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Service Tests and
Utilities 4
4
Introduction 4-2
Diagnostics - Self Test 4-2
Service Tests (Diagnostics) 4-3
Entering the Service Tests Menu 4-4
Ink Supply Station 4-6
Carriage Movement 4-8
Paper Advance Test 4-10
Service Utilities 4-13
Entering the Service Utilities Menu 4-14
EEROM Setup 4-16
Turn Drive Roller 4-21
Unlock Carriage 4-22
Prime Tubes 4-23
Change Cutter 4-24
Change Ink Tubes 4-25
Printer Information 4-26
HP DesignJets 500 and 800 Series Printers Service Manual 4-1
Service Tests and Utilities
Introduction
This chapter explains how to use the built-in Service Tests and
Service Utilities and what to do if any of the Service Tests fail. If
possible, always perform a Service Test on the component that you
are about to replace, just to make sure that is the component that has
failed. If the test on that component passes, there is no need to
replace it.
Phone Support
In certain circumstances, a Call Agent can try and troubleshoot the
O RT
PP Printer by requesting the Customer to perform a Service Test via the
SU
NE phone. Using this process, it can be determined whether the Printer
P HO
requires any on-site maintenance.
Diagnostics - Self Test
Initialization Sequences
Whenever the Printer is switched ON, it automatically performs a
series of internal self tests and mechanical initialization sequences.
If any of the parts fail, a system error will appear and you should
consult Chapter 2 - System Error Codes.
Entering Service Menu at Power Up - Only for Onsite Repair
If the Printer fails to initialize completely because of a System Error
and you need to use the Service Menu (Service Tests and Utilities),
the Printer can be powered up in Service Mode by pressing the Up
and Enter keys while switching the Printer ON. This will give you
access to some of the Service Tests and Utilities without having to
complete the System Initialization (if you perform some of the tests,
they will need to initialize the relevant part of the System).
4-2 HP DesignJets 500 and 800 Series Printers Service Manual
Service Tests and Utilities
Service Tests (Diagnostics)
The following is a list of all internal Service Tests available in the
Printer. Instructions for entering the Service Tests menu are given
on Page 4-4.
1 Ink Supply Station Page 4-6
The purpose of this test is to verify the operation of the Ink Supply
Station. A failure of the out-of-ink sensors or the springs in the Ink
Supply Station will eventually damage the Printheads because the
Printer will try to pump ink from an empty Ink Cartridge stall,
which will cause the Printhead to dry-fire.
2 Carriage Movement Page 4-8
The purpose of this test is to verify the movement of the scan-axis
components at several speeds. This test checks for the following
problems:
n Friction problems with worn out slider rod or Carriage Bushings.
n Blockage due to problems with the Service Station.
n Problems with encoder sensing.
3 Paper Advance Page 4-10
The purpose of this test is to identify whether there is too much
friction in the paper-axis drive system which is caused by defects
with the Transmission Gears, Drive Roller or the Paper-Axis Motor.
4 Troubleshooting Page 6-4
The Printer contains an internal Troubleshooting procedure which
helps you to diagnose and resolve the possible source of any Image
Quality or Line Quality defects. If Print Quality is poor at anytime,
the Troubleshooting procedure should be performed which will
determine whether the Printhead needs replacing (by marking it
with an exclamation mark) or not after performing various levels of
recovery actions.
HP DesignJets 500 and 800 Series Printers Service Manual 4-3
Service Tests and Utilities
Entering the Service Tests Menu
NOTE In order to enter the Service Utility Menu, please refer to the
instructions on Page 4-14.
1 Press the or key until the front panel displays the Setup Menu and
then press Enter.
Set-up menu Menu
Back
Press ENTER for
Set-up menu Enter
2 Once inside the Setup Menu, Press the following key combination
to access the special Service Menu.
Set-up menu Menu
IR Printer information
A
EP I/O set-up
ER Back
- SIT Front panel
ON Altitude = 0-1000 m.
Log Enter
For On-site Engineers, press the Up and Enter keys
to access the complete list of Service Tests.
Set-up menu Menu
T
OR Printer information
PP
SU I/O set-up
NE Front panel
Back
P HO
Altitude = 0-1000 m.
Log Enter
For Call Agents who will request the User to perform
certain troubleshooting actions, press the Down and Enter
keys to access a limited list of Service Tests.
3 Once inside the Service Tools Menu, press the or key until the
front panel displays Service Tests and then press Enter.
