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HP Designjet 400 Series Printers - Media Jamming Issues

	Parts required (part numbers are subject to change)
	Troubleshooting steps
	Media Axis (X-Axis) test
	Bail Cycle test
	Check/replace the Media spindle
	Check/replace the Rollfeed assembly
	Check/replace the Overdrive gear assembly and Overdrive clutch
	Instructions for entering Service mode
	Accuracy calibration

Document number: BPP90084

Last updated: 10-Jan-2003

Minimum skill level: 2

A media jam can happen at any time. It may occur when loading a new roll, during a print, or at the end of a roll. Some of the reasons for a media jam are improper loading of media, media not installed correctly on the spindle, third party media, bail not lifting, or the media being too thick. 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
Roll Feed Kit (required)	C4713-60146	C4714-60146
Spindle (required)	C4717-60005	C4719-60005
Overdrive Gear (required)	C1633-40019	C1633-40019
Overdrive Clutch (required)	C4713-60129	C4713-60129
X-Axis Motor (required)	C4713-60094	C4713-60094
Bail Assembly (required)	C4713-60093	C4714-60093
Encoder Strip (required)	C4713-60098	C4714-60098

NOTE: The HP Designjet 400 series printers have a very high rate of Cutter assembly failure. Because of this, the Cutter assembly must be replaced during any on-site repair (refer to page 8-21 of HP Designjet 400 Series Service Manual for teardown procedures). If the Cutter appears all right, 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 successfully printing internal test prints. If functionality is verified, no additional parts should be replaced.

1. Turn off the printer.
2. Lift the Top cover and lower the Media lever.
3. Ensure the pinch arm releases the pressure on the media.
4. Carefully move the Carriage and/or Cutter assemblies to their home positions (Carriage - far left, Cutter - far right).
5. Remove media from the printer.
6. Remove any small pieces of media that may be stuck in the media path.

NOTE: A manila file folder may be inserted into the media path to clear any unseen obstructions.

7. If an obstruction is removed, try loading both roll and sheet (preferably larger than 8.5 x 11 inches) media two times each to prove functionality.
8. If loading media is unsuccessful, or no problem is found with the media path, continue with the Media Axis test.

Media Axis (X-Axis) test

1. Turn off the printer.
2. Ensure the Top cover is closed and the Pincharm lever is up.
3. Enter Service mode 1 (instructions listed below).
4. Press the MEDIA LOAD button to start the test.
5. A steady Glossy LED indicates the test passed. Continue with the next section (Bail Cycle test).
6. A flashing Glossy LED indicates the test has failed. Replace the X-Axis Motor (refer to page 8-23 of the Service Manual). Following replacement, perform an Accuracy calibration (listed below) and 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 Partner Care Web site for review or download.

7. If the Media Axis test passes, or problems persist following X-Axis motor replacement, continue with the next section.

Bail Cycle test

1. Turn off the printer.
2. Remove media from the printer.
3. Return the Media lever to the up position, and close the Top cover.
4. Enter Service mode 1 (instructions listed below).
5. Press the SETUP button to start the Bail Cycle test.
6. Monitor the Best LED for status.
7. A steady Best LED indicates the test passed. Continue with the next section ("Check/replace the Media spindle").
8. Flashing LED indicates Fail. Check the Bail assembly for noticeable damage or wear, and replace as needed (refer to page 8-7 or the Service Manual).
9. Following replacement, attempt to verify functionality.
10. If problems persist, continue with the remaining steps.

Check/replace the Media spindle

1. Ensure the media is installed on the spindle correctly.
2. Remove the Media spindle from the printer.
3. Check the right side of the spindle for damage or wear, and replace if needed.
4. If the spindle is replaced, load media onto new spindle, and try reloading.
5. If loading is successful, repeat loading procedure with both roll and sheet media (preferably larger than 8.5 x 11 inches) two times each, to prove product functionality.
6. If loading media is unsuccessful, or no problem is found with the spindle, continue with the remaining steps.

