink submenu, scroll to “Ink cartridge information” and press Enter. Press Enter to confirm selection Use UP and DOWN keys to select Ink Supplies 3. In the Ink Cartridge Information submenu, scroll to the Ink Cartridge that you want information on and press Enter. Press Enter to confirm selection Use UP and DOWN keys to select 4.
• Original capacity of the ink cartridge in milliliters. • The warranty status of the Ink Cartridge. • The manufacturer of the Ink Cartridge (HP is recommended). • The expiration date of the Ink Cartridge. Obtaining Printhead Information 1. Scroll to the Ink Menu icon and press Enter. Press Enter to confirm selection Use UP and DOWN keys to select In the Printheads submenu, scroll to “Printhead information” and press Enter. Press Enter to confirm selection Use UP and DOWN keys to select 3.
• 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. • The current status of the Maintenance Cartridge. Ink Cartridge Status Messages Status Bars The front panel displays four horizontal bars.
Replace The Ink Cartridge is faulty and needs to be replaced before the printer can continue printing. Unknown The Ink Cartridge installed is not approved but the user has confirmed that he is using refilled or non-hp Ink Cartridges. Refer to the User’s Guide for further information regarding using refilled or non-hp approved Ink Cartridges. The main actions for all 4 status messages is as follows: 1. Reseat the Ink Cartridge. 2.
2. Clean the Carriage and Printhead flex circuits using the Carriage Interconnect Wiper ⇒ Page 91. 3. Replace the Printhead. 4. Perform the Electronic Systems Test ⇒ Page 105. NOTE: If all the Printheads are installed but have the Status message “Missing”, it is possible that the Carriage Assembly is faulty. Maintenance Cartridge Status Messages While Printing Detailed below are the Maintenance Cartridge status messages that may be displayed while printing.
• Check that the protective tape has been removed from the printhead. • Insert the Printhead into the Carriage Assembly but this time correctly close the cover using the latch. • Clean the electrical contacts on both the printheads and the printhead Carriage Assembly using the carriage interconnect wiper ⇒ Page 91. • Replace the Printhead with a new one. You Cannot Insert the Ink Cartridge Into the Printer 1. Ensure that you have the correct hp no.91 Ink Cartridge. 2.
Troubleshooting Printhead Error Codes Ink Supplies The Printhead Error Codes can be found on the Service Information Print (Setup Menu/Information Menu/ Internal Prints/Print Service Information/Current Information). The actual error code is a decimal number and it has to be converted to a binary number before it can be used. In order to convert the decimal error code to a binary error code, you can use a calculator.
Bit Meaning Bit Meaning 6th TEMP_EXTREMELY_LOW 16th FAILS_ENERGY_CALIBRATION 7th TEMP_TOO_HIGH 17th EMPTY_DUMMY 8th TEMP_TOO_LOW 18th FULL_DUMMY 9th BAD_ACUMEN_INFO 19th END_OF_LIFE 10th NO_PEN 20th OUT_OF_WARRANTY The binary number needs to be read from right to left so that the 1st bit corresponds to the right one of the binary number. For example, the error code 4099 is converted to binary number 10000000000011.
• Host Ink Cartridge: 775ml/26.2 floz • Introductory Ink Cartridge: 400ml/13.5 floz or • When the user confirms that they have used non-hp ink in empty over-ride mode. The actual end of warranty date is printed on the supply label.
Service Tests and Utilities • • • • • • Introduction .........................................................................................................94 Diagnostics - Self Test............................................................................................94 Phone Support .....................................................................................................94 Service Tests (Diagnostics) ....................................................................................
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. NOTE: 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.
5. 6. Sensors Test ⇒ page 112 • The purpose of this test is to verify the operation of the following Sensors: • Window Sensor. • Printhead Cleaner (PHC) Access Door Sensor. • Media Lever Sensor. • Media Sensor. Ink Delivery System Test ⇒ page 115 The purpose of this test is to verify the operation of the Ink Supply Tubes. 7. SVS Test ⇒ page 116 The purpose of this test is to verify the operation of the Service Station. 8.
Entering the Service Tests Menu NOTE: In order to enter the Service Utility Menu, please refer to the instructions on Page 4-60. 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 Call Agents who will request the User to Perform certain troubleshooting action, hold the Down arrow key and the Cancel key down and switch the printer ON using the front power switch.
NOTE: 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. NOTE: 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 there is a failure at this point, the Front Panel will display System Error Code 01.0:10. For more information on troubleshooting this error code, refer to page 47. • Checking voltage. If there is a failure at this point, the Front Panel will display System Error Code 03:10. For more information on troubleshooting this error code, refer to page 48. Check also System Error Code 01.0:10 (refer to page 47). • Clear GPIO psu_lpm.
Unit Hangs Up - If no System error code is displayed on the Front Panel but the Printer hangs up and the last message on the Front Panel is “Booting up the Carriage” it means that the Carriage ASIC could not be detected. Troubleshoot this problem in the same way as if System Error Code 02.1:10 had appeared. 5. Once the Carriage is booted up, the Service Station will be prepared and moved to a safe position so that the Carriage can be moved.
If you select No (the Carriage had not moved), the Front Panel will display System Error Code 42:10. For more information on troubleshooting this error code, refer to page 60. Check also System Error Code 01.1:10 (refer to page 47) or System Error Code 01.0:10 (refer to page 47). If you select Yes (the Carriage had moved), the Front Panel will display System Error Code 02:10. For more information on troubleshooting this error code, refer to page 48.
13. The Printer will test the PWM at 61 ips and display the results on the Front Panel. If some of the results are incorrect, the Front Panel will show “High Friction”. Depending on the actual results received, the following should be done: • • If PWM avg got is more than 32557 and PWM min diff got is less than 3100 then there is high friction along the Scan-Axis. In this case you should: • Clean the Slider Rods and Apply Oil along the complete axis of the Slider Rods.
• Starting Sausalito. • Starting GpioPwmImpact. • Set GPIO psu_lpm. If there is a failure at this point, the Front Panel will display System Error Code 01.0:10. For more information on troubleshooting this error code, refer to page 47. • Checking voltage. If there is a failure at this point, the Front Panel will display System Error Code 03:10. For more information on troubleshooting this error code, refer to page 48. Check also System Error Code 01.0:10 (refer to page 47). • Clear GPIO psu_lpm.
5. Before continuing, the following message will appear on the Front Panel. Remove the media if it is still loaded and make sure you stay out of the Print Platen area if the Window is open. 6. The Printer will now test the Paper Drive moving in an open loop in one direction and the following message will be displayed on the Front Panel. Press any key to continue the test: Check that the movement done is more than 100 encoder units (in absolute value).
If there is a failure at this point, the Front Panel will display System Error Code 81:10. For more information on troubleshooting this error code, refer to page 73. • Calib. Analog Encoder. If there is a failure at this point, the Front Panel will display System Error Code 56:03. For more information on troubleshooting this error code, refer to page 67.
If there is a failure at this point, the Front Panel will display: 12. Once the test is completed, OK will be displayed on the Front Panel and then you will be prompted to press any key to shut down the Printer. 3. Electronics Module Test The purpose of this test is to diagnose a failure in the operation of the: • Components of the Electronics Module. • Electronics Module to Carriage and ISS Communication. NOTE: This test does not test the EIO Card or the Hard Disk Drive. 1.
4. The printer will now get the Main Board (MB) information and display the information on the Front Panel. Press any key to continue the test: 5. The printer will now get the CPU Fan Speed and display the information on the Front Panel. Press any key to continue the test: If the CPU Fan Speed is less than 2500, the Front Panel will display System Error Code 05.1:10. For more information on troubleshooting this error code, refer to page 49. Tests and Utilities 6.
9. The printer will then check the Serial Number and Part Number and display the information on the Front Panel. Press any key to continue the test: If the Serial Number does not have assigned a correct 10 character format or the Part number does not have assigned a correct 6 character format, a fail message will appear on the Front Panel. In this case, re-enter in to the Service Tests submenu and use the diagnostic “13. Error 71:19 Recovery” to set the correct Serial Number (refer to page 126). 10.
• Starting Vacuum Fans. If there is a failure at this point, the Front Panel will display System Error Code XX.X:XX. For more information on troubleshooting this error code, refer to page 47. • Set GPIO psu_lpm. If there is a failure at this point, the Front Panel will display System Error Code 01.0:10. For more information on troubleshooting this error code, refer to page 47. • Checking voltage. If there is a failure at this point, the Front Panel will display System Error Code 03:10.
16. A message will appear on the Front Panel stating that the delSol has been detected and asking whether you would like to Continue. Press any key to continue: If there is a failure at this point, the Front Panel will display System Error Code 01.0:10. For more information on troubleshooting this error code, refer to page 47. 17. • Checking Vacuum Fans. • Switching on Vacuum Fans. • Testing Vacuum Fans. • Switching off Vacuum Fans.
• Checking GPIO channels. At this stage, the Printer reads and checks the default GPIO values in the Interconnect PCA when all the cables are connected and all the sensors give the default value or the current state. The results will be displayed on the Front Panel and you can press any key to scroll through the information. If any of the channels cannot be read, the Front Panel will display System Error Code 01.0:10. For more information on troubleshooting this error code, refer to page 47.
If you select No at this point, the Front Panel will display System Error Code 07:10. For more information on troubleshooting this error code, refer to page 50. Check also System Error Code 11:10 (refer to page 51) or System Error Code 02.1:10 (refer to page 48). If you select Yes, then the Front Panel will display: • Starting Carriage. If there is a failure at this point, the Front Panel will display System Error Code 02.1:10. For more information on troubleshooting this error code, refer to page 48.
25. When the Front Panel displays the following message, check that all the Ink cartridges are correctly installed. Press any key to continue. 26. The Printer will continue with the ISS Communication test and the following messages will be displayed on the Front Panel: • Starting ISS Ink Sup. If there is a failure at this point, the Front Panel will display System Error Code 01.2:10 (refer to page 48) or System Error Code 01.0:10 (refer to page 47). • Getting ISS data. • Checking ISS Ink Sup. 27.
• Paper Sensor. NOTE: IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE REPLACING RELEVANT SENSOR. IF THIS TEST PASSES, DO NOT REPLACE THE RELEVANT SENSOR. Perform the Sensors test as follows: 1. Before starting, first make sure that: • The Window is closed. • The Maintenance Cartridge Door is closed. • The Media Lever is in the lowered position. • Paper is unloaded.
4. Before starting to test the sensors, the following message will be displayed to prompt the user to set the sensors to the test default positions. Press any key to continue: 5. The Window Sensor will be tested first. When the following message is displayed on the Front Panel, open the Window and press any key to continue. 6. If the Window Sensor passes the test, the following message is displayed on the Front Panel. Close the Window and press any key to continue.
9. The Media Lever Sensor will be tested next. When the following message is displayed on the Front Panel, raise the Paper Lever and press any key to continue. 10. If the Media Lever Sensor passes the test, the following message is displayed on the Front Panel. Lower the Paper Lever and press any key to continue. If the Paper Lever Sensor fails the test, the Front Panel will display System Error Code 54:10. For more information on troubleshooting this error code, refer to page 67.
1. In the Service Tests submenu, scroll to “6. Ink Delivery System Test” and press Enter. 2. This test has not yet been implemented. 7. SVS Test The purpose of this test is to verify the operation of the Service Station. Perform the SVS test as follows: 1. In the Service Tests submenu, scroll to “7. SVS Test” and press Enter. 2. This test has not yet been implemented. 8.
2. A message will appear on the Front Panel asking whether you would like to check the APS. Select Yes or No by using the Up and Down keys and press Enter to confirm your selection. If you select No, the printer skips this test and goes to the next one: 3. A message will appear on the Front Panel asking you to insert all the Ink Cartridges. Insert all the Ink Cartridges and press any key to continue: 4.
Perform the Vacuum Fans test as follows: 1. In the Service Tests submenu, scroll to “9. Vacuum Fans Test” and press Enter. 2. This test has not yet been implemented. 10. OMAS Module Test The purpose of this test is to verify the operation of the Optical Paper Advance Sensor (OMAS) system. Perform the OMAS test as follows: 1. In the Service Tests submenu, scroll to “10. OMAS Test” and press Enter. 2. This test has not yet been implemented.
2. A message will appear on the Front Panel advising you that all user information/files will be removed. If you would like to proceed select Yes or No by using the Up and Down keys and press Enter to confirm your selection. If you select No, the process will end at this point. 3. If you select Yes, the Printer will begin the process to reset the EEROM and the following messages will appear on the Front Panel: • Starting Sausalito.
1. In the Service Tests submenu, scroll to “12. Color Sensor Test” and press Enter. 2. The Printer will initialize the Color Sensor and the Front Panel will display the following messages: • Starting Sausalito. If there is a failure starting the Sausalito, the Front Panel will display System Error Code 01.0:10. For more information on troubleshooting this error code, refer to page 47. • Starting Carriage. If there is a failure at this point, the Front Panel will display System Error Code 02.1:10.
The following message is displayed on the Front Panel, press any key to continue. 4. The Color Sensor information is read and the following message is displayed on the Front Panel, press any key to continue. 5. When the following message is displayed on the Front Panel, raise the Media Lever, load paper, lower the Media Lever, and press any key to continue. 6. The Printer will read the Red Reference and the Front Panel will display the following messages: 7.
8. Once the test is completed, OK will be displayed on the Front Panel. NOTE: If the customer reports color issues even through the test has passed, perform the Spectrophotometer test on page 148. 13. Aerosol Test The purpose of this test is to verify the operation of the Color Sensor. Perform the Aerosol test as follows: 1. In the Service Tests submenu, scroll to “13. Aerosol Test” and press Enter. 2. This test has not yet been implemented. 14.
• Checking voltage. If there is a failure at this point, the Front Panel will display System Error Code 03:10. For more information on troubleshooting this error code, refer to page 48. • Clear GPIO psu_lpm. If there is a failure at this point, the Front Panel will display System Error Code 01.0:10. For more information on troubleshooting this error code, refer to page 47. • Checking voltage. If there is a failure at this point, the Front Panel will display System Error Code 03:10.
• Allowing pens not operational. If there is a failure at this point, the Front Panel will display the corresponding error message (Error: Setting Pens operational or Error: Allowing pens not operational. 5. Once the test is completed, OK will be displayed on the Front Panel. 15.1 Service Special Utilities >>> Bag Broken Recovery This option allows to recover the Printer from a Bag Broken error. Tests and Utilities Perform the Bag Broken Recovery as follows: 1.
6 Light Gray 7 Cyan 6. Remove the failing Ink Cartridge as indicated by the Front Panel and install a new Ink Cartridge. 7. The front panel will display the System Error Code 01.2:10, turn Off and On the printer. 8. Repeat steps 1 & 2. 9. The Printer scans again for a Bag Broken error, if the error has been cleared the message “No Broken Bag detected on supplies” will be displayed on the Front Panel. 10.
12. If you select No, the following message will appear on the Front Panel. You can now remove the Broken Bag condition causing the initial problem. Select Yes or No by using the Up and Down keys and press Enter to confirm your selection. 13. If you select Yes, the following messages will appear on the Front Panel: • Start Supplies Conf. If there is a problem at this stage, the Front Panel will display System Error Code 01.0:10. For more information on troubleshooting this error code, refer to page 47.
• Getting Serial Number. • Checking Serial Number. • Starting Nvm. • Getting Part Number. If there is a failure at this point, the Front Panel will display System Error Code 79:03. For more information on troubleshooting this error code, refer to page 72. 5. The Printer will display the current Serial Number and the new Serial Number of the Printer. Use the Up and Down keys to go through the digits and press the Enter key to go to the next digit.
