HP Designjet 500 and 800 Series Printers - TWI: System Error 86:01, Noise Along the Carriage Path

Document number: BPP90131

Last Updated: 13-Aug-2003

Minimum skill level: 2

An unusual noise is heard when the carriage moves or system error 86:01 is being displayed on the printer’s front panel. General causes are media or other obstructions in the carriage path, the trailing cable, worn carriage bushings, lack of lubrication in the carriage path, a dirty encoder strip, the scan-axis motor, or the service station. Follow the steps listed below to accurately troubleshoot the issue, and replace the appropriate parts.

The steps below are designed to achieve remote resolution of the issue. If the troubleshooting steps below appear to resolve the issue, attempt to verify printer functionality by printing several internal prints. If the issue persists following the steps below, generate a CSO for service.
NOTE: The printer’s current firmware revision must be A.02.04 or higher for a new Service Station to work properly. If firmware is lower than A.02.04, download the newest available firmware before continuing with the remainder of this document.

1. Visually check for jammed media or other obstructions in the carriage path and remove any obstructions found (remove any loaded media as well).

2. Determine if the noise is normal. Some noise is normal. Specifically, it is normal to hear a slight clicking noise when the carriage moves under the left or the right-hand covers.

3. If an 86:01 error occurs during initialization and the carriage does not move out of the Service Station continue Step 4, otherwise go to Step 5.

4. Remove the right cover and check the cable connection between the Interconnect PCA and the Service Station motor. If connections appear normal, replace the Service Station (refer to pages 8-52 of the Service Manual).

5. Attempt to verify functionality, if problems persist, continue with the remaining steps.

6. Unlock the carriage as instructed below:

   1. Highlight the Set-Up menu and press the Enter key.

   2. Press the Up Arrow and Enter keys simultaneously and then press Enter.

   3. Scroll to Service Utilities and then press Enter.

   4. Scroll to Unlock Carriage and press Enter.

   5. Unplug the printer from the power source.

7. Move the carriage manually through the entire movement path to see if it encounters any obstructions or has more resistance in any particular spot. Remove any such obstructions if possible.

   NOTE: If the carriage will not move out from the service station, create a CSO for service (send ALL required parts as listed below). Otherwise continue with the remaining steps.

8. Clean and lubricate the carriage rail.

9. Slide the carriage manually back and forth several times to evenly spread the lubrication across the entire carriage rail.

10. Turn the printer on and attempt to verify functionality. If problems persist, generate a CSO for service (send ALL required parts as listed below).

Part description	24 inch models - C7769B, C7769C, C7779B, C7779C	42 inch models - C7770B, C7770C, C7780B, C7780C
Trailing cable (Required)	C7769-60305	C7770-60274
Carriage assembly (Required)	C7769-60376	C7769-60376
Belt tensioner kit (Required)	C7769-60176	C7769-60176
Carriage belt (Required)	C7769-60182	C7770-60014
Scan-Axis motor (Required)	C7769-60375	C7769-60375
Service Station assembly (Required)	C7769-60374	C7769-60374

NOTE: If removal and installation instructions are needed for reference during any repairs performed, refer to the HP Designjet 500/800 Series Service Manual available on the Computer Care Web site for review or download.

Troubleshooting steps

If any of the troubleshooting steps (including parts replacement) listed below solve the problem, attempt to verify printer functionality by printing several internal prints. If functionality is verified, no additional parts should be replaced.

1. Release the carriage as instructed in Steps 6a - 6e in the "Contact center agents" section listed above.

   NOTE: If the carriage will not come out of the service station area, replace the Service Station (refer to pages 8-52 of the Service Manual). Firmware must be upgraded to A.02.04 or higher. If replaced, attempt to verify functionality before continuing with the remaining steps.

2. If the carriage releases, or the problem persists following replacement of the service station, continue with the remaining steps.

   CAUTION: Ensure the printer is turned off and unpluged from the power source before continuing with Step 3 below.

3. Using a lint free cloth dampened with water, clean the trailing cable and the underside of the printer frame that holds the ink-tube system.

4. Clean the Encoder strip with a lint-free cloth dampened with water.

   WARNING: Be careful when working around the Encoder strip, as the edges are very sharp and can cause injury.

5. Inspect the Y-belt for damage or excessive wear, and replace if necessary (refer to pg 8-40 of the Service Manual).

6. Following inspection/replacement of the Y-belt, turn the printer on and attempt to verify functionality. If the problem persists, continue with the remaining steps.

7. Turn the printer off and replace the Carriage and Trailing cable (refer to pages 8-78 and 8-40 of the Service Manual).

   NOTE: When replacing the trailing cable, use the stiffener that ships with the 1000 series trailing cable. Remove the stiffener from the box and install on top of the HP Designjet 500/800 trailing cable with the concave side down.

8. Following replacement, turn the printer on and attempt to verify functionality. If problems persist continue with the remaining steps.

9. Turn the printer off and replace the Scan-Axis motor (refer to pages 8-29 of the Service Manual).

10. Following replacement, turn the printer on and verify functionality as instructed below.

Verify functionality

1. Turn the printer on.

2. Load media into the printer.

3. From the main front-panel menu, select the Ink menu and press Enter.

4. Select Troubleshooting and press Enter.

5. Follow the instructions on the front panel.

6. Have the customer send a file from the computer and make certain that the file prints correctly.

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