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HP Designjet 400 Series Printers - Media Loading Issues

	Parts required (part numbers are subject to change)
	Troubleshooting steps
	Sensors test
	Media Axis (X-Axis) test
	Check/replace the Rollfeed assembly
	Instructions for Entering Service mode
	Accuracy calibration

Document number: BPP90085

Last updated: 01-May-2002

Minimum skill level: 2

Media will not correctly load into the printer. Some of the most common causes of this issue are operator error, Top cover open, Pincharm down, or the media motor. Check to see if issue is related to roll only or both roll and sheet loads. 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
Media Deflector/Button (required)	C4713-60117	C4713-60117
X-Axis Motor/Gear (required)	C4713-60094	C4713-60094
Pincharm Sensor (required)	C4713-60034	C4713-60034
Front Panel Assy (required)	C4713-60091	C4713-60091
Rollfeed Kit (required)	C4713-60146	C4714-60146

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 on-site repair (refer to page 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, and remove all media.
2. Ensure the Top cover is closed and the Pincharm lever is in the up position (Media LED will flash during initialization if lever is down).
3. Turn the printer on and wait for the printer to complete initialization.
4. The Load Media light should turn on when ready for media.
5. If Load Media light does not turn on, make sure the top cover is closed and Pincharm lever is up.
6. Insert media until it stops, and align with the perforated line on the right side of the entry platen.
7. Press the MEDIA LOAD button. If no response from the printer, replace the Media Deflector/Button (refer to page 8-50 of the Service Manual).
8. Following replacement, attempt to verify functionality. If problems persist, continue with the remaining steps.

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.

9. If the printer fans turn on and media still will not load, replace the X-Axis Motor (refer to page 8-23). Following replacement, perform an Accuracy calibration (listed below) and attempt to verify functionality.
10. If problems persist, continue with the remaining steps.

Sensors test

1. Turn the printer off.
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 Type button to start the test. The Film, Media and Sheet LEDs are lit when the corresponding sensor is tripped.
5. Insert media, open the Top cover, or lower the Pincharm level to change the LEDs. Replace faulty sensors as needed. Refer to page 8-12 for Front panel (top cover sensor) replacement and page 8-24 for Pincharm sensor replacement.
6. Following replacement, attempt to verify functionality.
7. If the test passes or problems persist, continue with the remaining steps.

Media Axis (X-Axis) test

1. Turn the printer off.
2. Ensure Top cover is closed and Pincharm lever is up.
3. Enter Service mode 1 (instructions 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 (checking the Rollfeed assembly).
6. A flashing Glossy LED indicates the test has failed. Replace the X-axis motor (refer to page 8-23). Attempt to verify functionality before continuing.

NOTE: If all of the LEDs continue to flash after the Media Load button is pressed, replace the Media button (refer to page 8-50). Attempt to verify functionality before continuing.

7. If the test passes or the problem persists, continue with checking the Rollfeed assembly.

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. Push up on top portion of spring-loaded clamp. Clamp should spring back down immediately when released.
3. If the Rollfeed gearing moves easily, or the spring does not spring back, replace the Rollfeed assembly (refer to page 8-9).
4. Following replacement, verify printer functionality. Perform media loading procedure with both roll and sheet (preferably larger than 8.5 x 11 inches) media, two times each.

Instructions for Entering Service mode

Service mode 1

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

Service mode 2

1. Hold the MEDIA SOURCE button down and turn the printer on.
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 the printer off and enter Service mode 1 to complete the necessary test(s).

3. Press the appropriate button(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 the printer off.
3. Press and hold in the MEDIA SOURCE button and turn the printer on (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 the REPRINT button.

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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