Service tools Menu
Back
Service tests
Service calibrations
Service utilities Enter
4-4 HP DesignJets 500 and 800 Series Printers Service Manual
Service Tests and Utilities
4 Press the Enter key to begin a specific test when the required
Service Test is highlighted.
Service tests Menu
Troubleshooting
Aerosol Fan test
Back
Ink Supply Station
Paper advance test
Carriage movement test Enter
HP DesignJets 500 and 800 Series Printers Service Manual 4-5
Service Tests and Utilities
Ink Supply Station
O RT
PP
E SU
ON The purpose of this test is to verify the operation of the Ink Supply
PH
Station. A failure of the out-of-ink sensors or the springs in the Ink
Supply Station will eventually damage the Printheads because the
Printer will try to pump ink from an empty Ink Cartridge stall,
which will cause the Printhead to dry-fire.
NOTE This Service Test can be performed by the End User with the
guidance of a HP Support person via the phone.
WARNING IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE
REPLACING THE INK SUPPLY STATION. IF THIS TEST
PASSES, DO NOT REPLACE THE INK SUPPLY STATION.
Perform the Ink Supply Station test as follows:
1 In the Service Tests submenu, scroll to "Ink Supply Station" and
press Enter.
Service tests Menu
Troubleshooting
Aerosol Fan test
Back
Ink Supply Station
Paper advance test
Carriage movement test Enter
2 Once the test starts, the following message will appear on the Front
Panel. Open the Ink Cartridge door and remove ALL the Ink
Cartridges:
ISS Test
Remove all the ink
cartridges
4-6 HP DesignJets 500 and 800 Series Printers Service Manual
Service Tests and Utilities
3 Once all the Ink Cartridges are removed the Printer will check the
Ink Supply Station. During this short period, the following message
will be displayed:
ISS Test
Please wait.
Checking
4 If the Printer detects all the out-of-ink signals, the Ink Supply
Station has passed the test and the following message will appear on
the Front Panel:
ISS Test Menu
Test result OK. Back
INK SUPPLY STATION OK.
Press ENTER to return to
menu Enter
WARNING IF THIS TEST PASSES, DO NOT REPLACE THE INK
SUPPLY STATION.
5 If the Printer does not detect all the out-of-ink signals then the Ink
Supply Station must be faulty and the following message will
appear on the Front Panel:
ISS Test
Test result 22:10
Faulty INK SUPPLY
STATION
Call HP representative
In this case, to resolve the problem, try the following:
1 Replace the Ink Supply Station Assembly Page 8-48.
HP DesignJets 500 and 800 Series Printers Service Manual 4-7
Service Tests and Utilities
Carriage Movement
O RT
PP
E SU
ON The purpose of this test is to verify the movement of the scan-axis
PH
components at several speeds. This test checks for the following
problems:
n Friction problems with worn out slider rod or Carriage Bushings.
n Blockage due to problems with the Service Station.
n Problems with encoder sensing.
NOTE This Service Test can be performed by the End User with the
guidance of a HP Support person via the phone.
WARNING IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE
REPLACING THE CARRIAGE ASSEMBLY. IF THIS TEST
PASSES, DO NOT REPLACE THE CARRIAGE ASSEMBLY.
Perform the Carriage Movement test as follows:
1 In the Service Tests submenu, scroll to "Carriage movement" and
press Enter.
Service tests Menu
Troubleshooting
Aerosol Fan test Back
Ink Supply Station
Paper advance test
Carriage movement test Enter
2 The test will start and the following message will appear on the
Front Panel:
Carriage movement
Carriage movement test
Moving Carriage.
Please wait
3 Once the Printer has completed the test it will analyze the data
received while performing the test. Once the data has been
analyzed, the following message will appear on the Front Panel:
Carriage movement Menu
Carriage movement test Back
Ready to display results.
Press ENTER Enter
4-8 HP DesignJets 500 and 800 Series Printers Service Manual
Service Tests and Utilities
4 If you press Enter, the Front Panel will display a list of the
different results you can view. You can make your selection using
the arrow keys and press Enter to view the selection.
Test results. Select item Menu
for more information
Back
PWM
Speed offset
Stabilization distance Enter
5 If you selected PWM, the Front Panel will display the results of the
PWM test:
PWM results
Average value of the PWM
Average: XXX Standard deviation value of
Std dev: X the PWM
6 If you selected Speed offset, the Front Panel will display the results
of the Speed offset:
Speed offset results
Average value of the speed offset
Average (ips): X Standard deviation value of
Std dev (ips): X the speed offset
7 If you selected Stabilization distance, the Front Panel will display
the results of the Stabilization distance:
Stabilization distance
results
Stabilizat. dist. (mm): XX
HP DesignJets 500 and 800 Series Printers Service Manual 4-9
Service Tests and Utilities
Paper Advance Test
O RT
PP
E SU
ON The purpose of this test is to identify whether there is too much
PH
friction in the paper-axis drive system which is caused by defects
with the Transmission Gears, Drive Roller or the Paper-Axis Motor.
