HP Designjet L65500 Printer
Maintenance and troubleshooting guide (second edition)
Table of contents
2 Printer status
3 Printer calibration
4 Hardware maintenance
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5 Software maintenance
6 Troubleshoot substrate issues
7 Troubleshoot print-quality issues
8 Troubleshoot ink cartridge and printhead issues
9 Troubleshoot other issues
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11 When you need help
Appendix A Preset creation flowchart
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1 Safety precautions
General safety guidelines
WARNING! Internal circuits use hazardous voltage capable of causing death or serious personal
injury.
No operator serviceable parts inside. Refer servicing to qualified service personnel.
The disconnecting devices for servicing are two Branch Circuit Breakers located in the building's Power
Distribution Unit (PDU).
Electric shock hazard
Due to risk of electrical shock, do not attempt the following actions:
Dismantle the electrical control cabinet.
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Dismantle the drying and curing subsystems of the printer.
Remove or open any other closed system covers or plugs.
NOTE: Fuses that blow after being replaced may indicate malfunctioning electrical circuits within the
system. Have the system checked by qualified service personnel, and do not attempt to replace the fuse
again.
Mechanical hazard
The printer has moving parts that can cause injury. To avoid personal injury, take the following
precautions when working close to the printer.
Keep your clothing and all parts of your body away from the printer's moving parts.
Avoid wearing necklaces, bracelets and other hanging objects.
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If your hair is long, try to secure it so that it will not fall into the printer.
Take care that sleeves or gloves do not get caught in the printer's moving parts.
Avoid standing close to the fans, which could cause injury and could also affect print quality (by
obstructing the air flow).
Heat hazard
The drying and curing subsystems of the printer operate at high temperatures and can cause burns if
touched. To avoid personal injury, take the following precautions.
Avoid direct contact with the drying and curing area of the printer.
Take special care when accessing the substrate path.
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General safety guidelines
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Fire hazard
CAUTION: The drying and curing subsystems of the printer operate at high temperatures.
To avoid the risk of fire, take the following precautions when operating the printer:
Do not manipulate the heating modules.
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Load substrates that withstand temperatures of 125°C.
Heavy substrate hazard
Special care must be taken to avoid personal injury when handling heavy substrates.
Handling substrate rolls always requires at least two people. Care must be taken to avoid back
strain and/or injury.
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Always use a forklift, pallet truck or other handling equipment to lift substrates.
Always wear personal protective equipment including boots and gloves.
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Ink handling
Your printer does not use solvent inks and does not have the traditional problems associated with them.
However, HP recommends that you wear gloves when handling ink cartridges or printhead cleaner rolls.
Warnings and cautions
The following symbols are used in this manual to ensure the proper use of the printer and to prevent
the printer from being damaged. Follow the instructions marked with these symbols.
WARNING! Failure to follow the guidelines marked with this symbol could result in serious personal
injury or death.
CAUTION: Failure to follow the guidelines marked with this symbol could result in minor personal injury
or damage to the product.
Warning labels
Label
Explanation
Current leakage may exceed 3.5 mA.
The printer can be connected to power supplies at different
voltages.
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Label
Explanation
Identifies the main earth terminal
Danger of electric shock. Do not touch.
Danger of electric shock. Do not touch.
Danger of electric shock. In case of operation of the fuse, parts
of the printer that remain energized may represent a hazard
during servicing. Therefore, ensure that the printer is
completely turned off before servicing.
Printer parts may sometimes become hot. Do not touch.
Use protective gloves for handling printer parts, supplies or
waste.
When substrate has been loaded, the carriage descends into
its normal position, and could crush your hand or anything else
left underneath it.
Danger that your hands may become trapped between
gearwheels
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Warning labels
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Label
Explanation
When the printer is printing, the printhead carriage travels back
and forth across the substrate.
Beware of this moving part.
Emergency stop buttons
There are four emergency stop buttons distributed around the printer. If an emergency occurs, simply
push one of the emergency stop buttons to stop all printing processes. A system error message is
displayed on the front panel, and the fans turn at maximum speed. Ensure that all emergency stop
buttons are released before restarting the printer.
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2 Printer status
Check printer status
You can check the current status of the printer in the following ways:
The HP Internal Print Server displays the status of the printer, the loaded substrate and the ink
system. The latest alerts are summarized at the bottom of the main window (see Printer alerts
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The front panel displays the ink levels by default; otherwise, you can see the ink levels by selecting
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the the Ink System icon
the front panel.
. In addition, the most important current alert, if any, is displayed in
Printer alerts
The printer can communicate two types of alerts:
Errors: When the printer is unable to print.
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Warnings: When the printer needs attention for an adjustment, such as a calibration, preventive
maintenance or ink cartridge replacement.
Printer alerts appear primarily at the HP Internal Print Server, but one alert at a time also appears at the
front panel.
HP Internal Print Server: A summary list of alerts appears at the bottom left of the main window.
To display a more complete and detailed list, select Information > Alerts.
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Front-panel display: The front panel shows only one alert at a time, which is judged to be the
most important. It generally requires the user to press the OK key for confirmation, but in the case
of a warning, it disappears after a while. Some alerts reappear when the printer is idle and there
is nothing more important to report.
