HP Z5200 Owners Manual

							Problems with Image Clipping ........................................................................................... 44
Some objects are missing from the printed image ............................................................. 45
A PDF file is clipped or objects are missing ....................................................................... 45
2  System Error Codes Introduction .................................................................................................................. ....................... 46
Continuable and Non-Continuable Error Co des ................................................................................. 4 7
System Error Code Brief  Descriptions .......................................................................................... ...... 47
System Error Codes - Full Descriptions ........................................................................................ ..... 50
3  Diagnostic Menu Introduction .................................................................................................................. ....................... 74
Diagnostics - Self Test .......................................................................................................  74
Service Tests (Diagnostics) ................................................................................................... ............. 74
Entering the Service Tests Menu ....................................................................................... 76 1. Scan Axis ...................................................................................................... 76
2. Paper Drive ................................................................................................... 87
3. Electronics Module ........................................................................................ 90
4. Carriage Assembly ........................................................................................ 95
5. Sensors ....................................................................................................... 101
6. Color Sensor (ESP) ..................................................................................... 104
7. Ink Delivery System (IDS) ........................................................................... 106
8. Service Station ............................................................................................ 110
9. I/O Information ............................................................................................ 117
10. Unit Information ......................................................................................... 117
11. EEROM Reset ........................................................................................... 119
12. Set Unit Configuration ............................................................................... 120
13. Error 71:19 Recovery ................................................................................ 120
.......................................................................................................................................................... 123
4  Service Menu Entering the Service Utilities Menu ........................................................................................... ....... 124
Introduction .................................................................................................................. .... 125
......................................................................................................................... 126
1. Turn Drive Roller ..........................................................................................................  126
2. Purge Tubes ................................................................................................................  128
3. Set SN ......................................................................................................................... 130
4. Reset Life Counters ..................................................................................................... 13 1
5. Diagnostic Print ........................................................................................................... . 1 3 2
6. Set Date and Time ....................................................................................................... 13 2
7. Enable/Disable Firewall ............................................................................................... 133
8. Enable/Disable Sleep Mode ........................................................................................ 134
9. SNMP Language Write Access ................................................................................... 135
10 Borderless Cut Distance ............................................................................................. 137
Service Calibrations .......................................................................................................... ............... 138
Entering the Service Calibrations Menu .......................................................................... 139
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							Scan Axis Calibration ....................................................................................................... 139
Service Station Calibration .............................................................................................. 140
Paper Advance Calibration .............................................................................................. 140
Drop Detector Calibration ................................................................................................ 145
Line Sensor Calibration ................................................................................................... 146
Carriage PCA .................................................................................................................. . 149
Color Sensor (ESP) Calibration ....................................................................................... 149
5  Parts and Diagrams Printer Support ............................................................................................................... .................. 152
Center Covers (Front) ......................................................................................................... ............. 153
Center Covers (Rear) .......................................................................................................... ............. 154
Right Cover ................................................................................................................... ................... 155
Left Cover .................................................................................................................... ..................... 156
Right Hand Assemblies .................................................................................................................... 157
Left Hand Assemblies .......................................................................................................... ............ 158
Carriage Assembly ............................................................................................................. .............. 159
Scan-Axis Assemblies .......................................................................................................... ............ 160
Paper Path Assemblies (Front) ................................................................................................. ....... 161
Paper Path Assemblies (Rear) .................................................................................................. ....... 162
Tools 1 ....................................................................................................................... ....................... 163
Tools 2 ....................................................................................................................... ....................... 164
Miscellaneous Parts ........................................................................................................... .............. 165
6  Removal and Installation Introduction .................................................................................................................. ..................... 169
Safety Precautions ...........................................................................................................  169
Electrostatic Discharge (ESD) Precautions ..................................................................... 169
Required Tools ................................................................................................................  169
Service Calibration Guide to Removal and Installation .................................................................... 170 Using the Service Calibration Guide ........................ ........................................................ 170
