HP Designjet T1100, T1100ps, T610, T1120 & T1120ps Service Manual (2009 Edition)

HP’s Designjet service manual, Version 6, dated March 19, 2009, covers the T1100, T1100ps, T610, T1120, and T1120ps large-format printers.

Search, Bookmarks, and PDF Contents

Finding procedures: The text is searchable across all seven chapters, and embedded bookmarks link to chapters and individual service topics. Some front-panel readouts appear as images.

The single printable PDF runs 490 pages, including the cover, the copyright and safety page, four numbered pages with blank bodies, and three appendices in the system error code chapter.

Print Diagnostics, Carriage Repair, and Calibration

These selected service topics are part of a manual that also covers Pen to Paper Space solenoid replacement and EEROM recovery procedures.

• Print quality: The Service Image Quality Diagnostic Print and Nozzle Health plots help distinguish printhead defects from alignment and paper advance problems.

• Fault diagnosis: System error tables cover firmware and paper advance faults, with model-specific checks for a blank front panel.

• Assembly replacement: Removal and installation procedures cover the carriage assembly, service station, and formatter, plus drive belt replacement and trailing cable routing.

• Ink delivery: Ink Delivery System (IDS) tests check pressurization, ink supply recognition, and leakage. The Purge Tubes utility covers incomplete automatic priming and re-priming installed tubes.

• Post-repair checks: The Service Calibration Matrix ties Paper Advance, Line Sensor, and Drop Detector calibrations to the assemblies removed or replaced.

HP specifies these repair procedures for HP-qualified service personnel.

Firmware Faults and Paper Feed Diagnosis

Error 79:04: The appendix explains how to distinguish hardware failures from print job, corrupt data, network, user interaction, and intermittent firmware faults. It also covers printer log collection and firmware recovery in diagnostics boot mode. That recovery method requires a PLT firmware file. Standard FMW files are used for updates through the Embedded Web Server.

Error 81:YZ: The troubleshooting covers motor and encoder faults and identifies chassis damage that can make the printer unrepairable. Separate media-handling guidance covers roll and sheet loading, skew, jams, and printhead crashes.

Formatter, Backup Memory, and Chassis Differences

Electronics diagnosis: The blank-panel procedure for the T1120 and T1120ps uses formatter and power supply LEDs. Built-in Electronics Module tests cover supply voltages, formatter memory and hard drive information, and carriage-to-mainboard communication. The repair procedures work at the assembly level. Network diagnosis covers the formatter interface and accessory Jetdirect cards. The formatter I/O test excludes the T610.

Backup memory: The T1100, T1100ps, and T610 store backup NVM on the PrintMech PCA. The T1120 and T1120ps store it on the Media Advance Encoder PCA and have a separate hard drive removal procedure. The manual explains how reusing boards or replacing both NVM-bearing assemblies at once can erase calibrations, affect PostScript capability, or leave the printer unusable.

Formatter revisions: The New Formatter Design section compares PATA and SATA layouts and shows the move from a removable RAM module to onboard memory. The newer formatter requires firmware 6.0.0.4 or later on the T610 and T1100.

Chassis differences: Rewinder service applies to the 44-inch printers. Aerosol fan procedures apply to T1100, T1100ps, and T610 units built before mid-February 2008.

Service safety: HP warns about electrical shock during internal service and specifies disconnecting power before removing electronics. Cover sensors are disabled in the Service Tests menu.

Ink Supplies and Calibration Checks

HP 72 supply tables list cartridge capacity options and compatible printhead part numbers. Ink supply troubleshooting explains status messages, printhead replacement, and electrical contact cleaning with the Flex Contacts Cleaning Tool.

Printhead alignment covers pen-to-pen, bidirectional, and carriage thetaZ checks, with acceptance limits and media requirements. Paper advance coverage distinguishes calibration for the loaded paper type from the service print-and-scan procedure. Carriage PCA calibration resets ink-short thresholds after board replacement. The matrix identifies checks that also apply when a part was removed just to reach another assembly.

Parts Views, Alignment Tools, and Maintenance Kits

The Scan-Axis Assemblies (T1120/T1120ps) and Paper Path Assemblies (Rear) exploded views pair part numbers with removal procedures. The T1120 and T1120ps list the trailing cable and ink supply tubes as one service part.

Media drive positioning and pinchwheel alignment call for Tool Kit Q6683-67001, Media Driver Adjustment Tool Q6675-67009, and Manual Pinch Arm Alignment Tool Q5669-20595.

Preventive maintenance links component life counters to model-specific kits for scan-axis wear parts, the service station, and the cutter. It also covers carriage bushing lubrication, drive roller and overdrive cleaning, and how incorrectly seated full-bleed foam can damage the carriage.

Carriage Voltage Checks at a Glance

In the Carriage Assembly diagnostic, the specified carriage supply voltage (+Vs) is 30.6–33.3 V for the T1120 and T1120ps and 43.6–46.3 V for the T1100, T1100ps, and T610.

The same diagnostic specifies 26.5–33 V for the printhead supply check, labeled Pens Voltage (Vpp) on the front panel.