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1. In Firmware Version 4 x x x the following Ke petit Car Fm pets mE Ege Paler micis text will also be added here Pets Goss und ane RR raise penam bring 3 Calibrations are not reported within SM RE a mee this list Blue Line Calibration Carriage m Pat clit ettet s PCA Setup and Vacuum Fan wee pan mE pharma Coat Parca pena pendng Mm ptedeg menie pening General Calibrations LED Gain Offset and Line Sensor to Black relate to the Line Sensor and these are done when performing the Line Sensor Calibration E Drop Detector relates to the Drop Detector or Service Station calibration B Paper Advance relates to the Service Paper Advance Calibration B Printhead Alignment relates to the Printhead Alignment which changes to pending when a Printhead is replaced and the Printhead Alignment has not been performed Media Specific Calibrations This section shows the following for each type of media Color Calibration B Paper Advance per media type and optimized for Text drawing and Graphics System Error Codes 2 syiom vorcoes KJ System Error Codes Introduction System error codes are hexa decimal based numbers generally caused by internal system errors The following pages contain a list of system error codes and their respective description
2. invent 6 Remove six T 10 screws 1 that secure the Interconnect PCA Cover 7 Remove the Interconnect PCA Cover from the Printer 8 Disconnect ALL cables from the Interconnect PCA CA 9 Remove five T 10 screws Type 1 that secure the Interconnect PCA 10 Remove the Interconnect PCA from the Printer to Interface Card Removal r E 1 Remove the JetDirect Card if installed 2 Remove three T 15 screws Type that secure the cover 3 Remove the Main PCA Cover from the Printer 0000000000000 4 Remove one T 10 screw Type 1 that secures the Interface Card 5 Disconnect the Interface Card from the Main PCA and remove from the Printer wexowmusn PCI Removal 1 Remove the Rear Door Page 8 2 Remove the Right Connector Cover Page 8 18 3 Remove the JetDirect Card if installed 4 Remove three T 15 screws Type that secure the Main PCA cover 5 Remove the Main PCA Cover from the Printer CD 6 Disconnect the Trailing Cable from the PCI PCA 7 Disconnect ALL cables connected to the Gamut PCI PCA 8 Remove T 10 screw Type 1 that secures the Gamut PCI PCA Q inveni 9 Disconnect the Gamut PCI PCA from the Main PCA and remove from the Printer
3. invent 21 12 Fail moving Service Station 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 E If the System Error continues replace the Service Station Page 8 23 21 13 Problem with the Service Station 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 Make sure that the Service Station path is clear Remove any visible obstacles e g screws plastic parts etc restricting the movement of the Service Station f the System Error continues replace the Service Station Page 8 23 23 10 Problem with the APS 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 Check that the APS cable is not damaged and is correctly connected to the E Replace the APS Assembly gt Page 8 62 Replace the Page 8 119 If the System Error continues replace the PCI PCA Page 8 98 invent System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Correcti
4. dyt aSseii ly DIESE 5 Sensors test Ink Delivery system test 7 SV5 Aerasol FAN test B Air Pump System test 9 1 vacuum FANS test 18 Others 2 n the Others submenu scroll to 10 5 Enable Connectivity and press Enter ie Bag Broken Recovery 18 2 I0 Information 18 3 Unit Information 18 4 Check Ink Supplies 18 5 Enable connectivity Press Enter Press Enter to confirm selection Use UP and DOWN keys to select YES Press UP DOWN to change an ENTER to select 3 Use the Arrow keys to select Yes to enable connectivity and press the Enter key to confirm the selection The printer will display the following Press any key to shutdown the system 4 Press any key on the Front Panel and the printer will reboot when the printer has fully intialized connectivity will be enabled Tl EEROM Reset The purpose of this diagnostic is to reset the EEROM values Perform an EEROM Reset as follows 1 In the Diagnostics Tests submenu scroll to 11 EEROM Reset and press Enter Diagnostics menu L 2 SEMSUlLS Les 6 Ink Delivery system tes E 7 SvS Aerosol FAN test Ws Air Pump System test 9 Vacuum FANS test 18 Others 11 EEROM Reset 2 A message will appear on the Front Panel advising you that all user information files will be removed If you would like to pro
5. Scan Axis Assemblies Q1273 60300 Ink Supply Tubes SRK Tubes w o Trailing Cables Serv 23 91273 60228 60228 au Belt and Tensioner Belt and Tensioner Assembly 6007 Scan Axis Motor 01273 60239 Encoder Strip and Encoder Sensor Kit 5 0127360108 Ink Supply Tubes Clips 2 01273 60266 Rear Tube Brackets Q1273 60158 Trailing Cable Data and power Figure 9 Scan Axis Assemblies Drive Roller and Media Axis Motor Q1273 60039 1 Drive Roller Q1273 60248 Drive Roller Encoder Kit Q1273 60242 Gears and Drive Roller Brake Kit 0127380247 1 Motor Carriage Stopper includes Carriage 5 Q1273 60252 Stopper Screw and Media Axis Motor Bracket Figure 10 Drive Roller and Media Axis Motor Paper Path Assemblies Q1273 60041 Center Platen Q1273 60060 EEEN Front Platen Q1273 60058 Input Roller Q1273 60103 Input Roller Levers Q1273 60073 Media Deflectors Figure 11 Paper Path Assemblies Center Guide and Pinchwheel Assembly 9127350235 1 Guide 01273 60040 BENE Complete Pinchwheels Assembly Q1273 60104 3 Pinchwheels Kit only contains the wheels Q1273 60082 Media Lever Sensor 01273 60276 ot Media Lever Assembly Figure 12 Center Guide and Pinchwheel Assembly Media Entry Assemblies Q1273 60274 Left Roll Module
6. Use UP DOWN to scroll BACK to move cursor or ENTER to confirm 5 Once the new Serial Number has been entered the Front Panel will display the Serial Number and Model Number of the Printer Press the Enter key to confirm the Serial Number or the Cancel key to exit the utility without making any changes Press Enter to confirm SE 71 19 Recovery New serial number Ssa4831981M Fart Number i DARA Press ENTER to confirm or BACK to modify Press Cancel to exit If there is a failure at this point the Front Panel will display System Error Code 79 03 For more information on troubleshooting this error code refer to Page 2 21 6 message will appear on the Front Panel asking you if you would like to change the Part Number of the Printer Select Yes or No by using the Up and Down keys and press Enter to confirm your selection If you select No the process will end at this point Press Enter to confirm selection Use UP and DOWN keys to select Woo you want to change the Part Number af the unit YES Press UP DOWN to change ENTER to select or CANCEL to abort 7 f you select Yes the Front Panel will display the new Serial Number and Part Number Press the Enter key to accept If there is a failure at this point the Front Panel will display System Error Code 79 03 For more information on trou
7. from the Rear Door 2 Open the Rear Door slightly as shown 3 To release the right hand hinge of the Rear Door move the Rear Door to the right and then towards you 8 16 HP Designjet 4000 4020 Printer Series Service Manual CD 4 To release the left hand hinge of the Rear Door move the Rear Door to the right and then bend the hinge slightly as shown 5 Remove the Rear Door from the Printer Right Connector Cover Removal 1 Remove the Rear Door Page 8 16 2 Remove two 20 screws B from the Right Connector Cover 3 Remove the Right Connector Cover from the Printer Left Connector Cover Removal 1 Remove the Rear Door Page 8 16 2 Remove two 20 screws Type B from the Left Connector Cover 3 Remove the Left Connector Cover from the Printer Front Panel Removal 1 Remove the Right Cover Page 8 2 Remove the Rear Door Page 8 16 3 Remove the Right Connector Cover Page 8 18 4 Disconnect the Front Panel Cable from the Interconnect PCA 5 Disconnect the Ferrite clip located on the rear of the Electronics Module from the front of the Printer CD 6 Move the Front Panel Cable including the ferrite out of the Electronics Module 7 Release the Front Panel Cable from the Right Arc 8 Disconnect the Ferrite clip from the Right
