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DesignJets 500, 510 and 800 SeriesService ManualHP Large-Format Printers

Table of Contents8HP DesignJets 500, 510 and 800 Series Printers Service ManualPinch-Arm Sensor 8-71Fork Idler, Tensioner and Idler Pulley 8-74Encoder

5-1HP DesignJets 500, 510 and 800 Series Printers Service Manual5Service Calibrations 5Service Calibrations 5-2Entering the Service Calibrations Men

Service Calibrations5-2HP DesignJets 500, 510 and 800 Series Printers Service ManualService CalibrationsThe following is a list of all internal servic

Service Calibrations 5-3HP DesignJets 500, 510 and 800 Series Printers Service ManualEntering the Service Calibrations Menu1 Press the ↑ or ↓ key unti

Service Calibrations5-4HP DesignJets 500, 510 and 800 Series Printers Service Manual4 Press the Enter key to begin a specific calibration when the req

Service Calibrations 5-5HP DesignJets 500, 510 and 800 Series Printers Service ManualPrinthead Alignment (includes PPS Calibration)The purpose of the

Service Calibrations5-6HP DesignJets 500, 510 and 800 Series Printers Service Manual2 The following message will appear asking you if you want to perf

Service Calibrations 5-7HP DesignJets 500, 510 and 800 Series Printers Service ManualColor CalibrationThe purpose of this Calibration is to calibrate

Service Calibrations5-8HP DesignJets 500, 510 and 800 Series Printers Service ManualIf the calibration fails, then the following message will appear o

Service Calibrations 5-9HP DesignJets 500, 510 and 800 Series Printers Service ManualAdvance CalibrationThe purpose of this Service Calibration is to

Service Calibrations5-10HP DesignJets 500, 510 and 800 Series Printers Service Manual5 The following drawing shows you the pattern that will be printe

1-1HP DesignJets 500, 510 and 800 Series Printers Service ManualTroubleshooting 1Introduction 1-2Troubleshooting System Error Codes 1-3Performing a

Service Calibrations 5-11HP DesignJets 500, 510 and 800 Series Printers Service ManualFactory Advance CalibrationThe purpose of this Service Calibrati

Service Calibrations5-12HP DesignJets 500, 510 and 800 Series Printers Service Manual3 If media is not loaded, the following message appears on the fr

Service Calibrations 5-13HP DesignJets 500, 510 and 800 Series Printers Service Manual7 Re-enter the Advance Calibration and select "Measure patt

6-1HP DesignJets 500, 510 and 800 Series Printers Service Manual6Print Quality 6Print Quality 6-2Print Quality Troubleshooting Checklist 6-2How to

Print Quality6-2HP DesignJets 500, 510 and 800 Series Printers Service ManualPrint QualityPrint Quality Troubleshooting ChecklistWhen faced with a Pri

Print Quality 6-3HP DesignJets 500, 510 and 800 Series Printers Service Manualthe Printer as indicated previously.  If the output obtained using the

Print Quality6-4HP DesignJets 500, 510 and 800 Series Printers Service ManualHow to Use the Troubleshooting ProcedureWhat is the Troubleshooting Proce

Print Quality 6-5HP DesignJets 500, 510 and 800 Series Printers Service Manual2Press the ↑ or ↓ key until the front panel highlights Troubleshooting a

Print Quality6-6HP DesignJets 500, 510 and 800 Series Printers Service Manualthe front panel, indicate whether there are problems with them. The sorts

Print Quality 6-7HP DesignJets 500, 510 and 800 Series Printers Service ManualTroubleshooting Procedure FlowchartPrinter checks whether Printhead

Troubleshooting1-2HP DesignJets 500, 510 and 800 Series Printers Service ManualGuide to Troubleshooting the PrinterIntroductionThis chapter will guide

Print Quality6-8HP DesignJets 500, 510 and 800 Series Printers Service ManualNo Printing Defects Found Using the Troubleshooting ProcedureIf all the t

Print Quality 6-9HP DesignJets 500, 510 and 800 Series Printers Service ManualSolving Color Accuracy problems These are two areas you should review wh

Print Quality6-10HP DesignJets 500, 510 and 800 Series Printers Service ManualMediaAlways make sure that the customer is using the appropriate media f

7-1HP DesignJets 500, 510 and 800 Series Printers Service Manual7Parts and Diagrams 7Printer Support 7-2Right Hand Cover 7-4Left Hand Cover 7-6Top

Parts and Diagrams7-2HP DesignJets 500, 510 and 800 Series Printers Service ManualPrinter SupportPrinter Support for HP DesignJet 500 and 800 SeriesRe

Parts and Diagrams 7-3HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 1: Printer Support4331225Bin Flint on the HPDesignJet 500 an

Parts and Diagrams7-4HP DesignJets 500, 510 and 800 Series Printers Service ManualRight Hand CoverRight Hand Cover for HP DesignJet 500 and 800 Series

Parts and Diagrams 7-5HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 2: Right Hand Cover41235

Parts and Diagrams7-6HP DesignJets 500, 510 and 800 Series Printers Service ManualLeft Hand CoverLeft Hand CoverReferenceonDrawingHP Part Number Quant

Parts and Diagrams 7-7HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 3: Left Hand Cover12323

Troubleshooting 1-3HP DesignJets 500, 510 and 800 Series Printers Service ManualNOTE The layout shown below will be used to refer to both types of fro

Parts and Diagrams7-8HP DesignJets 500, 510 and 800 Series Printers Service ManualTop Cover and DeflectorsTop Cover and DeflectorsReferenceonDrawingHP

Parts and Diagrams 7-9HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 4: Top Cover and Deflectors2134