Check/replace the Rollfeed assembly

1. Remove the Media spindle from the printer.
2. Check the right Rollfeed assembly for tension. Spring should be strong, but can be overpowered.
3. Push up on the top portion of spring-loaded clamp. It should spring back down immediately when released. If spring tension is too strong or the spring does not spring back, replace the right Rollfeed assembly (refer to page 8-9 of the Service Manual).
4. If the Rollfeed assembly gear wheel moves easily, replace the Rollfeed assembly (refer to page 8-9 of the Service Manual).
5. Following replacement, attempt to verify printer functionality.
6. If no problems with the Rollfeed assembly are noticed or the problem persists, continue with the remaining steps.

Check/replace the Overdrive gear assembly and Overdrive clutch

1. Open the Top cover.
2. Manually lift the bail assembly.
3. Try turning the Overdrive backwards by hand.
4. If the Overdrive moves backwards, replace the Overdrive gear and Overdrive clutch assembly (refer to page 8-50 of the Service Manual). Attempt to verify functionality.
5. If the Overdrive locks and does not move backwards, trip the Top cover sensor and leave the Top cover open.

NOTE: This will allow viewing of the Overdrive wheels during the media loading procedure.

6. Load a sheet of 8.5 x 11-inch media.
7. Watch the media as it runs between the Overdrive wheels and the bail. If the Overdrive clutch is defective and Overdrive is not turning, the sheet will buckle when it hits the wheels, forming a media bubble.
8. Repeat several times since this is an intermittent issue. If repeatable, replace the Overdrive clutch (refer to page 8-50 of the Service Manual).
9. Following replacement of the Overdrive gear and Overdrive clutch assemblies, perform an accuracy calibration (listed below) and verify functionality.

Instructions for entering Service mode

Service mode 1

1. Hold the REPRINT button down, and turn on the printer.
2. Continue to hold the REPRINT button until LEDs on front panel begin sequencing.
3. Press the appropriate key(s) to perform the necessary test.

Service mode 2

1. Hold the MEDIA SOURCE button down and turn on the printer.
2. Continue to hold the MEDIA SOURCE button until LEDs on front panel begin sequencing.

NOTE: Service mode 2 contains tests that need a complete initialization or the printer (same as normal operation mode). If a system error occurs while trying to access Service mode 2, turn off the printer and enter Service mode 1 to complete the necessary test(s).

3. Press the appropriate key(s) to perform the necessary test.

Accuracy calibration

1. Place a sheet of polyester film over the top of the printer for approximately 10 minutes to let it stabilize to the environmental conditions. Use a sheet approximately 24 x 36 inches, 61 x 91 cm (D-size). If sheet media is not available, roll media can be used if cut into a 24 X 36 inch sheet. When using polyester film, load it with the matte (dull) side down.

NOTE: If a polyester or matte film is not available use HP Coated media when performing an Accuracy calibration.

2. Turn off the printer.
3. Press and hold in the MEDIA SOURCE button and turn on the printer, (entering Service mode 2).
4. Set the Media Type on the front panel to Coated Media.
5. Load the film with the matte (dull) side down, in portrait orientation.
6. When the Ready LED lights up, press REPRINT.

NOTE: The Ready LED will begin to flash. Allow several minutes for the printer to complete the calibration print.

7. The printer will eject the sheet, and the Load Media LED will light up.
8. Unload the sheet from the printer.
9. Wait until the ink on the sheet is dry.
10. Cut the sheet along the dotted line and reload facedown into the printer in the direction indicated by the arrows on the calibration plot.

NOTE: The Ready LED will begin to flash. The printer takes less than 10 minutes to read the calibration sheet, calculate the calibration data, and save the data in the EEROM.

11. Unload the sheet from the printer.
12. The Accuracy calibration is now complete.
13. Turn the printer off then on, 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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