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The following alerts require a service engineer:
Preventive maintenance #1 required
Preventive maintenance #2 required
Preventive maintenance #3 required
Preventive maintenance #4 required
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Check printer status
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3 Printer calibration
Align the printheads
Precise alignment between printheads is essential for color accuracy, smooth color transitions and sharp
edges in graphical elements.
To align the printheads, go to the HP Internal Print Server and select Printer > Printhead alignment.
You can select automatic or manual alignment; the HP Internal Print Server will recommend one or the
other, but you can always choose.
Automatic alignment is a fully automated procedure that ensures optimal print quality in most cases.
The printer prints some patterns and scans them with the built-in line sensor. This is the
recommended method for any smooth, high-quality substrates (including vinyl, banners or backlit).
If the printheads have many defective nozzles, automatic alignment may not give good results.
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The procedure takes about 14 minutes and consumes 9 inches of substrate.
Manual alignment provides reasonable print quality when automatic alignment is not possible,
typically because a highly-textured or non-white substrate is loaded (mesh, perforated, some
fabrics, transparent, colored). The printer prints 8 series of patterns, and you must choose the best
result from each of the series (for example, number 10 in the picture below).
The procedure takes about 15 minutes and consumes 9 inches of substrate.
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Troubleshoot printhead alignment
Automatic printhead alignment may fail occasionally. In some cases, you may see the front panel error
message "Automatic Printhead Alignment is cancelled because of scanning errors". In other cases,
there is no error message but the print quality is not satisfactory. Here are some possible explanations.
There is some problem with substrate advance (see Substrate-advance compensation
on page 7). After fixing any substrate-advance issue, retry automatic printhead alignment.
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You are using a highly-textured (some banners), non-white or very reflective (some satinated
offset) substrate. Please use manual printhead alignment in these cases.
The substrate is wrinkled. Check that the substrate is correctly loaded with uniform tension. If
necessary, try adjusting substrate parameters such as tension or drying and curing temperatures.
The substrate is not wide enough. Repeat the alignment process using a substrate roll at least 24
inches (610 mm) wide.
The printer window was open during the printhead alignment process.
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If the problem persists, please try using manual printhead alignment, or call your service representative
Printhead alignment diagnostic plot
The printer offers a printhead alignment diagnostic plot, to assess the quality of the current printhead
alignment. To print it, start the HP Internal Print Server and select Printer > Printhead alignment >
Diagnostics plot.
1. The colored crosses on the left side of the plot should show the lines well aligned with each other.
2. The vertical lines to left of center should be straight, without kinks.
3. Of the four vertical lines at the top right of the plot, the leftmost two should be straight, without kinks.
Substrate-advance compensation
Accurate substrate advance is important to print quality because it is part of controlling the proper
placement of dots on the substrate. If the substrate is not advanced the proper distance between
printhead passes, light or dark bands appear on the print, and there may be an increase in graininess.
The printer has a substrate-advance sensor and is calibrated to advance correctly with all the substrates
appearing in the front panel. When you select the type of loaded substrate, the printer adjusts the rate
at which to advance the substrate while printing. However, if you are using a custom substrate or not
satisfied with the default calibration of your substrate, you may wish to change the substrate-advance
substrate-advance compensation will solve your issue.
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Substrate-advance compensation
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You can view and change the substrate-advance compensation of the currently loaded substrate at any
time from the HP Internal Print Server by selecting the print job and then the Printing Adj. button, or by
selecting Printer > Printing adjustments.
If you prefer the print quality after changing the figure in the Advance field, press the Apply button, and
thereafter your preferred substrate-advance compensation will always be used for that particular
substrate type.
The substrate-advance sensor may not work correctly if it is dirty. See Clean the substrate-advance
NOTE: Some substrates are invisible to the substrate-advance sensor; in which case, the sensor will
not work and should be turned off. You can turn it off by using the Automatic Tracking (OMAS) field in
the Loaded Substrate window of the HP Internal Print Server. An alert will advise you if necessary.
NOTE: The substrate-advance sensor scans the back side of the substrate, which it expects to be of
a single color and shade. It is not guaranteed to work correctly if the back side has been printed on; in
this case, there may be no alert from the printer, but the sensor should be turned off.
Color calibration
Color calibration enables your printer to produce consistent colors with a particular substrate type, even
if printheads, ink cartridges and environmental conditions change. After color calibration, you can expect
to get prints with the same colors from any two different printers situated in different geographical
locations.
The color calibration test chart is printed using the following print mode, depending on the ink density
used with your substrate.
Six passes for 100% ink density
Eight passes for 150% ink density
Fourteen passes for 250% ink density
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For this reason, you are strongly recommended to have fine-tuned the appropriate print mode before
starting color calibration. To fine-tune your substrate preset for a specific print mode, see the User's
guide.
To start color calibration from the HP Internal Print Server, select Substrate > Color calibration, then
click the Calibrate button.
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The calibration process is fully automatic and can be performed unattended after you have loaded
substrate of the type you wish to calibrate. The process takes about 18 minutes and consists of the
following steps.