8. 1 invent 2 Media Drive Test The purpose of this test is to diagnose a failure in the operation of components related to the Media Axis You must perform the Media Drive Test after System Error Code 81 System Error Code 41 XX System Error Code 73 XX Perform the Paper Axis test as follows In the Diagnostics Tests submenu scroll to 2 Media Drive test and press Enter Electronics module test Carriage assembly test Sensnrs test Ink Delivery system test S herocol FAM tact 2 The Printer will start to initialize the Scan Axis system and the Front Panel will display the following information Starting Gamut Starting Tests PWM Starting Tests E Set GPIO psu lpm If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 Checking voltage If there is a failure at this point the Front Panel will display System Error Code 03 10 For more information on troubleshooting this error code refer to Page 2 5 Check also System Error Code 01 0 10 refer to Page 2 3 B Clear GPIO psu lpm If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 Checking voltage If there is a failure at this point the Fr
9. 5 Remove the Line Sensor from the Carriage Assembly E Line Sensor Calibration Chapter 5 Removal and Installation LA inveni Media Deflector Removal Switch off the product and remove the power cable 1 Remove one 20 screw Type B that secures the Media Deflector that needs to be replaced DOO O n 2 Release the clip securing the Media E AL ume ond p te Deflector 3 Remove the Media Deflector slide upwards first from the Printer 8 126 HP Designjet 4000 4020 Printer Series Service Manual CD Front Platen Removal 1 Open the Window 4 2 Remove three T 15 screws and two cross head screws that secure the Front Platen 3 Release the clip on the left hand side of the Front Platen 4 Pull out the left hand side of the Front Platen 5 Slide the Front Platen to the Left and then remove from the Printer CA Center Platen Removal Remove the Right Cover Page 8 6 Remove the Left Cover Page 8 9 Remove the Top Cover Page 8 11 Remove the Service Station Page 8 23 pM x Remove the Middle Left Spittoons Page 8 71 Remove one T 15 screw Type P that secures the Center Platen Gear x 7 Remove the Center Platen Gear from the Printer Removal ard tslaron 8 Remove one 15 screw that secures the small Gear 9 Remove the small Gea
10. Designjet 4eeeps Fast Ethernet EWS address http 1 4 http 15 23 58 238 2 Once inside the Printer Setup Menus menu press the UP or Down arrow key and the Cancel key together T WA Information menu lt U ar I nen v 7 Y 43 B Press P configuration menu p Cow Printing defaults menu DOWN I O setup Press Cancel You are now in the Service Tools Menu 3 Use the Arrow keys to scroll to the Service Tests menu and press the Enter key Press Enter 4 In the Service Tests submenu scroll to Log management and press Enter Press Enter 6 The Front Panel displays the following Use the Up and Down keys to select an option and press Enter Press Enter to confirm selection Media path issues Others Use UP and DOWN keys to select If you select Media path issues the printer will capture all relevant media path information which will help when troubleshooting 84 and 81 X system errors If you select Others the printer will capture generic printer information which will help when troubleshooting 79 04 system errors 7 The logged information files are located from the Embedded Web Server http IP Address hp device 3432 8828 tmp The file that holds the tracer information and should be downloaded is the Print log file CA 0 sessctiod
11. enter PHC ER Maintenance go Use UP and El Reset life counters ElDiagnastic Print DOWN keys Sleep mode Replace cutter to go through Set RTC clock v d E Maintenance the d Ig Its 2 Press the Enter key to reset the Printhead Cleaning level go to next digit Use UP and DOWN keys to go through the digits Press Cancel to exit Press Enter to contirm Spittoon PHC K1 99 Spittoon PHC K2 180 Reset ink level Press ENTER to accept or BACK CANCEL to exit Press Cancel to exit PHC Spittoon Ink Level eec D 5 From firmware version 12 1 1 2 the level at which the Black Printhead Cleaner warning is displayed can be changed 6 Press the Enter key to reset the display threshold of when the Black Printhead Cleaner warning is displayed Ink Level Threshold 7 Use up and down keys to change the full values You can change the values to 80 75 70 65 60 55 50 45 pont i invent ort 10 Media standby behavior The purpose of this Service Utility is to set the way the printer holds the media in standby mode Perform the utility as follows In the Service Utilities submenu scroll to Media standby behavior and press Enter b Replace cutter ir Set RTC clock WHE PHC Maintenance e Back
12. 2 The Printer will display the current time and the new time Use the Up and Down keys go through the digits and press the Enter key to go to the next digit You can press the Cancel key at any time to exit the utility without making any changes Press Enter to go to next digit Press Cancel to exit amp t RTC value Use UP and P oe DOWN keys Use UP DOWM to scroll move cursor ENTER to to go through the digits 3 Once the new time has been entered the Front Panel will display the time that you have requested Press the Enter key to confirm the time or the Cancel key to exit the utility without making any changes or the Back key to modify again Press Enter to confirm If the current RTC Clock cannot be set it could point to a possible Firmware error set RTC New RTC value 15 91 41 18 22 2084 Press ENTER to confirm BACK to modify CANCEL exit Press Cancel to exit 4 Ifthe utility exits correctly OK will be displayed on the Front Panel invent o 9 PHC Maintenance ont 5 The purpose of this Service Utility is to reset the black printhead cleaner oe once it has been replaced Perform the Black Printhead Cleaner reset utility as follows 1 In the Service Utilities submenu scroll to Maintenance and press Enter Press Enter to
13. Figure 5 Left Hand Cover Right Hand Assemblies 01273 60255 Service Station Includes Drop Detector Q1273 60226 Aerosol Fan Assembly Q1273 60257 Vacuum Fan Assembly Q1273 60236 Drop Detector 5 Q1273 60273 Service Station Cable Includes Printhead Cleaner Door Switch Q1273 60084 Aerosol Filter Q1273 60086 Right Bracket invent Figure 6 Right Hand Assemblies Left Hand Assemblies 1 0127360244 Ink Supply Station without APS Q1273 60227 Air Pressurization Pump APS Q1273 60229 Left Bracket 01273 60245 01273 60099 01273 60227 ISS to Cartridge Cable Most Left Spittoons Middle Lett Spittoons CD Figure 7 Left Hand Assemblies Carriage Assembly Carriage Assembly does not include Cutter NM EN Carriage PCA Encoder and Line Sensors Q1273 60271 6027 Cotter Cutter Assembly 0 01273 60246 Line Sensor Encoder Sensor this sensor is included within the Encoder Strip and Encoder Sensor Kit pn Q1273 60070 91273601 60111 a 4 Setup Printhead Kit 01273 60232 Flex Cables Q1273 60157 Carriage PCA Q1273 69157 EE Carriage PCA Refurbished Carriage Stopper includes Carriage Q1273 60252 Stopper Screw and Media Axis Motor Bracket Q1271 60420 BENE GW Maintenance Kit Generic Figure 8 Carriage Assembly