Parts and Diagrams7-10HP DesignJets 500, 510 and 800 Series Printers Service ManualRollfeed ModuleRollfeed ModuleReferenceonDrawingHP Part Number Quan

Parts and Diagrams 7-11HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 5: Rollfeed Module11322

Parts and Diagrams7-12HP DesignJets 500, 510 and 800 Series Printers Service ManualBack Platen AssemblyBack Platen AssemblyReferenceonDrawingHP Part N

Parts and Diagrams 7-13HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 6: Back Platen Assembly123

Parts and Diagrams7-14HP DesignJets 500, 510 and 800 Series Printers Service ManualElectronics ModuleElectronics ModuleReferenceonDrawingHP Part Numbe

Parts and Diagrams 7-15HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 7: Electronics Module1243page for more detailsRefer to the

Parts and Diagrams7-16HP DesignJets 500, 510 and 800 Series Printers Service ManualCooling FanNOTE The cooling fan orientation for the HP DesignJet 50

Parts and Diagrams 7-17HP DesignJets 500, 510 and 800 Series Printers Service ManualPower SupplyPower SupplyReferenceonDrawingHP Part Number Quantity

Troubleshooting1-4HP DesignJets 500, 510 and 800 Series Printers Service ManualSolving Print Quality ProblemsThe Printer contains an internal Troubles

Parts and Diagrams7-18HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 8: Power Supply21

Parts and Diagrams 7-19HP DesignJets 500, 510 and 800 Series Printers Service ManualCutter AssembliesCutter AssembliesReferenceonDrawingHP Part Number

Parts and Diagrams7-20HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 9: Cutter Assemblies1344562

Parts and Diagrams 7-21HP DesignJets 500, 510 and 800 Series Printers Service ManualInk Delivery SystemInk Delivery SystemReferenceonDrawingHP Part Nu

Parts and Diagrams7-22HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 10: Ink Delivery System4123

Parts and Diagrams 7-23HP DesignJets 500, 510 and 800 Series Printers Service ManualService Station and SpittoonService Station and SpittoonReferenceo

Parts and Diagrams7-24HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 11: Service Station and Spittoon132

Parts and Diagrams 7-25HP DesignJets 500, 510 and 800 Series Printers Service ManualService Station HolderService Station HolderReferenceonDrawingHP P

Parts and Diagrams7-26HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 12: Service Station Holder254163

Parts and Diagrams 7-27HP DesignJets 500, 510 and 800 Series Printers Service ManualPinch-Wheel Assemblies* Pinch Arm Mechanism includes the Pinch Arm

Troubleshooting 1-5HP DesignJets 500, 510 and 800 Series Printers Service ManualTroubleshooting Paper-Axis ShutdownsA Paper-Axis shutdown can happen w

Parts and Diagrams7-28HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 13: Pinch-Wheel Assemblies51234

Parts and Diagrams 7-29HP DesignJets 500, 510 and 800 Series Printers Service ManualScan-Axis MotorScan-Axis MotorReferenceonDrawingHP Part Number Qua

Parts and Diagrams7-30HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 14: Scan-Axis Motor12

Parts and Diagrams 7-31HP DesignJets 500, 510 and 800 Series Printers Service ManualDrive Roller Encoder SensorDrive Roller Encoder SensorReferenceonD

Parts and Diagrams7-32HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 15: Drive Roller Encoder Sensor1234

Parts and Diagrams 7-33HP DesignJets 500, 510 and 800 Series Printers Service ManualPrint Platen AssemblyPrint Platen AssemblyReferenceonDrawingHP Par

Parts and Diagrams7-34HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 16: Print Platen Assembly12

Parts and Diagrams 7-35HP DesignJets 500, 510 and 800 Series Printers Service ManualCarriage AssemblyCarriage AssemblyReferenceonDrawingHP Part Number

Parts and Diagrams7-36HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 17: Carriage Assembly12345

Parts and Diagrams 7-37HP DesignJets 500, 510 and 800 Series Printers Service ManualVacuum FanVacuum FanReferenceonDrawingHP Part Number Quantity Desc

Troubleshooting1-6HP DesignJets 500, 510 and 800 Series Printers Service ManualProblems with the Vacuum FanIf you have problems loading either Roll or

Parts and Diagrams7-38HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 18: Vacuum Fan1

Parts and Diagrams 7-39HP DesignJets 500, 510 and 800 Series Printers Service ManualInterconnect CableInterconnect CableReferenceonDrawingHP Part Numb

Parts and Diagrams7-40HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 19: Interconnect Cable1

Parts and Diagrams 7-41HP DesignJets 500, 510 and 800 Series Printers Service ManualPaper-Axis MotorPaper-Axis MotorReferenceonDrawingHP Part Number Q

Parts and Diagrams7-42HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 20: Paper-Axis Motor12

Parts and Diagrams 7-43HP DesignJets 500, 510 and 800 Series Printers Service ManualDrive RollerDrive RollerReferenceonDrawingHP Part Number Quantity

Parts and Diagrams7-44HP DesignJets 500, 510 and 800 Series Printers Service ManualFigure 21: Drive Roller123

Parts and Diagrams 7-45HP DesignJets 500, 510 and 800 Series Printers Service ManualMiscellaneous ItemsMiscellaneous ItemsReferenceonDrawingHP Part Nu

8-1HP DesignJets 500, 510 and 800 Series Printers Service Manual8Removal and Installation8Screw Types 8-4Left Hand Cover 8-5Right Hand Cover 8-7Fr

Removal and Installation8-2HP DesignJets 500, 510 and 800 Series Printers Service ManualIntroductionThis chapter is a step by step guide to the remova