1. The Closed-Loop Color Calibration and Ink Restriction Test Chart is printed, which contains scales
of patches of each ink used in your printer.
2. The test chart is scanned and color-measured using the HP Embedded Spectrophotometer. If the
scan cannot be completed successfully, a message is displayed on the front panel; see Color
3. From the measurements made by the spectrophotometer, the printer calculates the necessary
correction tables to apply to your print jobs, for consistent color printing on that substrate type.
Calibration should be done in any of the following circumstances:
Whenever a printhead is replaced
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Whenever a new substrate type is introduced that has not yet been calibrated with the current set
of printheads
Whenever you notice excessive color differences between prints. Such color differences can be
caused by aging and wear of the printheads, changes in substrate characteristics between one roll
and another, changing environmental conditions and so on.
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Whenever you replace a printhead, an alert will remind you to perform color calibration, unless you have
disabled the alerts. If printhead alignment and/or substrate-advance compensation are also needed,
color calibration should always be the last operation.
You can check the color calibration status of your substrates with the HP Internal Print Server or the
front panel. In the HP Internal Print Server, select Substrate > Color calibration > Show all.
Default status indicates that the substrate has never been calibrated. In this case, the factory
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default color tables will be applied to print jobs.
Done status indicates that a color calibration has been performed successfully on this substrate.
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Obsolete status indicates that a printhead has been changed since the substrate was last
calibrated, and therefore the substrate should be recalibrated.
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Color calibration
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Color calibration is based on the color measurement of printed color patches, using the HP Embedded
Spectrophotometer. Some characterisitics of substrates, such as surface roughness or transparency,
may make reflective color measurement of some substrate types very inaccurate. Color calibration of
these substrates will fail or produce unacceptable printing results.
The suitability of particular substrate types for color calibration can be found in the table of supported
substrate types in the User's guide. Only substrates wider than 36 inches (914 mm) can be calibrated.
It is possible to recover from a bad color calibration by restoring the factory default calibration. In the
HP Internal Print Server, select Substrate > Color calibration > Reset.
You should calibrate a substrate type before creating its color profile; however, you can later recalibrate
without needing to recreate the color profile.
Ink restrictions
Ink restrictions allow you to set the maximum amount of each primary ink (cyan, magenta, yellow, black,
light cyan, light magenta) that can be laid down onto a given substrate.
To adjust ink restriction percentages from the HP Internal Print Server, select Substrate > Edit >
Color.
Ink restriction percentages can be set from 50% to 100% for all inks by filling in the appropriate boxes.
In general, a figure of about 80% is recommended.
High percentage settings (approaching 100%) use more ink and may therefore increase color gamut,
at the cost of leaving less margin for the operation of the color calibration system, which may reduce
color consistency.
Lower percentages use less ink, provide a smaller color gamut and a higher range of compensation for
best color consistency.
NOTE: Ill-defined ink restrictions may lead to unpredictable results. You can restore the default ink
restriction settings by selecting Substrate > Edit > Color > Reset.
The Closed-Loop Color Calibration and Ink Restriction Test Chart contains printed ink ramps in 2%
steps, which can be useful as a visual guide for selecting the ink restriction percentages.
To print the Closed-Loop Color Calibration and Ink Restriction Test Chart, select Substrate > Edit >
Color > Print plot.
Color profiles
Color calibration provides consistent colors, but consistent colors are not necessarily accurate. For
instance, if your printer prints all colors as black, its colors may be consistent but they are not accurate.
In order to print accurate colors, it is necessary to convert the color values in your files to the color values
that will produce the correct colors from your printer, your inks and your substrate. An ICC color profile
is a description of a printer, ink and substrate combination that contains all the information needed for
these color conversions.
These color conversions are performed by your Raster Image Processor (RIP), not by the printer. For
further information on the use of ICC profiles, see the documentation for your application software and
for your RIP.
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4 Hardware maintenance
Maintain the ink cartridges
During the normal lifetime of a cartridge, no specific maintenance is required. However, in order to
maintain the best print quality, replace a cartridge when it reaches its expiration date. An alert notifies
you when any cartridge reaches its expiration date.
Maintain the printheads
During the normal lifetime of a printhead, no regular maintenance is required. However, in order to
maintain the best print quality, replace a printhead when it reaches its expiration date. An alert notifies
you when any printhead reaches its expiration date.
Printheads may need to be cleaned and aligned from time to time: see Clean the printheads
TIP: If you remove an unexpired printhead from the printer, planning to reuse it later, the best way to
protect it is by replacing the protective caps that you removed before inserting it into the printer.
Maintain the substrates
Keep substrates in their sealed wrapping material while they are in storage, and store rolls vertically to
avoid the migration of plasticizers in some materials.
Move substrates from the storage area to the print production area at least 24 hours before use, so that
they can adapt to its temperature and humidity.
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Check the printheads
If you believe that one or more of the printheads is performing poorly:
1. Go to the HP Internal Print Server and select Printer > Printhead cleaning.
2. Press the Check button to perform routine cleaning.
3. If the problem persists, press the Print button in the same window to print the following display.
Each color is printed by a single printhead and shows the performance of that printhead.