14. 4 Remove the Trailing Cable and Carriage Power Cable from the groove in the Top Crane DU Removal and Installation invent Installation of the new Trailing Cable Old type of connector New type of connector 1 Mark on the Trailing Cable 42 about 65mm from the neck of the connectors using a marker pen 2 Install the new Trailing Cable into the Top Crane HP Designjet 4000 4020 Printer Series Service Manual 8 4 invent 3 Align the marking of the Trailing Cable with the screw area as indicated by the two arrows 4 Install the Carriage Power Cable into the Top Crane 5 Ensure the Power Cable and the Trailing Cable are at the same length CA Installing the Trailing Cable into the old type of Top Crane Cover 6 Install the securing Cable Bracket in place 7 Install one T 15 screw into the Cable Bracket and secure the cables Go to step10 Installing the trailing cable into the new type of Top Crane Cover 8 Install the Top Crane Cover invent m 9 Secure the cables with one T15 screw 10 Insert the Trailing Cable and Carriage Power Cable into the first Cable Holder 11 Insert the Cable Holder through the two slots of the new Ink Tube Carrier CA 12 Insert the Trailing Cable and Carriage Power Cable into all the Cable Holders and insert all the Cable Holders into the slots of the Ink Tube Carrier
15. System Error Problem Description Corrective Action invent 86 10 Initializing Scan Axis Motor failure 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 Check that the Carriage Belt is correctly installed B Replace the Encoder Strip and Encoder Sensor Page 8 72 f the System Error continues replace the Scan Axis Motor Page 8 88 86 11 Scan Axis length too short Try the following Open the Window and check for any visible obstacles restricting the movement of the Carriage Assembly If there is a wrinkled mass of media inside the paper path lift the Pinchwheels using the Media Lever and clear the obstruction B Replace the Encoder Strip and Encoder Sensor Page 8 72 91 02 The HP Instant Support troubleshooting tool has detected that at least one Printhead has been replaced without having a specific error and without being recovered cleaned Advise the customer that the next time they want to replace a Printheads they should make sure that at least a Printhead Recovery is performed 91 10 The HP Instant Support troubleshooting tool has detected that at least for one Printhead t is currently in warranty less than 1000cc of ink used That the previous 2 Printheads had been found defective within the warranty period In this case it is possible that the Printe
16. se tivation Once the Printhead Alignment is completed the following message will be displayed on the Front Panel Press the Enter key to continue Calibration successfully completed Press 4 to continue If the Printhead Alignment fails for any reason a warning message will appear on the Front Panel In this case try the following Enter the Front Panel menu and retry the Printhead Alignment If the Alignment completes successfully then perform the Color Calibration E f the Alignment fails again check the Alignment pattern to see if any of the Printheads are printing incorrectly If necessary perform a Printhead Recovery through the Front Panel and retry the Printhead Alignment 11 The Printer will now perform the Color Calibration When the following message appears on the front panel you must select whether you would like to continue with the calibration by pressing the Enter key Press Back or Cancel to exit the calibration Press Cancel ales Scan Axis Calibration Prass Enter ack key Press ENTER to proceed wi Close Loop Color calibration BACKS CANCE 12 Once the Color Calibration is completed the following message will be displayed on the Front Panel Press the Enter key to continue Color calibration Calibration successfully All CIC profiles are deleted so you completed will need to perform Color Calibration prose contine again for every new media that is
17. warum calihratinn 2 When the following message appears on the front panel you must select whether you would like to continue with the calibration by pressing the Enter key Press Back or Cancel to exit the calibration Press Cancel B piis Drop Detector Calibration Press Enter ack Key Exit to proceed Press ENTER to proceed wit Drop Detector calibration BACK CAMCEL to exit 3 The Printer will start to calibrate the Drop Detector Once the Drop Detector has been calibrated the results will be displayed on the Front Panel Press any key on the Front Panel to finish the calibration Drop Detector Calibration DD Offset Range 96 To g 4 Once the calibration is completed OK will be displayed on the Front Panel Service Calibrations DU invent 5 Line Sensor Calibration The purpose of this Service Calibration is to calibrate the intensity of the line sensor in the Carriage PCA An incorrect calibration can result in edge detection failures during media loading and incorrect reading of prints that are used for alignment or calibration Pertorm the Line Sensor Calibration whenever Edge detect procedure fails during media loading Carriage is disassembled or replaced E Line Sensor is disassembled or replaced E Banding is detected in prints B Misalignment between colors is detected Perform the Line Sensor Calibration as follows 1 In the Service Calibrations
18. 1 In the Diagnostics Tests submenu scroll to Error 71 19 Recovery and press Enter fy OYO ATI USUL PAW LESL 8 Air Pump System test 9 Vacuum FANS test 2 The Printer will check if the System Error Code 71 19 has been recorded and the following message will appear on the Front Panel Checking SE log If the Printer fails to find the System Error Code 71 19 the Front Panel will display Error Utility not available In this case press any key to exit If System Error Code is detected the Printer will start the recovery procedure and the following messages will be displayed on the Front Panel Starting NvmBackup Starting NvmMain Getting Serial Number Checking Serial Number Starting Nvm Getting Part Number If there is a failure at this point the Front Panel will display System Error Code 79 03 For more information on troubleshooting this error code refer Page 2 21 4 The Printer will display the current Serial Number and the new Serial Number of the Printer Use the Up and Down keys to go through the digits and press the Enter key to go to the next digit You can press the Cancel Press Enter to go to next digit Press Cancel to exit key at any time to exit the utility without making any changes 71 19 Recovery Wcurrent Serial Number Serial Number Use UP and DOWN keys to go through the digits
19. 5 Remove one T 10 screw 1 that secures the Encoder Strip on the right hand side of the Printer CA 6 Release the Encoder Strip from the locating pins on the right hand side of the Printer 7 Release the Spring Clip from the Bracket on the left hand side of the Printer 8 Pull the Encoder Strip out of the left hand side of the Printer 9 Remove the Carriage Page 8 75 invent Removal and Installation 10 Remove one 8 Type L screw that secures the Encoder Sensor to the Carriage Assembly Tl Remove the plastic cover from the Encoder Sensor 12 Remove the Encoder Sensor from the Printer Scan Axis Calibration Chapter 5 HP Designjet 4000 4020 Printer Series Service Manual 8 74 CD Carriage Removal 1 Remove the Right Cover Page 8 6 2 Press the two side of the Carriage PCA Cover and unclip from the Carriage Assembly 3 Disconnect the Trailing Cable from the Carriage PCA 4 Release the ALL the clips securing the Carriage Flex Cables to the Carriage PCA by pulling upwards invent 5 Disconnect the Flex Cables from the Carriage PCA 6 Disconnect the Line Sensor Cable and the Encoder Sensor Cable from the Carriage PCA 7 Push inwards the four clips that secure the Carriage PCA 8 Remove the Carriage from the Printer 1 Install
20. Anaiogseritor Common cop G20 20041110 zevere 7903 et 4010005 1344 0 000000 ipclLoyer c 766 20041027 7 severr 715 Dyt 7020005 AAMMI 11 720621 Nvmceompound one 1029 20041027 a 7119 thet 08000 4 151513 11 720881 1029 200477 Bend Ems Coin rinna Code FM Version Merken Debe 1 1ut Qu 3112 10 461 ym Mis c m 20050218 4 tdi y zou AI 24242 3 179994 r sapophitNarvtwl cop 5431 20041112 3 61041 0221010009 1 0 334037 recites 20041100 4 25301 Det pannos A 1343 11720621 5454 20041027 Serisi Humber Situs tme n Used Max fecovery Error Code Vederw g tf 55h 35 8 2h n t n 1 16462452 2h 0 1 2 Yalow 10402452 14 0 0 ah 0 1 1 16455697 33 8 2h 0 6 3 Megeres 0 16481097 335 p 2h 0 0 1 8452154338 0 2h n n 1 V6452UJA 23 8 0 2h 0 i 0 1 1646103 23 0 0 5 Dci 0 10429970 252 0 2h 0 0 1 10429727 25 8 D 9 13421727253 0 2h n n i 18423976252 0 0 f Cyin y 10455974 23 8 th u Cyan 0 16455652 33 8 0 Ah 0 0 System Warning Error B The Line and Internal Code do not provide much information but are useful in the case of escalating a problem to the division different internal error codes can point to the same error code e g 01 10 10 B Media Usage in square meters and Date from the Printer s Internal Clock