Troubleshooting 1-7HP DesignJets 500, 510 and 800 Series Printers Service ManualHP-GL/2 color differences in different HP DesignJet PrintersColor diff

Removal and Installation 8-3HP DesignJets 500, 510 and 800 Series Printers Service ManualElectrostatic Discharge (ESD) PrecautionsTo prevent damage to

Removal and Installation8-4HP DesignJets 500, 510 and 800 Series Printers Service ManualScrew TypesType Torx Length (mm)Head Type Thread Type Part Num

Removal and Installation 8-5HP DesignJets 500, 510 and 800 Series Printers Service ManualLeft Hand Cover RemovalWARNING Switch off the printer and rem

Removal and Installation8-6HP DesignJets 500, 510 and 800 Series Printers Service Manual4. Remove 1 T-20 screw (Type F) from the front of Left Hand Co

Removal and Installation 8-7HP DesignJets 500, 510 and 800 Series Printers Service ManualRight Hand CoverRemovalWARNING Switch off the printer and rem

Removal and Installation8-8HP DesignJets 500, 510 and 800 Series Printers Service Manual4. Remove 1 T-20 screw (Type F) from the front of the Right Ha

Removal and Installation 8-9HP DesignJets 500, 510 and 800 Series Printers Service ManualFront PanelRemovalWARNING Switch off the printer and remove t

Removal and Installation8-10HP DesignJets 500, 510 and 800 Series Printers Service ManualWindow and Top CoverRemovalWARNING Switch off the printer and

Removal and Installation 8-11HP DesignJets 500, 510 and 800 Series Printers Service ManualMedia DeflectorsRemovalWARNING Switch off the printer and re

Removal and Installation8-12HP DesignJets 500, 510 and 800 Series Printers Service Manual3. Lift tab up and slide Middle Deflector to the right and li

Troubleshooting1-8HP DesignJets 500, 510 and 800 Series Printers Service ManualThe Priming Procedure FailsWhen the customer first receives the Printer

Removal and Installation 8-13HP DesignJets 500, 510 and 800 Series Printers Service ManualLeft End Roll-FeedRemovalWARNING Switch off the printer and

Removal and Installation8-14HP DesignJets 500, 510 and 800 Series Printers Service Manual5. Move Left End Roll-Feed down and remove from Printer.

Removal and Installation 8-15HP DesignJets 500, 510 and 800 Series Printers Service ManualRight End Roll-FeedRemovalWARNING Switch off the printer and

Removal and Installation8-16HP DesignJets 500, 510 and 800 Series Printers Service Manual5. Remove Right Hand Roll-Feed.

Removal and Installation 8-17HP DesignJets 500, 510 and 800 Series Printers Service ManualBack PlatenRemovalWARNING Switch off the printer and remove

Removal and Installation8-18HP DesignJets 500, 510 and 800 Series Printers Service Manual4. Unclip the Media Sensor from underneath the Back Platen.5.

Removal and Installation 8-19HP DesignJets 500, 510 and 800 Series Printers Service ManualMedia SensorRemovalWARNING Switch off the printer and remove

Removal and Installation8-20HP DesignJets 500, 510 and 800 Series Printers Service ManualFormatterRemovalWARNING Switch off the printer and remove the

Removal and Installation 8-21HP DesignJets 500, 510 and 800 Series Printers Service ManualLAN CardRemovalWARNING Switch off the printer and remove the

Removal and Installation8-22HP DesignJets 500, 510 and 800 Series Printers Service Manual4. Remove the LAN Card from the Printer.

Troubleshooting 1-9HP DesignJets 500, 510 and 800 Series Printers Service Manualmessage on the Front Panel: Open the Window and you will see the foll

Removal and Installation 8-23HP DesignJets 500, 510 and 800 Series Printers Service ManualSpittoonRemoval WARNING Switch off the printer and remove th

Removal and Installation8-24HP DesignJets 500, 510 and 800 Series Printers Service ManualElectronics ModuleRemoval WARNING Switch off the printer and

Removal and Installation 8-25HP DesignJets 500, 510 and 800 Series Printers Service Manual4. Remove 1 T-10 screw (Type B) from the back of the Electro

Removal and Installation8-26HP DesignJets 500, 510 and 800 Series Printers Service ManualInstalling the Electronics ModuleNOTE When installing theElec

Removal and Installation 8-27HP DesignJets 500, 510 and 800 Series Printers Service ManualPower SupplyRemoval WARNING Switch off the printer and remo

Removal and Installation8-28HP DesignJets 500, 510 and 800 Series Printers Service Manual4. Remove 2 T-10 screws (Type B) that secure Power Supply to

Removal and Installation 8-29HP DesignJets 500, 510 and 800 Series Printers Service ManualScan-Axis Motor AssemblyRemoval WARNING Switch off the print

Removal and Installation8-30HP DesignJets 500, 510 and 800 Series Printers Service Manual6. Remove the left hand side of the Belt from the Scan-Axis M

Removal and Installation 8-31HP DesignJets 500, 510 and 800 Series Printers Service ManualInstalling the Scan-Axis MotorNOTE When installing the Scan-

Removal and Installation8-32HP DesignJets 500, 510 and 800 Series Printers Service ManualCutter AssemblyRemovalWARNING Switch off the printer and remo

Technical Marketing,Barcelona Division,Hewlett-Packard Espanola, S.A.Avda. Graells, 50108190 Sant Cugat del VallesSpainFor HP Internal Use Only©Copyri

