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DesignJet Z2100
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Designjet Z Series — Service Manual
6-35
Removal and Installation - Left Cover
17.
Remo
ve one T-
1
5
scr
ew t
hat
secures the
Left
Co
ver (top fr
ont, accessible Ink Cartri
dge
Door).
18
.
Unc
lip the Left T
rim.
19
.
Remo
ve the Le
ft
Co
ver f
rom the Pr
inter
.
256
258
Table of Contents
Main Page
Using this Manual
4
Purpose
4
Readership
4
Part Numbers
4
Conventions
4
Table of Contents
3
Troubleshooting
5
Using the Front Panel
7
Key Function
7
Service Key Combinations
7
General Troubleshooting
8
Introduction
8
Troubleshooting System Error Codes
8
Performing a Service Test on a failed Assembly
8
Performing the Necessary Service Calibrations
9
The Printer does not Power ON
9
What to do if the Front Panel is blank or system error 08:YZ is displayed
9
The Printer Continuously Rejects Printheads
10
Cover Sensors are not Working
11
The Line Sensor has Problems Detecting Media
11
Problems with Color Accuracy
11
Troubleshooting Media Jams/Printhead Crashes
11
The printer has problems ejecting sheet media
12
Banding at variable extreme environmental conditions
12
Worm marks on HP Coated media with light area fills
12
Solving Media-Handling Problems
13
Software Troubleshooting
14
General advice:
14
Installation
14
Problems with Image Clipping
14
Another Possible Explanation
15
Output Only Contains a Partial Print
15
Some objects are missing from the printed image
16
Corrective Action
16
If the spool file size is bigger than 1GB, part of the image will be clipped
16
Corrective Action
16
When the image needs to be rotated, parts of the image might be clipped or disappear
17
Description:
17
Corrective Action
17
Adobe Photoshop
17
It is not possible to open images that have more than 300,000 pixels in any direction (width or length)
17
Corrective Action
18
It is not possible to print images that have more than 30,000 pixels in any direction (Print menu gets grayed out)
18
Corrective Action
18
Image will be clipped if it is longer than 32768 pixels
18
Corrective Action
18
Carriage stops between swaths leaving some horizontal marks in the middle of the plot
18
Corrective Action
19
Image does not get correctly centered
19
Corrective Action
19
Portrait or landscape orientation is not taken into account
19
Corrective Action
19
Image is printed in letter size
19
Corrective Action
20
Adobe Acrobat
20
Image is printed in letter size
20
Corrective Action
20
Clipped images when printing long files
20
Corrective Action
21
Microsoft Powerpoint
21
Part of the image is lost when printing big slides in landscape orientation
21
Corrective Action
21
Adobe Photoshop CS for Mac
21
It is not possible to open images that have more than 300.000 pixels in any direction (width or length)
21
Corrective Action
22
It is not possible to print images that have more than 30.000 pixels in any direction (Print menu gets grayed out)
22
Corrective Action
22
Image will be clipped if it is longer than 32768 pixels
22
Corrective Action
22
It is not possible to print longer than 455inches
22
Corrective Action
23
Adobe Illustrator/InDesign for Mac
23
Corrective Action
23
It is not possible to print longer than 109inches
23
Corrective Action
23
Print Quality Troubleshooting
24
Print Quality Troubleshooting Actions
24
The Service Image Quality Diagnostic Print
25
What is the Service Image Quality Diagnostic Print?
25
Considerations for Printing the Diagnostic Print
26
Printing the Diagnostic Print
26
Reading the Diagnostic Print Results
28
Diagnostic Part 1: Printhead Reliability
28
Corrective Action
29
Diagnostic Part 2: Printhead Alignment
29
Corrective Action
30
Diagnostic Part 3: Printheads & Paper Advance
30
Banding
31
The plot is printed in Best or Normal mode (according to the menu option selected) with Error Hiding ON. The top band has 100% ink density patches while the bottom band has 50% ink density patches.
