DesignJet Plotter Repair

Link: http://www.computercareonline.com/designjet-parts-by-model-c-67.html

Error Codes for HP DesignJet 500 / 510 / 800 Plotter
Computer Care offers this information with NO specific warranty, use at your own risk.
part names are linked back to our parts website.
Specific error codes, issues and fixes may be linked to other articles of interest.
Chapter 8 Remove and Replace Guide may be downloaded from the clickable link provided.
The full service manual is available where indicated.

Follow up:

01:10 2-7 (Article)
01:11 2-7
01:12 2-7
01:13 2-8
02:10 2-8 (Article)
02:13 2-8
03:10 2-9 (Article)
04:11 2-9
05:10 Warning (Only applicable to HP DesignJet 800 Series) (Article)
05:11 2-10
06:03 (only applicable for Designjet 800 series)
08:11 2-10 (Article)
11:11 2-10 (Article)
11:13 2-10
12:11 2-10
21:10 2-11 (Article)
21:11 2-11 (Article)
22:10 2-11 (Article)
41:10 2-11 (Article)
41:13 2-12
42:10 2-12
43:10 2-12 (Article)
43:11 2-12
56:10 2-12
56:13 2-13
61:04 2-13
61:05 2-14
64:04 2-14
71:04 2-15
71:06 2-15
72:04 2-16
73:04 2-16
79:04 2-17
81:01 2-17 (Article)
81:11 2-17
85:10 2-18
86:01 2-18 (Article)
86:11 2-18
86:13 2-19
87:13 2-19
93:10 2-19

Introduction
are hexa-decimal based numbers generally
caused by internal system errors. The following pages contain a list
of and their respective descriptions and
recommended corrective actions. Only try one recommended action
at a time and check if the error code has disappeared.
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.
NOTE
Even though the customer can continue working with a
Continuable Error Code, an on-site visit should still be planned
to troubleshoot the problem.
- Explanation
consist of 4 digits which explain which
component/system is failing and what action should be taken to
resolve the problem.
The following table explains the first 2 digits of the System Error Code:
Code
Component/System
01
Main PCA/Electronics Module
02
Carriage/Carriage PCA
03
Power Supply Unit
04
Network Card
05
Formatter
06
Hard Disk Drive
07
Interconnect PCA
08
Front Panel
11
Trailing Cable
12
Carriage Flex Circuit

17
Interconnect Cable
21
Service Station
22
Ink Supply Station
23
Pressure System (APS)
24
Ink Delivery System
25
Spittoon
31
Cutter
32
Take-up Reel
33
Sheet Feeder
34
Dryer/Blower
41
Paper-Axis Motor
42
Scan-Axis Motor
43
Vacuum Fan
44
Aerosol fan
51
Window Sensor
52
Drop Detector
53
Media Sensor
54
Pinch-Arm Sensor
55
Line Sensor
56
Drive Roller Encoder Sensor
57
Ink Leak Detector
58
Color Sensor
59
Media Type Sensor
61
Language Interpreting
62
Input/Output through Parallel Port
63
Input/Output through Network Card
64
Input/Output through USB Port
65
Input/Output
71
Memory Management
72
Generic Firmware
73
Servo
79
Assertion
81
Media Advance
82
Media Cut
83
Single-Sheet Feeding
Code
Component/System

The following table explains the last 2 digits of the System Error Code:
84
Roll Feeding
85
Media-Axis Encoder Reading
86
Carriage Movement
87
Scan-Axis Encoder Reading
91
Printhead Firing
92
Servicing
93
Ink Pumping
Code
Recovery Action
Response
00
Replace
Possible for
customer to
perform
action
01
Reseat/Reconnect/Clean/Adjust (manually)
02
Calibrate/Adjust (using Automatic Process)
03
Power OFF
04
Upgrade System Firmware
05
Upgrade Driver
06
Add Accessory
07
Escalate
08
Send Plot Again
09
Wrong Part Installed
10
Replace
On-Site
visit
required
11
Reseat/Reconnect/Clean/Adjust (manually)
12
Calibrate/Adjust (using Automatic Process)
13
Power OFF
14
Upgrade System Firmware
15
Upgrade Driver
16
Add Accessory
17
Escalate
18
Send Plot Again
19
Wrong Part Installed
Code
Component/System

Error Log Utility
The Error Log utility contains a record of the last 10 system error
codes the Printer has experienced. The purpose of this information
is to:

Determine whether the Printer is experiencing repetitive failures.

Determine whether the previous problems are causing the current
failure in the printer.

Determine whether there are additional symptoms to the current
system error code.
The information that is stored for each error code is:

The reported System error code.