21. Perform the Paper Advance Calibration as follows 1 In the Service Calibrations submenu scroll to Paper Advance Calibration and press Enter Drop Detector calibration Line sensor calibratian s blue line calib mm warum ralihratinn invent 2 In the Paper Advance Calibration submenu scroll to Print Calibration Pattern and press Enter Paper Advance Calibration Werint Calibration Pattern Scan Calibration Pattern clean Drive Roller 3 When the following message appears on the front panel you must select whether you would like to continue with the calibration by pressing the Enter key Press Back or Cancel to exit the calibration Press Cancel B a Print Calibration Pattern Prass Enter ack key IG Exil to proceed Press ENTER tn proceed with Print Calibration Pattern por BACK CANCEL to exit 4 The Printer will start to calibrate the Analog Encoder and the following message will be displayed on the Front Panel Print Calibration Pattern a Calibrating Analog Encoder Please wait If the Calibration is not done or if the values are out of the limits a warning message will appear on the Front Panel In this case try the following Check that the Printer has the latest Firmware version If not update the Firmware to the latest version Retry the Paper Advance Calibration B If the problem continues replace
22. Paper advance calibration Calibration successfully completed Press 4 to continue If the Paper Advance Calibration fails for any reason a warning message will appear on the Front Panel In this case try the following Retry the Paper Advance Calibration E f necessary perform a Printhead Recovery through the Front Panel and retry the Calibration You will need to re enter the Paper Advance Calibration submenu and scroll to Scan Calibration Pattern and press Enter Paper Advance Calibration __ Print Calibration Pattern b Scan Calibration Pattern NA EA M SRM Press Enter Clean Drive Roller 11 When the following message appears on the front panel you must select whether you would like to continue with the calibration by pressing the Enter key Press Back or Cancel to exit the calibration Press Cancel B wie Scan Calibration Pattern Press Enter ack key fey oat to proceed Press ENTER to proceed with Scan Calibration Pattern or BACK CANCEL to exit 12 A message will appear advising you that you will need to load the Calibration Pattern in to the Printer Make sure that you rotate the printed pattern 90 clockwise and reload it printed side down so that the black arrows go into the printer first Press the Enter key to continue Press ENTER to proceed with the load of the printed pattern cut sheet as roll for scanning Rotate
23. Spitioon Usage Left to Right Spitioon 1 000cc Sptioon2 000cc Spttoon 3 000cc Sotioon4 0 00 cc Black Cleaner 1 008cc cleaner spticon 2 0 08 ec Preventative maintenance Usage Preventive maintenance kt 81 0 Preventive mantenance kt 22 0 Done V Local ntranet UJ invent Media Used Sections Total media used in the Printer Printer Usage Total printed media 12 12 1130 4 f Total number of prints 31 Media used for each media type Media Usage per Media High Gloss Photo Paper HP 10 30 m 110 8 2 Productivity Photo Gloss 6 92 74 4 ft Bond Paper HP 6 81 m 73 3 ft It is possible that the sum of the media used for each media type is lower that the total amount of media used in the Printer This is because only the total media used in the Printer is saved in the backup EEROM which is located in the ISS PCA When the Hard Disk Drive is replaced the total media used per media type is reset to zero 0 but the total media used is recovered from the backup EEROM Printhead Section The Printheads currently being used are not counted B Total Insertions This is linked with the crane of the Ink Supply Tubes When the Ink Supply Tubes are replaced the total insertions amount will be reset to zero O Slat 1 Slot 2 Sint 3 Slat 4 sint 5 Slot Slot 7 Slot 8 Color Yelow Yellow Magenta Magenta Black Black Cyan Cyan Product Mumber SISTA C505
24. Trailing Cables Removal Remove the Right Cover Page 8 6 Remove the Left Cover Page 8 9 Remove the Top Cover Page 8 17 Remove the Rear Door Page 8 16 Remove the Right Connector Cover Page 8 18 Disconnect the Trailing Cable from the Interconnect PCA and the Gamut PCA xd 7 Release the two plastic clips securing the Trailing Cable and the Carriage Power Cable invent 8 Press the two sides of the Carriage PCA Cover and unclip from the Carriage Assembly 9 Disconnect the Trailing Cable and Carriage Power Supply Cable from the Carriage PCA i md p t Li 1 10 Open the Carriage Cover and remove ALL the Printheads from the Carriage Assembly CD 11 Remove five T 15 screws that secure the Ink Supply Tubes to the Carriage Assembly 12 Remove one T 15 screw from each plastic holder at the rear of the Printer 13 Disconnect the Electrical Cable from the rear of the Ink Cartridge Tube Connector Removal and Installation 9 36 14 15 invent Disconnect the Air Tube from the Ink Supply Tubes There are two types of Air Tube The old type has a blue connector on the end the new type does not If the printer has a serial number of before SG6A9H900Z DJ4000 SG6ABH9014 DJ4500 it will have the old type If the Air Tube has the old type of blue connector on the end disconnect it a
25. invent Media Sensor Removal 1 Remove the Rear Door Page 8 16 Remove the Right Connector Cover Page 8 18 3 Disconnect the Media Sensor cable from the Interconnect PCA 4 Release the Media Sensor cable from the clip located on the Electronics Module 5 Unclip the Media Sensor the Center Guide invent 6 Pull the cable through the hole and remove the Media Sensor from the Printer LA Meat and Installation Encoder Disc and Sensor Removal 1 Remove the Left Cover Page 8 9 2 Remove the Rear Door Page 8 16 3 Remove the Left Connector Cover Page 8 19 4 Remove the Ink Supply Station Page 8 60 5 Disconnect the Encoder Sensor cable from PrintMech invent Removal and Installation 7 Release the Encoder Sensor cable from the clip located on the Encoder Disc Cover 8 Unclip the Encoder Disc Cover and remove from the Printer 9 Remove one T 8 screw Type D that secures the Encoder Sensor to the Chassis 8 138 HP Designjet 4000 4020 Printer Series Service Manual mera tition 10 Remove the Encoder Sensor from the Printer 11 Carefully peel the Encoder Disc from the Drive Roller invent Media Lever Assembly Removal 1 Remove the Right Cover Page 8 6 2 Remove the Rear Door Page 8 16 3 Raise the Media Lever 4 Remove one T 15
26. loaded in to the Printer If the Color Calibration fails for any reason a warning message will appear on the Front Panel In this case try the following Enter the Front Panel menu and retry the Color calibration B If the Calibration fails again check the Calibration pattern to see if any of the Printheads are printing incorrectly If necessary perform a Printhead Recovery through the Front Panel and retry the Calibration 13 Once the complete Scan Axis calibration is completed successfully OK will be displayed on the Front Panel invent 2 Service Station Calibration The purpose of this Service Calibration is to calibrate the Service Station in relation to the Carriage Assembly Perform the Service Station Calibration whenever Carriage Assembly is disassembled or replaced Service Station is disassembled or replaced Perform the Service Station Calibration as follows 1 In the Service Calibrations submenu scroll to Service Station Calibration and press Enter Paper d advance calibration Drop Detector calibration Line Sensor calibration Platen blue line calib c23811h5ratinn 2 When the following message appears on front panel you must select whether you would like to continue with the calibration by pressing the Enter key Press Back or Cancel to exit the calibration Press Cancel Service Station calibrati