31
Troubleshooting Banding Problems
31
Corrective Action
32
No Printing Defects Found in the Diagnostic Print
32
The Advanced Diagnostic Prints
33
What are the Advanced Diagnostic Prints?
33
Printing the Advanced Diagnostics Print
33
Reading the Advanced Diagnostic Print Results
35
Paper Advance
35
Corrective Action
37
Visual Alignment Diagnostic
38
Reading the Printhead Alignment Diagnostic Print
39
Nozzle Health
40
Corrective Action for Nozzle Defects
41
Force Drop Detection
41
Troubleshooting Print Quality Problems
42
Print Quality General Advice
42
Horizontal Lines Across the Image (Banding)
42
Description of problem
42
Corrective Action
42
Lines are Missing, Too Thin, or Too Thick
43
Description of problem
43
Corrective Action
43
Problems with Stepped Lines
44
Description of problem
44
Corrective Action
44
Lines are Printed Double or in Wrong Colors
45
Description of problem
45
Corrective Action
45
Lines are discontinuous
45
Lines are Blurred (Ink Bleeds from Lines)
46
Description of problem
46
Corrective Action
46
Problems with Graininess
46
Description of problem
46
Corrective Action
47
Paper is not Flat
47
Description of problem
47
Corrective Action
48
Print Scuffing or Scratching when Touched
49
Description of problem
49
Corrective Action
49
Marks on the Media
49
Ink marks on the back of the paper
49
Corrective Action
49
Horizontal Smears on the Paper
49
Corrective Action
50
Pinchwheel Marks
52
Corrective Action
52
Rear Tray Marks
52
Corrective Action
52
Starwheel Marks
53
Corrective Action
53
Dark Ink Marks on the Media due to cockle
54
Corrective Action
54
Problems with the Edges of objects
55
Stepped or not sharp
55
Corrective Action
55
Darker than expected
55
Corrective Action
55
Bronzing
55
Corrective Action
55
Black and white prints do not look neutral
56
Horizontal lines at the end of a cut sheet print
56
Corrective Action
56
Vertical lines of different colors
56
Corrective Action
56
White spots on the print
57
Corrective Action
57
Problems with Color Accuracy
57
Corrective Action
57
Color accuracy using EPS or PDF images in page layout applications
58
Ink Supplies Troubleshooting
59
Introduction to Ink Supplies
59
What are Ink Supplies?
59
Ink Cartridges
59
Available Ink Cartridges
61
Printheads
61
Available Printheads
62
General Information About the Ink Supplies
62
General Precautions When Handling Ink Supplies
63
When Should You Replace the Ink Supplies?
63
Ink Cartridge Levels, Information, and Replacement
63
Ink Cartridge Levels
63
“View Ink Levels” Direct Access Key
63
“View Ink Levels” from the ink menu
64
Obtaining Ink Cartridge Information
64
Changing an Ink Cartridge
65
Printhead Information, Replacement and Alignment
67
Obtaining Printhead Information
67
Changing a Printhead
68
Aligning Printheads
70
Reinsert Printheads Procedure
70
Image Quality Maintenance Procedure
70
Scanning errors during alignment
71
Ink Cartridge and Printhead Status Messages
72
Ink Cartridge Status Messages
72
Printhead status messages
72
Printhead Error Codes
73
Solving Ink Supplies Problems
74
You Cannot Insert the Ink Cartridge Into the Printer