The code line in the Firmware where the error was triggered.

The date when the error code was triggered.
Accessing the Error Log Utility
1 Press the up arrow
or down arrow key until the front panel displays the
Setup Menu and
then press Enter
.
2 Press the
up arrow
or down arrow key until the front panel highlights Log.
Press the
Enter key.
Menu
Back
Enter
Press ENTER for
Set-up menu
Set-up menu
Menu
Back
Enter
Set-up menu
Expansion cards
I/O set-up
front panel
Altitude = 0-1000 m.
Log

3 Press the
up arrow
or down arrow key until the front panel highlights Errors. Press
the Enter key.
4 Press the up arrow or down arrow key until the front panel highlights the error code
that you want to see information on.
Press the Enter key.
5 The front panel displays information on the selected item
.
NOTE
To view information on another Error Code, press BACK and
the front panel will return to the previous screen
Menu
Back
Enter
Log
Printheads
Errors
Menu
Back
Enter
Error log
Select for more info:
1 Error 21:10
2 Error 01:11
3 Error 21:11
4 Error 43:10
Error log
Error code: 21:10
linefeed.c, 217
Date: 20-Sep-01

System Error:
01:10
Problem
Description:
Electronics Module failure. The possible cause could be:
1. The Electronics Module is of the wrong type (a 16 MB
Electronics Module will not work in a 24" Model).
2. Reading, writing or initializing the EEROM failed.
3. One of the ASIC's was not found within the Serial Bus that
connects the Electronics Module to the Carriage Assembly.
4. One of the ASIC's did not respond to the Serial Bus that connects
the Electronics Module to the Carriage Assembly.
5. The Electronics Module is requesting a move to the Service
Station while the previous move is still being completed.
6. The Electronics Module Cooling Fan has reached its current
limit.
Corrective Action:
Replace the Electronics Module
Page 8-24.
System Error:
01:11
Problem
Description:
The Electronics Module Cooling Fan badly connected.
Corrective Action:
Reconnect the Cooling Fan (located on top of the Electronics
Module). If the Cooling Fan continues to fail, check that the
connector pins in the Electronics Module are NOT bent.
System Error:
01:12
Problem
Description:
The EEROM is not configured correctly (the product number may
be missing).
Corrective Action:
Configure the EEROM correctly using the EEROM setup utility

Page 4-17.

System Error:
01:13
Problem
Description:
Electronics Module failure. The possible cause could be:
1. One of the ASIC's in the Electronics Module is reporting that it is
too hot.
2. The interruptions from the Scan-Axis servo or from the Paper-
Axis servo are not coming as regularly as they are expected or
are coming too late.
Corrective Action:
Try the following:

Switch the Printer Off and wait a few minutes. Switch the Printer
On again and check if the Error Code has disappeared.

If the Error Code continues, replace the Electronics Module

Page 8-24.
System Error:
02:10
Problem
Description:
Carriage failure. The possible cause could be:
1. The Carriage PCA is not compatible with the rest of the Printer.
2. The Carriage ASIC has problems initializing.
3. The +2.5V reference voltage generated in the Carriage PCA is
out of range.
4. One of the Carriage ASIC's cannot be found within the Serial
Bus that connects the Electronics Module to the Carriage.
5. One of the Carriage ASIC's did not respond to the Serial Bus that
connects the Electronics Module to the Carriage Assembly.
Corrective Action:
Replace the Carriage Assembly
Page 8-78.
System Error:
02:13
Problem
Description:
Carriage failure. The possible cause could be:
1. One of the ASIC's in the Carriage is reporting that it is too hot.
Corrective Action:
Try the following:

Switch the Printer Off and wait a few minutes. Switch the Printer
On again and check if the Error Code has disappeared.

If the Error Code continues, replace the Carriage Assembly

Page 8-78.

System Error:
03:10
Problem
Description:
Power Supply failure.
Corrective Action:
Replace the Power Supply Unit
Page 8-27.
System Error:
04:11
Problem
Description:
LAN Card not detected.
Corrective Action:
Power OFF the Printer and reconnect the LAN Card.
System Error:
05:09 Error (Only applicable to HP DesignJet 500 Series)
Problem
Description:
Formatter installed instead of HP-GL/2 Accessory Card.
Corrective Action:
Power OFF the Printer and remove the Formatter and install the HP-
GL/2 Accessory Card
Page 8-20.
NOTE: If this Error Code appears on a DesignJet 800 Series Printer,
then the model number configured in the Printer is incorrect (the
Printer thinks it's a DesignJet 500 Series Printer). In this case
reconfigure the model number
Page 4-17.
System Error:
05:10 Warning (Only applicable to HP DesignJet 800 Series)
Problem
Description:
Formatter not detected.
Corrective Action:
Power OFF the Printer and reseat the Formatter.
System Error:
05:10 Error (Only applicable to HP DesignJet 800 Series)
Problem
Description:
Formatter failure.
Corrective Action:
Power OFF the Printer and replace the Formatter
Page 8-20.
System Error:
05:10 Error (Only applicable to HP DesignJet 500 Series)
Problem
Description:
HP-GL/2 Accessory Card failure.
Corrective Action:
Power OFF the Printer and replace the HP-GL/2 Accessory Card