If a significant number of printhead nozzles are blocked, you will see missing lines in this display,
as shown below.
4. In the same window, select any printheads that are showing missing lines, and press the Hard
clean button.
5. When the hard clean has finished, press the Print button again to see whether the printheads have
improved.
6. Check that the printheads' electrical contacts are clean. See The front panel recommends replacing
7. If you still see five or more missing lines in any one color, you are recommended to replace that
printhead. With fewer missing lines, the printer can maintain good quality when printing with four
or more passes.
If the above printout seems blurred or grainy, you may need to change the substrate-advance
Clean the carriage cover
The printhead carriage cover is designed to reflect the radiation of the drying lamps in order to avoid
overheating the printheads. If the cover becomes dirty, it reflects less heat. To avoid possible damage
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to the printheads, the carriage cover may need to be cleaned about once every two months, depending
on your use of the printer. An alert is displayed when the cover needs to be cleaned.
1. Go to the front panel and select Clean carriage cover from the Preventive Maintenance menu
. The carriage moves into the electrical compartment.
2. Open the printhead access door.
3. Press the OK key on the front panel.
4. Clean the carriage cover with a lint-free cloth.
5. If you find dried ink that you cannot remove with the dry cloth, try dampening the cloth with isopropyl
alcohol. After cleaning, wait for the cover to dry.
6. Close the door and press the OK key on the front panel.
Clean the carriage rails
The rails along which the carriage moves may need to be cleaned about once every two years,
depending on your use of the printer. An alert is displayed when they need to be cleaned.
1. Go to the front panel and select Clean carriage rails from the Preventive Maintenance menu
. Press OK to continue.
2. The carriage beam is automatically raised, as when loading substrate.
3. When the carriage beam has stopped rising, turn off the printer.
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Clean the carriage rails 13
4. Standing at the front of the printer, clean the front rail using a lint-free cloth dampened with isopropyl
alcohol. You can access the rail from above.
NOTE: If you are in California, instead of isopropyl alcohol please use a VOC-certified cleaner
such as a properly diluted 'Simple Green ® All-Purpose Cleaner'.
5. Standing at the rear of the printer, clean the rear rail in the same way. You can access the rail from
below, through the gap between the platen and the pinches.
6. Wait until the rails are dry.
7. Move the carriage manually into the electrical compartment.
8. Turn the printer back on.
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9. Select Carriage beam position > Move to printing (normal) from the front panel's Substrate
menu to lower the carriage beam into its normal position, close to the substrate. This process
takes about two minutes to complete.
replacing the foams, also replace both of the oil wicks.
Clean the exterior of the printer
Clean the outside of the printer and all other parts of the printer that you regularly touch as part of normal
operation with a damp sponge or a soft cloth and a mild household cleaner such as non-abrasive liquid
soap.
WARNING! To avoid an electric shock, make sure that the printer is turned off and unplugged before
you clean it. Do not let water get inside the printer.
CAUTION: Do not use abrasive cleaners on the printer.
Clean the ink deposits
There are three ink deposits, one for each printhead. They may need to be cleaned every three or four
months, depending on your use of the printer. An alert is displayed when the ink deposits are 85% full,
and again when they are full and need to be cleaned.
1. Go to the front panel and select Clean ink deposits from the Preventive Maintenance menu
.
2. Wait until the printhead carriage has stopped moving, then open the printhead access door in the
side of the printer.
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Clean the exterior of the printer 15
3. Clean the interior of each ink deposit with a cotton swab or cloth dampened with distilled water. If
you cannot remove the dried ink this way, try using isopropyl alcohol instead of distilled water.
4. Also clean the area around the ink deposits; but do not try to clean the printhead area.
5. Close the printhead access door.
Clean the line sensor and aerosol inlets
In the course of normal use, the line sensor becomes gradually blinded by light deposits of dried ink.
An alert is displayed when the line sensor needs to be cleaned, which may be about every two months,
depending on your use of the printer. When you see the alert, follow this procedure to clean the sensor.
1. Go to the front panel and select Clean line sens. & inlets from the Preventive Maintenance menu
.
2. The printer raises the carriage beam so that you can access the sensor.
3. Wait for the front panel to announce that the sensor is ready for cleaning.
4. Dampen a cotton swab with isopropyl alcohol. Swabs are provided in the Cleaning Kit.
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5. Reach underneath the line sensor and clean it with the cotton swab as shown.
6. Use a brush to clean accumulated dust from the aerosol inlets. Do not use the brush on any other
parts.
7. Look for condensation under the carriage, and remove it with a clean lint-free cloth if necessary.
8. Press the OK button on the front panel. The printer lowers the carriage beam to its normal position.
WARNING! Do not insert your hands or anything else into the printer while the carriage is
descending.
Clean the main roller
The main roller should be cleaned whenever it is visibly dirty, or when you notice that substrate advance
is no longer smooth and regular.
Clean the main roller with a clean cloth dampened with water, and make sure that the roller is dry before
printing. Do not use petroleum-based cleaning liquids.