74
You Cannot Insert the Printhead Into the Printer
75
The front panel says to reset or replace a printhead
75
Maintaining and Cleaning the Printheads
76
Clean the printheads
76
Flex Contacts Cleaning Tool
76
System Error Codes
79
Introduction
80
Continuable and Non-Continuable Error Codes
80
System Error Code Brief Descriptions
81
Reading a System Error Code
81
System Error Code Table
81
Corrective Actions Table
83
System Error Codes - Full Descriptions
85
01.0:YZ
85
01.1:YZ
85
01.2:YZ
85
01.3:YZ
86
02.1:YZ
86
03:YZ
86
03.0:10
87
06:YZ
87
08:YZ (or Front Panel is blank)
87
11:YZ
87
21:YZ
88
21.1:YZ
88
2x.n:10
89
22.0:YZ
89
22.1:YZ
89
22.2:YZ
90
22.3:YZ
90
24:YZ
90
31:01
91
31:02
91
31:03
91
41:03
91
41:YZ
91
42:03
92
42:YZ
92
44:YZ
92
47:03
93
47:YZ
93
48:YZ
93
51:YZ
93
52:10
94
55:YZ
94
56:YZ
94
58:YZ
95
59.1:09
95
59.2:00
95
59.3:09
95
61:YZ
95
63:YZ
96
64:YZ
96
65:YZ
96
68:YZ
97
71:YZ
97
71:19
97
72:YZ
97
74:YZ
98
74.1:YZ
98
75.21:YZ
98
75.22:YZ
98
76:YZ
98
77:YZ
99
78:08
99
78.1:YZ
99
79:YZ
99
79.1:YZ
99
81:YZ
100
85:YZ
101
86:01
102
87:YZ
102
93:YZ
102
94:YZ
103
System Error Codes
79
Service Tests and Utilities
105
Introduction
106
Diagnostics - Self Test
106
Initialization Sequences
106
Phone Support
106
Service Tests (Diagnostics)
107
Using the Front Panel
109
Key Function
109
Service Key Combinations
109
Entering the Diagnostic Tests Menu
110
1. Scan Axis
110
Star Wheel Lifter test
111
PRS Test
113
Scan Axis Test
115
Cutter test
120
2. Paper Drive
122
3. Electronics Module
126
4. Carriage Assembly
131
5. Sensors
137
6. Color Sensor ESP (spectrophotometer)
140
7. Ink Delivery System (IDS)
142
Ink Delivery System
143
Check Ink Supplies
145
Check Leakage
147
8. Service Station
149
Service Station
149
Primer Motor
151
Aerosol Fan
153
9. I/O Information
155
10. Unit Information
156
11. EEROM Reset
157
12. Set Unit Configuration
159
13. Error 71:19 Recovery
159
Set Serial Number
159
Select Right S/N
160
14. Others
162
Service Utilities
163
Entering the Service Utilities Menu
163
1. Turn Drive Roller
165
2. Purge Tubes
166
3. Set SN
169
4. Reset Life Counters
170
5. Diagnostic Print
171
6. Set Date and Time
172
7. Enable/Disable Firewall
173
Service Calibrations
175
Service Calibrations
176
Using the Front Panel
177
Key Function
177
Service Key Combinations
177
Entering the Service Calibrations Menu
178
Scan Axis Calibration
178
Service Station Calibration
179
Paper Advance Calibration
180
Drop Detector Calibration
186
Service calibrations also need to be performed after removing or replacing certain printer components. If you have removed or replaced printer components, check the Service Calibration Guide to Removal and Installation to see which tests and calibrat...
186
Reset Calibration Flag
186
Calibrate Drop Detector
187
Line Sensor Calibration
189
Service calibrations also need to be performed after removing or replacing certain printer components. If you have removed or replaced printer components, check the Service Calibration Guide to Removal and Installation to see which tests and calibrat...