This test should be performed when a Paper-Axis shutdown occurs
which is not caused by a paper jam.
The Paper Advance test will perform the following tests:
n Paper-Axis Motor test.
n Drive Roller Encoder-Sensor test.
n Drive Roller test.
NOTE This Service Test can be performed by the End User with the
guidance of a HP Support person via the phone.
WARNING IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE
REPLACING PAPER-AXIS COMPONENTS. IF THIS TEST
PASSES, DO NOT REPLACE ANY PAPER-AXIS COMPONENTS.
Perform the Paper Advance test as follows:
1 In the Service Tests submenu, scroll to "Paper Advance test" and
press Enter.
Service tests Menu
Troubleshooting
Aerosol Fan test Back
Ink Supply Station
Paper advance test
Carriage movement test Enter
2 The test will first check if the Paper-Axis Motor is working by
moving it slightly backwards and forwards. If this test passes, the
following message will be displayed (press Enter to continue to the
next stage of the test):
Paper Advance test Menu
Back
Paper-axis motor test
passed.
Press ENTER to continue Enter
WARNING IF THIS TEST PASSES, DO NOT REPLACE THE PAPER-
AXIS MOTOR.
4-10 HP DesignJets 500 and 800 Series Printers Service Manual
Service Tests and Utilities
3 If the test fails while checking the Paper-Axis Motor, then the
following message will be displayed:
Paper Advance test
System error 41:10
Paper-axis motor failed
In this case, to resolve the problem, replace the Paper-Axis Motor
Page 8-84.
4 If the Paper-Axis Motor test passes, the Printer will try to read the
Drive Roller Encoder-Sensor while moving the Paper-Axis Motor.
If the Printer can read the signals from the Encoder-Sensor, then the
test has passed and the following message will be displayed (press
Enter to continue to the next stage of the test):
Paper Advance test Menu
Back
Roller encoder sensor
test passed.
Press ENTER to continue Enter
WARNING IF THIS TEST PASSES, DO NOT REPLACE THE DRIVE
ROLLER ENCODER-SENSOR.
5 If the Printer has problems reading the signal from the Drive Roller
Encoder-Sensor, then the test has failed and the following message
will be displayed:
Paper Advance test
System error 56:10
Roller encoder sensor
failed
In this case, to resolve the problem, replace the Drive Roller
Encoder Sensor Page 8-38.
HP DesignJets 500 and 800 Series Printers Service Manual 4-11
Service Tests and Utilities
6 It is possible that while performing this test, a Paper-Axis shutdown
occurs, in which case the following message will be displayed:
Paper Advance test
System error 81:11
Paper-axis shutdown
In this case, to resolve the problem, try the following:
1 Open the Window and check for any visible obstacles that could be
restricting the movement of the Drive Roller.
2 Try cleaning the Drive Roller using the Turn Drive Roller service
utility Page 4-21. Also try cleaning the Drive Roller Gears.
3 Replace the Drive Roller Page 8-86.
4 Replace the Gear Assemblies Page 8-92.
WARNING Only replace one component at a time and try the Service Test
again before replacing another component. Using this procedure
you will be able to determine exactly which component failed.
5 If the Drive Roller Encoder-Sensor test passes, the Printer will try
turning the Drive Roller and the following message will appear on
the Front Panel:
Paper Advance test
Moving Drive Roller.
Please wait
6 Once the test is completed, the results will be displayed on the front
panel:
Test results
Average value of the PWM
Average PWM: XX Standard deviation value of
Std dev PWM: X the PWM
4-12 HP DesignJets 500 and 800 Series Printers Service Manual
Service Tests and Utilities
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 4-14.
1 EEROM Setup Page 4-16
The purpose of this Service Utility is to modify identification
parameters such as serial and model numbers, as well as the Font
Type. This only needs to be performed when EEROM failures
cannot be recovered where both the current EEROM (located in the
Main PCA) and the backup EEROM (located in the Ink Supply
Station) contain false values or because both of them have failed.
2 Turn Drive Roller Page 4-21
The purpose of this Service Utility is to rotate the Drive Roller in
order to clean it.
