Designjet T120/T520 Eprinter Series: Service Manual
Designjet T120/T520 Eprinter Series: Service Manual
Service Manual
© 2012 Hewlett-Packard Development Legal notices
Company, L.P.
This document contains proprietary
1st edition, August 2012 information that is protected by copyright. All
rights are reserved. No part of this document
may be photocopied, reproduced, or translated
to another language without the prior written
consent of Hewlett-Packard Company.
Notices
Warranty WARNING WARNING
The information contained in this The procedures described in this manual are to The Warning symbol calls attention to a
document is subject to change without be performed by HP-qualified service procedure, practice, or the like, which, if
notice. personnel only. not correctly performed or adhered to,
could result in personal injury. Do not
Hewlett-Packard makes no warranty Electrical Shock Hazard proceed beyond a Warning symbol until
of any kind with regard to this the indicated conditions are fully
material, including, but not limited to, Serious shock hazard leading to death or injury understood and met.
the implied warranties of may result if you do not take the following
merchantability and fitness for a precautions: CAUTION
particular purpose.
● Ensure that the AC power outlet (mains) The Caution symbol calls attention to an
Hewlett-Packard shall not be liable for has a protective earth (ground) terminal. operating procedure, practice, or the like,
errors contained herein or for incidental which, if not correctly performed or
or consequential damages in connection ● Disconnect the printer from the power adhered to, could result in damage to or
with the furnishing, performance, or use source prior to performing any destruction of part or all of the printer.
of this material. maintenance. Do not proceed beyond a Caution symbol
until the indicated conditions are fully
● Prevent water or any other liquids from understood and met.
running onto electrical components or
circuits, or through openings in the
enclosure.
Electrostatic Discharge
Safety Symbols
Customer Assurance
Spain
ENWW iii
Using this manual
This service manual contains information necessary to test, maintain, and service the following:
For information about using these printers, see the user's guide.
Readership
The procedures described in this service manual are to be performed by HP Certified service personnel only.
Part numbers
Part numbers for printer service parts are located in Parts and diagrams on page 119.
ENWW v
Table of contents
2 Troubleshooting .......................................................................................................................................... 33
Printer troubleshooting flowchart ...................................................................................................................... 34
Basic printer troubleshooting ............................................................................................................................. 35
System error codes .............................................................................................................................................. 38
Paper troubleshooting ........................................................................................................................................ 57
Communication troubleshooting ........................................................................................................................ 62
Ink-supplies troubleshooting .............................................................................................................................. 66
Print-quality troubleshooting ............................................................................................................................. 78
Update the firmware ........................................................................................................................................... 91
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5 Removal and installation ........................................................................................................................... 135
Introduction ....................................................................................................................................................... 137
Customer Self Repair parts ............................................................................................................................... 139
Videos available ................................................................................................................................................. 140
Recommended checks after replacing parts .................................................................................................... 140
Top Cover ........................................................................................................................................................... 141
Front Cover ........................................................................................................................................................ 144
Right Cover ........................................................................................................................................................ 147
Ink Cartridge Cover ............................................................................................................................................ 150
Left Cover .......................................................................................................................................................... 152
Roll Cover ........................................................................................................................................................... 154
Back Cover ......................................................................................................................................................... 157
Front Panel ........................................................................................................................................................ 159
Front Panel Cable .............................................................................................................................................. 165
Central Cover ..................................................................................................................................................... 166
Upper-Roll Paper Guide ..................................................................................................................................... 171
Left Roll Support ............................................................................................................................................... 174
Right Roll Support ............................................................................................................................................. 179
Top Cover Sensor ............................................................................................................................................... 182
Top Cover Sensor Cable ..................................................................................................................................... 185
Encoder Strip ..................................................................................................................................................... 187
Ink Cartridge Cover PCA Assembly .................................................................................................................... 192
Power Supply ..................................................................................................................................................... 196
Main PCA ............................................................................................................................................................ 198
Paper Motor ....................................................................................................................................................... 204
Encoder PCA and Index ...................................................................................................................................... 206
Encoder Disk ...................................................................................................................................................... 210