189
Carriage PCA
192
Color Sensor ESP (spectrophotometer) Calibration
192
Parts and Diagrams
195
Introduction
196
Printer Support
197
Center Covers (Front)
199
Center Covers (Rear)
201
Right Cover
203
Left Cover
205
Right Hand Assemblies
207
Left Hand Assemblies
209
Carriage Assembly
211
Scan-Axis Assemblies
213
Paper Path Assemblies (Front)
215
Paper Path Assemblies (Rear)
217
Took Kits
219
Miscellaneous Parts
221
Removal and Installation
223
Introduction
224
Safety Precautions
224
Electrostatic Discharge (ESD) Precautions
224
Required Tools
225
System Diagrams
226
Primer components
226
Primer schematic
226
Electronic layout
227
Main electronics and cabling
228
Ink supply station schematic
229
Service Calibration Guide to Removal and Installation
230
Using the Service Calibration Guide
230
The Service Calibration Matrix
230
Performing the Service Calibrations and Diagnostic Tests
234
Window
235
Removal
235
Front Cover
239
Removal
239
Media Output Assembly
240
Removal
240
Right Front Trim
241
Removal
241
Left Front Trim
243
Removal
243
Right Ink Cartridge Door
245
Removal
245
Left Ink Cartridge Door
247
Removal
247
Right Cover
249
Removal
249
Left Cover
252
Removal
252
Rear Tray
258
Removal
258
Rear Cover
259
Removal
259
Media Lever
260
Removal
260
Media Lever Position Sensor
263
Removal
263
Cutter Assembly
265
Removal
265
Right Rear Tray Support
266
Removal
266
Left Rear Tray Support
268
Removal
268
Front Panel
270
Removal
270
Top Cover
273
Removal
273
Window Position Sensor
276
Removal
276
Ink Supply Tubes Support Rail
278
Removal
278
Service Station
282
Removal
282
Drop Detector
286
Removal
286
Aerosol Fan Assembly
287
Removal
287
Primer Assembly
289
Removal
289
PrintMech PCA
293
Removal
293
Pen to Paper Space (PPS) Solenoid
295
Removal
295
Spindle
297
Removal
297
Left Spindle Holder
298
Removal
298
Right Spindle Holder
299
Removal
299
Clean Out Assembly
300
Removal
300
Out Of Paper Sensor
301
Removal
301
Left Roll Guide
304
Removal
304
Right Roll Guide
305
Removal
305
Encoder Strip (with spring and attachment nut)
306
Removal
306
Clean Encoder Strip Procedure
308
Encoder Strip
313
Removal
313
Trailing Cable (with Carriage PCA Cover)
314
Removal
314
Installation
319
Carriage Assembly and Trailing Cable
322
Removal
322
Extra High PRS Wedge
331
Replacement
331
Carriage Rear Bushing
335
Removal
335
Belt Assembly
337
Removal
337
Scan-Axis Motor
338
Removal
338
Carriage Rail Oiler
342
Removal
342
Color Sensor ESP (spectrophotometer)
344
Removal
344
Line Sensor
350
Removal
350
Carriage Cover (includes Carriage Latch)
355
Removal
355
Carriage PCA
360
Removal
360
Right Ink Supply Station
365
Removal
365
Left Ink Supply Station
369
Removal
369
Ink Supply Tubes
373
Removal
373
Formatter
381
Removal
381
Hard Disk Drive
383
Removal
383
Installation
383
Electronics Module (Main PCA and PSU)
385
Removal
385
Starwheel Assembly
388
Removal
388
Installation
389
Set the Starwheel Assembly to the DOWN Position (Z2100/Z3100/ Z3100ps only)
391
Print Zone Overdrive
393
Removal
393
Left Spittoon
397
Removal
397
Encoder Disk and Encoder Sensor
400
Removal
400
Installation
401
Media Advance Drive
403
Removal
403
Installation
405
Media Advance Roller
408
Removal
408
Pinchwheel Assembly
414
Removal
414
Installation
415
Pinch Roller
422
Removal
422
Rubber Pinchwheel Kit
423
Replacement
423
Left Starwheel Lifter
427
Removal
427
Installation
429
Right Starwheel Lifter
430
Removal
430
Installation
433
Starwheel Motor
434
Removal
434
Full Bleed Foam
436
Removal
436
Preventive Maintenance
437
Preventive Maintenance
438
Moisture on the Printer
438
Noisy Carriage Bushing
438
Belt Swelling
438
Cleaning the Printer
438
Carriage Assembly Lubrication
438
General Cleaning
439
Cleaning the Drive Roller and Overdrive
439
Level of Printer Usage
439
Preventive Maintenance Kits
441
Preventive Maintenance Kit #1
441
Preventive Maintenance Kit #2
442
Preventive Maintenance Kit #3
442
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