HP Designjet T1100/T1100ps/T610/T1120/T1120ps Service Manual (P/N Q6683-90901)

• Covers the HP Designjet T1100, T1100ps, T610, T1120, and T1120ps large-format printer series in a 490-page PDF of HP’s service manual, Version 6, March 19, 2009.
• Factory-level diagnostic print samples include the Service Image Quality Diagnostic Print and Nozzle Health plots for separating printhead defects from alignment and media-advance problems.
• System error lookups address 79:04 firmware faults and 81:YZ paper-advance failures, with T1120/T1120ps formatter and power-supply LED diagnosis for a blank front panel.
• Specific removal and installation routines cover the carriage assembly, service station, and formatter, plus belt replacement and trailing-cable routing.
• Ink Delivery System (IDS) tests check pressurization, supply recognition, and leakage. Purge Tubes procedures address incomplete priming and re-priming of existing tubes.
• Paper Advance, Line Sensor, and Drop Detector calibrations are tied to post-repair checks through the Service Calibration Matrix.

Model Coverage and Hardware Differences

The model codes below distinguish the 24-inch and 44-inch chassis builds.

Rewinder service applies only to 44-inch printers. On T1100/T1100ps/T610 models, backup nonvolatile memory (NVM) is on the PrintMech PCA. T1120/T1120ps machines omit that board and use the Media Advance Encoder PCA instead; their trailing cable and ink supply tubes are listed as one service part. Separate hard disk drive removal is documented for these later models.

The earlier models’ aerosol-fan procedures are limited to units built before mid-February 2008. The New Formatter Design section compares PATA and SATA layouts and explains the switch to onboard RAM. It specifies firmware 6.0.0.4 or later for the newer formatter on T610/T1100 printers.

Documented Subsystems and Diagnostics

The 79:04 appendix separates job, corrupt-data, network, user-interaction, and intermittent firmware causes from hardware failures. Firmware updating in diagnostics boot mode and printer-log collection are documented. Diagnostic-mode recovery requires a separate PLT firmware file; standard FMW updates are not suitable for that method.

For 81:YZ, the troubleshooting also identifies signs of nonrepairable chassis damage, not just motor and encoder faults. Media-handling sections address roll and sheet loading, skew, jams, and head crashes.

Electrical repair coverage focuses on built-in Electronics Module tests and assembly replacement, not component-level circuit-board repair. These tests check power-supply voltages, formatter memory and hard disk drive information, and carriage-to-mainboard communication. Network troubleshooting covers the formatter interface and accessory Jetdirect cards; the formatter I/O Tests exclude the T610.

Replacement warnings explain how reused NVM boards or simultaneous replacement of the formatter and backup-NVM board can erase calibrations, affect PostScript capability, or leave the printer unusable.

Specifications and Calibration Details

Supply tables identify HP 72 ink cartridges, their capacity options, and compatible printheads by part number. Ink-supply troubleshooting covers printhead replacement, status messages, 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 user calibration for the loaded paper type from the service-level print-and-scan procedure. The Carriage PCA calibration resets ink-short thresholds after board replacement. Required checks also apply when an assembly is removed only to reach another component.

Preventive maintenance links component life counters to model-specific kits for scan-axis wear parts, the service station, and the cutter. The procedures cover carriage-bushing lubrication and drive-roller/overdrive cleaning. Full-bleed foam replacement includes a warning that incorrect seating can damage the carriage assembly.

Parts Diagrams and Repair Tools

Model-specific parts tables link assemblies to their removal procedures. Exploded views such as Scan-Axis Assemblies (T1120/T1120ps) and Paper Path Assemblies (Rear) identify the belt and ink-tube hardware and rear feed components.

Media-drive positioning and pinchwheel alignment procedures identify dedicated tooling, including Tool Kit Q6683-67001, Media Driver Adjustment Tool Q6675-67009, and Manual Pinch Arm Alignment Tool Q5669-20595.

HP specifies these repair procedures for HP-qualified service personnel. Since handling formatter boards and power supplies involves electrical hazards, always verify the machine is fully disconnected from power before inspecting internal routing or removing electronic assemblies. The manual also warns that cover sensors are disabled in the Service Tests menu.