Page 8-20.

System Error:
05:11
Problem
Description:
Formatter not detected. Formatter.

System Error:
6:03
Explanation
Hard disk error on the formatter verify functionality of the machine by removing the formatter, continue past the system error 05:10 Install a designjet 500 driver to print with. Solution: replace the formatter
Recommended action
1.Turn the printer off and unplug the power cable from the back of the printer.
2.Remove the Formatter card and re-install the Formatter card. Click here for detailed instructions on formatter card removal.
3.Plug the power cable in and turn the printer on.
4.Continue past system error 05:10, and attempt to print via the HP Designjet 500 print driver.
Click here to download HP drivers. (The link is http://h20000.www2.hp.com/bizsupport/TechSupport/Home.jsp?locale=en_US.
5.If the printer prints fine using the Designjet 500 driver, the formatter card is faulty and should be replaced

System Error:
08:11
Problem
Description:
Front Panel cannot be detected.
Corrective Action:
Reconnect the Front Panel.
System Error:
11:11
Problem
Description:
Trailing Cable badly connected.
Corrective Action:
Reconnect the Trailing Cable correctly.
***NOTE** Before removing or replacing trailing cable - Turn the plotter off, move the carriage all the way to the right, turn the plotter back on, check to see if error is still present.
System Error:
11:13
Problem
Description:
Problem with setting the voltage of the Printheads.
Corrective Action:
Try the following:

Check that the Trailing Cable is connected correctly at both ends.

Replace the Trailing Cable
Page 8-40.

Replace the Carriage Assembly
Page 8-78.
System Error:
12:11
Problem
Description:
A short detected in the Carriage Assembly.
Corrective Action:
Try the following:

Remove ALL the Printheads and clean the flex contacts on the
Printheads and in the Carriage Assembly.

Replace ALL the Printheads.

Replace the Carriage Assembly
Page 8-78.

System Error:
21:10
Problem
Description:
Service Station failure. The possible cause could be:
1. The steps counted by the Service Station motor are not consistent
with the expected length of the current movement.
2. The Aerosol Fan has reached its maximum current limit.
3. The Service Station motor has shutdown because of blockage.
Corrective Action:
Replace the Service Station Assembly
Page 8-52.
System Error:
21:11
Problem
Description:
Service Station cannot be detected or the Service
Station is badly adjusted.
Corrective Action:
Try the following:

Reconnect the Service Station Assembly.

Reposition the Service Station trip lever.
System Error:
22:10
Problem
Description:
Ink Supply Station failure. The possible cause could be:
1. Reading, writing or initializing the backup EEROM failed.
2. One of the out-of-ink sensors (located in the Ink Supply Station)
is not reporting what it should during the initializing process
while depressurizing.
Corrective Action:
Replace the Ink Supply Station
Page 8-48.
System Error:
41:10
Problem
Description:
Paper-Axis Motor failure.
Corrective Action:
Replace the Paper-Axis Motor
Page 8-84.

System Error:
41:13
Problem
Description:
Error in the Paper-Axis Motor Encoder quadrature.
Corrective Action:
Try the following:

Switch the Printer Off and wait a few minutes. Switch the Printer
On again and check if the Error Code has disappeared.

If the Error Code continues, replace the Paper-Axis Motor

Page 8-84.
System Error:
42:10
Problem
Description:
Scan-Axis Motor failure.
Corrective Action:
Replace the Scan-Axis Motor
Page 8-29.
System Error:
43:10
Problem
Description:
Vacuum Fan failure.
Corrective Action:
Replace the Vacuum Fan
Page 8-64.
System Error:
43:11
Problem
Description:
Vacuum Fan not detected.
Corrective Action:
Reconnect the Vacuum Fan.
System Error:
56:10
Problem
Description:
Drive Roller Encoder Sensor error.
Corrective Action:
Try the following:

Replace the Drive Roller Encoder Sensor
Page 8-38.