3 Unlock Carriage Page 4-22
The purpose of this Service Utility is to unlock the Carriage
Assembly which is normally locked by the Service Station in order
to cap the Printheads. Once unlocked, the Carriage Assembly can
then be moved freely along the Printer by hand.
4 Prime Tubes Page 4-23
The purpose of this Service Utility is to prime the Ink Supply Tubes
after they have been replaced (or if a situation arises where you need
to force the priming procedure).
5 Change Cutter Page 4-24
The purpose of this Service Utility is to move the Cutter Assembly
to a position where it can be replaced.
6 Change Ink Tubes Page 4-25
The purpose of this Service Utility is to move the Carriage
Assembly to a position where it makes the removal of the Ink
Supply Tubes much easier.
7 Printer Information Page 4-26
The purpose of this Utility is the following:
n Report basic parameters for call qualification.
n Identify potential problems.
HP DesignJets 500 and 800 Series Printers Service Manual 4-13
Service Tests and Utilities
Entering the Service Utilities Menu
1 Press the or key until the front panel displays the Setup Menu and
then press Enter.
Set-up menu Menu
Back
Press ENTER for
Set-up menu Enter
2 Once inside the Setup Menu, Press the following key combination
to access the special Service Menu.
Set-up menu Menu
R Printer information
AI
R EP I/O set-up
Back
E
SIT Front panel
O N- Altitude = 0-1000 m.
Log Enter
For On-site Engineers, press the Up and Enter keys
to access the complete list of Service Tests.
Set-up menu Menu
O RT Printer information
PP
SU I/O set-up
NE Front panel
Back
P HO
Altitude = 0-1000 m.
Log Enter
For Call Agents who will request the User to perform
certain troubleshooting actions, press the Down and Enter
keys to access a limited list of Service Tests.
3 Once inside the Service Tools Menu, press the or key until the
front panel displays Service Utilities and then press Enter.
Service Menu Menu
Back
Service tests
Service calibrations
Service utilities Enter
4-14 HP DesignJets 500 and 800 Series Printers Service Manual
Service Tests and Utilities
4 Press the Enter key to begin a specific utility when the required
Service Utility is highlighted.
Service utilities Menu
Change ink tubes
Unlock Carriage
Back
Turn Drive Roller
Prime tubes
EEROM Setup Enter
HP DesignJets 500 and 800 Series Printers Service Manual 4-15
Service Tests and Utilities
EEROM Setup
The purpose of this Service Utility is to modify identification
parameters such as serial and model numbers, as well as the Font
Type. This only needs to be performed when EEROM failures
cannot be recovered where both the current EEROM (located in the
Main PCA) and the backup EEROM (located in the Ink Supply
Station) contain false values or because both of them have failed.
Also, you can use this utility to reset the usage counters for parts
that have been replaced in order to correctly reflect the true usage of
the relevant parts.
WARNING After any change in the EEROM, switch the Printer OFF and
ON again in order to ensure that the change takes effect in all the
subsystems of the Printer.
Perform the EEROM Setup as follows:
1 In the Service Utilities submenu, scroll to "EEROM Setup" and
press Enter.
Service utilities Menu
Change ink tubes
Unlock Carriage
Back
Turn Drive Roller
Prime tubes
EEROM Setup Enter
2 The Printer will display a list of EEROM Setup options. You can
make your selection using the arrow keys and press Enter to view
the selection.
EEROM Setup options Menu
Model number
Serial number
Back
Font type
Reset usage counter
Reset to default Enter
If you want to select the Model Number
a If you want to select the Model number, then you should select
"Model number" and press Enter. A list of all the printer model
numbers available will appear on the front panel. The current
model selected will have the symbol next to the model number.
Use the arrow keys to scroll through the selections, and press
Enter to make the selection. Once the selection is made the
4-16 HP DesignJets 500 and 800 Series Printers Service Manual
Service Tests and Utilities
symbol will appear next to the selected model number. To
return to the EEROM setup options menu, press Back.
Select model number Menu
C7769B
C7770B
C7779B
Back
C7780B
C7779C Enter
If you want to select the Serial Number
a If you want to select the Serial number, then you should select
"Serial number" and press Enter. The following information will
be displayed on the front panel. You will need to use the arrow
keys to scroll through the complete list because the front panel
only allows 6 lines to be displayed at one time.
Enter serial number
Current: ESA80035674 Current Serial Number
New: _ encoded into the EEROM
0 Digits of the serial number
1 that you will be selecting
2 will appear here
3
4
5
6
7
Use the arrow keys to scroll
8
9 through the list of digits and
press ENTER to select the
A
ones that you require in order
B
C to make the new serial
number
D
E
F
ES