Troubleshooting1-10HP DesignJets 500, 510 and 800 Series Printers Service ManualNOTE If you need to reseat the Start-up Printheads, make sure you re-i

Removal and Installation 8-33HP DesignJets 500, 510 and 800 Series Printers Service ManualLeft Encoder HolderRemovalWARNING Switch off the printer and

Removal and Installation8-34HP DesignJets 500, 510 and 800 Series Printers Service Manual4. Disconnect the Trailing Cable and unclip the Ferrite and r

Removal and Installation 8-35HP DesignJets 500, 510 and 800 Series Printers Service ManualCutter BushingRemovalWARNING Switch off the printer and remo

Removal and Installation8-36HP DesignJets 500, 510 and 800 Series Printers Service ManualCutter Guide BracketRemovalWARNING Switch off the printer and

Removal and Installation 8-37HP DesignJets 500, 510 and 800 Series Printers Service Manual4. Remove 1 T-10 screw (Type B) from the Cutter Guide Bracke

Removal and Installation8-38HP DesignJets 500, 510 and 800 Series Printers Service ManualDrive Roller Encoder SensorRemovalWARNING Switch off the prin

Removal and Installation 8-39HP DesignJets 500, 510 and 800 Series Printers Service Manual6. Depress the clip and remove the Encoder Sensor Cover.7. R

Removal and Installation8-40HP DesignJets 500, 510 and 800 Series Printers Service ManualTrailing CableRemovalNOTE Refer to the table on Page 8-4 for

Removal and Installation 8-41HP DesignJets 500, 510 and 800 Series Printers Service Manual6. Remove all the Printheads.7. Loosen 1 T-8 screw that secu

Removal and Installation8-42HP DesignJets 500, 510 and 800 Series Printers Service Manual9. Move the Tubes Assembly clear from the Carriage Assembly.1

Troubleshooting 1-11HP DesignJets 500, 510 and 800 Series Printers Service ManualUsing the Power Switch LED to TroubleshootIn certain circumstances th

Removal and Installation 8-43HP DesignJets 500, 510 and 800 Series Printers Service Manual12. Remove the clip securing the Trailing Cable.13. Disconne

Removal and Installation8-44HP DesignJets 500, 510 and 800 Series Printers Service Manual15. Move the Carriage Assembly to the right so that the Trail

Removal and Installation 8-45HP DesignJets 500, 510 and 800 Series Printers Service Manual18. Remove the Plastic Holder from the Printer.19. Release t

Removal and Installation8-46HP DesignJets 500, 510 and 800 Series Printers Service Manual21. Unclip the Ferrite and remove.22. Slide the Trailing Cabl

Removal and Installation 8-47HP DesignJets 500, 510 and 800 Series Printers Service ManualInstalling the Trailing CableNOTE When installing the Traili

Removal and Installation8-48HP DesignJets 500, 510 and 800 Series Printers Service ManualInk Supply StationRemovalWARNING Switch off the printer and r

Removal and Installation 8-49HP DesignJets 500, 510 and 800 Series Printers Service Manual5. Remove 1 T-15 screw (Type E) from the top of the Assembly

Removal and Installation8-50HP DesignJets 500, 510 and 800 Series Printers Service ManualInterconnect PCARemovalWARNING Switch off the printer and rem

Removal and Installation 8-51HP DesignJets 500, 510 and 800 Series Printers Service Manual4. Lift the Interconnect PCA and remove.

Removal and Installation8-52HP DesignJets 500, 510 and 800 Series Printers Service ManualService Station and Aerosol FanRemovalNOTE Refer to the table

Troubleshooting1-12HP DesignJets 500, 510 and 800 Series Printers Service Manualthe Interconnect Cable. Try the following:1 Check that the Interconnec

Removal and Installation 8-53HP DesignJets 500, 510 and 800 Series Printers Service Manual5. Remove 2 T-15 screws (Type E) from inside the Service Sta

Removal and Installation8-54HP DesignJets 500, 510 and 800 Series Printers Service ManualInstalling the Service Station/Aerosol FanNOTE When installin

Removal and Installation 8-55HP DesignJets 500, 510 and 800 Series Printers Service ManualCutter GuideRemovalWARNING Switch off the printer and remove

Removal and Installation8-56HP DesignJets 500, 510 and 800 Series Printers Service ManualPrint PlatenRemovalWARNING Switch off the printer and remove

Removal and Installation 8-57HP DesignJets 500, 510 and 800 Series Printers Service ManualService Station HolderRemovalWARNING Switch off the printer

Removal and Installation8-58HP DesignJets 500, 510 and 800 Series Printers Service Manual10. Remove 1 T-15 screw (Type E) that secures the Service Sta

Removal and Installation 8-59HP DesignJets 500, 510 and 800 Series Printers Service ManualInterconnect CableRemovalWARNING Switch off the printer and

Removal and Installation8-60HP DesignJets 500, 510 and 800 Series Printers Service ManualInk Supply TubesRemoval1. Perform the Service Utility "C

Removal and Installation 8-61HP DesignJets 500, 510 and 800 Series Printers Service Manual5. Open the Ink Cartridge Access Cover.6. Remove all the Ink

Removal and Installation8-62HP DesignJets 500, 510 and 800 Series Printers Service Manual8. Remove the Top Cover and Window - Refer to Page 8-10.9. Lo

Troubleshooting 1-13HP DesignJets 500, 510 and 800 Series Printers Service ManualUsing the Boot-Up Sequence to TroubleshootWhen you Power On the Print

Removal and Installation 8-63HP DesignJets 500, 510 and 800 Series Printers Service Manual11. Unclip the tubes from the Tubes Guide.12. Release the Tu

