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HP Designjet 400 Series Printers - Bail Lift Issues

	Parts required (part numbers are subject to change)
	Troubleshooting steps
	Bail Cycle test

KRS document number: BPP90075

Last updated: 22-Aug-2001

Minimum skill level: 2

The Bail assembly is not raising correctly or not raising at all. Common causes of Bail problems are paper jams, a broken Bail wire, damage to the Bail assembly, or Carriage positioning issues. Use the steps listed in this document to accurately determine the cause of the failure and replace the appropriate parts.

Parts required (part numbers are subject to change)

Part description	Model numbers - C4713A, C4715A, C6080A, C6082A	Model numbers - C4714A, C4716A, C6081A, C6083A
Cutter (Required) See note below	C4713-60040	C4713-60040
Bail Assembly (Required)	C4713-60093	C4714-60093
Bail Lift Cam (Required)	C3190-40020	C3190-40020
Bail Link (Wire/Cable) (Required)	C4713-60182	C4713-60182
Bail Engaging Lever (Required)	C3190-40022	C3190-40022
Bail Lift Cam Gear (Required)	C3190-40019	C3190-40019
Bail Engaging Lever Gear (Required)	C1633-40027	C1633-40027
Bail Cable Spring (Required)	C3190-80013	C3190-80013
Bail Engaging Lever Support (Required)	C4713-40016	C4713-40016

NOTE: The HP Designjet 400 series printers have a very high rate of Cutter assembly failure. Due to this fact, the Cutter assembly must be replaced during any Onsite repair (refer to pages 8-21 of the HP Designjet 400 Series Service Manual for teardown procedures). If the Cutter appears OK, it still must be replaced at some point during the service call.

Troubleshooting steps

If parts are replaced or fixed in any of the steps listed below, attempt to verify printer functionality by turning the printer on and printing internal test prints. If functionality is verified, no additional parts should be replaced.

1. Turn the printer off.
2. Lift the top cover and check for a paper jam or other physical obstruction to Bail movement. If paper jam occurred, lower the media lever and remove paper. Check that paper is completely removed by looking for any small pieces in the paper path.

NOTE: A manila file folder may be used to clear debris from paper path.

3. Check Carriage movement manually. The carriage should contact both the far-right and far-left plastic housings.
4. Manually raise and lower bail to check for freedom of movement. Check bail for damage; if necessary, replace the Bail assembly (refer to pages 8-7 of the HP Designjet 400 Series Service Manual). Following replacement, attempt to verify functionality.

NOTE: If Removal and Replacement instructions are needed for reference during any repairs performed, refer to the HP Designjet 400 Series Service Manual available on the Computer Care site for review or download.

5. If no problems with the bail are found, or problems persist, continue with the remaining steps.
6. Check the Bail link (wire/cable) by pushing or lifting the Bail Engaging Lever tab to the left and releasing it. If it springs back to the right, the wire is intact and operating normally, continue with Step 9.
7. If the Lever does not spring back, replace the Lever, Cam, and Bail Link Wire/Cable (refer to pages 8-28).
8. Attempt to verify functionality. If problems persist continue with the remaining steps.
9. Gently clean the Encoder strip with a lint free cloth dampened with water. Move carriage as needed to wipe entire length of strip.

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

10. Attempt to verify printer functionality. If problems persist, continue troubleshooting by performing the Bail Cycle test.

Bail Cycle test

1. Turn the printer off.
2. Remove any paper from the printer.
3. Return media lever to the up position, and close the top cover.
4. Enter Service Mode 1:
1. While holding the MEDIA SOURCE key down, turn the printer on.
2. Continue to hold the MEDIA SOURCE key until LEDs on front panel begin sequencing.
5. To start the Bail cycle test, press the SETUP key when all the LEDs begin to flash.
6. Open the top cover and watch for Bail movement.
7. If the test passes, the Best LED on the front panel will light up. Turn the printer off, then on and attempt to verify functionality.
8. If the test fails (Best LED will flash) or the Bail does not raise, continue with the remaining steps.
9. Replace the Bail Lift Cam Gear, Bail Engaging Lever Gear, Bail Cable Spring and the Bail Engaging Lever Support (refer to pages 8-28).
10. Following replacement, load paper and verify printer functionality.

Copyright Hewlett-Packard Co. 2001
This information is subject to change without notice and
is provided "as is" with no warranty.
Hewlett-Packard shall not be liable for any direct,
indirect, special, incidental or consequential damages
in connection with the use of this material.

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