15.3 Service Special Utilities >>> IO Information This option allows you to view the information relating to the IO. View the IO Information as follows: 1. In the Service Tests submenu, scroll to “15. Service Special Utilities” and press Enter. 2. In the Service Special Utilities submenu, scroll to “15.3 IO Information “and press Enter. 3. The Printer will start to initialize and the Front Panel will display the following messages: • Getting IO Interface. • Getting Interface info.
1. In the Service Tests submenu, scroll to “15. Service Special Utilities” and press Enter. 2. In the Service Special Utilities submenu, scroll to “15.4 Unit Information “and press Enter. 3. The Printer will start to initialize and the Front Panel will display the following messages: • Starting Nvm. • Getting FW version. • Getting Serial Number • Getting Part Number. If there is a failure at this point, the Front Panel will display System Error Code 79:03.
1. In the Service Tests submenu, scroll to “15. Service Special Utilities” and press Enter. 2. In the Service Special Utilities submenu, scroll to “15.5 Check Ink Supplies” and press Enter. 3. The Printer will start to initialize and the Front Panel will display the following messages: • Starting Sausalito. If there is a failure at this point, the Front Panel will display System Error Code 01.0:10. For more information on troubleshooting this error code, refer to page 47.
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Service Utilities The following is a list of all internal Service Utilities available in the Printers. Instructions for entering the Service Utilities menu are given on page 133. 1. Turn Drive Roller ⇒ page 134 The purpose of this Service Utility is to rotate the Drive Roller and the Overdrive in order to clean them. 2.
Entering the Service Utilities Menu 1. Once the message “Ready” is displayed on the front-panel, scroll to the “Printer Setup Options” icon and press the Enter key. Press OK to confirm selection Use UP and DOWN keys to select For Call Agents who will request the user to perform certain Service Utilities, once inside the “Setup” menu, press the Down arrow key and the Cancel key together. You are now in the Service Tools Menu.d O PH NE RT PPO U S Press Cancel key 3.
5. Use the Arrow keys to scroll through the “Service Utilities” selections and press the Enter key to begin a specific operation when the required Service Utility is highlighted. NOTE: If the printer is not used for 135 seconds, the printer exits out of the Service Utilities Menu and you must repeat the above steps to enter Service Utilities again. NOTE: In some cases a quick press of a button may not be recognized by the Printer.
2. The Printer checks to see if media is loaded. If media is loaded, the Front Panel will display the following message. Unload the media and start again from step 1: 3. The Drive Roller begins to turn slowly and the following message is displayed on the Front Panel: 4. Refer to the Cleaning Instructions on page 452. 5. Once you have finished cleaning the Drive Roller and the Overdrive, press the Cancel key to finish the utility. 6.
Tests and Utilities 2. If the Ink Cartridges are not suitable for priming, the following message will appear on the Front Panel. Replace the installed Ink Cartridges with Ink Cartridges that are new or contain less than 88% of ink. Press any key to finish the utility. 3. When the following message appears on the front panel, you must select whether you would like to continue with the procedure by pressing the Enter key, in which case the Printer will reboot.
8. Once the tubes system has been purged, the following message will instruct you to open the Window: 9. Open the right cover and make sure the Maintenance Cartridge is installed in the Service Station. 10. When the following message appears on the Front Panel, open the Carriage cover and check the window on top of each Setup Printhead. If the Ink Supply Tubes have been primed correctly, the windows will contain ink.
14. Once the Printhead Alignment is completed, the following message will be displayed on the Front Panel. Press the Enter key to continue. 3. Set SN The purpose of this Service Utility is to set the Serial Number of the Printer. Tests and Utilities Perform the Set SN utility as follows: 1. In the Service Utilities submenu, scroll to “Set SN” and press Enter. 2. The Printer will display the current Serial Number and the new Serial Number of the Printer.
• Reset ALL the counters related to a Preventive Maintenance Kit (PMK). • Reset only the counters related to a specific replaced part. NOTE: ALWAYS RESET THE LIFE COUNTER OF A CORRESPONDING PART ONLY AFTER REPLACING IT. Perform the Reset Life Counters utility as follows: 1. In the Service Utilities submenu, scroll to “Reset Life Counters” and press Enter. 2.
3. Once you have selected a Life Counter to reset, the following message will be displayed on the Front Panel. Press the Enter key to reset the selected Life Counter or press Back/Cancel to exit without resetting the Life Counter. If the Usage Counter information cannot be read, the Front Panel will display “Unable to get usage counter”. This could point to a possible Firmware error. 4. If the utility exits correctly, OK will be displayed on the Front Panel. 5.
3. Make sure media is loaded, the Pinch Lever is lowered and that the Ink System is correctly installed. Press the Enter key to print the Diagnostic Print or press Back/Cancel to exit without printing the Diagnostic Print. 4. The selected Diagnostic Print will now be printed. For further information on how to use troubleshoot Image Quality problems, refer to “How to Use the Image Quality Service Diagnostic Print” on page 181. 6.
7. Replace Cutter The purpose of this Service Utility is to move the Carriage to a position where the Cutter can be replaced easily. Tests and Utilities Perform the Replace Cutter utility as follows: 1. In the Service Utilities submenu, scroll to “Replace Cutter” and press Enter. 2. When the following message appears on the front panel, you must select whether you would like to continue with replacing the Cutter by pressing the Enter key. Press Back or Cancel to exit the utility. 3.
2. The Printer will display the current time and the new time. Use the Up and Down keys to go through the digits and press the Enter key to go to the next digit. You can press the Cancel key at any time to exit the utility without making any changes. 3. Once the new time has been entered, the Front Panel will display the time that you have requested. Press the Enter key to confirm the time or the Cancel key to exit the utility without making any changes or the Back key to modify again.
3. When the following message appears on the front panel, you must select whether you would like to enable of disable the firewall. Use the Up and Down keys to make your selection and press the Enter key. 4. The system upgrades the internal memory to reflect the chosen selection. 5. If the utility exits correctly, OK will be displayed on the Front Panel. 10. Prime Printhead X The purpose of this Service Utility is to prime a specific pen.
• Allowing pens not operational. If there is a failure at this point, the Front Panel will display an error code. For more information on troubleshooting this error code, refer to page 47. 5. If the utility exits correctly, OK will be displayed on the Front Panel. 11. Open/Close SOL The purpose of this Service Utility is to open and close the Color Sensor shutter to verify correct operation.
Secure Disk Erase provides three different levels of security: • Non-Secure Fast Erase: all pointers to the information are erased. The information itself remains on the hard disk until the disk space it occupies is needed for other purposes, and it is then overwritten. While it remains on the disk, it is difficult for most people to access, but may be accessed using software designed for the purpose.
In the Disk Wipe DoD 5330.22-M submenu, scroll to “Disk Wipe DoD 5330.22-M” and press Enter. 6. When the following message appears on the Front Panel, you must select whether you would like to perform a complete erase of the Hard Disk Drive using the previously selected erase mode by pressing Enter. Press Back or Cancel to exit the utility 7. When the following message appears on the Front Panel, you must select whether you want to continue and completely erase of the Hard Disk Drive by pressing Enter.
13. Enable/Disable SCAPA The purpose of this Service Utility is to enable or disable the Scan Axis Pen Alignment (SCAPA) process which is used as a compensation/adjustment factor during the printhead alignment. The advantage of this process is that it allows the printhead alignment to be carried out at the beginning of the roll (during the first 3 meters). Perform the Enable/Disable SCAPA utility as follows: 1. In the Service Utilities submenu, scroll to “Enable/Disable SCAPA” and press Enter. 2.
2. In the Service Utilities submenu, scroll to ###### and press Enter. 3. At the end of the test the Front Panel will display the results: Compare the value of L seen in the Front Panel to the results that should be seen in the following media: Paper Min L* Max L* Nominal L* HP Bright White 90.12 95.70 91.91 HP Premium Instant Dry Gloss 92.38 97.24 93.81 HP Premium Instant Dry Photo Satin 92.13 97.36 93.74 HP Universal Coated 89.51 94.65 91.08 HP Universal Heavy Weight Coated 88.
Tests and Utilities 150 Chapter 4 Service Tests and Utilities
Service Calibrations • • Service Calibrations ........................................................................................... 152 Entering the Service Calibrations Menu ................................................................. 153 • 1. Scan Axis Calibration............................................................................... 154 • 2. Paper Advance Calibration ....................................................................... 157 • 3. Drop Detector Calibration............
Service Calibrations The Printer has several calibration procedures that must be performed under certain conditions. The following is a list of all internal service calibrations available in the Printers. See page 153 for instructions on how to enter the service calibrations menu. NOTE: REMEMBER THAT CERTAIN CALIBRATIONS ARE REQUIRED EVEN IF AN ASSEMBLY HAS BEEN DISASSEMBLED TO GAIN ACCESS TO ANOTHER ASSEMBLY OR COMPONENT. 1.
Entering the Service Calibrations Menu 1. Once the message “Ready” is displayed on the front-panel, scroll to the “Printer Setup Options” icon and press the Enter key. Press OK to confirm selection Use UP and DOWN keys to select 2. Once inside the “Printer Setup Menus” menu, press the UP or Down arrow key and the Cancel key together. You are now in the Service Tools Menu. O PH NE RT PPO U S Press Cancel key 3.
5. Use the Arrow keys to scroll through the “Service Calibrations” selections and press the Enter key to begin a specific operation when the required Service Calibration is highlighted. NOTE: If the printer is not used for 135 seconds, the printer exits out of the Service Calibrations Menu and you must repeat the above steps to enter Service Calibrations again. 1.
3. If media is not loaded, the following message appears on the front panel. Load media in to the Printer and start again from step 1. Before continuing, the Printer will check the following: • The Media Lever is in the lowered position. • The correct paper type is loaded (check list on previous page). • The correct paper size (minimum paper size 24 inches). If these conditions are not met, a warning will be displayed on the Front Panel and you will need to restart the Calibration from step 1.
6. The Printer will start to calibrate the Line Sensor position to the Black Printhead. It will print a line of black dots and then scan them: 7. Once the Line Sensor has been calibrated, the results will be displayed on the Front Panel. Press Enter to finish the calibration or press Back or Cancel to exit the calibration. 8. The Printer will now perform the Printhead Alignment.
• 11. If the Alignment fails again, check the Alignment pattern to see if any of the Printheads are printing incorrectly. If necessary, perform a Printhead Recovery through the Front Panel and retry the Printhead Alignment. The Printer will now perform the Color Calibration. When the following message appears on the front panel, you must select whether you would like to continue with the calibration by pressing the Enter key. Press Back or Cancel to exit the calibration. 12.
• Scan Calibration Pattern - The Printer scans the Paper Advance Calibration pattern in order to calibrate the nominal advance of the media. NOTE: Only scan the Calibration Pattern in the Printer that was used to actually print it. Using the Calibration in a different Printer could cause it to experience media advance problems. After scanning the Calibration Pattern, it should be discarded.
• Check that the Printer has the latest Firmware version. If not, update the Firmware to the latest version. • Retry the Paper Advance Calibration. • If the problem continues, replace the Encoder Strip and Encoder Sensor ⇒ Page 331. 5. Once the Analog Encoder has been calibrated correctly, the following message will appear on the Front Panel. Press the Enter key in order to start the media load process. 6.
• If necessary, perform a Printhead Recovery through the Front Panel and retry the Calibration. NOTE: Remove the pattern from the printer and leave it to dry for a few minutes before continuing with the Calibration. NOTE: MAKE SURE NO MEDIA IS LOADED INTO THE PRINTER BEFORE STARTING TO SCAN THE CALIBRATION PATTERN. 10. You will need to re-enter the Paper Advance Calibration submenu and scroll to “Scan Calibration Pattern” and press Enter. 11.
NOTE: Only scan the Calibration Pattern in the Printer that was used to actually print it. Using the Calibration in a different Printer could cause it to experience media advance problems. After scanning the Calibration Pattern, it should be discarded. NOTE: When Loading the Calibration Pattern, use the Cutter blade on the Print Platen to align the edge of the sheet.
• If the problem continues, replace the Media-Axis Motor ⇒ See page 349. NOTE: After the Paper Advance Calibration has been performed correctly, you MUST perform the Clean Drive Roller procedure. If this is NOT done, the Printer will not perform correctly and could cause Print Quality problems. NOTE: Before starting the Clean Drive Roller procedure, make sure you first load media into the Printer that the customer will normally use to print. 15.
1. In the Service Calibrations submenu, scroll to “Drop Detector Calibration” and press Enter. 2. When the following message appears on the front panel, you must select whether you would like to continue with the calibration by pressing the Enter key. Press Back or Cancel to exit the calibration. 3. The Printer will start to calibrate the Drop Detector. Once the Drop Detector has been calibrated, the results will be displayed on the Front Panel.
Perform the Line Sensor Calibration as follows: Service Calibrations NOTE: Make sure you load one of the following media into the Printer before performing this calibration: • HP Bond Paper. • HP Glossy Media. • HP Coated Paper. • HP Productivity Photo Gloss. • HP Heavyweight Coated Paper. • HP Super Heavyweight Coated Paper. • HP Bright White Inkjet Paper. 1. In the Service Calibrations submenu, scroll to “Line Sensor Calibration” and press Enter. 2.
If these conditions are not met, a warning will be displayed on the Front Panel and you will need to restart the Calibration from step 1. NOTE: Make sure you keep your hands away from the Print Platen as the Carriage will be moving at high speed and you could injure yourself or damage the Carriage Assembly. 4. The Printer will start to calibrate the Line Sensor. Once the Line Sensor has been calibrated, the results will be displayed on the Front Panel.
8. 9. Once the Printhead Alignment is completed, the following message will be displayed on the Front Panel. Press the Enter key to continue. • If the Printhead Alignment fails for any reason, a warning message will appear on the Front Panel. In this case, try the following: • Enter the Front Panel menu and retry the Printhead Alignment. If the Alignment completes successfully, then perform the Color Calibration.
Perform the Vacuum Calibration as follows: 1. In the Service Calibrations submenu, scroll to “Vacuum Calibration” and press Enter. 2. When the following message appears on the front panel, you must select whether you would like to continue with the calibration by pressing the Enter key. Press Back or Cancel to exit the calibration. 3. The Printer will set the default nominal and real values of the Vacuum Fan. 4. Once the calibration is completed, OK will be displayed on the Front Panel. 6.
Service Calibrations Print OMAS Calibration Pattern 1. In the OMAS Calibration submenu, scroll to “Print Calibration Pattern” and press Enter. 2. When the following message appears on the front panel, you must select whether you would like to continue with the calibration by pressing the Enter key. Press Back or Cancel to exit the calibration. 3. If media is already loaded, the following message appears on the front panel and the media is unloaded. 4.
• Raise the Media Lever. • Load the media. • Lower the medial lever. 7. Select the media (HP Universal ID gloss). 8. Select the media length. 9. The media calibration process starts and front panel shows the following messages: • Calibrating paper advance. • Trimming roll edge. Please wait. Service Calibrations 10. The Front Panel then prompt you to unroll 1 meter of media to avoid back tension. Unroll 1 meter of media and press Enter.
11. The Printer will start to print the OMAS Calibration Pattern. This could take several minutes during which the following message will be displayed on the Front Panel. 12. Once the OMAS Calibration Pattern has been printed successfully, the following message will be displayed on the Front panel. Press the Enter key to continue. If the OMAS Calibration fails for any reason, a warning message will appear on the Front Panel. In this case, try the following: • Retry the Paper Advance Calibration.
3. A message will appear advising you that you will need to load the OMAS Calibration Pattern in to the Printer. Make sure that you rotate the printed pattern 90° clockwise and reload it printed-side down. Press the Enter key to continue. NOTE: Take note that the OMAS Calibration Pattern will be loaded as a Roll and NOT as a Sheet. 4. Load the OMAS Calibration Pattern following the instructions on the Front Panel.