If the problem persists, replace the Encoder Disk Assembly.

System Error:
56:13
Problem
Description:
Error in the Drive Roller Encoder Sensor quadrature.
Corrective Action:
Try the following:

Switch the Printer Off and wait a few minutes. Switch the Printer
On again and check if the Error Code has disappeared.

If the Error Code continues, replace the Drive Roller Encoder
Sensor
Page 8-38.
System Error:
61:04
Problem
Description:
Firmware Error.
Corrective Action:
Try the following:

Switch the Printer Off and wait a few minutes. Switch the Printer
On again and check if the Error Code has disappeared.

If the Error Code reappears, check for a new Firmware release.

If the new Firmware release does not solve the problem, or if new
Firmware release was not available, then contact the HP
Response Center (or directly to the Division) supplying the
following information:
Model and Serial Number of the Printer.
Firmware release of the Printer (use the Printer Information
utility
Page 4-27).
The complete Error Code information, including the linefeed
where the error occurred (use the Error Log utility to obtain this
information
Page 2-5).

System Error:
61:05
Problem
Description:
Error Processing Job. This Error Code only appears in HP DesignJets
800 Series, or in the HP DesignJet 500 Series with an HP-GL/2 card
installed, when processing either a PostScript or HP-GL/2 file.
Corrective Action:
Try the following:

Switch the Printer Off and wait a few minutes. Switch the Printer
On again and resend the file that you were trying to print.

If the Error Code reappears after resending the file, then try
generating the file again and try to print again.

If the file that is causing this error is PostScript, check if it is
Binary. If the file is Binary, use AppleTalk to send the file to the
Printer. If AppleTalk is not being used to send the Binary file to
the Printer, then change the PostScript settings to Binary through
the Front Panel (Set-up menu / PS settings / Encoding / Binary).

If the Error Code continues to reappear, check for a new release
of the Driver.
System Error:
64:04
Problem
Description:
Firmware Error (USB Port).
Corrective Action:
Try the following:

Switch the Printer Off and wait a few minutes. Switch the Printer
On again and check if the Error Code has disappeared.

If the Error Code reappears, check for a new Firmware release.

If the new Firmware release does not solve the problem, or if new
Firmware release was not available, then contact the HP
Response Center (or directly to the Division) supplying the
following information:
Model and Serial Number of the Printer.
Firmware release of the Printer (use the Printer Information
utility
Page 4-27).
The complete Error Code information, including the linefeed
where the error occurred (use the Error Log utility to obtain this
information
Page 2-5).

System Error:
71:04
Problem
Description:
Problem allocating Memory. This Error Code only appears in HP
DesignJets 800 Series, or in the HP DesignJet 500 Series with an HP-
GL/2 card installed.
Corrective Action:
Try the following:

Switch the Printer Off and wait a few minutes. Switch the Printer
On again and check if the Error Code has disappeared.

If the Error Code reappears, check for a new Firmware release.

If the new Firmware release does not solve the problem, or if new
Firmware release was not available, then contact the HP
Response Center (or directly to the Division) supplying the
following information:
Model and Serial Number of the Printer.
Firmware release of the Printer (use the Printer Information
utility
Page 4-27).
The complete Error Code information, including the linefeed
where the error occurred (use the Error Log utility to obtain this
information
Page 2-5).
System Error:
71:06
Problem
Description:
Out of Memory problem. This Error Code only appears in HP
DesignJets 800 Series, or in the HP DesignJet 500 Series with an
HP-GL/2 card installed, when processing either a PostScript or HP-
GL/2 file.
Corrective Action:
Try the following:

Check the amount of RAM in the Printer using the Front Panel
(use the Printer Information utility
Page 4-27). If necessary,
install more memory into the Formatter.

If the problem continues, try processing the file in the PC instead
of the Printer (select Avoid out of memory in Advanced options
in the Driver).

System Error:
72:04
Problem
Description:
Problem in the Scan-Axis (Firmware Error).
Corrective Action:
Try the following:

Switch the Printer Off and wait a few minutes. Switch the Printer
On again and check if the Error Code has disappeared.

If the Error Code reappears, check for a new Firmware release.

If the new Firmware release does not solve the problem, or if new
Firmware release was not available, then contact the HP
Response Center (or directly to the Division) supplying the
following information:
Model and Serial Number of the Printer.
Firmware release of the Printer (use the Printer Information
utility
Page 4-27).
The complete Error Code information, including the linefeed
where the error occurred (use the Error Log utility to obtain this
information
Page 2-5).
System Error:
73:04
Problem
Description:
Servo Error.
Corrective Action:
Try the following:

Switch the Printer Off and wait a few minutes. Switch the Printer
On again and check if the Error Code has disappeared.