27. 13 Install the Ink Supply Tubes Trailing Cable and Carriage Power Cable into the Printer The rest of the installation procedure is the same as the removal procedure but in reverse invent Ink Supply Tubes Removal Remove the Right Cover Page 8 6 Remove the Left Cover Page 8 9 Remove the Top Cover Page 8 11 Remove the Rear Door gt Page 8 16 po es Remove the Right Connector Cover Page 8 18 Disconnect the Trailing Cable from the Interconnect PCA and the Gamut PCA 7 Release the two plastic clips securing the Trailing Cable 8 Press the two side of the Carriage Cover and unclip from the Carriage Assembly 9 Disconnect the Trailing Cable and the Carriage Power Cable from the Carriage PCA mim it u cam il d 10 Open the Carriage Cover and remove ALL the Printheads from the Carriage Assembly Removal ard tslaron 11 Remove five T 15 screws that secure the Ink Supply Tubes to the Carriage Assembly 12 Remove one T 15 screw from each plastic holder at the rear of the Printer 13 Disconnect the Electrical Cable from the rear of the Ink Cartridge Tube Connector D Removal and Installation 14 Disconnect the Air Tube from the Ink Supply Tubes There are two types of Air Tube The old type has a blueconnector on the end the new type does not If the printer has a serial number of before SG6A9H900Z DJ400
28. 4 Release the Ink Supply Tubes and Trailing Cable from the clip underneath the Top Cover 5 Remove the Ink Supply Tubes and Trailing Cable from within the Top Cover and lay them on the Print Platen HP Designjet 4000 4020 Printer Series Service Manual 8 11 invent 6 Remove one T 10 Type I screw that secures the ESD Strip to the Top Cover on the left hand side of the Printer 7 Disconnect the ESD Strip from the Top Cover 8 Remove three T 15 screws Type G that secure the Rear Door 9 Open the Rear Door 10 Remove four T 15 screws Type H that secure the Top Cover from the rear of the Printer Tl Using a flat head screwdriver release the Top Cover from the right hand side of the Printer invent 12 Release the Top Cover from the rear of the Printer 13 Raise the right hand side of the Top Cover and pull out to the right 1 Position the Metallic Support on to the Top Cover invent Removal and Installation 2 Lock the Metallic Support on to the Top Cover 3 Install the 1 20 screw that secures the Metallic Support to the Top Cover Remove the Window Page 8 4 from the old Top Cover and install it on the new Top Cover HP Designjet 4000 4020 Printer Series Service Manual 8 15 Removal and Installation UJ invent Rear Door Removal 1 Remove three T 15 screws
29. Arc invent 9 Remove two T 15 screws Type G that secure the Front Panel to the Printer 10 Remove the Front Panel from the Printer O 5565 Service Station Removal 1 Remove the Right Cover Page 8 2 Remove the Rear Door Page 8 16 3 Remove the Right Connector Cover Page 8 18 4 Disconnect the cable from the Printhead Cleaner Door Switch 5 Disconnect the Service Station and Aerosol Fan Cables from the Interconnect PCA invent 6 Uncap the Carriage Assembly by manually pulling out the Printhead Cleaner tray 7 Move the Carriage Assembly out of the Service Station 8 Remove four T 15 screws Type J that secure the Service Station to the Chassis 9 Disconnect Aerosol Fan Tube from the Chassis 10 Remove the Service Station from the Printer E Reset Counter PHC spittoon Chapter 4 E Service Station Calibration gt Chapter 5 Removal ard tslaron Removal of the Service Station Scraper 1 Release the clip securing the Scraper to the Service Station 2 Remove the Scraper from the Service Station 0000000000000 Vacuum Fan Removal 1 Remove the Right Cover Page 8 2 Remove the Rear Door Page 8 16 3 Remove the Right Connector Cover Page 8 18 4 Remove the Service Station Page 8 23 5 Release the Pinchwheel Lever
30. B Removing leakage 10 Once the process is completed OK will be displayed on the Front Panel invent 10 2 Others gt gt gt IO Information This option allows you to view the information relating to the IO View the IO Information as follows 1 In the Diagnostics Tests submenu scroll to 10 Others and press Enter LALI gage dostull Ly Leste Sensors test Ink Delivery system test SvyS Aern snl FAM test Air Pump System test Vacuum test e Others Im Co E Others 10 1 Bag Broken Recovery 18 2 IU Information 10 35 Unit Information ME 16 4 Check Ink Supplies 3 The Printer will start to initialize and the Front Panel will display the following messages Getting IO Interface Getting Interface info If there is a failure at this point the Front Panel will display System Error Code 74 00 For more information on troubleshooting this error code refer Page 220 If no active interface is found the Front Panel will display active interface found Press any key to finish 4 Once the IO information is obtained it is displayed on the Front Panel Press any key to exit IU Information 16 23 60 239 Gateway 15 23 5B5 1 Net Mask 255 255 246 0 Press any key to finish 5 Once the process is completed OK will be displayed on the Front Panel ii Ford ies 10 3 Others g
31. RTC help you to understand if the Printer has been used media usage and how much time has passed since the last error Printhead Error Log Printheads ago History of the last three Printheads used O represents the current Printhead used Status 0 Working 1 No Pen Detected 2 Replace 4 Reseat 8 Remove Ink Used Percentage of the Warranty life 1000 Error Code Specific error code generated by the Printer when the Printhead has been replaced Max Recovery 0 No manual Printhead recovery has been performed on the Printhead or higher At least one Printhead recovery has been performed Printhead Frror Log Printheads ago Serial Number Status Usage time Ink Used Max Recovery Error Code 1 Yellow 16455695 33 8 0 2h 1 0 16462452 33 6 0 2h 16462452 33 8 0 2h 15455685 33 8 2h 1 1 n 1 2 Yellow 1 n 1 Calibrations Status This page contains the following information General Calibrations performed by Service Engineers B Media Specific Calibrations performed by the User Calibrations Status Daw Asg 23 2084 tmr ieee Serai ees Information on these 3 Calibrations eee p iie abate ane will be added in Firmware Version 4 x x x i i gh Prats Peer pendir pen mg rar bet MP rij Pager penang pening MR
32. System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action invent 61 08 1 The file cannot be printed because it is password protected Resend the file without password protection 63 04 Input Output problem through the Network Card Try the following Check that the Network cable is correctly connected to the Network Card B If a Gigabit Ethernet Card is being used make sure it is correctly installed If necessary replace the Gigabit Ethernet Card Check that the Printer has the latest Firmware version If not update the Firmware to the latest version If the System Error continues replace the Main gt Page 8 105 64 04 Input Output problem through the USB Port Try the following Check that the USB cable is correctly connected to the Printer Check that the USB Card is correctly installed Check that the Printer has the latest Firmware version If not update the Firmware to the latest version E Replace the USB card 65 04 Input Output problem through an unknown port Try the following Check that the unknown port cable is correctly connected to the Printer Check that the Printer has the latest Firmware version If not update the Firmware to the latest version 66 08 Cannot print file on current paper type The paper type has changed since