6. The Printer will scan the OMAS Calibration Pattern which could take several minutes. Once the calibration is completed successfully, the following message will be displayed on the Front Panel. Press the Enter key to continue. If the OMAS Calibration fails for any reason, a warning message will appear on the Front Panel. In this case, try the following: • Check that the OMAS Calibration Pattern was not incorrectly cut (trimming the actual pattern) during the media load process.
3. The calibration process will execute and the front panel will display the result in mDeg. 4. Press Enter to accept the result. 7. Primer Calibration The purpose of this Service Calibration compute the offset error between the optimum position of the Primer Assembly with respect to the Carriage. The calibration is a visual procedure so you will have to remove the Right Hand cover before starting. Perform the Primer Assembly as follows: Remove the Right Cover ⇒ See page 264). 2.
6. Once the Left Scan-Axis Offset has been calculated the Front Panel prompts you use the Up/Down keys to move the carriage until the RIGHT edge of the Left Alignment Mark on the Carriage Cover is perfectly aligned with the Primer positioning indicator. 7. Use the Up (move left) and Down (move right) keys to move the Carriage until the RIGHT edge of the Left Alignment Mark is correctly aligned with the Primer Positioning Indicator and press ENTER.
While the Carriage is moving the Front Panel shows the actual position and the direction of movement and prompts you to press ENTER when done. The Front Panel shows the actual left offset value and the system calculates the Fight Scan-Axis Offset. 9. Once the Right Scan-Axis Offset has been calculated the Front Panel prompts you use the Up/ Down keys to move the carriage until the LEFT edge of the Right Alignment Mark is correctly aligned with the Primer Positioning Indicator and press ENTER.
10. Use the Up and Down keys to move the Carriage until the LEFT edge of the Right Alignment Mark is correctly aligned with the Primer Positioning Indicator and press ENTER. Carriage Right Alignment Mark Cover Primer Positioning Indicator NOT ALIGNED Up key Carriage Movement Down key ALIGNED NOTE: To more easily detect the exact position while aligning the Carriage to the Primer it is a good idea to lightly press down on the Primer while you are moving the Carriage.
12. The calibration process continues and front panel shows the following messages as the new norminal offset value is read and saved to NVM: • Reading Nominal Offset. • New Nominal Offset is [ActualValue]. • Saving to nvm. • Saved. 13. Once the calibration is completed, OK will be displayed on the Front Panel. 14. Replace the Right Hand Cover (See page 264). 8. Platen Blue Line Calibration The purpose of this Service Calibration is to calibrate the blue line which is marked on the Print Platen.
3. A message will appear on the Front Panel requesting you to raise the Media Lever and to place a sheet of white media on the Print Platen aligned with the Blue Line. Press the Enter key to continue once the sheet is in placed. Service Calibrations Align sheet with Blue Line without covering it 4. The Printer will start to calibrate the Blue Line and the following message will be displayed on the Front Panel. 5.
Print Quality • • • • Print Quality 6 Initial Print Quality Troubleshooting Actions ...........................................................180 How to Use the Image Quality Service Diagnostic Print ........................................... 181 • What is the Image Quality Service Diagnostic Print? ........................................ 181 • Considerations for Printing the Diagnostic Print ................................................ 182 • Diagnostic Part 1: Printhead Problems...............
Print Quality Initial Print Quality Troubleshooting Actions For the majority of print quality problems, a Call Agent can try to troubleshoot the Printer by requesting that the customer performs the following troubleshooting actions. Using this process, most problems can resolved without the need of an on-site visit. Perform the following actions in the order described: 1.
9. If you have any doubt about the created ICC media profile, recreate it, or re-install the default one (from the color center, ‘Create and Install ICC profile’ or ‘Manage paper -> restore Factory ICC profile’). If the issue is the color difference between the printer and the monitor, ensure that the monitor has been calibrated, refer the customer to the HP LFP Knowledge Center for details on how to perform this, use the url: http://www.hp.com/go/knowledge_center/djz6100. 10.
Print Quality • Visual Alignment Print. Used to check pen alignment reliability. • Visual Media Advance. Used to check advance reliability • Force Drop Detection. Used to reset the nozzle health historic data base and force new drop detection. • Plot for escalation only. Used to check more details of the Nozzle Health. • Paper Advance Sensor. This option allows the Paper Advance Sensor to be disabled and forces the advance control to use the analog encoder system.
Make sure media is loaded, the Pinch Lever is lowered and that the Ink System is correctly installed. Press the Enter key to print the Diagnostic Print or press Back/Cancel to exit without printing the Diagnostic Print. 4. The selected Diagnostic Print will now be printed. Diagnostic Part 1: Printhead Problems The Nozzle print test is designed to check if the Printhead nozzles print correctly. The Image Quality Service Best should always be used to print this plot.
Print Quality The method of improving Nozzle Defects is to: 1. To clean the printheads, go to the printer's front panel and select the ink, then Image quality maintenance > Clean printheads. Then select which printheads you would like cleaned. You can clean all of the printheads or only some of them. Your choices are: • Clean all • Clean M-Y • Clean LM-LC • Clean PK-LG • Clean MK-C Cleaning all of the printheads takes about five minutes. Cleaning any two printheads takes about three minutes.
If the Printer is experiencing vertical misalignment problems, the Alignment Test will show something like this: 3. If the Printer is experiencing bi-directional misalignment problems, the Alignment Test will show something like this: Corrective Action 1. Perform a Printhead Alignment, using the same paper type with which you were experiencing unacceptable image quality, if feasible (some paper types are not suitable for Printhead Alignment).
Print Quality The plot is printed in Best or Normal mode (according to the menu option selected) with Error Hiding ON. The first top band has 100% ink density patches while the bottom band has 50% ink density. Troubleshooting Banding Problems If banding does not occur in ALL the colors, then it is more than likely a Printhead problem. In this case, try the following: 1. Check that the appropriate print quality settings are being used. 2.
Force Drop Detection. • Disable Paper Advance Sensor. Print Quality • Visual Alignment Diagnostic Print This plot helps you to visually check any alignment problems of the printer. You use it to precisely measure the alignment error with one dot row accuracy. The plot is split in four areas. The three first are the same plot printed at different speed: 30, 40 and 60 ips to check most of the pen alignment.
Print Quality At 30 ips At 40 ips At 60 ips Dye Overlap What to see in the Auto Pen Alignment Diagnostics: 1. At the left we have four checks for the pen to pen alignment in scan axis direction (Pen2Pen-Fwd or Pen2Pen-Rev). It is forward and reverse. a. The top pattern is related to the front printhead (nearest to the user when doing the pen replacement). b.
The top pattern is related to the front printhead (nearest to the user when doing the pen replacement). b. The bottom pattern is related to the rear printhead (more far to the user when doing the pen replacement) The area to check is the junction (marked with a “-”) of the black with the rest of colors. 4. The alignment in scan axis direction between both printhead of the same color is marked as 4a (in forward direction die2dieSAD-Fwd) and 4b (in reverser direction die2dieSAD-Rev).
Print Quality What to see in the Dye Overlap Alignment. The area to check is only the bottom junction pattern for all the colors. The clearest band has to be around the 0 (±3 dots). Every band is equal to 1 dot error. In order to solve any problem in the alignment, try the following: • Repeat the printhead alignment. Most recommended papers are glossy papers were pen alignment accuracy is best.
Print Quality REAR PRINTHEADS 1-3-5-7 FRONT PRINTHEADS 2-4-6-8 The second part is the bottom left. This part does not need to be looked at, it is only for escalation purposes. The third part is the bottom right. This test is designed to check if the Printhead nozzles print correctly. The test prints out every single nozzle of each Printhead. No error hiding or Printhead Alignment algorithm is applied. For each Printhead, you can see both the adjacent and the consecutive nozzles.
Print Quality To fix issues found in this third part: NOTE: If the printer has nozzle defects, it does not mean that you will not get perfect print quality results. The printer has automatic procedures to hide many nozzle defects. 1. Recover the Printheads using the option through the Front Panel (Main menu/Image quality maintenance/clean Printheads). 2. Reprint the Nozzle Print test to check that the defective nozzles have been corrected. 3. If the problem continues, replace the faulty Printhead.
Print Quality There is an advance issue a List of types of media which are NOT used (non navigable) by the OMAS media sensor: HP or HP Approved Clear Film HP or HP Approved Backlit Clean OMAS and reload the paper HP or HP Approved types of Mattt film HP or HP Approved types of Polypropylene Launch the user advance calibration adjustment A non HP or HP Approved Media b In order to perform this Calibration, you should order the Paper Advance Calibration Kit (Part Number Q127360296) which contains two c
Print Quality Clean the paper advance sensor window The paper advance sensor is the very small rectangular window (less than 1 square centimeter in size and shown in the graphic below) found near the sixth platen roller from the right. Very gently wipe off any dust and loosened ink deposits from the sensor window, using a clean, absorbent, lint-free cloth, slightly dampened with isopropyl alcohol. The User Advance Calibration.
At the front panel, select the icon, then Image quality maintenance > Paper advance calibration > Calibrate paper advance. The printer automatically calibrates the paper advance and prints a paper advance calibration image. 2. Wait until the front panel displays the status screen and re-print your print. NOTE: The calibration procedure takes approximately three minutes. Do not worry about the paper advance calibration image. The front-panel display shows any errors in the process.
Print Quality -3 -2 -1 -0 1 2 3 -3 -2 -1 -0 1 2 -3 3 -2 -1 -0 1 2 3 Interpreting plot results The three plots are all printed using Photo Black ink in 6-pass print mode (even on Gloss paper) and should should each be similar. The white/lightest band of must be within the center ±1 area for a PASS result. This should be true for all three plots or the printer will have differential banding (a difference of advance between the left and right).
This defect has the follow possible causes: • OMAS is not clean or is defective so you should repeat the plot with OMAS disabled. This will allow you to establish if this is an OMAS related fault. If the same fault is detected the problem cannot be attributed to OMAS. • The Drive roller is not clean so it slips against the media. • Any other component affecting the media advance: • Spindle/Back Tension • Input roller • Pinchwheels 0.6 to 0.7 mm 0.6 to 0.
Print Quality Example defective nozzle plot This example is caused by a defective nozzle so there is no issue with the paper advance. 0.6 to 0.7 mm 0.6 to 0.
This section describes the common symptoms seen, and how to solve the issues. There is banding in the image If banding does not occur in ALL the colors, then it is more than likely a Printhead problem. In this case, try the following: 1. Check that the appropriate print quality settings are being used. 2. Recover the printheads using the option through the Front Panel (Image quality maintenance > Clean printheads).
Print Quality Lines are too thick, too thin, or missing 1. Check that the paper type you have loaded corresponds to the paper type selected in the front panel and in your software. To check on the front panel, use the View loaded paper key. 2. Check that you are using appropriate print-quality settings for your purposes. See Select print quality on User Guide. 3. If the resolution of your image is greater than the printing resolution, you may notice a loss of line quality. You can find the Max.
Large quantities of data may be necessary to print a high-quality large format print job, and in some specific workflow there may be issues that can lead to some objects missing from the output. Here are some suggestions to help you to avoid this problem. • Select a smaller page size and scale to the desired final page size in the driver or in the front panel. • Save the file in another format, such as TIFF or EPS, and open it with another application. • Use a RIP to print the file.
Print Quality To correct this kind of problem: 1. Align the printheads. 2. Check that you are using appropriate print-quality settings. Lines are blurred (ink bleeds from lines) Humidity can cause ink to soak into the paper, making the lines blurred and fuzzy. Try the following: 1. Check that your environmental conditions (temperature, humidity) are suitable for high-quality printing. 2. Check that the paper type selected in the front panel is the same as the paper type you are using.
Print Quality 1. Check that the paper type you have loaded corresponds to the paper type selected in the front panel and in your software. To check on the front panel, use the View loaded paper key. 2. Check that you are using appropriate print-quality settings for your purposes. See Select print quality on User Guide. In some cases, you can overcome a print-quality problem merely by selecting a higher print quality level.
Print Quality 3. Check that you are using appropriate print-quality settings. See Select print quality on User Guide. In some cases, you can overcome a print quality problem merely by selecting a higher print-quality level. For instance, if you have set the print-quality slider to Fast, try setting it to Best. If you change the print-quality settings, you may wish to reprint your job at this point in case the problem has been solved. 4. Try aligning the printheads.
The black ink pigment can smudge when touched by a finger or pen. This is particularly noticeable on the following materials: vellum, translucent bond, films, productivity photo paper, and natural tracing paper.
Print Quality • If necessary, try changing to a non-paper-based material such as transparent film Smears or scratches on the front of glossy paper Glossy paper may be extremely sensitive to the bin or to anything else that it contacts soon after printing. This will depend on the amount of ink printed and the environmental conditions at the time of printing. Avoid any contact with the paper surface and handle the print with care.
The Color Sensor Test, refer to page 119 for details. This tests the covers that open and close on the Spectrophotometer. 2. Turn on the error log and check to see if there is an warning error 94:08. This would indicate that the measured values displayed when performing the color calibration were out of specification. 3. If the Spectrophotometer fails the test replace the Spectrophotometer (service part Q6651-60039). 4.
Print Quality 9. In the PostScript driver for the HP Designjet Z6100, go to the Color Management section and set the CMYK input profile to the same HP Designjet 4000 color space that you selected in the application (the emulation color space). NOTE: RGB. When trying to emulate another printer you should always use CMYK colors, not 10. Set the rendering intent to Relative Colorimetric, or to Absolute Colorimetric if you want to emulate the whiteness of the paper. 11.
If the front-panel graphic language setting is Automatic (the default), try the other settings: PostScript for a PostScript file, HP-GL/2 for an HP-GL/2 file, etc. Then send the file again. When you have finished this particular print, remember to reset the graphic language to Automatic. The output contains only a partial print • If you pressed Cancel before all the data were received by the printer, you ended the data transmission and will have to print the page again.
Print Quality resolution of such images automatically. You can find this option in he Advanced tab, under Document Options > Printer Features. • Save the file in another format, such as TIFF or EPS, and open it with another application. • Use a RIP to print the file.
• To eliminate aeroworms, select a higher IQ print setting. See Selecting Print Quality in the User’s Guide. CAD Lines look misaligned, images are blurred This issue can be seen even after the customer has performed the Printhead Alignment procedure. The misalignment is most highlighted in CAD drawings, there are double-lines and images are ‘ghosted’. See the two examples below.
Print Quality PEG wick Wiper Cap Spittoon Ink absorber Vacuum ports for aerosol extraction Rib that interacts with a pin on the Carriage Assembly to cap the Printheads (a total of two, one on each side) To cap the Printheads: • The Carriage Assembly is first positioned over the Service Station. • The Maintenance Cartridge moves towards the back of the printer which allows Pin #1 and Pin #2 on the Carriage Assembly to push against Rib #1 and Rib #2 to lift the caps into contact with the Printheads.
• Rib #1 or Rib #2 of the Maintenance Cartridge, • Pin #1 or Pin #2 of the Carriage Assembly You should also check all the other elements of the Maintenance Cartridge (plastic of each cap etc.) and make sure the vacuum ports are clear. If they are blocked, you can clear them with a T-8 Torx bit but you should also check to make sure the Aerosol Fan is operating correctly.
Print Quality Universal PDQ Gloss Photobase 10Mil (DMPDQ2-G) Photo Paper > HP Premium ID Gloss Mat and Gloss canvas Torino17M Matte, Poly/Cotton 17 Mil/Artist Stretch Canvas Fine Art material > Canvas DMBP5 Backprint Film 5Mil/125 Microns Photo Paper > Photo Gloss Paper Mural Pro Digital Wallcovering Paper 228 gsm Fine Art Material > Fine Art Paper Universal PDQ Gloss Photobase 10Mil (DMPDQ2-L) Photo Paper > HP Premium ID Gloss Ketmere Photographic K.