Clean the substrate edge holders
If you sometimes print with very small side margins, ink may accumulate on the substrate edge holders,
which can cause smears on your prints and blocked nozzles in the printheads.
Check the substrate edge holders monthly for dried ink. If necessary, clean them with a lint-free cloth
dampened with isopropyl alcohol.
TIP: It is not normally necessary to remove the edge holders from the printer, and doing so may
damage them. When not required, they can simply be pushed to the side, away from the substrate.
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Clean the pinch wheels
If the pinch wheels are dirty, they can be cleaned by advancing the substrate (less than a meter).
Cleaning the wheels manually could damage them, and is not recommended.
Clean the platen
The platen should be cleaned whenever it is visibly dirty, or when you notice marks on the back of the
substrate.
Before cleaning the platen, locate the substrate-advance sensor and be careful to avoid scratching it
Clean the platen with a clean cloth dampened with water, and make sure that the platen is dry before
printing.
Clean the printheads
Periodic printhead cleaning is performed automatically, as long as the printer is turned on. However,
you should clean the printheads if you are experiencing poor image quality and cannot resolve the issue
by other methods. This ensures that there is fresh ink in the nozzles and helps to prevents clogged
nozzles.
If you have printed the printhead status plot, you know which colors are failing. Clean the printheads
that are not performing adequately. If you are not sure which printheads to clean, clean all of the
printheads.
To clean the printheads, go to the HP Internal Print Server and select Printer > Printhead cleaning.
HP recommends the Check and Clean option.
If you decide on a hard clean, you can select which printheads to clean.
Clean the substrate-advance sensor
No alert is displayed to remind you to clean the substrate-advance sensor. You should clean it
periodically (every one to three months, depending on the printer usage and substrate type—see note
below), whenever you clean the platen, and whenever you have printed by accident directly onto the
NOTE: Porous substrates or liners can allow small amounts of ink to pass through to the platen and
sensor window, to the extent that a clean sensor can become dirty before finishing a single roll. For this
reason, it is best to disable the sensor when loading a porous substrate, and to clean the platen and
sensor before loading another substrate.
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The sensor is located between the second and third group of three pinches, in the middle of the platen.
TIP: You may need a ladder to reach the sensor.
TIP: Cleaning is easily done by reaching over the carriage beam in its low position. If you try to do it
by putting your arms below the beam in its high position, you will find it more difficult to access the sensor
and to check that it is clean.
1. Unload the substrate.
2. Wipe the sensor with one of the cotton swabs provided in the Cleaning Kit, slightly dampened with
isopropyl alcohol, to remove dried ink. If the sensor window is heavily coated with dried ink, you
may need to apply some pressure while wiping, helping the cotton to absorb the ink. Continue
cleaning with fresh swabs until the cotton stays clean and the sensor window looks clean.
When reflecting ambient light, a clean sensor shows a blue-colored reflection that should extend
uniformly across its whole surface. You can see this reflection by moving closer and slightly
changing your angle of view.
3. Wait 3 or 4 minutes before reloading the substrate, so that the alcohol can evaporate completely.
Clean the temperature sensors
An alert is displayed when the temperature sensors need to be cleaned, which may be about every two
months, depending on your use of the printer. When you see the alert, follow this procedure to clean
the sensors.
1. Go to the front panel and select Clean temperature sensors from the Preventive Maintenance
menu
. Press OK to continue.
2. Unload the substrate.
3. When the substrate has finished unloading, press an emergency stop button to turn off the
mechanical and drying components of the printer. This is advisable for your own safety.
4. Wait until the dryers cool down.
CAUTION: In the following procedure you will be working close to surfaces that are hot during
normal printer operation. Check that they are cool before proceeding.
5. Dampen a cotton swab with distilled water. Swabs are provided in the Cleaning Kit.
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Clean the temperature sensors 19
6. Use the swab to clean the lenses of both temperature sensors (drying and curing).
7. Check that the lenses are clean by looking directly at them from underneath the printer.
Alternatively, continue cleaning until the cotton swab remains clean after cleaning.
8. Press OK at the front panel to tell the printer that the sensors have been cleaned.
9. Ensure that the emergency stop buttons are released, then restart the printer.
Maintain the printhead primers
A problem with the printhead primers is indicated by one of the following error codes.
The code 46.1:01 indicates a problem with the yellow/magenta primer.
The code 46.2:01 indicates a problem with the light cyan/light magenta primer.
The code 46.3:01 indicates a problem with the cyan/black primer.
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To correct the problem:
1. Go to the front panel and start the process to replace the printhead in question (see the User's
guide).
2. After lifting the printhead cover, you will see two 'O' rings that seal the joints between the printhead
cover and the printhead. Apply a little oil, grease or water to the 'O' rings to improve their
performance.
3. Close the printhead cover, the carriage cover and the printhead access door.
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Replace the carriage oiler foams
The printhead carriage contains two chunks of foam impregnated with oil that continuously lubricate the
carriage rails. They may need to be replaced about every two or three months, depending on your use
of the printer. Replacement foams are available in the Cleaning Kit.