If the Error Code reappears, check for a new Firmware release.

If the new Firmware release does not solve the problem then
replace the Page 8-24.

If the problem continues, contact the HP Response Center (or
directly to the Division) supplying the following information:
Model and Serial Number of the Printer.
Firmware release of the Printer (use the Printer Information
utility
Page 4-27).
The complete Error Code information, including the linefeed
where the error occurred (use the Error Log utility to obtain this
information
Page 2-5).

System Error:
79:04
Problem
Description:
Firmware Error.
Corrective Action:
Try the following:

Switch the Printer Off and wait a few minutes. Switch the Printer
On again and check if the Error Code has disappeared.

If the Error Code reappears, check for a new Firmware release.

If the new Firmware release does not solve the problem, or if new
Firmware release was not available, then contact the HP
Response Center (or directly to the Division) supplying the
following information:
Model and Serial Number of the Printer.
Firmware release of the Printer (use the Printer Information
utility
Page 4-27).
The complete Error Code information, including the linefeed
where the error occurred (use the Error Log utility to obtain this
information
Page 2-5).
System Error:
81:01
Problem
Description:
Paper-Axis shutdown.
Corrective Action:
If this error code appeared but was NOT caused by a paper jam, then
try the following:

Perform the Paper Advance Test
Page 4-11.

If the problem persists, replace the Encoder Disk Assembly.
System Error:
81:11
Problem
Description:
Paper-Axis shutdown (during the Paper Advance test).
Corrective Action:
Refer to Error Code 81:01.

System Error:
85:10
Problem
Description:
Paper-Axis Encoder error. The Drive Roller Encoder Sensor cannot
find the zero position of the Encoder Disk.
Corrective Action:
Try the following:

Replace the Drive Roller Encoder Sensor
Page 8-38.

If the Error Code continues, replace the Drive Roller
Page 8-86.
System Error:
86:01
Problem
Description:
Carriage-Axis shutdown.
Corrective Action:
If this error code appeared but was NOT caused by a paper jam, then
try the following:

Too much friction in the Slider Rod. Enter the Printer Information
utility (
Page 4-27) and check the Scan-Axis usage. If the
percentage is close to 100%, then lubricate the Slider Rod.

The Carriage is bumping into the Service Station. If the carriage
is stuck at the right hand side of the Printer and cannot be moved
out to the center of the Print Platen it is because the Service
Station cannot uncap the Printheads. In this case replace the
Page 8-52.

Perform the Carriage Movement test
Page 4-8.
System Error:
86:11
Problem
Description:
Carriage-Axis shutdown (during the Carriage Movement test).
Corrective Action:
Refer to Error Code 86:01.

System Error:
86:13
Problem
Description:
Carriage-Axis shutdown (Firmware Error).
Corrective Action:
Try the following:

Switch the Printer Off and wait a few minutes. Switch the Printer
On again and check if the Error Code has disappeared.

If the Error Code reappears, check for a new Firmware release.

If the new Firmware release does not solve the problem, or if new
Firmware release was not available, contact the HP Response Center
(or directly to the Division) supplying the following information:
Model and Serial Number of the Printer.
Firmware release of the Printer (use the Printer Information
utility
Page 4-27).
The complete Error Code information, including the linefeed
where the error occurred (use the Error Log utility to obtain this
information
Page 2-5).
System Error:
87:13
Problem
Description:
Unable to read the Carriage Encoder Sensor.
Corrective Action:
Try the following:

Switch the Printer Off and wait a few minutes. Switch the Printer
On again and check if the Error Code has disappeared.

If the Error Code continues, replace the Carriage Assembly

Page 8-78 or the Encoder Strip
Page 8-76.
System Error:
93:10
Problem
Description:
Ink System startup failed (also see Page 1-7 for more information).
Corrective Action:
Try the following:

Check for a leak in the Printer. If a leak is evident (there is ink on
Printer components), replace the Ink Supply Tubes
Page 8-60.

Perform the Prime Tubes utility (Refer to Page 4-24) and check
how long it takes to complete the procedure. If it takes too long to
complete the procedure and there is no leak in the Printer, then
replace the Ink Cartridges. If it takes a short time to complete the
procedure, then replace the Ink Supply Tubes
Page 8-60.

Computer Care is not responsible for typographical errors, ownership of any proprietary information or ideas remains the sole property of the original writer.
Computer Care has one intention here, to place information in the hands of the owners of these machines so they can make informed decisions about the service of their plotter.

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