The Service Calibration Matrix ......................................................................................... 171
Performing the Service Calibrati ons and Diagnostic Tests .............................................. 172
Window ........................................................................................................................ ..................... 174
Front Cover ................................................................................................................... ................... 177
Media Output Assembly ......................................................................................................... .......... 178
Right Front Trim .............................................................................................................. ................. 179
Left Front Trim ............................................................................................................... ................... 181
Right Ink Cartridge Door  ...................................................................................................... ............. 182
Left Ink Cartridge Door ....................................................................................................... .............. 183
Right Cover ................................................................................................................... ................... 185
Left Cover .................................................................................................................... ..................... 188
Rear Tray ..................................................................................................................... .................... 194
Rear Cover .................................................................................................................... ................... 195
Media Lever ................................................................................................................... ................... 196
Media Lever Position Sensor ................................................................................................... ........ 198
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							Cutter Assembly ............................................................................................................................... 199
Right Rear Tray Support ....................................................................................................... ........... 200
Left Rear Tray Support ........................................................................................................ ............. 201
Front Panel ................................................................................................................... .................... 203
Top Cover ..................................................................................................................... .................... 205
Window Position Sensor ........................................................................................................ .......... 208
Ink Supply Tubes Support Rail ................................................................................................. ........ 209
Service Station ............................................................................................................... .................. 214
Drop Detector ................................................................................................................. .................. 217
Aerosol Fan Assembly .......................................................................................................... ........... 219
PrintMech PCA ................................................................................................................. ................ 220
Pen to Paper Space (PPS) Soleno id ............................................................................................. ... 221
Spindle ....................................................................................................................... ...................... 223
Left Spindle Holder ........................................................................................................... ................ 224
Right Spindle Holder .......................................................................................................... .............. 224
Clean Out Assembly ......................................................................................................................... 225
Out Of Paper Sensor ........................................................................................................... ............. 226
Left Roll Guide ............................................................................................................... ................... 229
Right Roll Guide .............................................................................................................. ................. 230
Encoder Strip (with spring and attachment nut) ...............................................................................  231
Clean Encoder Strip Procedure ................................................................................................. ....... 234
Encoder Strip ................................................................................................................. ................... 236
Trailing Cable .......... ....................................... .......................... ..................................... ................... 237
Carriage Assembly (with or without Tra iling Cable) ......................................................................... 244
Carriage Rear Bushing ......................................................................................................... ............ 254
Belt Assembly ................................................................................................................. .................. 256
Scan-Axis Motor ............................................................................................................... ................ 257
Carriage Rail Oiler ........................................................................................................... ................. 260
Color Sensor (ESP) ............................................................................................................ .............. 262
Line Sensor ................................................................................................................... ................... 267
Carriage Cover (includes Carriage Latch) ...................................................................................... .. 272
Carriage PCA .................................................................................................................. ................. 276
Right Ink Supply Station ...................................................................................................... ............. 280
Left Ink Supply Station ....................................................................................................... .............. 284
Ink Supply Tubes .............................................................................................................................. 288
Formatter ..................................................................................................................... ..................... 296
Hard Disk Drive ............................................................................................................... ................. 297
Electronics Module (Main PCA and PSU) ........................................................................................  298
Starwheel Assembly ............................................................................................................ ............. 301
Print Zone Overdrive .......................................................................................................... .............. 302
Left Spittoon ................................................................................................................. .................... 306
Encoder Disk and Encoder Sensor ............................................................................................... ... 308
Media Advance Drive ........................................................................................................... ............ 311
Pinchwheel Assembly ........................................................................................................... ........... 314
Pinch Roller .................................................................................................................. ...