Removal and Installation8-64HP DesignJets 500, 510 and 800 Series Printers Service ManualVacuum FanRemovalWARNING Switch off the printer and remove th

Removal and Installation 8-65HP DesignJets 500, 510 and 800 Series Printers Service Manual5. Unclip the Vacuum Fan Assembly from underneath the Printe

Removal and Installation8-66HP DesignJets 500, 510 and 800 Series Printers Service ManualPinch-ArmRemovalWARNING Switch off the printer and remove the

Removal and Installation 8-67HP DesignJets 500, 510 and 800 Series Printers Service ManualPinch-Arm Mechanism RemovalWARNING Switch off the printer an

Removal and Installation8-68HP DesignJets 500, 510 and 800 Series Printers Service Manual5. Open the Media Guide by unclipping it.6. While pulling the

Removal and Installation 8-69HP DesignJets 500, 510 and 800 Series Printers Service ManualPinch-Arm LeverRemovalWARNING Switch off the printer and rem

Removal and Installation8-70HP DesignJets 500, 510 and 800 Series Printers Service Manual4. Remove 1 T-15 screw (Type E) that secures the Lever to the

Removal and Installation 8-71HP DesignJets 500, 510 and 800 Series Printers Service ManualPinch-Arm SensorRemovalWARNING Switch off the printer and re

Removal and Installation8-72HP DesignJets 500, 510 and 800 Series Printers Service Manual4. Remove 1 T-20 screw (Type C) from the Right Deflector Brac

Troubleshooting1-14HP DesignJets 500, 510 and 800 Series Printers Service ManualInitializing various components of the Main PCA.Initializing a portion

Removal and Installation 8-73HP DesignJets 500, 510 and 800 Series Printers Service Manual7. Disconnect the Pinch-Arm Sensor Cable from the Interconne

Removal and Installation8-74HP DesignJets 500, 510 and 800 Series Printers Service ManualFork Idler, Tensioner and Idler PulleyRemovalWARNING Switch o

Removal and Installation 8-75HP DesignJets 500, 510 and 800 Series Printers Service Manual5. Pull out the Belt from the right hand side of the Printer

Removal and Installation8-76HP DesignJets 500, 510 and 800 Series Printers Service ManualEncoder StripRemovalWARNING Switch off the printer and remove

Removal and Installation 8-77HP DesignJets 500, 510 and 800 Series Printers Service Manual5. Release the Encoder Strip from the Service Station Holder

Removal and Installation8-78HP DesignJets 500, 510 and 800 Series Printers Service ManualCarriage Assembly (Including Belt)Removal1. Perform the Servi

Removal and Installation 8-79HP DesignJets 500, 510 and 800 Series Printers Service Manual11. Release the latch and lift up the Carriage cover.12. Rem

Removal and Installation8-80HP DesignJets 500, 510 and 800 Series Printers Service Manual14. Unclip the Tubes from the Carriage and lift up.15. Move t

Removal and Installation 8-81HP DesignJets 500, 510 and 800 Series Printers Service Manual17.Unclip the Carriage Cover (clip located on the left hand

Removal and Installation8-82HP DesignJets 500, 510 and 800 Series Printers Service Manual20. Slide the Trailing Cable out of the clip inside the Carri

Troubleshooting 1-15HP DesignJets 500, 510 and 800 Series Printers Service ManualUsing the Formatter/Accessory Card LEDs to TroubleshootIn certain cir

Removal and Installation 8-83HP DesignJets 500, 510 and 800 Series Printers Service ManualInstalling the Carriage Assembly NOTE When connecting theTra

Removal and Installation8-84HP DesignJets 500, 510 and 800 Series Printers Service ManualPaper-Axis MotorRemovalWARNING Switch off the printer and rem

Removal and Installation 8-85HP DesignJets 500, 510 and 800 Series Printers Service Manual6. Remove the Paper-Axis Motor (including the cables).

Removal and Installation8-86HP DesignJets 500, 510 and 800 Series Printers Service ManualDrive RollerRemovalWARNING Switch off the printer and remove

Removal and Installation 8-87HP DesignJets 500, 510 and 800 Series Printers Service Manual16. Disconnect the Pinch-Arm Sensor Cable from the Interconn

Removal and Installation8-88HP DesignJets 500, 510 and 800 Series Printers Service Manual19. Remove 1 screw (T-15) from the Right Back Trim and remove

Removal and Installation 8-89HP DesignJets 500, 510 and 800 Series Printers Service Manual22.Remove 4 screws (T-25) that secure the Top Part of the Pr

Removal and Installation8-90HP DesignJets 500, 510 and 800 Series Printers Service Manual25. Remove the Axle Spring.NOTE Be very careful whenremoving

Removal and Installation 8-91HP DesignJets 500, 510 and 800 Series Printers Service Manual28. Lift Drive Roller out of the Printer.NOTE Make sure you

Removal and Installation8-92HP DesignJets 500, 510 and 800 Series Printers Service ManualGear AssembliesRemovalWARNING Switch off the printer and remo

Troubleshooting1-16HP DesignJets 500, 510 and 800 Series Printers Service ManualFormatter/Accessory Card. If the green LED is NOT lit and the LED in t

Removal and Installation 8-93HP DesignJets 500, 510 and 800 Series Printers Service Manual17. Remove the Drive Roller - Refer to Page 8-86.18. Remove

9-1HP DesignJets 500, 510 and 800 Series Printers Service Manual9Preventive Maintenance 9Moisture on the Printer 9-2Noisy Carriage Bushing 9-2Belt

Preventive Maintenance9-2HP DesignJets 500, 510 and 800 Series Printers Service ManualPreventive MaintenanceMoisture on the PrinterUsers should use th