“Best Quality” or slider in the right position Resolution at which the image is rasterized/processed in the host (in pixels per printed inch, or pppi) Printing Resolution (PR) Resolution at which the image is printed (in dots per inch, or dpi) # passes Other info (OI)Bidirecti onal Typically, the higher the number of passes, the better the image quality, but at a lower speeds. Also, papers such as glossy paper need a longer drying time that will generally require a higher number of passes.
Ink Limiting Super Heavyweight Coated All 48 10p bidi Yes Heavyweight Coated Paper All 30 10p bidi Yes Coated Paper All 24 8p bidi Yes Coated Paper (CAD) All 24 6p Uni Yes Plain Paper All 22 4p bidi Yes Bright White Bond Paper All 22 Photo Gloss Paper Plg 38 Photo Gloss Paper (Less ink) Plg 32 Photo Semi-gloss/Satin paper Plg 38 Proofing Semi-gloss/Satin Paper P lg 38 Proofing Gloss Paper P lg 38 Proofing Matte Paper All 30 Canvas All 38 Fine Art paper All
All 38 600 1200x1200 10p bidi Yes Adhesive Vinyl All 32 600 1200x1200 10p bidi Yes Working with other commercially available media Print Quality Self Adhesive Adhesive polpropylene 217
Printing Black Ink Limiting All 24 8p Bidi Yes All 24 6p Bidi Yes All 24 8p Bidi Yes HP Universal Coated Paper (CAD) 95 g/m², 4.9mil/124 All 24 6p Bidi Yes HP Heavyweight Coated Paper 130 g/m², 6.6mil/144 All 30 HP Universal Heavyweight Coated Paper 120 g/m², All 30 HP Super Heavyweight Coated Plus Matte Paper All HP Colored Paper Fluorescent Yellow 100 g/m², All Media Type HP Coated Paper 95 g/m², 4.5mil/114 microns HP Coated Paper (CAD) 95 g/m², 4.
All 42 HP Professional Matte Canvas All 38 400 g/m², 22mil/559 microns 10p Uni 10p Uni No Print Quality HP Collector Satin Canvas No 430 g/m², 22mil/559 microns 42 HP Artist Matte Canvas 10p Dpi No 10p Uni No 10p Uni No 42 10p Uni No 42 10p Bidi No 48 10p Bidi No 44 380 g/m², 18mil/457 microns 600 HP Universal Matte Canvas 38 350 g/m², 18mil/457 microns HP Smooth Fine Art Paper 265 g/m², 16.5mil/420 microns HP Textured Fine Art Paper 265 g/m², 21.
Print Quality 220 Chapter 6 Print Quality
Parts and Diagrams • • • • • • • • • • • • • • • Printer Support...................................................................................................222 Center Covers....................................................................................................224 Electronics Module .............................................................................................226 Right Cover ..................................................................................................
Printer Support Reference on Figure HP Part Number Part Description Pagea 1 Q6651-60257 Leg Cover All N/A 2 Q6651-60254 Foot Assembly All N/A Q6651-60260 Parts and Diagrams Size 3 Q6652-60135 42-inch N/A Bin Assembly (Includes the Bin Support) Q6651-60259 4 5 Q6651-60262 Q6651-60255 Q6651-60261 N/A 42-inch N/A Foot Brace Assembly 60inch N/A Legs Assembly All N/A Q6651-60258 6 60inch 42-inch N/A Cross-Brace Assembly 60inch N/A 7 Q6651-60355 Stand Supports All N/A - Q6
1 Parts and Diagrams 7 2 3 4 5 6 Figure 1: Printer Support Printer Support 223
Center Covers Reference on Figure HP Part Number Part Description Q6651-60333 Parts and Diagrams 1 Size Pagea 42-inch Rear Door 60inch 283 Q6651-60331 Left Connector Cover 42-inch 287 Q6651-60122 Electronics Module Extension 60inch 288 3 Q6651-60332 Right Connector Cover All 281 4 Q1271-60369 Window Position Sensor All N/A 2 Q6652-60124 Q1273-60204 5 Q6652-60129 42-inch Window Q6651-60291 6 Q6652-60113 260 42-inch Top Cover a.
2 1 3 Parts and Diagrams 6 4 5 Figure 2: Center Covers Center Covers 225
Parts and Diagrams Electronics Module Reference on Figure HP Part Number Part Description 1 Q6651-60306 Electronics Module Cables Kit All N/A 2 Q1273-60237 EIO to PCI Interface Card All 360 3 Q6651-60268 OMAS Controller Card All 362 Q6652-60121 Pagea 42-inch Q6651-60305 4 Size Sausalito PCI PCA b 60inch 369 5 Q6651-60282 Main PCA Formatter (Includes Processor, Heatsink & Fan).
1 Parts and Diagrams 12 10 9 7 6 13 5 4 3 11 2 8 Figure 3: Electronics Module Electronics Module 227
Parts and Diagrams Right Cover Reference on Figure HP Part Number Part Description 1 Q6651-60293 Right Cover (without Maintenance Cartridge Door) All 264 2 Q6651-60318 Maintenance Cartridge Door All 413 3 Q6651-60321 Right Trim All 267 4 Q1273-60240 Front Panelb All 292 5 Q6651-60327 Front Panel Bezel All 292 6 Q6651-60343 Quick Reference Guide Holder All 264 a. Refers to the page in the Removal and Installation Chapter (if applicable) b.
1 5 2 Parts and Diagrams 6 3 2 4 Figure 4: Right Hand Cover Right Cover 229
Left Cover Reference on Figure HP Part Number Part Description 1 Q6651-60322 Left Trim All 272 2 Q6651-60292 Left Cover All 270 Parts and Diagrams a.
2 Parts and Diagrams 1 Figure 5: Left Hand Cover Left Cover 231
Parts and Diagrams Right Hand Assemblies Reference on Figure HP Part Number Part Description 1 Q1273-60086 Right Scan-Axis Bracket All - 2 Q6651-60284 Service Station Assemblyb All 300 3 Q6651-60266 Primer Valves and Primer Tubes Assembly All 296 4 Q1273-60084 Aerosol Filter All 307 5 Q1273-60226 Aerosol Fan Assembly All 307 6 Q1273-60273 Service Station Cable (Includes Maintenance Cartridge Door Sensor) All 300 7 Q6651-60286 Vacuum Fan Assembly All 304 8 Q1273-60236
2 Parts and Diagrams 4 3 1 6 7 8 9 5 10 Figure 6: Right Hand Assemblies Right Hand Assemblies 233
Parts and Diagrams Left Hand Assemblies Reference on Figure HP Part Number Part Description 1 Q6651-60328 Cartridge Trays All 409 2 Q6651-60288 Lower Ink Supply Station (without APS Assembly but including Cartridge Tray) All 321 3 Q6651-60287 Upper Ink Supply Station (without APS Assembly but including Cartridge Tray) All 321 4 Q6651-60315 Left Scan-Axis Bracket All N/A 5 Q6651-60325 Left Spittoon All 328 6 Q1273-60245 ISS to Cartridge Cable All N/A Q6652-60117 Pagea 42-i
8 6 7 Parts and Diagrams 5 9 4 1 3 2 Figure 7: Left Hand Assemblies Left Hand Assemblies 235
Carriage Assembly Reference on Figure HP Part Number 1 Q6651-60297 Part Description Line Sensor Assemblyb Q1273-60239 Parts and Diagrams 2 Q6652-60119 Size All Pagea 390 42-inch Encoder Sensorr (Includes Encoder Strip) 60inch 331 3 Q6651-60290 Carriage Assemblyc All 339 4 Q1273-60271 Cutter Assembly All 319 5 Q6651-60341 Carriage Stopper (includes Carriage Stopper Screw and Media-Axis Motor Bracket) All 339 6 Q6651-60271 Color Sensor All 392 7 Q6651-60335 Setup Printhe
9 3 2 Parts and Diagrams 1 5 4 6 8 7 Figure 8: Carriage Assembly Carriage Assembly 237
Scan-Axis Assemblies Reference on Figure HP Part Number Part Description Q1273-60239 Parts and Diagrams 1 Q6652-60119 Q6652-60128 Encoder Strip and Encoder Sensor Kit Q6652-60112 Scan-Axis Motor Q6652-60125 Ink Supply Tubes and Trailing Cable Q6652-60126 Ink Supply Tubes Clips Q6652-60118 Rear Tube Shelf and Brackets 60inch 312 60inch 312 60inch 312 42-inch Belt and Tensioner Assembly a.
Parts and Diagrams 2 1 3 6 4 5 Figure 9: Scan-Axis Assemblies Scan-Axis Assemblies 239
Drive Roller and Media-Axis Motor Reference on Figure HP Part Number Part Description Q6651-60320 Parts and Diagrams 1 2 Q6652-60123 Q1273-60242 Q6652-60109 Drive Roller Encoder Kit Q6652-60108 346 433 42-inch Drive Roller 60inch 433 42-inch Media Advance Driveb a. Refers to the page in the Removal and Installation Chapter (if applicable) b.
2 Parts and Diagrams 1 3 4 Figure 10: Drive Roller and Media-Axis Motor Drive Roller and Media-Axis Motor 241
Paper Path Assemblies Reference on Figure HP Part Number Part Description Parts and Diagrams Q6652-60111 b Center Platen Q6651-60295 2 Q6652-60115 Pagea 42-inch Q6651-60281 1 Size 60inch 400 42-inch Front Platen 60inch 398 3 Q6652-60120 Media Deflector All 397 4 Q1273-60103 Input Roller Lever All 411 Q1273-60058 5 Q6652-60114 42-inch Input Roller 60inch 411 6 Q6651-60270 OMAS Module All 351 7 Q6651-60269 OMAS Cable All 364 a.
2 1 3 Parts and Diagrams 7 4 6 5 Figure 11: Paper Path Assemblies Paper Path Assemblies 243
Center Guide and Pinchwheel Assembly Reference on Figure HP Part Number Part Description Size Q6651-60280 Parts and Diagrams 1 Q6652-60110 42-inch Complete Pinchwheel Assembly b Q6651-60345 2 Q6652-60130 Pagea 60inch 425 42-inch Center Guide 60inch 430 3 Q1273-60079 Media Sensor All 415 4 Q6651-60319 Media Lever Assembly All 420 5 Q1273-60082 Media Lever Sensor All 423 6 Q6651-60330 Pinchwheel Kit All 425 a.
2 3 Parts and Diagrams 1 5 4 6 Figure 12: Center Guide and Pinchwheel Assembly Center Guide and Pinchwheel Assembly 245
Media Entry Assemblies Reference on Figure HP Part Number 1 Q6651-60311 Part Description Right Rollfeed Module Assemblyb Q6651-60049 Parts and Diagrams 2 Q6652-60146 Size All Pagea 439 42-inch Spindle 60inch N/A 3 Q6651-60610 3" Spindle Adaptor All N/A 4 Q6651-60274 Spindle Hub All N/A 5 Q1273-60274 Left Rollfeed Module Assembly All 415 a. Refers to the page in the Removal and Installation Chapter (if applicable) b.
3 2 Parts and Diagrams 1 4 5 Figure 13: Media Entry Assemblies Media Entry Assemblies 247
Parts and Diagrams Take-Up Reel Assembly Reference on Figure HP Part Number Part Description 1 Q6706-60902 Take-Up Reel Deflector Support Assembly All 445 2 Q6706-60904 Take-Up Reel Motor All 442 3 Q6706-60910 Thumbscrew All 447 4 Q6706-60909 Take-Up Reel Receiver Sensor Housing Assembly All 447 5 Q6706-60908 Take-Up Reel Sensors Assembly All 447 Q6652-60903 Take-Up Reel Spindle Assemblyb Q6706-60905 7 Q6652-60901 - Q6652-60902 Q6706-60901 60inch Take-Up Reel Deflector
6 5 Parts and Diagrams 4 3 2 1 7 8 Figure 14: Take-Up Reel Assembly Take-Up Reel Assembly 249
Parts and Diagrams Miscellaneous Parts Reference on Figure HP Part Number 1 Q1273-60097 Right Arc All 439 2 Q1273-60098 Left Arc All 439 - Q6715A User’s Maintenance/cleaning kitb All Preventive Maintenance Kit # 1: 42-inch Q6651-60296 - Q6652-60116 Part Description • • • • Scan-Axis Motor (see page 238) Encoder Strip (see page 238) Belt Assembly (see page 238) Carriage Assembly without PCA, Cutter, and Color Sensor Size Pagea 60inch N/A ALL N/A Preventive Maintenance Kit # 2:
Parts and Diagrams 2 1 Figure 15: Arc Assemblies Miscellaneous Parts 251
Parts and Diagrams 252 Chapter 7 Parts and Diagrams
Removal & Installation Two contents lists are provided for this chapter to help you to quickly find the service part you want to replace. The first list is provided in Service Part Order and the second in Disassembly Order. Service Part Order • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Introduction .......................................................................................................257 Screw Types ......................................................................
Removal & Installation Service Part Order (Continued) • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Left Rollfeed Module Assembly ............................................................................ 440 Left Spittoon ......................................................................................................328 Left Trim ............................................................................................................
Disassembly Order Introduction ...................................................................................................... 257 Screw Types...................................................................................................... 259 Window (42-inch).............................................................................................. 260 Window (60-inch) ............................................................................................. 262 Right Cover...............
Removal & Installation Disassembly Order (Continued) • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • OMAS Cable ................................................................................................... 364 Sausalito PCI PCA ..............................................................................................369 Memory Module ................................................................................................373 CPU Fan ........................................
Introduction This chapter is a step-by-step guide to the removal and installation of the key components of the printer. You may find it useful to tick off the steps as they are performed. Use the illustrations for each procedure to identify the parts referred to in the text. The procedures appear in order of removal. So the whole machine can be stripped down by starting at the beginning of this chapter and working through the subsequent procedures.
A T8 Torx Screwdriver to remove the left cover. The blade must be longer then 5 cm with a maximum diameter of 9 mm.
Type Torx Length (mm) Head Type Thread Type Part Number A B C D E F G H I J K L M N O P Q R S T-20 T-20 T-10 T-8 T-15 T-15 T-15 T-15 T-10 T-15 T-8 T-8 T-20 T-20 T-20 T-15 T-20 T-15 T-15 17 10 7.0 5.5 9.5 12.7 12.7 8.0 20 9.5 12.7 35 12.7 11.6 18.
Window (42-inch) Removal WARNING!: Switch off the printer and remove the power cable. NOTE: Throughout this section the graphics actually show the HP Designjet 4000 Printer series but the steps of the procedure are identical for the HP Designjet Z6000 Printer series. Removal & Installation 1. Open the Window. 2. Unclip the Window hinges from the Top Cover.
Installation of New Window Top Cover 1. Identify the two ends of the Window hinge (four in total) - one end is clipped to the Window and the other to the Top Cover. Window 3. Clip the Window Hinges to the Top Cover. NOTE: Since the hinges are very hard to clip, you will need to forcefully clip the Window hinges to the Top Cover. Window (42-inch) 261 Removal & Installation 2. Slide the Window hinges on to the Window.
Window (60-inch) Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Open the Window. 2. Use a flat bladed screwdriver to compress and hold the spring compressed. 3. Pull the window towards you enough to release it from the left attachment.
4. Slide the Window to the left to release it from the right attachment. Removal & Installation 5. Remove the Window from the Printer.
Right Cover Removal WARNING!: Switch off the printer and remove the power cable. 1. Unclip the Quick Reference Guide Holder from the rear of the Printer. 1 Removal & Installation 2 2. Using a suitable small flat-blade screwdriver, unclip the Front Panel Bezel from the Right Cover. 3. Remove the Front Panel Bezel from the Right Cover.