 ................. 319
Left Starwheel Lifter ......................................................................................................... ................ 320
Right Starwheel Lifter ........................................................................................................ ............... 322
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							Starwheel Motor ............................................................................................................................... 325
Full Bleed Foam ............................................................................................................... ................  326
7  Preventive Maintenance Preventive Maintenance ........................................................................................................ ........... 328
Moisture on the Printer ....................................................................................................  32 8
Noisy Carriage Bushing ...................................................................................................  328
Belt Swelling ................................................................................................................. ...  328
Cleaning the Printer .........................................................................................................   328
Carriage Assembly Lubrication ........................................................................................ 328
General Cleaning .............................................................................................................  329
Cleaning the Drive Roller and Overdrive .........................................................................  329
Level of Printer Usage .....................................................................................................  32 9
Preventive Maintenance Kits ................................................................................................... ......... 330
Preventive Maintenance Kit #1 ........................................................................................  330
Preventive Maintenance Kit #2 ........................................................................................  331
8  Printer menu Map
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							1 Ink Supplies Troubleshooting & PrintQuality
●Introduction
●
Troubleshooting System Error Codes
●
Performing a Service Test on a failed Assembly
●
Performing the Necessary Service Calibrations
●
Solving Ink Supplies Problems
●
Solving Print Quality Problems
●
Using the Front Panel
●
The Printer does not Power ON
●
The Printer Continuous ly Rejects Printheads
●
What to do if the Front Panel is blank
●
Cover Sensors are not Working
●
The Line Sensor has Problems Detecting Media
●
Problems with Color Accuracy
●
Troubleshooting Media Jams/Printhead Crashes
●
Banding at variable extreme environmental conditions
●
Worm marks on HP Coated me dia with light area fills
●
Solving Media-Handling Problems
●
What to do when plastic parts on the Media Basket become damaged during printer setup
●
Solving Ink Supplies problems
●
Ink Cartridge Levels, Information, and Replacement
●
Printhead Information, Replacement and Alignment
●
Ink Cartridge and Printhead Status Messages
●
Solving Ink Supplies Problems
●
Maintaining and Cleaning the Printheads
●
Print Quality
●
The Service Image Quality Diagnostic Print
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							●Reading the Diagnostic Print Results
●
The Advanced Diagnostic Prints
●
Reading the Advanced diagnostic Print Results
●
Troubleshooting Print Quality Problems
Introduction
This chapter will guide you through the relevant  steps to take when troubleshooting the printer.
Troubleshooting System Error Codes
Chapter 2, System Error Codes on page 46 contains a list of system error codes and their respective
descriptions and recommended corrective actions.  Only try one recommended action at a time and
check if the error code has disappeared.
If you have an error code which is not documented  in this Service Manual or you have an error which
you cannot resolve, then report the error to the HP  Response Center or the nearest HP Support Office.
When reporting the error, have the following information ready:
● Model and Serial Number of the printer
● Which firmware revision the printer is us
ing (See Note below). Check firmware in Utilities /
Statistics /Code rev .
● The complete error number (See Note below).
● The Service Configuration Print.
● The Current configuration sheet.
● Which software application the customer
 is using (name, version, etc.).
NOTE:When reporting the System Error Code, make sure that you supply the full Error Code
and the firmware version. Without this inform ation, HP Support Personnel cannot help you.
Performing a Service Test on a failed Assembly
If possible, always perform a Service Test on the co mponent/assembly that you are about to replace,
just to make sure that is the component/assembly that has failed.
NOTE: If the test on that component/assemb ly passes, you should NOT replace it.
For information on the Service Tests and how to use them see Diagnostic Menu on page 73 & Service
Menu on page 124 .
Performing the Necessary Service Calibrations
Is the printer calibrated correctly after replacing a component? For information on the Service
Calibrations and how to use them see Chapter 5, Service Calibrations.
NOTE: Remember that certain Cali brations are required even if an Assembly has been
disassembled to gain access to another Assembly or Component.
2 Chapter 1   Ink Supplies Troubleshooting & Print Quality ENWW 
						

							Solving Ink Supplies Problems
For information on solving Ink Supplies problems see Solving Ink Supplies problems on page 9 in
this section.
Solving Print Quality Problems
For information on solving  Print Quality problems see Print Quality on page 23 in this section.
Using the Front Panel
Below is a diagram of the front panel.
Key Function
●Arrow
 Keys
Use the Arrow keys to scroll through a menu  or toggle between YES or NO when prompted.
● Cancel
Use the Cancel key to abort or stop 
a procedure or reject test results.
● OK
Use the OK key to select a menu option.
● Power
Use the Power key to turn the printer ON and OFF.
● Menu
Use the Menu key to enter the main menu.
● Back
Use the Back key to go back to the pr
evious menu or reject test results.
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							Service Key Combinations
●Diagnostic mode
With the printer OFF, press and hold the 
UP and  OK keys. While holding the  Up and  OK keys down,
press and hold the Power key to turn on the printer. Hold all three keys until the Power key stops
flashing, usually about 5 seconds.
● Service Menu (Service Engineers Only)
From the main menu, press and hold the 
Up and  Cancel  keys.
● Service Menu (For users)
From the main menu, press and hold the 
Down and Cancel  keys.
The Printer does not Power ON
1.Check that the power cord is  connected correctly to the Printer and to the Power Socket.