Preventive Maintenance 9-3HP DesignJets 500, 510 and 800 Series Printers Service ManualCleaning the Drive Roller/Print PlatenNOTE If ink is spilled on

Preventive Maintenance9-4HP DesignJets 500, 510 and 800 Series Printers Service Manualdisplays the following message:"Maintenance Advised"NO

10-1HP DesignJets 500, 510 and 800 Series Printers Service Manual10Functional Overview 10Introduction 10-2SKU Overview 10-2Electrical System 10-4P

Functional Overview10-2HP DesignJets 500, 510 and 800 Series Printers Service ManualIntroductionThis Chapter contains a simplified description of the

Functional Overview 10-3HP DesignJets 500, 510 and 800 Series Printers Service ManualResolution 2400 x 1200 dpi (Super Best) 2400 dpi (Super best) Lan

Functional Overview10-4HP DesignJets 500, 510 and 800 Series Printers Service ManualElectrical SystemIntroductionThe Printer’s engine electronics (Mai

Functional Overview 10-5HP DesignJets 500, 510 and 800 Series Printers Service ManualThe memory bus is also used to control Navata gate array. Navata

Troubleshooting 1-17HP DesignJets 500, 510 and 800 Series Printers Service ManualHow to Detect Problems Related to the Encoder DiskThe following infor

Functional Overview10-6HP DesignJets 500, 510 and 800 Series Printers Service Manual Power Supply Unit (PSU)The PSU is used to supply the power requir

Functional Overview 10-7HP DesignJets 500, 510 and 800 Series Printers Service Manual As explained earlier, the Power Supply provides +5.0V, +3.3V, +1

Functional Overview10-8HP DesignJets 500, 510 and 800 Series Printers Service ManualInk Delivery System (IDS)The Ink Delivery System (IDS) delivers in

Functional Overview 10-9HP DesignJets 500, 510 and 800 Series Printers Service ManualThese are the key functions of the ISS: Ink Cartridges support a

Functional Overview10-10HP DesignJets 500, 510 and 800 Series Printers Service ManualTubes AssemblyThe Tubes Assembly is the part of the Ink Delivery

Functional Overview 10-11HP DesignJets 500, 510 and 800 Series Printers Service ManualService StationThe purpose of the Service Station is to service

Glossary G-1Glossary 11acAlternating current.ANSI sizeAn American standard media size; e.g. D, EapplicationThe software you use to create your drawing

GlossaryG-2HP-GL/2 One of Hewlett-Packard's standard graphics languages for plotters and printers. Produces vector data. Newer than HP-GL.IDSInk

Glossary G-3PANTONEThe PANTONE MATCHING SYSTEM® is an international standard for color communication in the graphics art industry.penEven though the p

About this EditionThis is the 3rd edition of this Service Manual2nd edition, titledHP DesignJet 500, 510 and 800 Series Printers Service Manual

2-1HP DesignJets 500, 510 and 800 Series Printers Service ManualSystem Error Codes 22System Error Codes 1Introduction 2-2Continuable and Non-Continu

1What’s in this Service ManualThis manual contains information necessary to test, calibrate and service:- HP DesignJet 500 (models C7769B/C7770B)- HP

Index Index-1HP DesignJets 500, 510 and 800 Series Printers Service ManualIndex 12AAdvance Calibration 5-9BBack Platen 8-17Banding 1-6Belt 8-78Belt Sw

IndexIndex-2HP DesignJets 500, 510 and 800 Series Printers Service ManualFormatter/Accessory Card 1-14Front Panel 8-9, 10-6Functional OverviewElectric

Index Index-3HP DesignJets 500, 510 and 800 Series Printers Service ManualPaper-Axis Shutdowns 1-4Parts ListBack Platen Assembly 7-12Carriage Assembly

IndexIndex-4HP DesignJets 500, 510 and 800 Series Printers Service ManualDrive Roller Encoder Sensor 8-38Electronics Module 8-24Encoder Strip 8-76Fork

Index Index-5HP DesignJets 500, 510 and 800 Series Printers Service Manual1111 2-101113 2-101211 2-102110 2-112111 2-112210 2-114110 2-114113 2-124210

System Error Codes2-2HP DesignJets 500, 510 and 800 Series Printers Service ManualIntroductionSystem error codes are hexa-decimal based numbers genera

1 Service ManualDesignJets 500, 510 and 800 SeriesHP Large-Format Printers

System Error Codes 2-3HP DesignJets 500, 510 and 800 Series Printers Service Manual17 Interconnect Cable21 Service Station22 Ink Supply Station23 Pres

System Error Codes2-4HP DesignJets 500, 510 and 800 Series Printers Service ManualThe following table explains the last 2 digits of the System Error C

System Error Codes 2-5HP DesignJets 500, 510 and 800 Series Printers Service ManualError Log UtilityThe Error Log utility contains a record of the las

System Error Codes2-6HP DesignJets 500, 510 and 800 Series Printers Service Manual3 Press the ↑ or ↓ key until the front panel highlights Errors. Pres

System Error Codes 2-7HP DesignJets 500, 510 and 800 Series Printers Service ManualSystem Error: 01:10Problem Description:Electronics Module failure.