1. Go to the front panel and select Replace oiler foam from the Preventive Maintenance menu
. The carriage moves into the electrical compartment.
2. Open the printhead access door.
3. Slide off the cover of the left oiler foam.
4. Remove the old foam, insert the new foam, and replace the cover.
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5. Open the carriage cover to access the right oiler foam.
6. Slide off the cover of the right oiler foam.
7. Remove the old foam.
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8. Remove the screws and the oiler foam container, replace the foam, and reattach the container with
the screws.
9. Close the carriage cover and the printhead access door.
10. Press the OK key when finished.
Replace the line sensor box
An alert is displayed when the line sensor box needs to be replaced. The printer moves the carriage to
the right so that the box is easily accessible, and turns off power to the carriage. When you see the alert,
follow this procedure to replace the box.
1. Go to the front panel and select Replace sensor box from the Preventive Maintenance menu
.
2. The carriage moves out from the right cover.
3. Unscrew the three screws of the line sensor box and disconnect the connecting cable.
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Replace the line sensor box 23
4. Remove the line sensor box.
5. Connect the cable to the new line sensor box.
6. Place the new box into the printer and fix it in place with the screws. No tool is needed.
7. Press OK at the front panel.
8. The printer turns on power to the carriage and checks the sensor.
Replace the printhead cleaning roll and aerosol filters
The printhead cleaning roll is used to clean the printheads between printing passes. It must be replaced
periodically in order to maintain print quality. The frequency of replacement depends on your use of the
printer: approximately monthly with average use.
An alert is displayed when 75% of the roll has been used, and again when 95% of it has been used.
You can choose to replace the roll at any time.
If there is not enough of the roll to start a new job, the printer cancels the job.
Whenever you replace the printhead cleaning roll, you should also replace the aerosol filters. The roll
and the aerosol filters are supplied together in the same package.
TIP: You are recommended to wear gloves during these operations.
Replace the printhead cleaning roll
1.
Go to the front panel and select Replace cleaner roll from the Ink System menu
. Any unused
portion of the roll is wound on to the takeup roll at this time. You will be warned if the unused portion
is more than 5% of the whole roll.
TIP: If you forget to select Replace cleaner roll at the start of this procedure, do not attempt to
select it later. Instead, wait until you have replaced the aerosol filters and the cleaning roll, and
then select Check cleaner roll from the Ink System menu.
2. In order to replace the printhead cleaning roll, open the door on the front right of the printer.
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3. Grip the handle and pull the whole printhead cleaning roll assembly out through the door.
4. Slide both rolls off their axles and dispose of the roll with the used cleaning material according to
the instructions provided with the new roll. Keep the empty core to use as a takeup core.
5. Slide the new roll onto the upper axle. It clicks into place.
6. Pull the black knob on the upper left and move the pinch system aside.
7. Pass the leading edge of the roll over the upper rollers, and thread the cleaning material through
the rollers on the left.
8. There is a strip of polyester film on the leading edge of the cleaning material. Insert it into the hole
in the takeup core, which takes hold of it.
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Replace the printhead cleaning roll and aerosol filters 25
9. Slide the takeup core onto the lower axle. It clicks into place.
NOTE: If the cleaner roll has not been properly installed, you may see a message about clearing
a printhead cleaning roll jam. Pull the whole assembly out, wind a little of the roll forward, then slide
it back in again. The printer will check the roll again
10. Restore the pinch system by moving the black knob back into place. If you feel resistance because
the cleaning roll is too tight, turn the roll slightly counter-clockwise.
11. Grip the handle and push the whole printhead cleaning roll assembly back into the printer.
12. Close the door.
Do not empty the drain container: this is done by a service engineer during preventive maintenance.
Replace the aerosol filters
1. Open the printhead access door in the side of the printer, and lift the carriage cover.
2. The aerosol filter containers are on the near and the far sides of the printheads.
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3. Lift up the right-hand side of the filter container; it pivots on the left.
4. Pull the old filter out of the bottom of its container and dispose of it according to the instructions
provided with the new filter.
5. Unpack the new filters and ensure that the blue tabs at each end of each filter are at right angles
to the filter.
6. Insert the new filter into the container.
7. Ensure that the blue tabs on the filters are correctly engaged with the hooks on the containers,
otherwise the containers may not close completely.
8. Lower the container into position.
9. Lower the carriage cover and close the door. Press the OK key on the front panel.
10. If you forgot to select Replace cleaner roll before replacing the printhead cleaning roll, you should
now go to the front panel and select Check cleaner roll from the Ink System menu
.
Move the printer
If you wish to move the printer a short distance on the same site, across a horizontal floor with no steps
and no slopes of more than 5% inclination, see the following instructions. For more difficult movement
CAUTION: Slopes steeper than 5% may cause serious damage to the printer.
1. Turn off the printer.
2. Disconnect all power and network cables from the printer.
3. Disconnect all ink cartridges and remove them from the printer. Hold the cartridge connectors in
position with adhesive tape.