2. Check that the Power Switch on th e BACK of the Printer is in the ON position.
3. Check to see the LED on the  Front Panel Power Switch are  On.
4. Check that the Front-Panel Cable is correctly con nected to the Electronics Module. Also make sure
that the Front-Panel cable is not damaged.
5. Replace the Power Supply Unit 
 Refer Electronics Module (Main PCA and PSU) on page 298.
The Printer Continuously Rejects Printheads
1.Clean the flex contacts on the Printhead and  in the Carriage Assembly using the Carriage
Interconnect Wiper (Refer to 
Flex Contacts Cleaning Tool on page 22 ) and try again.
2. If ALL the Printheads are rejected (the status message on the Front Panel does NOT show  OK
for ALL the Printheads) then perform the Electronic Module Test 
 Refer 3. Electronics Module
on page 90 .
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							What to do if the Front Panel is blank
The LEDs of the formatter (visible through the cover) and the power supply can help you troubleshoot
a problem when the Front Panel is blank.
1. The following image shows the Power Supply LED, looking through the cover.
2.The following image shows the Formatter  LEDs, which are marked I, II and III.
▲Use the following table to interpret the LEDs and find the source of the problem. Remember that
you should read these LEDs when you push the 
Power button. Some combinations may require
the replacement of two or more components. In th is case, always replace one component at a time.
Test the printer to see if the problem has disa ppeared (check the LEDs again). If the same LED
sequence continues, replace the next component indicated in the table.
Power
Supply LEDFormatter
LED 1Formatter
LED 2Formatter
LED 3Front Panel
StatusSolution  (part replacement)
1OffOffOffOffOffPower Electronics Module (Main PCA and
PSU) on page 298
2OnOffOffOffOffMain PCA Electronics Module (Main PCA
and PSU) on page 298
3OnOnOffN/AN/AFormatter Formatter on page 296
4OnOn
(Flashing)OffOffN/AHard Disk Hard Disk Drive on page 297
5OnOnOn (flashing)OffN/AHard Disk Hard Disk Drive on page 297
6OnOnOnOffN/A1.Formatter Formatter on page 296
2. Main PCA 
Electronics Module (MainPCA and PSU) on page 298
7 On OnOn On (flashing) N/A Main PCA Electronics Module (Main PCAand PSU) on page 298
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							8OnOnOnOnFront Panel
(Light on)1.Front Panel Front Panelon page 203
2. Formatter 
Formatter on page 296
3. Main PCA 
Electronics Module (MainPCA and PSU) on page 298
4. Front Panel Cable 
Front Panel
on page 203
9 On OnOn On Off Front Panel Front Panel on page 203
Cover Sensors are not Working
1.Perform the Sensors Test  Refer 5. Sensors on page 101.
2. Check if the cable for the faulty sensor  is not damaged and is connected correctly.
3. Replace the faulty Sensor.
The Line Sensor has Problems Detecting Media
1.Check the type of media that is being used si nce the Line sensor may have problems detecting
transparent media or some types  of Non-HP media. Try loading white HP media in to the Printer
and check if the Line sensor detects it.
2. The Line Sensor is not calibrated correc tly. Perform the Line Sensor Calibration 
 Refer Line
Sensor Calibration on page 146.
3. The Line Sensor is damaged or  faulty. Replace the Line Sensor 
 Line Sensor on page 267.
Problems with Color Accuracy
The Color Sensor (ESP) is a powerful  tool unique to the Z series printers to main tain color accuracy. If
you notice any problems with co lors, perform the Color Sensor (ESP) calibration. Refer to 
Color Sensor
(ESP) Calibration on page 149.
Troubleshooting Media Jams/Printhead Crashes
The failure modes media jam and head crash are grouped together because in many cases a media
jam causes the media to lift up into the Carriage  path and cause a Printhead crash, thus causing many
media jam failures to be reported as head crashes.
1. Did the media jam occur when loading media?
●If the client has had media jams, it is common for pieces of media to get stuck in the media
path. Clear the media path.
NOTE:
When clearing a media jam, sometimes media is stuck in the paper path. To clear this,
you must lift the Media Lever and insert thicker media into the paper path to push out the media
that is still stuck there.
2. Is the customer using non-HP media?
●The use of non-HP media can easily be the cause of media jams and head crashes (especially
head crashes because HP media is specially fo
rmulated to avoid cockle, one of the primary
causes of head crashes). If the media is not  HP approved, advise the customer to use HP
media and check to see if the problem is now solved.
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