System Error Codes2-8HP DesignJets 500, 510 and 800 Series Printers Service ManualSystem Error: 01:13Problem Description:Electronics Module failure. T

System Error Codes 2-9HP DesignJets 500, 510 and 800 Series Printers Service ManualSystem Error: 03:10Problem Description:Power Supply failure.Correct

System Error Codes2-10HP DesignJets 500, 510 and 800 Series Printers Service ManualSystem Error: 05:10 Error (Only applicable to HP DesignJet 500 and

System Error Codes 2-11HP DesignJets 500, 510 and 800 Series Printers Service ManualSystem Error: 12:11Problem Description:A short detected in the Car

System Error Codes2-12HP DesignJets 500, 510 and 800 Series Printers Service ManualSystem Error: 41:10Problem Description:Paper-Axis Motor failure.Cor

2HP DesignJets 500, 510 and 800 Series Printers Service ManualUsing this ManualPurposeThis Service Manual contains information necessary to test, cali

System Error Codes 2-13HP DesignJets 500, 510 and 800 Series Printers Service ManualSystem Error: 56:10Problem Description:Drive Roller Encoder Sensor

System Error Codes2-14HP DesignJets 500, 510 and 800 Series Printers Service ManualSystem Error: 61:05Problem Description:Error Processing Job. This E

System Error Codes 2-15HP DesignJets 500, 510 and 800 Series Printers Service ManualSystem Error: 71:04Problem Description:Problem allocating Memory.

System Error Codes2-16HP DesignJets 500, 510 and 800 Series Printers Service ManualSystem Error: 72:04Problem Description:Problem in the Scan-Axis (Fi

System Error Codes 2-17HP DesignJets 500, 510 and 800 Series Printers Service ManualSystem Error: 79:04Problem Description:Firmware Error.Corrective A

System Error Codes2-18HP DesignJets 500, 510 and 800 Series Printers Service ManualSystem Error: 85:10Problem Description:Paper-Axis Encoder error. Th

System Error Codes 2-19HP DesignJets 500, 510 and 800 Series Printers Service ManualSystem Error: 86:13Problem Description:Carriage-Axis shutdown (Fir

3-1HP DesignJets 500, 510 and 800 Series Printers Service ManualInk Supplies Troubleshooting3What are the Ink Supplies? 3-2Ink Cartridges 3-2Printh

Ink Supplies Troubleshooting3-2HP DesignJets 500, 510 and 800 Series Printers Service ManualWhat are the Ink Supplies?For each of the four ink colors

Ink Supplies Troubleshooting 3-3HP DesignJets 500, 510 and 800 Series Printers Service ManualPrintheadsThe Printheads are extremely durable and do not

3HP DesignJets 500, 510 and 800 Series Printers Service Manuallocated in Chapter 7.ConventionsA small arrow ⇒ is used to indicate other parts of the

Ink Supplies Troubleshooting3-4HP DesignJets 500, 510 and 800 Series Printers Service ManualGeneral Information About the Ink SuppliesFor optimum resu

Ink Supplies Troubleshooting 3-5HP DesignJets 500, 510 and 800 Series Printers Service ManualSome General Precautions When Handling the Ink SuppliesCA

Ink Supplies Troubleshooting3-6HP DesignJets 500, 510 and 800 Series Printers Service ManualWhen Should You Replace the Ink Cartridges?When to change

Ink Supplies Troubleshooting 3-7HP DesignJets 500, 510 and 800 Series Printers Service ManualWhen Should You Replace the Printheads?In a normal situat

Ink Supplies Troubleshooting3-8HP DesignJets 500, 510 and 800 Series Printers Service Manual3 Reinsert the Cyan Printhead only and close the Carriage

Ink Supplies Troubleshooting 3-9HP DesignJets 500, 510 and 800 Series Printers Service ManualObtaining Ink Cartridge Information1 To get information o

Ink Supplies Troubleshooting3-10HP DesignJets 500, 510 and 800 Series Printers Service Manual5 The front panel displays information on the selected In

Ink Supplies Troubleshooting 3-11HP DesignJets 500, 510 and 800 Series Printers Service Manual3 Press the ↑ or ↓ key until the front panel highlights

Ink Supplies Troubleshooting3-12HP DesignJets 500, 510 and 800 Series Printers Service ManualAlso the % indicates the percentage over the expected lif

Ink Supplies Troubleshooting 3-13HP DesignJets 500, 510 and 800 Series Printers Service ManualInk Cartridge Status MessagesStatus Bars The front panel

Table of Contents4HP DesignJets 500, 510 and 800 Series Printers Service ManualTable of Contents 1Troubleshooting 1-1Introduction 1-2Troubleshooting S

Ink Supplies Troubleshooting3-14HP DesignJets 500, 510 and 800 Series Printers Service ManualPrinthead Status MessagesThere are two circumstances unde

Ink Supplies Troubleshooting 3-15HP DesignJets 500, 510 and 800 Series Printers Service ManualPrinthead History UtilityThe Printhead History utility c

Ink Supplies Troubleshooting3-16HP DesignJets 500, 510 and 800 Series Printers Service Manual3 Press the ↑ or ↓ key until the front panel highlights P

Ink Supplies Troubleshooting 3-17HP DesignJets 500, 510 and 800 Series Printers Service Manualminimum life expectancy of the Printhead was reached and

Ink Supplies Troubleshooting3-18HP DesignJets 500, 510 and 800 Series Printers Service ManualNow, if a Printhead is removed (even after Level 3 recove

Ink Supplies Troubleshooting 3-19HP DesignJets 500, 510 and 800 Series Printers Service Manualused is below 100%) and the maximum recovery action was

Ink Supplies Troubleshooting3-20HP DesignJets 500, 510 and 800 Series Printers Service Manualfollowing example, Printheads 2, 3 and 4 were removed too

Ink Supplies Troubleshooting 3-21HP DesignJets 500, 510 and 800 Series Printers Service ManualTroubleshooting Repetitive Ink Cartridge MessagesWhen yo