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Move the printer 27
4. Raise the feet so that the wheels (A) touch the ground. To raise a foot:
a. Use a 30 mm wrench to unlock the nut at the top of the foot.
b. Rotate the nut manually down the bolt. Leave about 2 cm (0.8 in) clearance at the bottom
between nut and foot.
c. Use a 15 mm wrench to rotate the foot upwards. Use the flat faces at the bottom of the bolt
to fit the wrench.
d. Raise the foot as far as the bolt allows.
e. Use the 30 mm wrench to relock the nut.
CAUTION: Take care to raise the feet as high as you can. They may break if they touch the
ground while the printer is in motion.
5. Push the printer from the outside corners of the top covers.
After moving the printer, you may in some cases need an electrician to reconnect the power cables.
You may also need to reconfigure the network: from the front panel, from the HP Internal Print Server
computer, and from the RIP computer. See the Installation guide for more details.
Printer maintenance kits
Maintenance kits contain printer components that may need to be replaced after long use. When one
of them is needed, an alert (such as “Preventive maintenance #2”) is displayed by the HP Internal Print
Server.
When you see the message, you should call your service representative (see HP Customer Care
Centers on page 49) and request the maintenance kit. The kits are installed by service engineers only.
You can see how close you are to needing preventive maintenance by selecting Information >
Maintenance in the HP Internal Print Server.
Cleaning kit
A cleaning kit is provided with the printer; it is intended to provide cleaning materials for about one year
of normal use. It contains oil for the carriage rails, replacement oiling foams, gloves, sponges and cotton
swabs.
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5 Software maintenance
Maintain the HP Internal Print Server
The HP Internal Print Server runs under Microsoft Windows on the computer supplied with the printer.
In that operating environment, there are various things you can check in order to maintain optimum
performance. You can make these checks after restarting the computer and before starting the HP
Internal Print Server.
The user account should be a Standard account and not an Administrator account.
No software should be installed on the computer except the software initially provided by HP.
If an antivirus program is installed, it should not be allowed to check the file system constantly.
●
●
●
●
In the Performance tab of the Task Manager, CPU usage should be below 5% (preferably below
3%).
Memory usage should be below 1 GB (preferably below 800 MB).
Free space on the hard disk should be at least 10 GB.
●
●
●
In the Control Panel, Hardware and Sound > Power Options, the high-performance power plan
should be selected and sleep mode disabled.
A blank screen saver should be used.
●
●
Press the start button and right-click Computer. Select Manage > Device Manager > Disk
drives. Right-click the hard disk, and select Properties > Policies. Ensure that Optimize for
performance, Enable write caching on the disk and Enable advanced performance are all
enabled.
Ensure that scheduled defragmentation is enabled. Press the start button and right-click
Computer. Select Manage > Disk Management. Right-click the hard disk, and select
Properties > Tools > Defragment Now, and ensure that Run on a schedule is enabled.
●
●
In the Control Panel, select System > Advanced system settings > Advanced > Performance
> Visual Effects > Custom. Ensure that all effects are disabled except Enable Desktop
composition, Enable transparent glass, Smooth edges of screen fonts and Use visual styles
on windows and buttons.
Open Internet Explorer and select Tools > Internet options > Connections > LAN settings. If a
proxy server is used, ensure that Bypass proxy server for local addresses is enabled.
●
●
●
Ensure that the computer is connected to the Internet and use Windows Update to ensure that all
available updates (including Windows Service Packs) have been installed successfully.
Start the HP Internal Print Server, and use File > Delete job to delete any jobs for which there is
no further use.
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Maintain the HP Internal Print Server 29
Update the firmware
The printer's various functions are controlled by software that resides in the printer, otherwise known
as firmware.
From time to time firmware updates will be available from Hewlett-Packard. These updates increase the
printer's functionality and enhance its features.
Firmware updates can be downloaded from the Internet and installed in your printer using the HP Internal
Print Server: select Firmware update from the Main tab.
Follow the instructions on your screen to download the firmware file and store it on your hard disk. Then
select the downloaded file and click Update.
The firmware includes a set of the most commonly used substrate presets. Extra substrate presets can
be downloaded separately; see the User's guide.
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6 Troubleshoot substrate issues
The substrate cannot be loaded successfully
A substrate cannot be loaded unless all printer subsystems (e.g. the ink system) are ready.
●
If the printer is unaware of the carriage beam position (after a printer recovery or shutdown), go to
●
the front panel and select the Substrate Management icon
, then Carriage beam position
> Carriage system recovery.
Check that the spindle is correctly inflated.
●
●
Try using the front panel to advance the substrate at least 10 ft (3 m), then move it back and try to
load it again. If it will not load, perhaps the substrate is not attached to the input core: try a different
roll.
The substrate has jammed
If the printer reports a substrate jam, follow these steps.
1. If the carriage is still moving or trying to move, press an emergency stop button as quickly as
possible to minimize damage to the printheads.
If the printer shuts itself down automatically before you reach an emergency stop button, turn off
circuit breaker ACB-1.
2. Wait about ten minutes for the printer to cool down.
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The substrate cannot be loaded successfully 31
3. If feasible, manually move the carriage slowly and carefully to the side, away from the substrate.
If this is not feasible because of the severity of the jam, try raising the carriage beam to its maximum
height.
