HPZ3200 86:01 and 87:11 codes

[sharadn]

Hello all,
I am back in Switzerland and starting to work on my printer again.
A short recap of my issue: I purchased a used printer with the 86:01 code and a shredded belt. It seemed like an easy fix at the time. I replaced the belt with one from LPS. After this I have always been getting the 86:01 error code on startup.
It seems that the printer does not know when the carriage is at the right hand side and it does not cap properly. The carriage then bumps up against the right hand side and bounces until is throws the code. The carriage will home properly when I do the diagnostic test for the service station but not on startup.

Here is the procedure from the manual for the 86:01 code
Problem Description:
Problem moving the carriage, most likely due to a paper jam.
Corrective Action:
Try the following:
Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer.
Open the Window and check for any visible obstacles restricting the movement of the carriage. If there is a wrinkled mass of media inside the paper path, lift the Pinch wheels (using the Media Lever) and clear the obstruction.
If there is no paper jam or obstacle blocking the carriage movement perform the following:
– Clean the encoder strip.[AN] replaced 3x
– Check the belt assembly. [AN] replaced with LPS belt
– All cables and connections between the Carriag PCA, Scan Axis Motor, and Main PCA.[AN] I checked and can see nothing obvious but I don't know how to check further
– Oil the carriage rails.[AN] done
Perform the Scan Axis Diagnostic Test ⇒ Page 3-6.[AN] Fails with the 87:11 code scan axis too short. There is no physical blockage
If the diagnostic test does not find any specific error, replace the Carriage Assembly ⇒ Page 6-100. [AN] replaced with what appears to be a new HP unit
Replace the Belt Assembly ⇒ Page 6-115.[AN] done
Replace the Scan Axis Motor ⇒ Page 6-116. [AN] Not done
Replace the Main PCA ⇒ Page 6-161. [AN] Not done

here is the procedure for the 87:11 code:
87:YZ
Problem Description:
Problem finding the Scan-axis encoder reading.
Corrective Action:
Try the following:
Upgrade the firmware.
Clean the Encoder Strip.[AN] done
Replace the Encoder Strip ⇒ Page 6-91. [AN] done
Replace the Carriage PCA ⇒ Page 6-138. [AN] done
Replace the Trailing Cables ⇒ Page 6-92 [AN] done

I replaced the entire carriage assembly including the trailing cables.
In order to eliminate firmware issues I purchased a virgin HD from LPS and installed it. I think it was successful but I am still getting the 86:01 code.
When I do the scan axis test I get the 87:11 code, scan axis is too short. I believe it is because the printer does not know where the carriage is. When I do the scan axis test it looks like the coder is reading the encoder strip properly. I have also had three difference encoder strips in there and this does not make a difference. The scan axis test shows a scan axis of 44".
The only thing I have not done is replace the main PCA board. When I run the electronics diagnostics it does not flag an error with the main PCA board.
If I could figure out why the printer does not know where the carriage is when it is at the service station I think I could solve the issue. Is there a device in the service station that reports the position of the carriage to the printer? I have not done anything to the service station.
I would appreciate any suggestions or input!
Here is my previous lengthy post for those who have time on their hands.
https://forum.luminous-landscape.com/index.php?topic=144757.0

[Kyle Jackson]

Welcome back! I thought maybe you'd solved the problem and went back to normal printing life, but I guess not so lucky. 

This one continues to baffle me and my limited experience. I think you've done all the normal / obvious stuff, plus a whole pantload more than that. At this point I don't know if any of us are able to say "oh it's just X" anymore. Having exhausted the usual possibilities I think you're in the realm of experimenting with anything that comes to mind until magically discovering the fix.

My own speculation is that it's something "mechanical" that is prevented the carriage from moving cleanly to the rightmost extent of travel in all operating states, and/or it can't sense correctly where that is. If you haven't already done so, I'd have the right side cover completely removed (and maybe the left as well) so you can clearly watch the capping/service station operation and what the carriage does at that end. You might spot something like maybe the capping station isn't fully retracting and the carriage hits it. That might indicate an issue with the service station (or it needs cleaning or something).