33. Tensioner to the Chassis S Move the Carriage Assembly slightly away from the right Scan Axis Bracket CD EN Release the Carriage Belt from the Scan Axis Motor on the left hand side of the Printer the 9 Release the Scan Axis Motor cable from the clips on the chassis 10 Remove two T 20 screws Type that secure the Scan Axis Motor We 11 Remove the Scan Axis Motor from the Printer Reset life counter scan motor Chapter 4 Removal and Installation inveni Media Axis Motor Removal 1 Remove the Rear Door Page 8 16 2 Remove the Left Connector Cover Page 8 19 3 Disconnect the Media Axis Motor cable from the PrintMech B 4 Remove two T 15 screws Type R that secure the Media Axis Motor 5 Loosen two T 20 screws Type B that secure the Media Axis Motor Bracket HP Designjet 4000 4020 Printer Series Service Manual 8 9 6 Remove the Media Axis Motor from the Printer E Paper Advance Calibration Chapter 5 CD Interconnect Removal 1 Remove the Rear Door Page 8 16 2 Remove the Left Connector Cover Page 8 19 3 Remove the JetDirect Card if installed 4 Remove three T 15 screws Type that secure the PCA cover a Finnppi 5 Remove the Main PCA Cover from the Printer
34. pe ii a PILETID s EEEEARAZESs ERBEN ZLERARAAS REET a Bbhiilbi ERBEN eae Ll VER TR d Eunana Printhead No 3 Printhead This is what you would see if there are nozzles not printing correctly 1 On the right of each Printhead Nozzle test there is a series of numbered stepped diagonal lines If one or more of the nozzles are malfunctioning or mis positioned you will see that the stepped lines are broken or misdirected in one or more places 2 On the left of each Printhead Nozzle test there is a series of horizontal straight lines If one or more nozzles are misdirected there will be unequal spaces between the corresponding lines How to fix the Nozzle Defects 1 Recover the printheads using the option through the Front Panel Ink Menu Printheads Recover Printheads 2 Reprint the Nozzle Print test to check that the defective nozzles have been corrected 3 Ifthe problem continues replace the faulty Printhead No Printing Defects Found the Diagnostic Print If all the test patterns from the Diagnostic Print are correct and you still experience Image Quality problems you can use the following procedures Print Banding Plot This should be used when printing in fast print mode
35. scroll to Turn Drive Roller and press Enter Reset life counters Diagnostic Print Sleep mode Benlace cutter 2 The Printer checks to see if media is loaded If media is loaded the Front Panel will display the following message Unload the media and start again from step 1 Turn Drive Roller Paper detected Please remove media completely and start again HP Designjet 4000 4020 Printer Series Service Manual 4 59 3 The Drive Roller begins to turn slowly and the following message is displayed on the Front Panel Turn Drive Roller Rotation started Please clean the roller Press CANCEL key to finish 4 Refer to the Cleaning Instructions on Page 9 3 5 Once you have finished cleaning the Drive Roller and the Overdrive press the Cancel key to finish the utility 6 Ifthe utility exits correctly OK will be displayed on the Front Panel Turn Drive Roller 2 Tubes The purpose of this Service Utility is to Prime the Tubes when the Ink Tubes are NOT new and they need to be re primed or automatic priming was not completed correctly Perform the Prime Tubes utility as follows 1 In the Service Utilities submenu scroll to Prime Tubes and press Enter Press Enter Prime Tubes p AW i s Set SN Reset life counters Diagnostic Print Sleep mode Penlace cutter 2 Ifthe Ink Cartridges are not suitable fo
36. the Front Panel will display System Error Code 07 10 For more information on troubleshooting this error code refer to Page 2 6 HP Designjet 4000 4020 Printer Series Service Manual 4 23 19 message will appear on the Front Panel asking whether you would like to check the Carriage Communication Select Yes or No by using the Up and Down keys and press Enter to confirm your selection If you select No the printer skips this test and goes to the next one Press Enter to confirm selection Electronics Module Do you want to check the Carriage Communication Use UP and DOWN keys select YES Press UP DOWN to change and ENTER tn select 20 f you select Yes the following message will appear on the Front Panel Electronics Module Has the carriage supply LED n been switched oan TES Press UP DOWN to change and ENTER to select 21 Open the Window and check that the Carriage power light is ON a green faint light on the carriage Select Yes or No by using the Up and Down keys and press Enter to confirm your selection If you select No at this point the Front Panel will display System Error Code 07 10 For more information on troubleshooting this error code refer to Page 2 6 Check also System Error Code 11 10 refer to Page 2 7 or System Error Code 02 1 10 refer to Page 2 4 If you select Yes then the Front Panel will display Starting Car
37. troubleshoot the problem as System Error Code 01 1 10 refer to Page 2 3 9 10 n invent At the end of 10 Carriage movements the Front Panel will display the maximum and minimum length in encoder units of the 10 movements and the overall average can Axis Max Min mov 11280 1885 eu Avg mov 1108 eu There 15 encoder feedback Encoder seems to be Press any Key to continue It Carriage movement has not been detected or if Carriage movement was very short the Front Panel will ask you Did the motor move If the answer is Yes the Carriage had moved press Enter If the answer is No the Carriage had not moved press the Back key If you select No the Carriage had not moved the Front Panel will display System Error Code 42 10 For more information on troubleshooting this error code refer to Page 2 14 Check also System Error Code 01 1 10 refer to Page 2 3 or System Error Code 01 0 10 refer to Page 2 3 If you select Yes the Carriage had moved the Front Panel will display System Error Code 02 10 For more information on troubleshooting this error code refer to Page 2 4 Check also System Error Code 11 10 refer to Page 27 or System Error Code 01 0 10 refer to Page 2 3 If any max or min movement length is outside the or 20 average then this warning message will be displayed on the Front Panel Some movements out of avg 20 range Intermittent movements PWM test needed This
38. 0 Scan Calibration Pattern Clean Drive Roller 16 When the following message appears on the front panel you must select whether you would like to continue with the cleaning of the Drive Roller by pressing the Enter key Press Back or Cancel to exit the calibration Press Cancel or the Back key to Exit Clean Drive Roller Press Enter to proceed Clean Drive Roller or BACK CANCEL exit 17 The Printer will begin the Drive Roller Cleaning procedure This could take several minutes during which the following message will be displayed on the Front Panel Clean Drive Roller la Cleaning Drive Roller Please wait seclts 4 Drop Detector Calibration The purpose of this Service Calibration is to calibrate the Drop Detector located in the Service Station in relation to the Carriage Assembly Perform the Drop Detector Calibration whenever Drop Detector is disassembled or replaced Perform the Drop Detector Calibration as follows 1 In the Service Calibrations submenu scroll to Drop Detector Calibration and press Enter L cl ce cm en TED 3 Scan Axis calibration lt A _ Service Station calibration n a d c di Paper advance calibration N Drop Detector calibration E v 1 Line Sensor calibration Platen blue line calib um Press Enter