4. Remove all substrate and pieces of substrate from the printing zone and from any other parts of
the printer into which they may have fallen. Check the curing zone in particular. If you are unable
to remove them all, please call your service representative (see HP Customer Care Centers
5. Before restarting the printer and reloading the substrate, check that all circuit breakers are on and
all emergency stop buttons released.
The substrate is not attached to the input core
If the roll is not firmly attached to the input core, you may see banding on your prints, or the printer may
report the end of the roll. To correct the problem, proceed as follows.
1. Unload the roll from the input spindle and load it onto the output spindle. Take care to avoid
telescoping.
2. Raise the pinches and, in the front panel's Substrate Management menu, raise the carriage beam
to its maximum height.
3. Unload substrate from the roll and pass it backwards through the printer towards the input spindle.
Attach it to the empty core on the input spindle, securing it with adhesive tape. Wrap a couple of
turns of substrate around the input core. Take care to align the substrate with the output roll.
4. Lower the pinches.
5. At the front panel, exit the Substrate Management menu, replying “Yes” when asked about
checking the substrate.
NOTE: If the substrate check fails, return the roll to the input side and attach it to an empty core
on the output side. Raise the pinches and use the front panel's Substrate Management menu to
move all the substrate onto the output core.
6. Select the correct substrate in the HP Internal Print Server.
7. Press the Form Feed key on the front panel, then the Back key, and wait until all the roll has been
wound onto the input spindle.
8. You may decide to cancel rewinding when the substrate is detached from the output roll. Then
attach it to the output core to print immediately, or rewind it completely onto the input core if you
want to remove the roll.
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The substrate sticks to the platen
When the substrate sticks to the platen, the most likely causes are excessive heat and excessive
vacuum. Therefore, try decreasing the drying temperature or the vacuum.
For information on how to adjust printer settings, see the User's guide.
The ink is still wet when the substrate emerges
1. Reduce the ink limits.
2. Increase temperature settings for drying and curing.
For information on how to adjust printer settings, see the User's guide.
There are ink marks on the substrate
This problem can be caused by the carriage touching the substrate and smearing the ink.
1. If the ink marks occur at the sides of the substrate and not in the center, check that the substrate
edge holders are correctly placed.
2. Check that the vacuum and tension levels are correct.
3. If you see large drops of ink, clean the printheads to remove any loose fibers.
For information on how to adjust printer settings, see the User's guide.
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The substrate sticks to the platen 33
7 Troubleshoot print-quality issues
General advice
When you have any print-quality problem:
To achieve the best performance from your printer, use only genuine HP supplies and accessories,
whose reliability and performance have been thoroughly tested to give trouble-free performance
and best-quality prints. For details of recommended substrates, see the User's guide.
●
Check that the substrate type selected in the HP Internal Print Server is the same as the substrate
type loaded into the printer.
●
CAUTION: If you have the wrong substrate type selected, you could experience poor print quality
and incorrect colors, and perhaps even damage to the printheads.
Check that your substrate has been color-calibrated.
●
●
●
Check that you are using the correct ICC profile for your substrate and print mode.
Check that you are using the most appropriate print-quality settings for your purposes (see the
User's guide).
Check that the environmental conditions (temperature, humidity) are in the recommended range
●
(see the User's guide).
Check that the printheads have been aligned.
●
●
●
Check whether there are any outstanding printer alerts.
Avoid touching the substrate while printing is in progress.
Banding
Banding means that your printed image suffers from added horizontal lines as shown (the color of the
lines may vary).
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If there are thin white lines across the width of the substrate:
1. From the HP Internal Print Server, clean and check the printheads, and check for blocked nozzles.
If there are blocked nozzles, increase the number of passes.
●
●
If there is a substrate-advance problem, decrease the substrate-advance setting.
2. If the problem persists, increase the number of passes.
If there are thin dark lines across the width of the substrate:
1. Increase the substrate-advance setting in the HP Internal Print Server.
2. If the lines are visible only in dark or saturated colors, try the following remedies in this order:
a. Increase the number of passes.
b. Lower the ink limit for the selected print mode.
c. Increase the drying temperature.
If you have adjusted the substrate-advance setting but there are still white and dark lines distributed
randomly across the same print:
1. Check the substrate-advance status in the HP Internal Print Server. If there is a warning message:
a. Unload the substrate and clean the substrate-advance sensor.
b. Reload the substrate and check it as usual.
c. If the warning message persists, probably the substrate type is invisible to the substrate-
advance sensor, so you should turn off the sensor (in the Loaded Substrate window in the HP
Internal Print Server) and adjust the substrate advance manually.
2. If the problem persists, increase the number of passes.
3. If the problem persists, recreate the substrate preset.
If there are one or more thick lines across the width of the substrate, where one color seems to be
missing:
2. Open the door on the front right of the printer and pull out the printhead cleaning roll assembly.
3. You should see ink on the upper, horizontal part of the roll and also on the vertical part of the roll.
If you see no ink on the vertical part of the roll, there may be a fault in the primer pump. In this case,
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