There is also the scan-axis motor on the drive belt. I can't imagine it somehow not working just at that end tho unless the carriage is fetching up on something. Or maybe the belt drive gear is slipping on the motor shaft somehow, so a new motor might be worth checking.

Since the printer can do all the tests I speculate that the electronics or cabling are okay. I really don't see how replacing the mainboard would affect it. I would've thought the Print Mech PCA would be a suspect before the Mainboard, but what do I know lol. But it's still there as an option I guess. Check all the connections on the Print Mech PCA for sure tho while the right side cover is off.

So yeah I'd say get the side covers off and watch it carefully, might spot something. Failing that it's probably experimentally replacing more stuff in whatever order makes sense: scan axis motor, service station, mainboard, print mech PCA..., until you have a whole new printer I guess 

[sharadn]

Thanks for the welcome
I actually order a refurbed HPZ3200 to use while messing around with this one. The whole idea of having a printer is to print, not to spend hours and hours working on it . Maybe a working printer beside it might shed some light!

My own speculation is that it's something "mechanical" that is prevented the carriage from moving cleanly to the rightmost extent of travel in all operating states, and/or it can't sense correctly where that is. If you haven't already done so, I'd have the right side cover completely removed (and maybe the left as well) so you can clearly watch the capping/service station operation and what the carriage does at that end. You might spot something like maybe the capping station isn't fully retracting and the carriage hits it. That might indicate an issue with the service station (or it needs cleaning or something).

It is clearly not hitting anything. The carriage goes completely and smoothly until it hits the right side and then sits there and bounces until the code is thrown. I think that for some reason the printer does not know that the carriage is at the end of the right side. It seems like a trailing cable issue, although maybe it is just a connection that I am not seeing.

[Kyle Jackson]

Hmm, well if it's the scan axis position function that's pooched, you've already replaced everything in the pipeline: the encoder strip, and the encoder + carriage PCA + trailing cables when you replaced the carriage assembly. The next connection is the Mainboard itself so maybe that's why it's on the list. I recall you were shopping Mainboards a while ago?

[degrub]

Just some thoughts -

Possible the carriage is not sensing "zero or home" position correctly ? Thus the count during moving over is not correct ? Or the encoding strip is not in correct position (in either direction ) ?

Maybe whatever device is not recording the number of counts correctly or has a memory issue ?

Microswitch / optical switch at far end not functioning correctly ( if it has one ? ) ?

Regardless, i would follow the testing/replacement logic provided in the manual explicitly. It was designed by the engineers as a fault tree.

[sharadn]

I finally got the printer to boot up completely! I found an excellent resource in Germany https://plotter-nrw.de/. hey are extremely helpful and honest. They told me to remove the brown backing on the trailing cable. The old carriage that I took out had it so I did not think that this would be a problem. I think that Ernst at one point mentioned this as a possibility but I did not follow up. I guess this was making too much resistance on the left hand side. T
Now that I can get it to boot up. I tried to print a diagnostic image but nothing came out. I guess the ink must be totally clogged. I am not sure what to do next. Shall I initialize the printer, take out all the cartridges and printheads and boot it up?
I am extremely happy to have at least solved problem 1!!!!!
Thank you to all of you who offered help and maybe this can be helpful to someone else.

[Kyle Jackson]

Hey that's great news!! 

What do you mean by "brown backing"? You mean some kind of packaging material from shipping?

Also make sure the trailing cable is routed under the carriage instead of over top of it. Both ways look correct at a glance, but the wrong way jams the cable into a tighter bend so the carriage has trouble sliding all the way to the right. Learned this when I replaced my Z3200 belt last week! 

Best to post a pic of the diag plot... If you mean the colour patches are blank... all of them tho??    In any case my first go-to is run the "Clean All Printheads" option, then repeat the diag plot, then repeat etc until it sorts out. Sometimes it takes manyyy rounds to recover them if it's been dormant a while.

For diag plots I often use the service version ("IQSB"). It burns more paper but it prints bigger patches at both full- and half-density. Sometimes the full density patches look normal but there are issues with fading/banding in the half-density patches that don't show up on the regular diag plot. Also shows printhead alignment. Anyhow... Main Menu > Up + Cancel > Service Utilities > Diagnostics Print > Image Quality Service Best.