39. 01 Printhead Cleaner not inserted correctly in slot 5 Try the following Open the Printhead Cleaner Access Door and check that the Black Printhead Cleaner is correctly seated in slot 5 of the Service Station and then close the Printhead Cleaner Access Door B Replace the Black Printhead Cleaner in slot 5 of the Service Station 29 5 01 Printhead Cleaner not inserted correctly in slot 6 Try the following Open the Printhead Cleaner Access Door and check that the Black Printhead Cleaner is correctly seated in slot 6 of the Service Station and then close the Printhead Cleaner Access Door B Replace the Black Printhead Cleaner in slot 6 of the Service Station inven System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action 29 6 01 Printhead Cleaner not inserted correctly in slot 7 Try the following Open the Printhead Cleaner Access Door and check that the Cyan Printhead Cleaner is correctly seated in slot 7 of the Service Station and then close the Printhead Cleaner Access Door B Replace the Cyan Printhead Cleaner in slot 7 of the Service Station 29 7 01 Printhead Cleaner not inserted correctly in slot 8 Try the following Open the Printhead Cleaner Access Door and check that the Cyan Pri
40. 10 Check also System Error Code 13 n 10 refer to Page 2 7 26 Once the test is completed OK will be displayed on the Front Panel ii Festa ies 4 Carriage Assembly Test The purpose of this test is to verify the operation of the Carriage Assembly Perform the Carriage Assembly test as follows 1 In the Diagnostics Tests submenu scroll to 4 Carriage Assembly Test and press Enter Scan Axis test Media Drive test Electronics module test APOSTA 2 This test has not yet been implemented invent 5 Sensors Test The purpose of this test is to verify the operation of the following Sensors Window Sensor Printhead Cleaner PHC Access Door Sensor Media Lever Sensor B Media Sensor Perform the Sensors test as follows Before starting first make sure that B The Window is closed The Printhead Cleaner Access Door is closed B The Media Lever is in the lowered position B Media is loaded In the Diagnostics Tests submenu scroll to 5 Sensors Test and press Enter Scan Axis test Media Drive test Electronics module test Carriage assembly test erncn The Printer will start to initialize and the Front Panel will display the following messages B Starting Gamut Starting Tests If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For mo
41. 2 3 meters for Argentina final cable that is connected to 5961 3590 5961 3590 5961 3588 Power Cord 2 5 meters for China invent Figure 14 Arc Assemblies Removal and Installation Introduction 8 2 Screw Types 8 3 Window 8 4 Right Cover 8 6 Left Cover 8 9 Top Cover 6 11 Rear Door 8 16 Right Connector Cover 8 18 Left Connector Cover 8 19 Front Panel 8 20 Service Station 8 23 Vacuum Fan 8 27 Aerosol Fan 8 29 Drop Detector 8 31 Trailing Cables 8 33 Ink Supply Tubes 8 46 ISS to Cartridge Cables 8 58 Cutter Assembly 8 59 Ink Supply Station ISS 8 60 APS Assembly 8 62 Most Left Spittoons 8 70 Middle Left Spittoons 8 71 Encoder Strip and Encoder Sensor 8 72 Carriage PCA 8 75 Carriage Flex Cables 8 80 Carriage Assembly 8 82 Belt Assembly 8 87 Scan Axis Motor 8 88 Media Axis Motor 8 91 Interconnect PCA 8 93 EIO to PCA Interface Card 8 96 Gamut PCI PCA 8 98 Memory Module 8 103 Main PCA Formatter 8 105 CPU Fan 8 107 Hard Disk Drive HDD 8 111 Power Supply Unit PSU 8 113 PrintMech PCA 8 119 Formatter Battery 8 122 Line Sensor Assembly 8 124 Media Deflector 8 126 Front Platen 8 127 Center Platen 8 129 Cartridge Trays 8 133 Input Roller 8 134 Media Sensor 8 135 Encoder Disc and Sensor 8 137 Media Lever Assembly 8 140 Media Lever Sensor 8 142 Pinchwheel Assembly 8 145 Center Guide 8 149 Drive Roller 8 152 Right Rollfeed Module Assem
42. 3 Printhead Problems 6 9 Nozzle Print Test 6 11 No Printing Defects Found in the Diagnostic Print 6 12 Print Quality General Advice 6 15 Troubleshooting Print Quality Problems 6 16 Horizontal Lines Across the Image Banding 6 16 Advanced Banding Troubleshooting for Experts 6 17 Dark Light Zone Banding DLZB 6 20 Lines are Missing or Thinner than Expected 6 21 Solid Bands or Lines Printed Over the Image 6 22 Problems with Graininess 6 23 Print Smudges when Touched 6 23 Paper is not Flat 6 24 Defect Near the Top of the Print 6 25 Problems with Stepped Lines 6 26 Lines are Printed Double or in Wrong Colors 6 26 Lines are Blurred Ink Bleeds from Lines 6 27 Problems with Color Accuracy 6 27 Problems with PANTONE Color Accuracy 6 28 Color Matching Between Different HP Designjet Printers 6 29 Problems with Image Clipping 6 31 Image is Completely Blank 6 32 Output Only Contains a Partial Print 6 32 Image is in One Portion of the Printing Area 6 33 Image is Unexpectedly Rotated PostScript Driver 6 33 Print is Distorted or Unintelligible 6 34 Print is a Mirror Image of the Original 6 34 One Image Overlaps Another on the Same Sheet 6 34 No Output from the Printer 6 35 Pinchwheel Marks when using Glossy Media 6 35 VLS in 1 Pass Printmodes 6 36 VLS in First 3 Meters after a Media Load 6 37 Bubbles Only occurs in Cyan Magenta and Yellow 6 37 Black Printhead Decap Problem 6 38 Paper Expansion Paper Advance PEPA 6 39 Bidirectional Offset in
43. B FHE Maintenance Media standby behaviour Backup print mode Feed Roller change Disk Wipe DoD 5220 22 M This test will perform a complete and secure erase of the HDD in accordance with the requirements of DoD 5228 22 M Press Enter to confirm Press ENTER tn proceed IBACK CANCEL to exit Press Cancel to exit Press the Enter key to confirm the HDD erase or the Cancel key to exit the utility without making any changes 3 f you pressed the enter key the front panel will ask you to confirm again Warning the HDD will be completelly erased and data Will be lost Press Enter to confirm Press ENTER to proceed or BACK CAMCEL to exit Press Cancel to exit Press the Enter key to confirm the HDD erase or the Cancel key to exit the utility without making any changes invent 4 After a short while the Disk Wipe sequence begins The level of file deletion is defined in the Sanitize Level menu shown in the previous section Depending on which sanitizing level was selected one of these screens is displayed D invent invent DoD Secure Fast Erase Secure Sanitizing Erase DoD 5220 22 M DoD 5220 22 M Fast erase 1 pass mode Secure sanitizing erase 5 pass mode Service Calibrations Service Calibrations 5 2 Entering the Service Calibrations Menu 5 3 Scan Axis Calibration 5
44. B PWM test If there is a failure at this point the Front Panel will display System Error Code 86 10 For more information on troubleshooting this error code refer Page 224 13 The Printer will test the PWM at 61 ips and display the results on the Front Panel can Axis avg range to 31150 avg got 27798 8 min diff limit 31686 min diff got 8824 Press any key to finish If some of the results are incorrect the Front Panel will show High Friction Depending on the actual results received the following should be done B PWM avg got is more than 31160 and PWM min diff got is less than 3100 then there is high friction along the Scan Axis In this case you should Clean the Slider Rods and Apply Oil along the complete axis of the Slider Rods After applying the Oil perform the test again Check that the Carriage Belt is installed correctly B f PWM min diff got is less than 3100 but PWM avg got is less than 31160 then there is a problem in the Scan Axis In this case you should Check that the Encoder Strip is clean If necessary clean Encoder Strip using a damp cloth Check that the Ink Supply Tubes and Trailing Cable are installed correctly If there is a failure processing the PWM results the Front Panel will display System Error Code 86 11 In this case try repeating the test again 14 Once the test is completed OK will be displayed on the Front Panel
