Have a customer with a Designjet Z5200 that is double printing lines leading to blurry print. It appears to complete the print head alignment correctly and that page looks great. We ran some diagnostics and calibrations to try to determine the issue.

(Visit 1) We were not able to complete the line sensor service calibration (failed with an error code 2, but the service manual does not list this) and while doing diagnostics the unit failed the carriage diagnostic with an error indicating a bad line sensor so we replaced the line sensor with a brand new one direct from HP.

(Visit 2) After installation of the new line sensor we still could not complete the line sensor calibration (still failing with a error code 2) however the carriage diagnostics were now passing the line sensor but now failing on the CSP (color sensor), oddly the color sensor stand along diagnostic passes and the calibration is successful.

(Visit 3) We replaced the carriage PCA board per the service manual (line sensor error). However the unit still fails the carriage diagnostics for the color sensor (still passes the standalone diags and calibration) and still will not calibrate the line sensor (now fails with an error code 2 or error code 5, again neither of these are in the service manual). Another odd issue is with the new carriage PCA the carriage does not move to the center (it moves off center to the right) during the scan axis diagnostic. I did check the trailing cable and there appears to be no damage and also cleaned the encoder strip.

At this point I am at a loss but don't want to keep throwing the client's money into this. The issue for the client is they really need to be able to use the unit and due to procurement procedures (it is government) it will be months before they can buy a replacement.