4. Remove two T-15 screws (Type G) that secure the Front Panel to the Right Cover. 6. Remove one T-15 screw (Type J) that secures the Right Cover. 7. Open the Window. Right Cover 265 Removal & Installation 5. Open the Maintenance Cartridge Door.
8. Open the Window and remove two T-15 screws (Type J) that secure the Right Cover. Removal & Installation Type J 9. Remove one T-15 screw (Type J) and one T-20 screw (Type A) that secure the Right Cover from the rear of the Printer. Type A 10. Remove the Right Cover from the Printer. CAUTION: When installing the Right Cover, make sure you leave the Maintenance Cartridge Door open, otherwise you could damage the Maintenance Cartridge Door Sensor.
Right Trim Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. Removal & Installation 2. Remove the Output Platen ⇒ See page 398. 3. Raise the Media Lever. 4. Remove one T-15 screw (Type F) that secures the Media Lever to the Linkage. 5. Disconnect the Media Lever from the Linkage.
6. Remove one T-15 screw (Type F) that secures the Media Lever to the Right Trim. 7. Lift the Media Lever and remove it from the Printer. Removal & Installation 1 2 8. Unroute the Media Lever Position Sensor cable from its clip to avoid putting strain on the Media Lever Position Sensor connections during the removal of the Right Trim. 9. Remove five T-15 (Type F) screws that secure the Right Trim.
10. Carefully rotate the Right Trim sufficiently to gain access to the Media Lever Position Sensor. 11. Unclip the Media Lever Position Sensor of its mounting Removal & Installation lugs on the Right Trim. 12. Remove the Right Trim from the Printer.
Left Cover Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Open the Window. 2. Remove two T-15 (Type J) screws that secure the Left Cover. 3. Remove one T-15 screw (Type J) that secures the Left Cover.
4. Remove two T-15 screws (Type J) secure the Left Cover. Removal & Installation 5. Remove the Left Cover from the Printer.
Left Trim Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Remove the Output Platen ⇒ See page 398. 2. Remove six T-15 screws that secure the Left Trim. 3. Carefully remove the Left Trim from the Printer.
Top Cover (42-inch) Removal WARNING!: Switch off the printer and remove the power cable. NOTE: Throughout this section the graphics actually show the HP Designjet 4000 Printer series but the steps of the procedure are identical for the HP Designjet Z6000 Printer series. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Left Cover ⇒ See page 270. 3. Release the three clips securing the Ink Supply Tubes 4. Release the Ink Supply Tubes and Trailing Cable from the clip underneath the Top Cover. 5.
6. Remove one T-10 (Type I) screw that secures the ESD Strip to the Top Cover (on the left hand side of the Printer). Removal & Installation 7. Disconnect the ESD Strip from the Top Cover. 8. Remove the three T-15 screws (Type G) that secure the Rear Door. NOTE: Each screw includes a washer (part number 3050-1267). 9. Open the Rear Door.
10. Remove four T-15 screws (Type H) that secure the Top Cover from the rear of the Printer. 11. Using a flat-head screwdriver, release the Top Cover Removal & Installation from the right hand side of the Printer. 12. Release the Top Cover from the rear of the Printer. 13. Raise the right hand side of the Top Cover and pull out to the right.
1. Position the Metallic Support on to the Top Cover. Removal & Installation 2. Lock the Metallic Support on to the Top Cover. 3. Install the T-20 screw that secures the Metallic Support to the Top Cover. 4. Remove the Window (⇒ See page 260) from the old Top Cover and install it on the new Top Cover. NOTE: When installing the Ink Supply Tubes and Trailing Cable on to the Top Cover, take note of the of the two red marks on the Ink Supply Tubes.
Top Cover (60-inch) Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Left Cover ⇒ See page 270. 3. Remove the Rear Door ⇒ See page 283. 4. Release the clip securing the Ink Supply Tubes and the 5. Release the Ink Supply Tubes and Trailing Cable from the clip underneath the Top Cover. 6. Press the clip to release it from the Top Cover. Top Cover (60-inch) 277 Removal & Installation Trailing Cable to the Top Cover.
7. Remove the clip from the Top Cover. Removal & Installation 8. Unroute the Trailing Cable from the Top Cover. 9. Position the Ink Supply Tubes so they are resting on the Platen. 10. Close the Window.
11. Remove the two locking plates. 12. Slide the Top Cover fully to the right to release the two 13. Lift the right end of the Top Cover to release it from the right Arch. 14. Slide the Top Cover to the right to release the two locking clips. Top Cover (60-inch) 279 Removal & Installation locking clips.
Removal & Installation 15. Remove the Top Cover from the Printer.
Rear Door (42-inch) Removal WARNING!: Switch off the printer and remove the power cable. NOTE: Throughout this section the graphics actually show the HP Designjet 4000 Printer series but the steps of the procedure are identical for the HP Designjet Z6000 Printer series. 1. Remove three T-15 screws (Type G) from the Rear Door. Removal & Installation NOTE: Each screw includes a washer (part number 3050-1267). 2. Open the Rear Door slightly (as shown). 3.
4. To release the left hand hinge of the Rear Door, move the Rear Door to the right (1) and then bend the hinge slightly (2). 2 1 Removal & Installation 5. Remove the Rear Door from the Printer.
Rear Door (60-inch) Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover ⇒ See page 270. 2. Remove seven T-15 screws (Type G) and the four T-15 screws (Type X) from the Rear Door. NOTE: Each Type X screw includes a washer (part number 3050-1267). 3. Open the Rear Door slightly (as shown, approximately 30 degrees). 4. Lift the left side of the rear door sufficiently to release it from the location stud.
Removal & Installation 5. Remove the Rear Door from the Printer.
Right Connector Cover Removal WARNING!: Switch off the printer and remove the power cable. 1. For the 42-inch model, remove the Rear Door ⇒ See page 281 2. For the 60-inch model, and optionally the 42-inch 3. For the 60-inch model, and optionally the 42-inch model, unroute the TUR cable from the Right Connector Cover. 4. Remove two T-20 screws (Type B) from the Right Connector Cover. Right Connector Cover 285 Removal & Installation model, disconnect the TUR connector.
5. Rotate the Right Connector Cover a few degrees counter-clockwise so it can be removed completely. Removal & Installation 6. Remove the Right Connector Cover from the Printer.
Left Connector Cover (42-inch) Removal WARNING!: Switch off the printer and remove the power cable. NOTE: Throughout this section the graphics actually show the HP Designjet 4000 Printer series but the steps of the procedure are identical for the HP Designjet Z6000 Printer series. 1. Remove the Rear Door ⇒ See page 281. 2. Remove two T-20 screws (Type B) from the Left Removal & Installation Connector Cover. 3. Remove the Left Connector Cover from the Printer.
Electronics Module Extension (60-inch only) Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove ten T-20 screws (Type B) from the Electronics Removal & Installation Module Extension. 2. Rotate the Electronics Module Extension approximately 90 degrees counter-clockwise. 3. Remove the Electronics Module Extension from the Printer.
Window Position Sensor Removal WARNING!: Switch off the printer and remove the power cable. 1. • • 2. • • 3. Remove the Window: For the 42-inch ⇒ See page 260. For the 60-inch ⇒ See page 262. Remove the Top Cover: For the 42-inch ⇒ See page 273. For the 60-inch ⇒ See page 277. Remove the Right Cover ⇒ See page 264. 4. Remove the Right Connector Cover ⇒ See page 285. 5. Disconnect the Window Position Sensor cable from the 6. Unroute the Window Position Sensor cables from the from cable clamp.
7. Unroute the Window Position Sensor cables from the Right Arc. 8. Remove three T-15 screws (Type J) that secure the Removal & Installation Window Position Sensor Holder to the Right Arc. 9. Remove the Window Position Sensor Holder from the printer. 10. Release the two clips of the Window Position Sensor Holder.
Removal & Installation 11. Remove the Window Position Sensor from the Holder.
Front Panel Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Right Connector Cover ⇒ See page 285. 3. Disconnect the Front Panel Cable from the Interconnect Removal & Installation PCA. 4. Disconnect the Ferrite clip (located on the rear of the Electronics Module) from the front of the Printer. 5. Move the Front Panel Cable (including the ferrite) out of the Electronics Module.
6. Release the Front Panel Cable from the Right Arc. 8. Remove two T-15 screws (Type G) that secure the Front Panel to the Printer. 9. Remove the Front Panel from the Printer. Front Panel 293 Removal & Installation 7.
Primer Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Right Connector Cover ⇒ See page 285. 3. Remove the Front Panel ⇒ See page 292. 4. Disconnect Primer Assembly cable from the from Removal & Installation Interconnect PCA. 5. Unroute the Primer Assembly cable from the from cable clamp. 6. Disconnect the two Primer Assembly tubes.
7. Remove four T-10 screws that secure the Primer Assembly to the Service Station. NOTE: Use a short screw driver, less than 10 cm in length. 8. Remove the Primer Assembly from the Service Station. Removal & Installation NOTE: When installing the Primer Assembly, use the identification marks on the Primer Assembly Tubes to ensure they are correctly connected.
Primer Valves Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Right Connector Cover ⇒ See page 285. 3. Remove the Front Panel ⇒ See page 292. 4. Disconnect both Primer Valves from the from Interconnect PCA. Removal & Installation NOTE: The upper connection is identified as number 5 and the lower connection as number 6. These identification numbers correspond to the actual Primer Valves identification. 5.
7. Disconnect the two Primer Assembly Tubes. Removal & Installation 8. Unclip the Primer Valve Tubes from the Service Station. 9. Disconnect the Primer Valve Tubes at the Y-Piece. 10. Unclip the lower Primer Valve.
11. Remove the lower Primer Valve (identified as 5). 12. Unclip and remove the upper Primer Valve (identified Removal & Installation as 6 and with an identification mark on the tube). 13. Remove the Primer Valves from the Printer. NOTE: When installing the Primer Valves, use the identification marks on the Primer Assembly Tubes and the identification numbers to ensure they are correctly connected. 14. Remove two T-15 screws that secure the Primer Valves Mounting Plate from the printer.
Removal & Installation 15. Remove Primer Valves Mounting Plate from the printer.
Service Station Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Primer Assembly ⇒ See page 294. 3. Primer Valves ⇒ See page 296. 4. Remove the Drop Detector ⇒ See page 309. 5. Remove the Right Connector Cover ⇒ See page 281. 6. Remove the Maintenance Cartridge ⇒ See the User’s Guide. 7. Disconnect the cable from the Maintenance Cartridge Removal & Installation Door Switch. 8.
9. Unroute the Service Station and Aerosol Fan Cables. 10. Unroute the Primer Assembly Valves tube from the Removal & Installation Service Station. 11. Lift the Primer and hold the Primer to its maximum position to avoid damaging it when you move the Carriage Assembly in the next step. 12. Move the Carriage Assembly out of the Service Station.
13. Remove two T-15 screws (Type J) that secure the rear of the Service Station to the Chassis. 14. Remove four T-15 screws (Type J) that secure the Service Station to the Chassis. Removal & Installation CAUTION: When removing the screws, please be very careful NOT to damage the Encoder Strip. 15. Disconnect the Aerosol Fan Tube from the Chassis. 16. Lower the right side of the Service Station.
17. Remove the Service Station from the Printer. NOTE: After installing the NEW Service Station, make sure you perform the following Service Utility: • Reset Counter PHC spittoon ⇒ Chapter 4. NOTE: After installing the NEW Service Station, make sure you perform the following Service Calibration: • Service Station Calibration ⇒ Chapter 5. Removal of the Service Station Scraper 1. Release the clip securing the Scraper to the Service Removal & Installation Station. 2.
Vacuum Fan Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Right Connector Cover ⇒ See page 285. 3. Remove the Primer Assembly ⇒ See page 294. 4. Remove the Primer Valves ⇒ See page 296. 5. Remove the Maintenance Cartridge ⇒ See the User’s Guide. 6. Remove the Service Station ⇒ See page 300. 7. Release the Pinchwheel Lever Sensor Cable from the Removal & Installation Vacuum Fan. 8.
9. Unclip the cables from the cable clamp. 10. Unroute both Vacuum Fan cables from the Interconnect 11. Remove four T-20 screws (Type B) that secure the Vacuum Fan to the Printer. 12. Remove the OMAS cable clamp from the printer. Vacuum Fan 305 Removal & Installation PCA.
13. Lower then lift the Vacuum Fan out of its attachment. 1 2 Removal & Installation 14. Remove the Vacuum Fan from the Printer. Cable 2 Cable 1 NOTE: When connecting the Vacuum Fan cables to the Interconnect PCA, make sure you connect the cable with the label marked Vacuum Fan 1 to connector 1 and the cable with the label marked Vacuum Fan 2 to connector 2. You can verify if both cables are labelled correctly by the actual markings on the Vacuum Fan.
Aerosol Fan and Filter Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Rear Door: • For the 42-inch model ⇒ See page 281. • For the 60-inch model ⇒ See page 283. 3. Remove the Right Connector Cover ⇒ See page 281. 4. Remove the Service Station ⇒ See page 300 5. Remove four T-15 screws (Type G) that secure the Removal & Installation Aerosol Fan to the Service Station. 6. Remove the Aerosol Fan from the Service Station.
7. If necessary, remove the Aerosol Fan Filter from the Aerosol Fan. Installing Removal & Installation When the new aresol Fan and Filter have been installed, it is important to check that the fan is funcioning correctly, otherwise the printer will suffer from Aerosol spray. To check that the fan is working correctly, make sure the printer is printing and check for airflow in the area of the rear of the Service Station.
Drop Detector Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Disconnect the Drop Detector Cable from the Service Removal & Installation Station Cable. 3. Release the Drop Detector Cable from the Service Station. 4. Pull out the Maintenance Cartridge fully from the Service Station to release the Carriage Assembly.
5. Lift the Primer and hold the Primer to its maximum position to avoid damaging it when you move the Carriage Assembly in the next step. 6. Slide the Carriage Assembly into the print path so you Removal & Installation access the Drop Detector. 7. Remove one T-8 screw (Type K) that secures the Drop Detector to the Service Station. 8. Slide the Drop Detector forward so you can release it from the Service Station.
9. Remove the Drop Detector from the Printer. NOTE: After installing the NEW Drop Detector, make sure you perform the following Service Calibration: Removal & Installation • Drop Detector Calibration ⇒ Chapter 5.
Ink Supply Tubes and Trailing Cable Removal WARNING!: Switch off the printer and remove the power cable. CAUTION: You MUST NEVER replace both the Hard Disk Drive and the Ink Supply Tubes and Trailing Cable at the same time. If both parts need to 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. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Left Cover ⇒ See page 270. 3.
8. Release the two plastic clips securing the Trailing Cable to the Right Arc. 9. Press the two side of the Carriage PCA Cover and unclip from the Carriage Assembly. 2 10. Disconnect the Trailing Cable from the Carriage PCA. 11. Open the Carriage Cover and remove ALL the Printheads from the Carriage Assembly.
12. Remove five T-15 screws (Type G) that secure the Ink Supply Tubes to the Carriage Assembly. 13. Remove the Ink Supply Tubes from the Carriage Removal & Installation Assembly and safely place to one side of the Printer. 14. Remove one T-20 screw (Type B) from each plastic holder at the rear of the Printer. 15. Remove one T-15 screw that attaches the bonding cable to the printer chassis. 16. Disconnect the Air Tubes from the Ink Cartridge Tube Connector.
17. Disconnect the Electrical Cable from the rear of the Ink Cartridge Tube Connector. 18. Unroute the Electrical Cable and Air Tubes from the 19. Twist the four latches at the rear of the Ink Cartridge Tube Connector and release the complete assembly. NOTE: Be careful not to damage the interconnecting cable. 20.Carefully slide the Ink Cartridge Tube Connector off the Ink Supply Station. Ink Supply Tubes and Trailing Cable 315 Removal & Installation rear of the Ink Cartridge Tube Connector.