Trailing Cable ..................................................................................................................................................... 213
Service Station ................................................................................................................................................... 220
Prime Pump ....................................................................................................................................................... 226
Carriage and Belt ............................................................................................................................................... 229
Carriage Belt ...................................................................................................................................................... 235
Right Gear Train Module .................................................................................................................................... 237
Starwheel Assembly .......................................................................................................................................... 239
Output Shaft ...................................................................................................................................................... 241
Output Tray ........................................................................................................................................................ 249
Multi-Sheet Tray Assembly ............................................................................................................................... 252
Multi-Sheet Tray Assembly Extensions ............................................................................................................ 253
Output Platen .................................................................................................................................................... 255
Carriage Motor ................................................................................................................................................... 260
Cutter Assembly ................................................................................................................................................ 264
Cutter Guide ....................................................................................................................................................... 271
Out-Of-Paper Sensor ......................................................................................................................................... 273
Out-Of-Paper Sensor Cable ............................................................................................................................... 276
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Output Tray Sensor Assembly ........................................................................................................................... 278
Output Tray Extender Sensor Cable .................................................................................................................. 281
Carriage Line Sensor .......................................................................................................................................... 284
Bundle Board ..................................................................................................................................................... 288
Bundle Board FFC cable ..................................................................................................................................... 290
Pinchwheels ....................................................................................................................................................... 295
Left Spittoon ...................................................................................................................................................... 301
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1 Printer fundamentals
● Overview
● Start-up sequence
● Subsystems
Overview
Feature HP Designjet T120 HP Designjet T520 More information
Paper source Roll and multi-sheet tray See the user's guide
Connectivity Wi-Fi, Fast Ethernet LAN, USB Important! LAN and Wi-Fi are
not compatible
Memory and languages 256 MB, HP-PCL3 (processing 1 GB, HP-GL/2 (processing in
in printer) computer)
ENWW Overview 1
about the printer, change printer settings, perform calibrations and tests, and so on. The front panel also
displays alerts (warning and error messages) when needed.
The front panel has a large central area to display dynamic information and icons. On the left and right sides
you can see up to six fixed icons at different times. Normally they are not all displayed at the same time.
To the right of the front panel is the Power key, with which you can turn the printer on or off. The key is
illuminated when the printer is on. It flashes when the printer is in transition between on and off.
● At the top left of the home screen is a message telling you which paper source is active.
● Press to view Web Services status and display your printer’s email address.
● Press to view connectivity status information and to perform network configuration. If a network cable
is connected, is displayed instead.
NOTE: It is not possible to use wireless and wired network connections simultaneously.
NOTE: The active paper source is indicated by a slightly larger icon, with a white tick in a green circle: .
The printer wakes from sleep mode and switches on the front-panel display whenever there is some external
interaction with it.
The following table shows an overview of the two types of support menu available, for more details see
Entering the support menus on page 96.
NOTE: The icons mentioned in this table will not be visible in the front panel: you must press the front panel
in the places where they normally appear, as shown in the front panel illustration at the start of this section.
Label Description
Support menu: This can be used by customers under the From the Home screen, press the following icons one after the
guidance of phone call agents assisting remotely. Using this other: , ,, .
menu, customers can perform troubleshooting tasks and access
printer information. If there is a system error, you may not be able to reach the home
screen. In this case, press the Power button and hold it down for
15 seconds.
Extended Support menu: Service engineers only From the Home screen, press the following icons one after the
other: , , , .
Start-up sequence
There are three states between power-on and the Home screen:
1. Electronics initialization
2. Firmware initialization
3. Mechanical initialization
1. The front panel moves from flashing white light to turning dark.
NOTE: At this stage, if something is broken, it will not be possible to enter the Support menu. To diagnose
what is happening, go to the front panel blank troubleshooting. (and add here the link). Subsequently, you
can enter the Support menu to troubleshoot if necessary.
2. A check that the Scan Axis and Paper Axis are unobstructed by scraps of paper or other items
10 Electronics initialization
27 Mechanical initialization
45 Ready state
NOTE: Initialization lasts around 45 s if there was a clean power-off (using the front panel Power button). If
there was a dirty power-off, the printer will require more time to inititialize (to ensure that the printhead is in
a good state).
The T120 and T520 printers have covers of different colors, and a different configuration of the roll cover, as
seen in the following table:
Components
Other than the cosmetic aspects of the covers, there are several sensors related to the subsystem covers.
The sensors are designed to detect the status of the cover, open or closed.
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● The Ink Cartridge Cover Sensor senses whether the Ink Cartridge Cover is open or closed. Opening the
Ink Cartridge Cover starts ink cartridge replacement automatically. The sensor is hosted in the printer
chassis.
● The Central Cover hosts the Top Cover Sensor to sense whether the Top Cover is open or closed.
IMPORTANT: Be careful to avoid damaging the sensor while removing the Central Cover. See Central
Cover on page 166.
● The Output Tray Sensor senses whether the Output Tray is open or closed. To avoid paper jams while
printing on roll paper, the tray should be closed.