Sample IQSB photo attached.


This all assumes your heads aren't full of air tho. Manyyy threads here now how to check for that... Weigh the heads, 60 grams is full. There are purge/prime kits available online to remove air from heads and printer ink tubes and re-prime the heads with ink.

[sharadn]

The printer came with a box of supplies and I found all new printheads and installed them. It never completes the printhead replacement. I have done it about three or more times with the same result. I also tried initializing the printer by taking out all the cartridges and printheads with the same result. According to LPS this has to do with air in the ink lines, here is the video: https://www.youtube.com/watch?v=bsZ1Dqye_Lo
Is there a way to bleed the lines without buying their special bleeding tool? Importing and post to Switzerland is expensive. It seems like there must be another way.

[Kyle Jackson]

The LPS syringe to pull air/ink from the ink tubes is the only one I've tried. The tip is notched a certain way so it can push open the check-valve ball and still draw air/link from the line thru the side notch. Here's a pic:
https://forum.luminous-landscape.com/index.php?topic=141083.msg1258671#msg1258671

With my rescued Z3200 I ended up doing much the same process that LPS suggests. Purged air from the printer ink tubes with the syringe. 5 of the heads weren't working right so I got new ones. (I think I later revived some of those heads for spares.) Also I used all ink carts with 75% full or more. Then did the fresh startup process with all heads and carts removed and installed them when prompted. Everything worked fine after that.

[sharadn]

Here is a photo of the brown backing that was on the trailing cables. It was providing too much resistance at the left hand side.
Maybe I will fabricate a tool like Ernst did in the post that you linked me to, very helpful.
It costs too much and takes too long to order the tool from LPS.

[Kyle Jackson]

I really don't think that plastic layer is supposed to be removed from the cable    I imagine it's partly for strain relief on the wires as they flex thru many thousands of head movements.

It's sounds like the cable might be mis-routed so it doesn't have full reach. Or it's the wrong cable for this machine, or was made the wrong length (defective). Was it an after-market cable instead of from HP?

[sharadn]

It came on the trailing cables with the carriage that came with the printer. It was also included in the replacement carriage (HP). For whatever reason both of them were preventing the carriage from moving completely to the left. That is why the scan axis test was saying the scan axis it too short. As soon as I removed it the printer booted fully. I don't have much choice but to live with it like this. If I need to replace the cables after a few years I will. Now I am trying to get ink flowing to the heads. Next problem to solve!

[Kyle Jackson]

Got a photo of the diag plot?

[sharadn]

If I did it would be totally white! Nothing is printing at all. When I had the covers off I could see air in the ink tubes. I bit the bullet and ordered the tool from LPS and will also order some cartridges from Ebay Germany. At least I am first base 

[Kyle Jackson]

If I did it would be totally white! Nothing is printing at all. When I had the covers off I could see air in the ink tubes. I bit the bullet and ordered the tool from LPS and will also order some cartridges from Ebay Germany. At least I am first base 

Sorry it wasn't clear to me earlier whether you meant the printer was refusing to print the diag plot, or instead the carriage was moving but nothing came out of all 12 channels. Which was it?

It seems incredibly unlikely to me that all 12 channels were completely blank, and without the printer giving any errors.

If you tried installing the new heads and it keeps giving the "replace printhead" message, yes that could be air in the lines and hopefully the kit from LPS will help.

The ink supply tubes from the ink cartridges to the carriage are in those black flex "cables" connected to the carriage. They have a rubber casing on them so it's not really possible to see the ink tubes themselves or if they have any air bubbles in them. I suspect the tubes you saw were the purge suction lines from the capping station to the priming pump at the righthand side of the printer. Air in those is normal.

[sharadn]

You are probably right about the purge lines. I don't know how long this printer has sat but I suspect a long time. I bought it from institution that puts on plays. So I think once it developed issues they just shut it off and let it sit. When I bought it it had the 86:01 code and a shredded belt which I thought would be pretty easy to fix. Well it turned out to be more difficult than that. Your help has been invaluable and I am sure I will revive this printer one way or another.