21. Remove the Ink Supply Tubes and Trailing Cable from Removal & Installation the Printer.
Installation of the Ink Supply Tubes and Trailing Cable NOTE: After installing the NEW Ink Supply Tubes and Trailing Cable, make sure you perform the following Service Utility: • Reset life counter scan cycles tubes/cable ⇒ Cable 1 • Chapter 4. NOTE: When installing the Ink Supply Tubes and Trailing Cable on to the Top Cover, take note of the of the two red marks on the Ink Supply Tubes.
ISS to Cartridge Cables Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover ⇒ See page 270. 2. Disconnect the ISS to Cartridge Cable from the ISS Removal & Installation PCA. 3. Release the clips securing the ISS to Cartridge Cable. 4. Remove the ISS to Cartridge Cable from the Printer.
Cutter Assembly Removal 1. Select “Replace Cutter” from Service Menu (refer to Chapter 4) and follow the instructions on the Front Panel. 2. Open the Window. Removal & Installation 3. Open the Carriage Cover. 4. Remove one T-15 screw (Type G) that secures the Cutter Assembly to the Carriage Assembly.
5. Slide the Cutter Assembly to the left and remove from Removal & Installation the Printer.
Ink Supply Station (ISS) Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover ⇒ See page 270. 2. Remove the Scan-Axis Motor ⇒ See page 346. 3. Remove the Left Spittoon ⇒ See page 328. 4. Pull out the top row of Cartridge Trays and remove the Ink Cartridges. 1 5. Close the top row of Cartridge Trays and pull out the bottom row. 6. Pull out the bottom row of Cartridge Trays and remove the Ink Cartridges.
7. Disconnect the top and bottom Air Tubes from the Ink Supply Tubes. 8. Disconnect the Electrical Cable from the rear of the Ink Removal & Installation Cartridge Tube Connector. 9. Unroute the Air Tubes and Electrical Connector. 10. Twist the four latches at the rear of the lower Ink Cartridge Tube Connector and release the complete assembly.
11. Lift the Cartridge Tube Connector off the Ink Supply Station. 12. Remove the Cartridge Tube Connector from the Ink Supply Station. 1 13. Unhook Ink Supply Station cables from the printer. 14. Remove the complete Ink Supply Station (upper and lower assemblies) from the Printer.
APS Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover ⇒ See page 264. 2. Remove: • The Left Connector Cover or the 42-inch model ⇒ See page 287. • The Electronics Module Extension the 60-inch model ⇒ See page 288. 3. Remove the Scan-Axis Motor ⇒ See page 346. 4. Remove the Left Spittoon ⇒ See page 328. 5. Remove the ISS ⇒ See page 321. 6. Disconnect the APS 1 (Top unit) valve electrical Removal & Installation connectors from the PCA. 7.
8. Unroute the APS 1 electrical connections from the left connector panel. Removal & Installation 9. Unroute the electrical connections from the printer. 10. Disconnect both air tubes from APS 1. 11. Remove one T-20 attachment screw from APS 1 (Top unit).
12. Remove APS 1 (Top unit) from the printer. 2 1 13. Remove the ISS ⇒ See page 321. 14. Disconnect the APS 2 (Top unit) valve electrical Removal & Installation connectors from the PCA. 15. Unclip the APS 2 electrical cable from the cable clamps in the left connector panel 16. Unroute the APS 2 electrical connection from the Media Path Cover Encoder.
17. Unroute the APS 2 electrical connection from the printer. 19. Remove one T-20 attachment screw from APS 1 (Top unit). 20.Remove APS 2 (Bottom unit) from the printer. 2 1 APS Assembly 327 Removal & Installation 18. Disconnect both air tubes from APS 2.
Left Spittoon Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover ⇒ See page 270. 2. Remove: • The Left Connector Cover or the 42-inch model ⇒ See page 287. • The Electronics Module Extension the 60-inch model ⇒ See page 288. 3. Remove the Scan-Axis Motor ⇒ See page 346. 4. Disconnect the Left Spittoon Fan cable from the Removal & Installation PrintMech PCA. 5. Unroute the Left Spittoon Fan cable.
6. Unroute the Left Spittoon Fan cable. 7. Remove two T-15 attachment screws (Type J) from the Scan-Axis Beam. 8. Remove two T-15 attachment screws from the Scan-Axis Beam. 9. Remove one T-15 attachment screw. Left Spittoon 329 Removal & Installation NOTE: Be very careful not to damage the encoder strip while removing the attachment screws.
10. Unclip the Spittoon attachment point so yo can rotate it in the next step. Removal & Installation 11. Rotate the Left Spittoon clockwise. 12. Remove the Left Spittoon from the Printer. NOTE: After installing the NEW Left Spittoon, make sure you perform the following Service Utility: • Reset life counter left spittoon ⇒ Chapter 4.
Encoder Strip and Encoder Sensor Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Left Cover ⇒ See page 270. 3. Uncap the Carriage Assembly by manually pulling out Removal & Installation the Printhead Maintenance Cartridges tray. 4. Lift the Primer and hold the Primer to its maximum position to avoid damaging it when you move the Carriage Assembly in the next step. 5. Move the Carriage Assembly out of the Service Station.
6. Remove one T-10 screw (Type I) that secures the Encoder Strip on the right hand side of the Printer. 7. Release the Encoder Strip from the locating pins on the Removal & Installation right hand side of the Printer. 8. Release the Spring Clip from the Bracket on the left hand side of the Printer. 1 2 9. Carefully pull the Encoder Strip out of the left hand side of the Printer. 10. Remove the Carriage PCA ⇒ See page 334.
11. Remove one T-8 (Type L) screw that secures the Encoder Sensor to the Carriage Assembly. Removal & Installation 12. Remove the plastic cover from the Encoder Sensor. 13. Remove the Encoder Sensor from the Printer. NOTE: After installing the NEW Encoder Strip and Encoder Sensor, make sure you perform the following Service Calibration: • Scan-Axis Calibration ⇒ Chapter 5.
Carriage PCA Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Press the two side of the Carriage PCA Cover and unclip from the Carriage Assembly. 1 2 Removal & Installation 1 3. Disconnect the Trailing Cable from the Carriage PCA. 4. Use a flat bladed screwdriver to release the ALL the clips, securing the Carriage Flex Cables to the Carriage Assembly, by pulling upwards.
5. Disconnect the Flex Cables from the Carriage PCA. 6. Disconnect the Line Sensor Cable and the Encoder 7. Disconnect the Color Sensor Cable from the Carriage PCA. 8. Push inwards the four clips that secure the Carriage PCA. Carriage PCA 335 Removal & Installation Sensor Cable from the Carriage PCA.
9. Remove the Carriage PCA from the Printer. NOTE: Once you have installed a NEW Carriage PCA, you MUST perform the following steps to ensure that the Printer will function correctly: 1. Power ON the Printer. 2. Execute the “Carriage Setup” Utility from the Service Utility Menu (Refer to Chapter 4 for more information). Removal & Installation 3. Install the Printheads once the Utility has been completed successfully. 4. Reset life counter Carriage PCA ⇒ Chapter 4.
Carriage Flex Cables Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Front Panel ⇒ See page 292. 3. Remove the Primer Assembly ⇒ See page 294. 4. Press the two side of the Carriage PCA Cover and 1 unclip from the Carriage Assembly. 2 5. Use a flat bladed screwdriver to release the ALL the clips, securing the Carriage Flex Cables to the Carriage Assembly, by pulling upwards. 6.
7. Remove eight T-8 screws (Type L) that secure the Carriage Flex Cables to the Carriage Assembly. 8. Open the Carriage Cover and remove ALL the Removal & Installation Printheads from the Carriage Assembly. 9. Remove the Carriage Flex Cable from the Printer.
Carriage Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Front Panel ⇒ See page 292. 3. Remove the Primer Assembly ⇒ See page 294. 4. Remove the Left Cover ⇒ See page 270. Removal & Installation 5. Remove the Encoder Strip ⇒ See page 331. 6. Pull out the Printhead Maintenance Cartridges tray. 7.
9. Press the two side of the Carriage PCA Cover and unclip from the Carriage Assembly. 1 2 1 Removal & Installation 10. Disconnect the Trailing Cable from the Carriage PCA. 11. Open the Carriage Cover and remove ALL the Printheads from the Carriage Assembly. 12. Remove five T-15 screws (Type G) that secure the Ink Supply Tubes to the Carriage Assembly.
13. Remove the Ink Supply Tubes from the Carriage Assembly and safely place to one side of the Printer. 15. Remove one T-20 screw (Type A) that secures the Belt Tensioner to the Chassis. 16. Lift the Primer and hold the Primer to its maximum position to avoid damaging it when you move the Carriage Assembly in the next step. Carriage Assembly 341 Removal & Installation 14. Disconnect the Aerosol Fan Tube from the Chassis.
17. Move the Carriage Assembly slightly away from the right Scan-Axis Bracket. 18. Release the Carriage Belt from the Scan-Axis Motor on Removal & Installation the left hand side of the Printer. 19. Remove one T-10 screw (Type C) that secure the Encoder Strip. 20.Remove four T-20 screws (Type N) that secure the right Scan-Axis Bracket.
21. Remove the right Scan-Axis Bracket from the Printer. 22. Remove the Carriage Stopper Screw (T-20) from the Removal & Installation Chassis. 23. Remove the Carriage Stopper from the Printer. 24.Slide the Carriage Assembly (including the belt) to the right and out of the Printer. 25. If the Carriage Assembly is to be replaced, make sure that you remove the Belt, the Carriage PCA, Color Sensor, Encoder and Line Sensors and the Cutter Assembly (in order to install them on the new Carriage Assembly).
• Reset life counter Carriage ME ⇒ Chapter 4. NOTE: After installing the NEW Carriage Assembly, make sure you perform the following Service Calibrations: Removal & Installation • Scan-Axis Calibration ⇒ Chapter 5. • Service Station Calibration ⇒ Chapter 5. • Line Sensor Calibration ⇒ Chapter 5.
Belt Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Left Cover ⇒ See page 270. 3. Remove the Top Cover ⇒ See page 277. 4. Remove the Encoder Strip ⇒ See page 331. 5. Remove the Carriage Assembly ⇒ See page 339. 6. Release the Belt from the bottom of the Carriage NOTE: After installing the NEW Belt Assembly, make sure you perform the following Service Utility: • Reset life counter scan cycles belt ⇒ Chapter 4.
Scan-Axis Motor Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Left Cover ⇒ See page 270. 3. Remove: • For the 42-inch model, the Left Connector Cover ⇒ See page 287. • For the 60-inch model, the Electronics Module Extension⇒ See page 288. 4. Uncap the Carriage Assembly by manually pulling out Removal & Installation the Printhead Maintenance Cartridges tray. 5.
6. Move the Carriage Assembly slightly away from the right Scan-Axis Bracket. 7. Remove one T-15 screw that secures the Belt Tensioner 8. Release the Carriage Belt from the Scan-Axis Motor on the left hand side of the Printer. 9. Disconnect the Scan-Axis Motor cable from the PrintMech PCA. Scan-Axis Motor 347 Removal & Installation to the Chassis.
10. Unroute the Scan-Axis Motor cable from the chassis. 11. Remove two T-20 screws (Type A) that secure the Scan-Axis Motor. Removal & Installation NOTE: Make sure you hold the Scan-Axis Motor securely when removing the screws. 12. Remove the Scan-Axis Motor from the Printer. NOTE: After installing the NEW Scan-Axis Motor, make sure you perform the following Service Utility: • Reset scan motor life counter ⇒ Chapter 4.
Media-Axis Motor Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover ⇒ See page 270. 2. Remove the Rear Door ⇒ See page 283. 3. Remove: • For the 42-inch model, the Left Connector Cover ⇒ See page 287. • For the 60-inch model, the Electronics Module Extension⇒ See page 288. 4. Disconnect the Media-Axis Motor cable from the 5. Detach the clamp of the ferrite core of the Media-Axis Motor cable from the printer chassis.
6. Remove the T-15 screws (Type R) identified (A) and loosen the T-15 screws (Type R) identified (B) that secure the Media-Axis Motor. B A Removal & Installation 7. Remove the Media-Axis Motor Bracket. 8. Remove two T-20 screws (Type B) that secure the Media-Axis Motor Bracket. 9. Remove the Media-Axis Motor from the Printer. NOTE: When reinstalling the parts, make sure you apply the grease (included with the support part) to the gears.
Optical Media Advance Sensor (OMAS) Removal WARNING!: Switch off the printer and remove the power cable. NOTE: The removal procedure differs depending on the Printer model, 42-inch or 60-inch. 42-inch model ONLY 1. Open the Rear Door. and go to step 4. 60-inch model ONLY 2. Remove the Left Cover ⇒ See page 270. Both models 4. Remove media if installed. 5. Squeeze the clips to unclip the Media Sensor from the Center Guide. 6. Let the Media Sensor hang below the Center Guide.
7. Squeeze the corners of the OMAS Access Cover release it from the bottom of the printer. Removal & Installation 8. Remove the OMAS Access Cover the printer. 9. Insert the T-20 thin bladed torx screwdriver (supplied with the replacement OMAS) into the access hole at the rear of the printer. 10. Remove and discard one T-20 screw which secures the OMAS horizontally to the printer.
11. From the bottom of the printer, remove and discard one T-20 screw which secures the OMAS vertically to the printer. 12. Carefully lower the OMAS from the printer as far as 13. Release the two locking clips of the large ribbon cable connector. 14. Disconnect the large ribbon cable from the OMAS. Optical Media Advance Sensor (OMAS) 353 Removal & Installation you can with the large ribbon cable still connected.
15. Remove the OMAS Sensor from the printer. Installation Removal & Installation NOTE: To simplify the installation of the OMAS an Attachment Screw Retainer has been added to hold the two T-20 attachment screws. This part is delivered attached to the replacement OMAS unit with the two attachment screws. It is also delivered as a separate part with the Center Platen in case the OMAS is completely removed during its replacement. 354 Chapter 8 Removal & Installation 1.
3. Lock the clips of the large ribbon cable connector. 4. Carefully push the OMAS fully up into its mounting so CAUTION: Make sure the OMAS is pushed completely up into its mounting or you will encounter an error during the OMAS calibration because it will not be able to focus on the paper. 5. Slide a sheet of paper over the OMAS window, if the paper is not stopped by the OMAS, repeat step 4 to ensure the OMAS is pushed fully up into its the mounting. 6.
7. Insert the T-20 thin bladed torx screwdriver into the access hole at the rear of the printer. 8. Fully tighten the T-20 horizontal attachment screw Removal & Installation which secures the OMAS to the printer. 9. Clip the Media Sensor to the Center Guide. 10. Clip the OMAS access cover back into place by sliding one edge of the cover into the slot and then applying enough pressure to it so you can clip it into the other slot. 11. Calibrate the OMAS ⇒ See page 167. 12.
Interconnect PCA Removal WARNING!: Switch off the printer and remove the power cable. 3. Remove three T-15 screws (Type A) that secure the Main PCA cover. 4. Remove the Main PCA Cover from the Printer. 1 2 Interconnect PCA 357 Removal & Installation 1. Remove the Right Connector Cover ⇒ See page 285. 2. Remove the JetDirect Card (if installed).
5. Remove six T-10 screws (Type I) that secure the Interconnect PCA Cover. Removal & Installation 6. Remove the Interconnect PCA Cover from the Printer. 7. Disconnect ALL cables from the Interconnect PCA. 8. Remove five T-10 screws (Type I) that secure the Interconnect PCA.
Removal & Installation 9. Remove the Interconnect PCA from the Printer.
EIO to PCA Interface Card Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Remove the Right Connector Cover ⇒ See page 285. 2. Remove the JetDirect Card (if installed). 3. Remove three T-15 screws (Type A) that secure the Main PCA cover. 4. Remove the Main PCA Cover from the Printer.