Due to the layout of the covers, it is important to bear in mind that some parts require removal before you
can remove a specific cover.
Related tests
Sensor tests for the Top Cover, Ink Cartridge Cover, and Output Tray operation. See Diagnostics menu
on page 100.
Electronics
Other than the sensor boards, there are no electronics related to this subsystem.
Printhead health systems: Service Station, Primer system, and Left Spittoon
Functionality
The service station is responsible for printhead maintenance. It takes action to clean ink residues and service
ink nozzles, and prevents ink from drying in critical zones by capping the printhead once printing has
finished.
The Primer system provides the necessary air pressure to the printhead to perform initialization. This system
also provides pressure to the necessary printhead service operations (by boosting air which pushes ink out
through the printhead nozzles, cleaning residues of dried ink and other particles).
The Left spittoon is a small container located to the left of the print-zone area, this is the area used by the
printhead to “spit” a small amount of ink at the end/beginning of the printing swath in order to ensure
correct nozzle heath for left-to-right printing.
Item Function
Off-axis coupling assembly This is a rubber spring link located on the side plate of the scan
axis (area where the Carriage moves). It links the primer system
with the Carriage when the Carriage is located in its maximum left
position. This system ensures the pressure from the primer
reaches the printhead for nozzle servicing.
Prime Pump This is an air pump which provides the necessary pressure for
printhead servicing and nozzle repair. The Prime Pump is
suspended on a rubber holder to minimize the noise that the
Prime Pump makes while in operation.
Primer Tubes The tubes take the air from the Prime Pump to the off-axis
coupling. There is a T link feature connected to a tube that goes
inside the service station; the purpose of this tube is to release
the air pressure from the system. The tube is pinched by the
shuttle of the service station when reaching a certain position;
this action closes the circuit and allows the system to be
pressurized. With the movement of the service station the tube is
released, allowing the pressure from the system to escape.
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NOTE: There is no pressure sensor in the system. The Prime Pump operates at a certain time to reach a
specific pressure level, the system is depressurized by releasing the pinching of the release tube in the
Service Station (by moving the service station).
NOTE: It is important to ensure the Carriage reaches the maximum left position; if not, the off-axis coupling
will not connect the Prime Pump with the Carriage. Also, the coupling is made of a rubbery material,
degradation of the material will affect Primer performance due to air leaks.
Electronics
The control driver of the Prime Pump is located on the remote controller board located on the right-hand side
of the printer. There is no encoder for the Prime Pump. This pump is managed only by a DC motor activated
for a certain period of time to create the required priming pressure.
Item Function
Printhead Wipers These are rubber paddles that are passed through the nozzle
plate of the printhead with the Service Station movement. They
clean the excess ink from the nozzle plate with a rubbing action.
Printhead Cap This caps and protects the nozzles from drying when they are not
printing.
Service Station Motor system This moves the shuttle with the wiper and the cap so that these
two items can perform their functions. The system is composed
of a DC motor and an encoder disk with an encoder sensor to read
the motor position.
Bottom Spittoon This part acts as an ink reservoir when spitting and nozzle health
operations are performed. It contains diapers that prevent the ink
becoming liquid.
Top Spittoon This seals the reservoir and completes the main body of the
service station.
Absorber Base This is made of foam and is located under the service station on
top of the printer structure. It works as an additional diaper in
case ink spills out of the Service Station.
Wiper Shuttle This mobile part is propelled by the motor that contains the Wiper
and Cap. Depending on the position, spitting, wiping, capping, or
priming can take place:
Spitting: The printhead “spits” a little ink into the spittoon to get
the nozzles conditioned and ready for the next swath of printing.
With the life primer system, tube pinching can present an issue (although it is designed to function for the life
of the printer).
When the Service Station is replaced, it is mandatory to reset the Preventive Maintenance Kit for the Service
Station, this will trigger a simple calibration that is done with the Service Station on the next printer startup.
The calibration measures the length of the Service Station (shuttle front bump to shuttle rear bump), which
ensures a correct capping position.
Electronics
All the controlled movements for the Service Station are done from the remote-controlled board located on
the right-hand side of the printer. Issues with the Service Station can also be related to this control board.
This comprises all the elements of the printer in contact with the paper, designed to hold, move, and manage
it in a controlled manner in order to print.
Paper can be loaded using a roll, which is mounted on the rear spindle, or single sheets loaded from the
Multi-Sheet Tray, or single sheets loaded singly.
The paper passes from its source (Roll, Single Tray, or Multi-Sheet Tray) until it touches the Out-Of-Paper
Sensor, when the printer detects the presence of the paper and proceeds to load it.
