TWI Designjet Documents library presented here as a courtesy of
The owners of this website have no affiliation to Hewlett Packard nor do we claim to represent HP
in any way shape or form.
Return to TWI Documents Library Index Page
In this document:
An ink leak has been detected underneath the Carriage assembly. Symptoms include ink drops on media, or excessive ink drops anywhere along the Y-axis (Carriage path). There are two root causes for this failure: a plastic injection failure in the Valve Housing, or a crack in the Valve Housing. In either case an on-site CE must be sent to replace the Service station, Tubes assembly and Ink Cartridges. CE must also thoroughly clean the Print Carriage, Print Platen, and Y-axis path free of excess ink. Following the replacement of parts, the new tubes system must be primed correctly and the EEROM Service station counter must be reset. Follow the steps in this document to resolve this issue.
NOTE: It is critical that the firmware is upgraded to the newest version before dispatching service. Old firmware will generate a 21:10 error after a new Service station is installed (firmware will be looking for Aerosol fan in SS assembly that is no longer included in the new SS assembly). Instructions for upgrading the printer's firmware are provided below.
500 and 800 24 inch models
500 and 800 42 inch models
C4844A, C4911A, C4912A, C4913A
C4844A, C4911A, C4912A, C4913A
NOTE: If Removal and Installation instructions are needed for reference during any repairs performed, refer to the HP Designjet 500 and 800 Series Service Manual available on the Partner Care Web site for review or download.
The symptoms listed in the summary usually indicate leaking ink tubes. Another check that can be performed is to bring the Carriage out either manually or by pressing the replace the ink system key. Look under the Carriage, if the tubes are leaking, there will usually be a drop of ink where the tubes connect to the septum.
NOTE: The printer firmware must be upgraded to A.02.04 or higher for the new Service Station to work. The new Service Station does not have an Aerosol fan and older firmware will check for the Aerosol fan, thus causing another system error.
CAUTION: Following repair, the setup printheads (included with Tubes assy) must be installed for correct priming of new Tubes assembly. If the priming process is not done correctly, the end user will most likely receive "Out of ink" or "Low of ink" messages, which may require another Tubes assembly replacement.
If this utility is running on Windows or Mac OS, follow the instructions under the System Maintenance Utility heading to update the printer's system software.
If the System Maintenance Utility fails to update the printer's system software, or to upgrade the printer from any other operating system (such a UNIX(R) or DOS), see the "Other Operating Systems" section.
NOTE: The update process may take several minutes. Do not turn the printer off before the drawing showing the printer being unplugged appears on the front panel display. If there are any problems during the upgrade, or if the upgrade does not work, it may be necessary to upgrade using the "Other Operating Systems" section below.
Once the printer is upgraded, the new firmware revisions should report on the front panel. To view and confirm the firmware revisions:
The printer must be configured to print from the computer that is running the System Maintenance Utility. If the printer receives prints but does not appear in the list, select All Printers in the View menu. If it still fails to appear, perhaps the printer is not turned on or cannot be contacted. Try printing a simple page to see if the computer can connect to the printer.
If the printer is not found select File, then New from the menu bar and enter the IP address. Continue the upgrade as above.
NOTE: If the printer is connected via an external HP Jetdirect box it will be necessary to connect directly via parallel cable and choose: system emergency from the menu bar. Continue the upgrade as listed above.
If the behavior of the printer is less preferred than before it was upgraded, it is possible to downgrade the printer by selecting Downgrade in the Version menu. A prompt will allow a choice from a list of previous firmware versions.
Other operating systems
NOTE: If the System Maintenance Utility has been downloaded correctly from www.hp.com but problems arise while upgrading printer firmware via the System Maintenance Utility, another download is not necessary. The files can be found in the default directory located in C:\Program Files\Hewlett-Packard\HP Designjet system Maintenance. Proceed to the heading "Upgrade Process."
If the operating system is any other operating system (such as UNIX or DOS), perform the next two steps, and then proceed under the heading "Upgrade Process."
If the System Maintenance Utility is unable to successfully upgrade firmware to a printer, send the files by connecting the printer to a PC through the parallel port.
CAUTION: Do not turn power off, or unplug the printer, until prompted, on the front panel display
CAUTION: Do not turn the power off, or unplug the printer, until prompted, on the front panel display
The steps outlined in the HP Designjet 500 and 800 Series Service Manual should cause the priming process to occur on initialization of the printer. If the priming process completed successfully, skip to the next section ("Resetting the Service Station counter"). If the priming process did not begin automatically, perform the following steps:
NOTE: The printer may require a new ink cartridge for any cartridge that indicates a level less than 20 ml of ink.
After the priming procedure is completed, the Service Station counter must be reset or the printer will give a premature Maintenance Advised message. After the printer returns to a Ready state, perform the following reset:
Windows (R) and MS Windows (R) are
U.S. registered trademarks of Microsoft Corp.
Copyright Hewlett-Packard Co. 2001
This information is subject to change without notice and
is provided "as is" with no warranty.
Hewlett-Packard shall not be liable for any direct,
indirect, special, incidental or consequential damages
in connection with the use of this material.
|One Day Only Sale Item!
772-2 Red Compatible Postage InkJet Cartridge for Pitney Bowes 2 tanks
817-5 Black Compatible Laser / Fax Toner for Pitney Bowes
OPTIMAIL Remanufactured Red Ribbon for Francotyp-Postalia 3pk
C7769-60182 DesignJet 500 / 800 Carriage Drive Belt 24 inch
C7770-60287 C7770-60276 DesignJet 500 / 800 42 Inch Plotter Maintenance Kit
C7769-60406 DesignJet 500 / 800 Cover kit for drive roller encoder sensor