5. Remove one T-10 screw (Type I) that secures the Interface Card. 6. Disconnect the Interface Card from the Main PCA and Removal & Installation remove from the Printer.
OMAS Controller Card Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Remove the Right Connector Cover ⇒ See page 285. 2. Remove the JetDirect Card (if installed). 3. Remove three T-15 screws (Type A) that secure the Main PCA cover. 4. Remove the Main PCA Cover from the Printer.
5. Disconnect the OMAS Controller Card to OMAS ribbon cable. 6. Disconnect the OMAS Controller Card to PrintMech Removal & Installation and Sausalito PCI connection cables. 7. Remove one T-10 screw (Type I) that secures the OMAS Controller Card. 8. Disconnect the OMAS Controller Card from the Main PCA and remove from the Printer. CAUTION: To remove the OMAS Controller Card without damaging it on the Emodule cover, you will need disconnect it first and then rotate it slightly in the direction indicated.
OMAS Cable Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Right Connector Cover ⇒ See page 285. 3. Remove the Service Station ⇒ See page 300. 4. Remove the OMAS ⇒ See page 351. 5. Remove one T-15 screw that secures the OMAS Cable Removal & Installation clamp from the printer. 6. Remove the OMAS Cable clamp from the printer. 7. Carefully Pull the OMAS Cable out of the Vacuum Beam.
8. Disconnect the OMAS Cable form the OMAS Controller Card. 10. Unroute and remove the OMAS Cable from the Printer. OMAS Cable 365 Removal & Installation 9. Unroute the OMAS Cable from the Ferrite Core.
Installation CAUTION: It is critical that the OMAS Cable is correctly positioned in the Vacuum Beam so that it does not cause physical interference to the Media Sensor. The following illustration shows a cross-section of the Vacuum Beam with the OMAS Cable correctly routed to avoid interference to the Media Sensor. Platen OMAS Cable Removal & Installation OMAS Media Sensor OMAS Controller Card OMAS 1.
2. Position the OMAS Cable in the Vacuum Beam slot so that the blue reinforcement enters first. 3. Carefully feed the OMAS cable through the Vacuum 4. Slide the Ferrite Core and its associated Attachment Plate (on the top) onto the OMAS Cable. 5. Push the Attachment Plate into its slot in the Vacuum beam until it is level with the edge of OMAS installation position. OMAS Cable 367 Removal & Installation Beam sufficiently to have approximately 20 cm hanging from the OMAS installation position.
6. Carefully pull the OMAS Cable back into the Vacuum Beam (from the Service Station end) until the straight fold immediately before the first diagonal fold (from the OMAS sensor end) is aligned with the slot, fold the OMAS Cable across the diagonal fold, and install the cable clamp to lock the OMAS Cable in the correct position. 7. Route the OMAS Cable to the Ferrite Core in the Right Removal & Installation Interconnect panel. 8. Feed the OMAS Cable through Ferrite Core. 9.
Sausalito PCI PCA Removal WARNING!: Switch off the printer and remove the power cable. 3. Remove three T-15 screws (Type A) that secure the Main PCA cover. 4. Remove the Main PCA Cover from the Printer. 1 2 Sausalito PCI PCA 369 Removal & Installation 1. Remove the Right Connector Cover ⇒ See page 285. 2. Remove the JetDirect Card (if installed).
5. Disconnect the Trailing Cable from the Sausalito PCI PCA. 6. Disconnect ALL cables connected to the Sausalito PCI Removal & Installation PCA. 7. Remove one T-10 screw (Type I) that secures the Sausalito PCI PCA. 8. Disconnect the Sausalito PCI PCA from the Main PCA, unclip it, and remove it from the Printer.
CPU Fan Removal WARNING!: Switch off the printer and remove the power cable. 3. Remove three T-15 screws (Type A) that secure the Main PCA cover. 4. Remove the Main PCA Cover from the Printer. 1 2 CPU Fan 371 Removal & Installation 1. Remove the Right Connector Cover ⇒ See page 285. 2. Remove the JetDirect Card (if installed).
5. Disconnect the CPU Fan Cable from the Formatter PCA. 6. Remove four cross-head screws from the CPU Fan and Removal & Installation remove the CPU Fan. Installation 1. When installing the new CPU Fan it is important to ensure the correct orientation of the CPU Fan. There are two manufactures of fan available: AAVID Fans - AAVID Labels faces outwards when it is installed correctly. Delta Fans - CE Label faces inwards, towards the printer when it is installed correctly.
Memory Module Removal WARNING!: Switch off the printer and remove the power cable. 3. Remove three T-15 screws (Type A) that secure the Main PCA cover. 4. Remove the Main PCA Cover from the Printer. 1 2 Memory Module 373 Removal & Installation 1. Remove the Right Connector Cover ⇒ See page 285. 2. Remove the JetDirect Card (if installed).
5. Push the Memory Module Connector clips up and down to release the Memory Module. Removal & Installation 6. Remove the Memory Module from the Printer.
Main PCA Formatter Removal WARNING!: Switch off the printer and remove the power cable. CAUTION: Do NOT remove the Fan or the Processor (located under the Fan) from the Main PCA Formatter - The Fan and the Processor are part of the Main PCA Formatter support part and should be replaced as one assembly. 1. Remove the EIO to PCI Interface Card ⇒ See page 360. 2. Remove the Sausalito PCI PCA ⇒ See page 369. 3. Remove the Memory Module ⇒ See page 373. 4.
6. Release the plastic locating pin that secures the Main PCA Formatter. Removal & Installation 7. Remove the Main PCA Formatter from the Printer. NOTE: When installing the Main PCA Formatter, make sure that you first locate it on the plastic locating pin and then install the screws.
Hard Disk Drive (HDD) Removal WARNING!: Switch off the printer and remove the power cable. 3. Remove three T-15 screws (Type A) that secure the Main PCA cover. 4. Remove the Main PCA Cover from the Printer. 1 2 Hard Disk Drive (HDD) 377 Removal & Installation 1. Remove the Right Connector Cover ⇒ See page 285. 2. Remove the JetDirect Card (if installed).
5. Disconnect ALL cables connected to the Hard Disk Drive. Removal & Installation 6. Remove one T-10 screw (Type I) from the HDD Holder. 7. Slide the Hard Disk Drive upwards and remove from the Printer. 1 NOTE: It is not necessary to remove the screws securing the HDD inside the metal casing. 2 NOTE: After installing the NEW HDD, make sure you perform the following User Calibrations: • Printhead Alignment. • Paper Advance Calibration. • Color Calibration.
Power Supply Unit (PSU) Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover ⇒ See page 270. 1. Remove the Right Connector Cover ⇒ See page 281. 2. Remove: • For the 42-inch model, the Left Connector Cover ⇒ See page 287. • For the 60-inch model, the Electronics Module Extension⇒ See page 288. 4. Remove three T-15 screws (Type A) that secure the Main PCA cover. Power Supply Unit (PSU) 379 Removal & Installation 3. Remove the JetDirect Card (if installed).
5. Remove the Main PCA Cover from the Printer. 1 2 6. Remove three T-15 screws (Type A) that secure the PSU Removal & Installation cover. 7. Remove the PSU Cover from the Printer. 1 2 8. Disconnect the Power Supply and Interconnect cables from the PrintMech PCA.
9. Remove six T-10 screws (Type I) that secure the Interconnect PCA Cover. Removal & Installation 10. Remove the Interconnect PCA Cover from the Printer. 11. Disconnect one cable from the Interconnect PCA. 12. Disconnect two power supply cables from the Main PCA.
13. Disconnect one cable from Hard Disk Drive. 14. Squeeze both Cable Clamps to release from the Removal & Installation Electronics Module. 15. Lower the cables out of the way. 16. Unroute the Interconnect Cables disconnected in step 8 from below the Power Supply Unit.
17. Remove four T-10 screws (Type I) that secure the Power Supply Unit. 18. Route the cables through the hole in the Electronics Removal & Installation Module. 19. Remove the Power Supply Unit from the Printer.
PrintMech PCA Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove: • For the 42-inch model, the Left Connector Cover ⇒ See page 287. • For the 60-inch model, the Electronics Module Extension⇒ See page 288. 2. Remove three T-15 screws (Type A) that secure the PSU Removal & Installation cover. 3. Remove the PSU Cover from the Printer. 1 2 4. Slide the PrintMech Cover out of the Printer.
5. Disconnect ALL cables from the PrintMech PCA. 6. Remove eight T-10 screws (Type I) that secure the Removal & Installation PrintMech PCA. 7. Remove the PrintMech PCA from the Printer.
Formatter Battery Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Remove the Right Connector Cover ⇒ See page 285. 2. Remove the JetDirect Card (if installed). 3. Remove three T-15 screws (Type A) that secure the Main PCA cover. 4. Remove the Main PCA Cover from the Printer.
5. Push the clip down and release the battery from the Main PCA.
Electronics Module Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Connector Cover ⇒ See page 285. 2. Remove the Left Connector Cover: • For the 42-inch model ⇒ See page 287. • For the 60-inch model ⇒ See page 288. 3. Disconnect ALL the cables connected to the right Removal & Installation Interconnect PCA and the Sausalito PCI PCA. 4. Unroute all the disconnected cables so they are clear of the Electronics Module. x 388 Chapter 8 Removal & Installation 5.
6. Remove two T-20 screws (Type B) that secure the left side Electronics Module. 7. Lift the Electronics Module sufficiently (approximately Removal & Installation 2 cm) to release it from the attachments. 8. Remove the Electronics Module from the Printer. 9.
Line Sensor Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Press the two side of the Carriage PCA Cover and 1 unclip from the Carriage Assembly. 2 Removal & Installation 1 3. Release the clip and disconnect the Line Sensor cable from the Carriage PCA. 4. Remove one T-15 screw (Type G) that secures the Line Sensor to the carriage Assembly.
5. Remove the Line Sensor from the Carriage Assembly. 6. Remove the protective foam from around the sensor. NOTE: After installing the NEW Line Sensor, make sure you perform the following Service Calibrations: Removal & Installation • Line Sensor Calibration ⇒ Chapter 5.
Color Sensor Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Open the Window. 2. Remove the Right Cover ⇒ See page 264. 3. Remove the Left Cover ⇒ See page 270. 4. Uncap the Carriage Assembly by manually pulling out Removal & Installation the Printhead Maintenance Cartridges tray. 5. Lift the Primer and hold the Primer to its maximum position to avoid damaging it when you move the Carriage Assembly in the next step. 6.
7. Move the Carriage to the fully left position. 8. Press the two sides of the Carriage PCA Cover, unclip it 9. Release the clip and disconnect the Color Sensor cable from the Carriage PCA. 10. Move the carriage sufficiently to the right to gain access the Color Sensor attachment screws. Color Sensor Assembly 393 Removal & Installation from the Carriage Assembly and remove it.
11. Remove two T-15 screw (Type G) that secures the Color Sensor to the carriage Assembly. Removal & Installation 12. Tilt the Color Sensor so it can be removed. 13. Remove the Color Sensor from the Carriage Assembly.
Color Sensor Actuator Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover ⇒ See page 270. 2. Remove the Left Spittoon ⇒ See page 328. 3. Slide out the top row of Ink Cartridges from the Ink Removal & Installation Supply Station 4. Disconnect the Color Sensor Actuator Assembly. 5. Remove one T-15 screw (Type G) that secures the Color Sensor Actuator Assembly to the printer.
6. Remove the Color Sensor Actuator Assembly to the printer.
Media Deflector Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove two T-20 screw (Type B) that secures the 2. Remove the Media Deflector (slide upwards first) from the Printer. 1 2 Media Deflector 397 Removal & Installation Media Deflector that needs to be replaced.
Output Platen Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Open the Window. 2. Remove four T-15 screws and two cross-head screws that secure the Output Platen. 3. Release the clips on the left and right hand sides of the Front Platen.
4. Pull out the right hand side of the Front Platen. 5. Carefully slide the Front Platen to the right and then 1 2 NOTE: If a NEW Front Platen is to be installed, make sure that you first remove ALL Media Deflectors (See page 397) from the OLD Front Platen and install them on the New Front Platen. Output Platen 399 Removal & Installation remove from the Printer.
Center Platen Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Left Cover ⇒ See page 270. 3. Remove the Top Cover ⇒ See page 277. 4. Remove the Service Station ⇒ See page 300. 5. For the 42-inch model, remove the Rear Door ⇒ See page 281. 6. Squeeze the corners of the OMAS Access Cover Removal & Installation release it from the bottom of the printer. 7.
8. Insert the T-20 thin bladed torx screwdriver (supplied with the replacement OMAS) into the access hole at the rear of the printer. Loosen approximately two turns the T-20 screw which secures the OMAS horizontally to the printer. 10. From the bottom of the printer, loosen approximately two turns the T-20 screw which secures the OMAS vertically to the printer. 11. Remove one T-15 screw (Type P) that secures the Center Platen Gear. Center Platen 401 Removal & Installation 9.
12. Remove the Center Platen Gear from the Printer. Removal & Installation 13. Remove one T-15 screw that secures the small Gear. 14. Remove the small Gear from the Printer. 15. Remove the two small Platen Gears by releasing the clips.
16. Remove two T-20 screws (Type Q) that secure the Gear Bracket. Removal & Installation 17. Remove the Gear Bracket from the Printer. 18. Move the Carriage Assembly fully to the right. 19. Remove all the T-10 screws (Type C) that secure the Center Platen: • 80 T-10 screws for the 42-inch model • 116 T-10 screws for the 60-inch model.
20.Remove the Secondary Spittoon Blank. 2 1 Removal & Installation 21. Remove the Center Platen from the Printer.
Installation of the Foams Removal & Installation Before installing the Center Platen, make sure you check the foams that are stuck on the Vacuum Beam. These foams should ONLY be changed if they are damaged. In the circumstance where they do need to be changed, use the following illustrations to guide you: Foams will need to be trimmed when stuck to the Vacuum Beam NOTE: Make sure you take note of the positions of the Foams located underneath the center Platen.
page 351. 2. Install the Center Platen. NOTE: When reinstalling the parts, make sure you apply the grease (included with the support part) to the gears. 3. Position the Attachment Screw Retainer on the OMAS and secure it with the T-8 attachment screw provided with Center Platen. Removal & Installation 4. Verify that the two T-20 attachment screws are correctly positioned in the Attachment Screw Retainer. 5.
6. Lock the clips of the large ribbon cable connector. Carefully push the OMAS fully up into its mounting so it protrudes slightly (approximately 0.1 mm) above the Center Platen. To ensure the OMAS is correctly positions, slide a sheet of paper over the Platen Ribs until it is stopped by the OMAS. This ensures the OMAS is protruding slightly above the platen.
10. Insert the T-20 thin bladed torx screwdriver into the access hole at the rear of the printer. 11. Fully tighten the T-20 horizontal attachment screw Removal & Installation which secures the OMAS to the printer. 12. Clip the Media Sensor to the Center Guide. 13. Clip the OMAS access cover back into place by sliding one edge of the cover into the slot and then applying enough pressure to it so you can clip it into the other slot. 14. Calibrate the following: • OMAS ⇒ See page 167.
Cartridge Tray Removal WARNING!: Switch off the printer and remove the power cable. 1. Release the Tray Lever of the required color and pull Removal & Installation out the Tray. 2. Remove the Ink Cartridge if installed. 3. Press down on the Tray clip.
4. Pull the Tray completely out of the Printer. Removal & Installation NOTE: Note that each Cartridge Tray is different even though they look very similar. When selecting the Cartridge Tray from the Support Part (it contains eight Cartridge Trays), choose the Tray that exactly matches the one that you have just removed.