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To perform the paper feed, the printer catches the paper in between the Drive Roller and the Pinch Rollers
(Pinch Rollers are spring-loaded pushing the paper down on top of the Drive Roller), then the paper is pushed
forwards on top of the Print Platen in the print zone, which is where the printing operation is performed. The
paper advance is provided by a motor that moves the Drive Roller. The exact position of the Drive Roller and
hence the paper is controlled by an Encoder Disk located on the roller axis.
The printed paper then passes between the Output Shaft and the Starwheels (which keep the paper tension
as flat as possible for printing) to exit on the Output Platen, where it is held in case of cut sheet or is cut to
fall on the output basket in the case of roll paper.
The Output Shaft is designed to over-advance the Drive Roller movement slightly, and hence create the
necessary paper tension to keep the paper as flat as possible. The Starwheels are spring-loaded and are
designed to create force on top of the paper, this is done so as to leave the paper unmarked and at the same
time allow the Output Shaft force to be appropriately transmitted.
In the Roll configuration, the rewinder module generates back force while printing to facilitate paper control.
A key electrical element of the paper path is the Paper Sensor (also known as the Out-Of-Paper Sensor or
OOPS). This sensor is located at the beginning of the Print Platen; it detects paper insertion for roll load and
single-sheet load.
Electronics
In the paper-path driving system, the only electrically active element is the Drive Roller. The Drive Roller is
impelled by the drive roller motor and it contains an Encoder Disk on the axis to determine its position. The
Encoder Disk is read by two sensors. One, the “encoder sensor”, designed to read the encoder, counts the
Encoder Disk (the Encoder Disk outer marks) and another one, the “encoder index sensor”, determines the
start position (the 0 position) of the Drive Roller by reading the inner thicker lines of the Encoder Disk.
NOTE: Every time the printer starts up, it searches for the 0 position of the Drive Roller. If this search fails
(which means that the index sensor is faulty), the printer will give a system error and will be unable to
initialize.
It contains the rewinder, which rewinds the paper for paper ejection, and provides an opposite tension to the
paper advance for better paper control.
● The Right Support holds the spindle in position to rotate over passive rollers.
In the T520, the right support also contains the dampers for the roll cover opening movement control
(the internal dampers perform a braking action preventing sudden movement during the opening
operation).
NOTE: The right support for the T120 models does not contain dampers. The T120 and T520 have two
different assemblies from the factory, nevertheless both can be replaced by the damper option of T520
(identical from the external point of view), and there is only one service part available.
● The spindle is designed to hold the paper rolls, and receive the motion from the rewinder gear in the
Left Support. It consists of a central bar and two hubs; the right hub is fixed to determine the right-side
loading position of the paper, and the moveable left hub adjusts to the width of the paper.
● The Roll Cover (T520 only) shields the roll from dust.
NOTE: The Roll Cover is a passive part, with no sensor: the printer does not know its status.
Electronics
The Rewinder Motor and Encoder system are directly controlled by the Main PCA.
The system includes a set of three telescopic trays, which are extended to collect the cut-sheet paper printed
from the Multi-Sheet Tray.
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There are two roll-paper control tabs that are deployed automatically when the telescopic trays of the
Output Tray are in the closed position. This is a purely mechanical action as the tabs are pushed up by the
output trays when closed. The purpose of those tabs is to control the shape of the roll paper when coming
out of the paper path.
Electronics
The only electronic component related to the Output Platen is the Output Tray Sensor located underneath
the output trays. The sensor is activated when the three output trays are fully closed. The sensor cable is
routed via the front of the machine and is directly connected to the main PCA.
It comprises 1) a cutter module that cuts the paper with two rotary blades, 2) a Cutter Bridge attached to the
Carriage that catches and releases the Cutter to perform the cutting operation and then to leave it in capping
position, 3) a Cutter Guide that holds the movement of the Cutter along the printer width.
In order to operate the Cutter, it needs to be in the parked position. If not, the Cutter will not be engaged by
the Cutter Bridge and the printer will not perform the cutting action.
The printer does not have any feedback about the cutter engagement action. Hence, if for any reason the
engagement is not performed correctly, the printer will continue operating as if the engagement has
occurred.
1. Pre-activation phase: The Cutter Engagement Feature of the Bridge gets into the funnel of the Cutter
Module grooving the Cutter to ensure the correct position for activation.
2. Hook catching: The cutter bridge continues moving to the left pushing down the cutter hook (in orange),
after the left side of the cutter bridge passes the Carriage stops and the cutter hook returns to its
position due to its spring motion.
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