Ink Supplies Troubleshooting3-22HP DesignJets 500, 510 and 800 Series Printers Service ManualExpiration message. NOTE In order to determine the correc

Ink Supplies Troubleshooting 3-23HP DesignJets 500, 510 and 800 Series Printers Service ManualPrinthead Error CodesPrinthead Error Codes consist of 4

Table of Contents 5HP DesignJets 500, 510 and 800 Series Printers Service ManualObtaining Printhead Information 3-10Ink Cartridge Status Messages 3-12

Ink Supplies Troubleshooting3-24HP DesignJets 500, 510 and 800 Series Printers Service ManualSummary of Solving Ink Supplies ProblemsMost of the probl

4-1HP DesignJets 500, 510 and 800 Series Printers Service ManualService Tests and Utilities4Introduction 4-2Diagnostics - Self Test 4-2Service Test

Service Tests and Utilities4-2HP DesignJets 500, 510 and 800 Series Printers Service ManualIntroductionThis chapter explains how to use the built-in S

Service Tests and Utilities 4-3HP DesignJets 500, 510 and 800 Series Printers Service ManualService Tests (Diagnostics)The following is a list of all

Service Tests and Utilities4-4HP DesignJets 500, 510 and 800 Series Printers Service ManualEntering the Service Tests MenuNOTE In order to enter the S

Service Tests and Utilities 4-5HP DesignJets 500, 510 and 800 Series Printers Service Manual4 Press the Enter key to begin a specific test when the re

Service Tests and Utilities4-6HP DesignJets 500, 510 and 800 Series Printers Service ManualInk Supply StationThe purpose of this test is to verify the

Service Tests and Utilities 4-7HP DesignJets 500, 510 and 800 Series Printers Service Manual3 Once all the Ink Cartridges are removed the Printer will

Service Tests and Utilities4-8HP DesignJets 500, 510 and 800 Series Printers Service ManualCarriage MovementThe purpose of this test is to verify the

Service Tests and Utilities 4-9HP DesignJets 500, 510 and 800 Series Printers Service Manual4 If you press Enter, the Front Panel will display a list

Table of Contents6HP DesignJets 500, 510 and 800 Series Printers Service ManualPrint Quality 6-1Print Quality 6-2Print Quality Troubleshooting Checkli

Service Tests and Utilities4-10HP DesignJets 500, 510 and 800 Series Printers Service ManualIf the values obtained in the test are more than the accep

Service Tests and Utilities 4-11HP DesignJets 500, 510 and 800 Series Printers Service ManualPaper Advance TestThe purpose of this test is to identify

Service Tests and Utilities4-12HP DesignJets 500, 510 and 800 Series Printers Service ManualWARNING IF THIS TEST PASSES, DO NOT REPLACE THE PAPER-AXIS

Service Tests and Utilities 4-13HP DesignJets 500, 510 and 800 Series Printers Service Manual6 It is possible that while performing this test, a Paper

Service Tests and Utilities4-14HP DesignJets 500, 510 and 800 Series Printers Service ManualService UtilitiesThe following is a list of all internal S

Service Tests and Utilities 4-15HP DesignJets 500, 510 and 800 Series Printers Service ManualEntering the Service Utilities Menu1 Press the ↑ or ↓ key

Service Tests and Utilities4-16HP DesignJets 500, 510 and 800 Series Printers Service Manual4 Press the Enter key to begin a specific utility when the

Service Tests and Utilities 4-17HP DesignJets 500, 510 and 800 Series Printers Service ManualEEROM SetupThe purpose of this Service Utility is to modi

Service Tests and Utilities4-18HP DesignJets 500, 510 and 800 Series Printers Service Manualkeys to scroll through the complete list because the front

Service Tests and Utilities 4-19HP DesignJets 500, 510 and 800 Series Printers Service Manuald If you press Enter, the new serial number will be store

Table of Contents 7HP DesignJets 500, 510 and 800 Series Printers Service ManualRemoval and Installation 8-1Introduction 8-2Safety Precautions 8-2Elec

Service Tests and Utilities4-20HP DesignJets 500, 510 and 800 Series Printers Service ManualIf you want to Reset the Usage CounterNOTE You should only

Service Tests and Utilities 4-21HP DesignJets 500, 510 and 800 Series Printers Service ManualIf you want to Reset the EEROM to the Default ValuesNOTE

Service Tests and Utilities4-22HP DesignJets 500, 510 and 800 Series Printers Service ManualTurn Drive RollerThe purpose of this Service Utility is to

Service Tests and Utilities 4-23HP DesignJets 500, 510 and 800 Series Printers Service ManualUnlock CarriageThe purpose of this Service Utility is to

Service Tests and Utilities4-24HP DesignJets 500, 510 and 800 Series Printers Service ManualPrime TubesThis purpose of this Service Utility is to prim

Service Tests and Utilities 4-25HP DesignJets 500, 510 and 800 Series Printers Service ManualChange CutterThe purpose of this Service Utility is to mo

Service Tests and Utilities4-26HP DesignJets 500, 510 and 800 Series Printers Service ManualChange Ink TubesThe purpose of this Service Utility is to

Service Tests and Utilities 4-27HP DesignJets 500, 510 and 800 Series Printers Service ManualPrinter InformationThe purpose of this Utility is the fol

Service Tests and Utilities4-28HP DesignJets 500, 510 and 800 Series Printers Service ManualEach parameter of the Printer Information is explained as

Service Tests and Utilities 4-29HP DesignJets 500, 510 and 800 Series Printers Service ManualPrinter is designed to support. If the percentage is more