Input Roller Removal WARNING!: Switch off the printer and remove the power cable. 1. Raise the right lever to release the right hand end of the 2. Pull out the right hand end of the Input Roller from the Printer. 3. Move the Input Roller to the right to disengage it from the Printer. Input Roller 411 Removal & Installation Input Roller.
Removal & Installation 4. Remove the Input Roller from the Printer.
Maintenance Cartridge Door Removal WARNING!: Switch off the printer and remove the power cable. 2. Unclip and remove the Maintenance Cartridge Door from Right Cover. Maintenance Cartridge Door 413 Removal & Installation 1. Open the Maintenance Cartridge Door.
Maintenance Cartridge Door Sensor Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Disconnect the Maintenance Cartridge Door Sensor Removal & Installation cable. 3. Release one T-10 screw the attaches the Maintenance Cartridge Door Sensor assembly to the printer. 4. Remove the Maintenance Cartridge Door Sensor assembly to the printer.
Media Sensor Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Rear Door ⇒ See page 283. 2. Remove the Right Connector Cover ⇒ See page 285. 3. Disconnect the Media Sensor cable from the 4. Release the Media Sensor cable from the clip located on the Electronics Module. 5. Unclip the Media Sensor from the Center Guide. Media Sensor 415 Removal & Installation Interconnect PCA.
6. Pull the cable and connector through the mounting hole Removal & Installation and remove the Media Sensor from the Printer.
Encoder Disc and Sensor Removal WARNING!: Switch off the printer and remove the power cable. CAUTION: Please handle the Encoder Disc very carefully since any finger prints, scratches or stains could cause the Printer to malfunction. 1. Remove the Left Cover ⇒ See page 270. 2. Remove: • For the 42-inch model, the Left Connector Cover ⇒ See page 287. • For the 60-inch model, the Electronics Module Extension⇒ See page 288. Removal & Installation 3. Remove the Ink Supply Station ⇒ See page 321. 4.
6. Release the Encoder Sensor cable from the clip located on the Encoder Disc Cover. 7. Unclip the Encoder Disc Cover and remove from the Removal & Installation Printer. 8. Remove one T-8 screw (Type D) that secures the Encoder Sensor to the Chassis. 9. Remove the Encoder Sensor from the Printer.
Removal & Installation 10. Carefully peel the Encoder Disc from the Drive Roller.
Media Lever Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. Removal & Installation 2. Remove the Rear Door ⇒ See page 283. 3. Raise the Media Lever. 4. Remove one T-15 screw (Type F) that secures the Linkage to the Spring. 5. Remove the Linkage from the Spring.
6. Remove one T-20 screw (Type A) that secures the Spring to the Spacer. 8. Raise the Media Lever to gain access to the linkage attachment screw. 9. Remove one T-15 screw (Type F) that secures the Media Lever to the Linkage. Media Lever Assembly 421 Removal & Installation 7. Remove the Spring and plastic washer.
10. Remove the Media Lever Linkage from the Printer. 11. Remove one T-20 screw (Type O) that secures the Removal & Installation Media Lever to the Right Trim. 12. Raise the Media Lever. 13. Remove the Media Lever from the Printer.
Media Lever Sensor Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Right Trim ⇒ See page 267. 3. Remove the Right Connector Cover ⇒ See page 281. 4. Remove the Output Platen ⇒ See page 398. 5. Disconnect the Media Lever Sensor cable from the 6. Unroute the Media Lever Sensor cable from the cable clamp. 7. Release the Media Lever Sensor Cable from the three clips on the Vacuum Fan.
Removal & Installation 8. Remove the Media Lever Sensor from the Printer.
Pinchwheel Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Rear Door ⇒ See page 283. 5. Remove one T-20 screw that secures the Linkage to the Spring. 6. Disconnect the linkage from the Pinch Wheel cam-arm. Pinchwheel Assembly 425 Removal & Installation 3. Remove the Service Station ⇒ See page 300. 4. Raise the Media Lever.
7. Disconnect the spring from the Pinch Wheel cam-arm. 8. Remove one T-20 screw that secures the Cam to the Removal & Installation Cam Lever. 9. Insert a plastic stud in to each Pinchwheel Subassembly (the Plastic Studs can be found in the replacement Pinchwheel Assembly kit). 10. For the 60-inch model, remove one T-20 screw that secures the attachment plate to the center Pinchwheel Subassembly.
11. For the 60-inch model, remove the attachment plate from the center Pinchwheel Subassembly. 12. Remove two T-20 screws (Type M) from each Pinchwheel Subassembly (a 90 degree angle screwdriver is included with the replacement Pinchwheel Assembly). 13. Remove the complete Pinchwheel Assembly (including the Cam and Cam Lever) from the Printer. NOTE: Before installing the NEW Pinchwheel Assembly, insert the plastic studs in to each Pinchwheel subassembly.
Removing individual Pinchwheel Rollers 1. To remove an individual Pinchwheel roller, push apart Removal & Installation the metal part that secures the Pinchwheel roller and then pull out the individual Pinchwheel roller.
Important Information on Installation of Pinchwheels Removal & Installation The Pinchwheel Assembly contains 3 white Pinchwheels and several black Pinchwheels.
Center Guide Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Left Cover ⇒ See page 270. 3. Remove the Primer Assembly ⇒ See page 294. 4. Remove the Right Connector Cover ⇒ See page 281. 5. Remove: • For the 42-inch model, the Left Connector Cover ⇒ See page 287. • For the 60-inch model, the Electronics Module Extension⇒ See page 288. Removal & Installation 6. Remove the Service Station ⇒ See page 300. 7.
11. Remove two T-20 screws (Type B) that secure the right side Electronics Module. 12. Remove two T-20 screws (Type B) that secure the left side Electronics Module. 13. Lift the Electronics Module sufficiently (approximately 2 cm) to release it from the attachments. 14. Remove the Electronics Module from the Printer.
15. Remove one T-15 screw (Type E) and two T-20 screws (Type A), that secure the Center Guide, from the right hand side of the Printer. Type E Type A 16. Remove two T-15 screws (Type E), that secure the Removal & Installation Center Guide, from the left hand side of the Printer. 17. Remove one T-15 screw (Type S), that secures the Center Guide, from underneath the Printer. 18. Remove the Center Guide from the Printer.
Drive Roller Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover ⇒ See page 264. 2. Remove the Left Cover ⇒ See page 270. 3. Remove the Right Connector Cover ⇒ See page 281. 4. Remove: • For the 42-inch model, the Left Connector Cover ⇒ See page 287. • For the 60-inch model, the Electronics Module Extension⇒ See page 288. 5. Remove the Service Station ⇒ See page 300. 7. Remove the Media-Axis Motor ⇒ See page 349. 8.
14. Remove one T-20 screw (Type B) that secures the cover on the right hand side of the Printer. Removal & Installation 15. Remove the Cover. 16. Remove three T-20 screws that secure the cover on the left hand side of the Printer. 17. Remove the Cover.
18. Remove T-20 screws that secure the Media-Axis Motor Bracket to the side-plate. 19. Remove two T-20 screws (Type A) that secure the 20.Remove the Media-Axis Motor Bracket from the Printer. 21. For the 60-inch model, use a flat bladed screwdriver to unclip the Roller Middle Support Cover. Drive Roller 435 Removal & Installation Media-Axis Motor Bracket to the Chassis.
22. For the 60-inch model, rotate the Roller Middle Support Cover vertically. 23. For the 60-inch model, release the Roller Middle Removal & Installation Support Cover from its attachment point. 24.For the 60-inch model, remove the Roller Middle Support Cover. 25. Remove the Drive Roller by sliding it to the right, then downwards and then out of the Printer. 1 2 NOTE: When reinstalling the parts, make sure you apply the grease (included with the support part) to the gears.
Installation of the Drive Roller When installing the Drive Roller, several different datums have to be met in order to ensure that the Drive Roller has no axial play. Use the following illustrations to ensure that ALL the datums are met: Media-Axis Motor Bracket Drive Roller Bearing Sideplate 1 2 1 1. Datum between Media-Axis Motor Bracket and Drive Roller Bearing 2. Datum between Media-Axis Motor Bracket and Sideplate 3 Removal & Installation 3.
instructions: 1. Place the Media-Axis Motor Bracket in the correct position on the Printer. Make sure you keep it pushed down (as shown in the illustration) until the first screw has been installed and fully tightened. 2. Install the first screw (T-15) in the position shown. Make Removal & Installation sure you tighten the screw fully so that the Media-Axis Motor Bracket cannot be moved. 3. Check that there is no play (movement) between the Media-Axis Motor Bracket and the Drive Roller.
Right Rollfeed Module Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Input Roller ⇒ See page 411. 2. Remove the Media Spindle (if installed). 3. Remove four T-20 screws that secure the Right Rollfeed 4. Remove the Right Rollfeed Module from the Printer. Right Rollfeed Module Assembly 439 Removal & Installation Module.
Left Rollfeed Module Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover ⇒ See page 270. 2. Remove the Ink Supply Station ⇒ See page 321. 3. Remove the Input Roller ⇒ See page 411. 4. Remove the APS Assembly ⇒ See page 324. 5. Remove the Left Spittoon ⇒ See page 328. 6. Remove the Media Spindle (if installed). 7. Remove one T-15 screw that secures the APS Mounting Removal & Installation Plate to the Printer. 8.
9. Remove the APS Mounting Plate support from the Printer. 10. Remove four T-20 screws that secure the Left Rollfeed Removal & Installation Module to the Printer. 11. Remove the Left Rollfeed Module from the Printer.
Take-Up Reel Motor Removal WARNING!: Switch off the printer and remove the power cable. 1. Close the Paper Bin (if open). 2. Disconnect the Take-Up Reel Motor from the Parallel Removal & Installation Port on the rear of the printer. 3. Remove the two rear T-20 screws that attach the TakeUp Reel Motor to the Right Leg Assembly. 4. Loosen the two front T-20 screws that attach the TakeUp Reel Motor to the Right Leg Assembly.
5. Disconnect the Take-Up Reel Sensors from the Take-Up Reel Motor. 6. Lift the Take-Up Reel Motor sufficiently so you can remove it from the Right Leg Assembly.
Take-Up Reel Left Hand Module Removal WARNING!: Switch off the printer and remove the power cable. 1. Close the Paper Bin (if open). 2. Remove one rear T-20 screws that attaches the Take-Up Removal & Installation Reel Left Hand Module to the Left Leg Assembly. 3. Loosen the two front T-20 screws that attach the TakeUp Reel Left Hand Module to the Left Leg Assembly. 4. Lift the Take-Up Reel Left Hand Module sufficiently so you can remove it from the Left Leg Assembly.
Take-Up Reel Deflector Supports Removal WARNING!: Switch off the printer and remove the power cable. 3. Remove the two T-20 screws that attach the Left Hand Deflector Support to the Left Leg Assembly. 4. Remove the Left Hand Deflector Support. Take-Up Reel Deflector Supports 445 Removal & Installation 1. Close the Paper Bin (if open). 2. Remove the Take-Up Reel Deflector from the printer.
5. Remove the two T-20 screws that attach the Right Hand Deflector Support to the Right Leg Assembly. Removal & Installation 6. Remove the Right Hand Deflector Support.
Take-Up Reel Sensors Removal WARNING!: Switch off the printer and remove the power cable. 3. Remove the blue thumbscrew that attaches the Take-Up Reel Sensors to the Right Foot Assembly. 4. Slide the Take-Up Reel Sensors off the Right foot Assembly. Take-Up Reel Sensors 447 Removal & Installation 1. Close the Paper Bin (if open). 2. Disconnect the Take-Up Reel Sensors.
5. Remove one T-15 screw that attaches the cover of the receiver sensor to the housing. Removal & Installation . 6. Remove the cover of the receiver sensor to the housing. 7. Disconnect the connector from the receiver sensor. 8. Remove the receiver sensor from the housing.
9. Unroute the Take-Up Reel Transmitter Sensor cable. 10. Unrclip and remove the Take-Up Reel Transmitter Removal & Installation Sensor from the X-Brace Assembly.
Removal & Installation 450 Chapter 8 Removal & Installation
Preventive Maintenance • • • • • • • • • • • • Moisture on the Printer ........................................................................................452 Noisy Carriage Bushing......................................................................................452 Belt Swelling......................................................................................................452 Cleaning the Printer............................................................................................
Preventive Maintenance Moisture on the Printer Users should use the Printer in an environment between 20% and 80% relative humidity. To recover from moisture condensation, turn the Printer Off, and, using the main roller as a reference, wait until the Printer is completely dry before using it again. Noisy Carriage Bushing To prevent noisy movement of the carriage, remove aluminum or dust particles from the bushing at the back of the carriage, and from the slider path along which the bushing moves.
Cleaning the Platen CAUTION: If wide paper is used to print after narrower paper is used for some time, you may find that the left hand side of the Center Platen has become dirty and will leave marks on the back of the paper if not cleaned. It is recommended to clean the Center Platen on a regular basis (at least every few months or when required) as follows: 1. Unload any media loaded from the Printer. 2.
4. Clean the Cutter ramp with the damp cloth. 5. Clean the exposed part of the wheels with a dry cloth. Ideally, clean the whole circumference of these wheels (you can use Turn Drive Roller Utility on page 134).
number Q6715A (HP Designjet Z6100 User Maintenance Kit). NOTE: When the message is displayed on the Front Panel, a ‘silent’ warning message is added within the system error log ‘8:01’. This helps when reviewing the error log history, to see if the message has been displayed. Cleaning Procedure From the Customer Preventative Maintenance Kit use the cloth shown. 2. Make sure that the printer is idle and that Carriage Assembly is in the area of the Service Station on the right side of the printer. 3.
Preventive Maintenance 5. Hold the cloth in an inverted u shape around the encoder strip. 6. Carefully wipe along the length of the Encoder Strip until there is no ink residue remaining on the Encoder Strip. Do not remove the Carriage Assembly from the Service Station yet. 7. Use enough force to remove the ink residue but be very careful not to scratch the Encoder Strip with your fingernail or any other object. 8. Lower the Printer Window. 9.
10. Switch Off the Printer from the back. 11. Open the Printer Window and move the Carriage Assembly further to the left. Preventive Maintenance 12. Clean the part of the Encoder Strip inside the Service Station. 13. Close the Printer Window and turn On the printer. 14.
Use a clean, absorbent, lint-free cloth that you have slightly dampened with isopropyl alcohol to very gently wipe any dust and loosened ink deposits from the sensor window. Applying Oil to the Overdrive Preventive Maintenance Occasionally, it maybe necessary to oil the Overdrive in order to stop the rollers from squeaking: 1. Open the Window. 2. There are small holes in the Center Platen beside some of the rollers. 3. A bottle of oil is supplied with the Maintenance Kit.
Change the maintenance absorber An alert appears on the printer front panel when the maintenance absorber is reaching its maximum saturation and again when the absorber should be changed. CAUTION: The absorber can become excessively dry and fail to function correctly in climates where the relative humidity is consistently below 25%. CAUTION: A saturated or excessively dry maintenance absorber can cause severe damage to the printheads and other parts of the printer.
7. Lift the tab on the absorber until it is clear of the spittoon and you can easily grip the tab. 8. Lift and remove the absorber from the spittoon. 9. Dispose of the soiled maintenance absorber according to your local regulations. Preventive Maintenance Insert the maintenance absorber 1. Grip the new maintenance absorber as shown. 2. Insert the back edge of the absorber into the fitting in the spittoon. 3. Use your thumb to slide the absorber to the back of the fitting in the spittoon. 4.
“Maintenance #1 required” The following message is triggered depending on the total quantity of ink spitted in each Spittoon. “Maintenance #2 required” Once one of the maintenance advised messages is displayed, the preventive maintenance kit must be used to replace the most worn parts of the printer. Use the Removal and Installation Chapter of this Service Manual as a guide to replace the necessary parts.
Preventive Maintenance 462 Chapter 9 Preventive Maintenance