45. Blue is in the center Green is on the Right 1 When only the Amber LED is On The Printer has been switched Off from the Front Panel after having pressed the On Off button B The Power Supply Unit only delivers a 5 V Standby power that is needed to restart the Printer after the Front Panel On Off button is pressed the Formatter Main PCA will initiate the Printer to start 2 When the Blue LED is On Deliver standard ATX power for the Electronics Module PCAs 4 12V 5V 5V 12V etc All the functions of the Electronics Module are fully operational EWS etc 3 When the Green LED is On Deliver analog 24V and 42V to enable printing The Printer monitors and reports different signals PSU fan issues 24V and 42V delivery failures specific System Error reported pointing to PSU failure PSU PS Left LED on Printer Status Blue Front Panel LED ED Status Status ON OFF Red Front Panel Standby with Embedded Web Black Server up and running Gre isi iiy bro ig Any Notposibe Using the LEDs to Troubleshoot In certain circumstances the LEDs located on the Interconnect PCA and PrintMech PCA can help to troubleshoot the Printer The LEDs can either be ON or Off and using different combinations can indicate different problems Interconnect PCA 5V Comes from the PSU after the fuse on Interconnect PCA Used to power On Front Panel and some Interconnect Electr
46. Bracket and Drive Roller Bearing 2 Datum between Media Axis Motor Bracket and Sideplate 3 Datum between Drive Roller Bearing and Sideplate Left Hand Side of the Printer Radial Retainer Sideplate Drive Roller 1 Datum between Drive Roller and Radial Retainer 2 Datum between Drive Roller and Sideplate Right Hand Side of the Printer mera tation To make sure that ALL the datums are met when installing the Media Axis Motor Bracket make sure you follow these instructions Place the Media Axis Motor Bracket in the correct position on the Printer Make sure you keep it pushed down as shown in the illustration until the first screw has been installed and fully tightened Install the first screw T 15 in the position shown Make sure you tighten the screw fully so that the Media Axis Motor Bracket cannot be moved Check that there is no play movement between the Media Axis Motor Bracket and the Drive Roller If there is play then check that the screw installed in the previous step is fully tightened 4 Install the remaining two screws 1 15 that secure the Media Axis Motor Bracket CA 555 Right Rollfeed Module Assembly Removal Remove the Right Cover Page 8 6 Remove the Service Station Page 8 23 Remove the Vacuum Fan Page 8 27 Remove the Input Roller gt Page 8 134 Remove the Media Spindle if installed Remove one T 15 screw
47. Cartridges previously had a Bag Broken error then the message No Broken Bag detected on supplies will be displayed on the Front Panel If there is a problem while reading the Acumen the Front Panel will display System Error Code 26 n 10 For more information on troubleshooting this error code refer to Page 2 10 Check also System Error Code 13 n 10 refer to Page 2 7 System Error Code 01 2 10 refer to Page 2 4 or System Error Code 01 0 10 refer to Page 2 5 If it is not possible to get the ISS Data the Front Panel will display System Error Code 74 00 For more information on troubleshooting this error code refer to Page 220 If the Printer detects that an Ink Cartridge had previously experienced a Bag Broken error the Front Panel will display System Error Code 26 n 10 For more information on troubleshooting this error code refer to Page 2 10 Check also System Error Code 01 2 10 refer to Page 2 4 or System Error Code 01 0 10 refer to Page 2 5 6 If no Ink Cartridges have been identified with Bag Broken the Printer will try a Self Recovery test When the following message is displayed on the Front Panel remove the Left Cover and check if the tubes from the APS to the ISS are clean Select Yes or No by using the Up and Down keys and press Enter to confirm your selection Press Enter to confirm selection Use UP and DOWN keys to select If you select No the Front Panel will display System Error Cod
48. Computer Device v Enable SpoolSmat os Print Quality Image is Completely Blank It a file is sent to the Printer and the image comes out completely blank this is probably because the incorrect Graphic Language has been selected Try the following to resolve the problem 1 If the Front Panel graphic language setting is set to Automatic try choosing a setting specific to the current requirement e g Select PostScript for a PostScript file 2 Send the file again to see if the problem is now resolved Once the file has been printed make sure you reset the graphic language back to Automatic Setup Menu Printing Defaults Menu Graphic Language If the problem continues then try the following 1 If the Front Panel graphic language setting is not set to Automatic then set it to Automatic so that the Printer can determine which type file it is receiving 2 Select HP GL 2 if PostScript files are not being used and if image position problems or timing problems have been experienced in the past 3 Select TIFF JPEG PDF or CALS G4 only if the file of the appropriate type is sent directly to the Printer without going through a Printer driver This is normally done only from the Embedded Web Server EWS in which case the language setting is done by the EWS and does not need to be done manually The PS and PDF options are available in the HP Designjet 4000ps but not in the HP Designjet 4000 O
49. Cover from the Printer Removal and Installation 2 inveni a 5 Remove three T 15 screws Type A that 7 secure the PSU cover 6 Remove the PSU Cover from the Printer 7 Disconnect the Power Supply and Interconnect cables from the PrintMech PCA d 4 invent 8 Remove six T 10 screws Type I that secure the Interconnect PCA Cover 9 Remove the Interconnect PCA Cover from the Printer 10 Disconnect one cable from the Interconnect PCA Removal and tslaron 11 Disconnect two cables from the Main PCA 12 Disconnect one cable from the Gamut PCA 13 Disconnect one cable from Hard Disk Drive i LAN M MU 1 I k MAMMA V L A M MM 11 1 1 Y a M Li i mera tation 14 Bend the edge of the Cable Support Bracket so that it can be released 15 Move the Cable Support Bracket to the left to release it from the Electronics Module 16 Lower the Cable Support Bracket so that the cables can be accessed wexowmusn 17 Release the Power Supply Cable from the Cable Support Bracket 18 Remove four 10 screws Type 1 that secure the Power Supply Unit 19 Route the cables through the hole in the Electronics Module and remove the Power Supply Unit from the Prin
50. Light Color Density Areas 6 40 Ink Contamination on Yellow Printhead 6 40 Satellites in Black Lines 6 41 HP Designjet 4000 4020 Printer Series Service Manual 6 1 Print Quality e we sow ev invent Print Quality Troubleshooting Actions When faced with a Print Quality problem perform the following actions in order to resolve the problem Printer Configuration B Check that the paper type selected in the Front Panel is the same as the paper type loaded into the Printer Check that the correct Optimized For print quality setting is being used This can be done either through the driver or through the front panel Setup Menu Printing Defaults Menu Image Quality Print Quality Optimized For Make sure that the correct Print Quality settings are used for different types of print content Refer to Page 6 3 for further information Dry time should be set to Automatic Perform Printhead recovery Ink Menu Printheads Recover Printheads Media B Select the correct media type through the front panel when loading it Make sure that HP or HP approved media is being used Perform the Printhead Alignment Ink Menu Printheads Align Printheads The Printhead Alignment can take up to 15 minutes Check if the latest version of the firmware is installed If not install the latest firmware revision For further information refer directly to the Troubleshooting section that covers the different Print Qual
51. Limiting is OFF turn it ON E Never use HP Coated Media for High Density prints As a substitute use HP Heavy Coated Media Banding due to Ink Cartridge replacement while printing A user has removed the Ink Cartridge while the printer was printing which has caused the printer to stop If the user does not replace the Ink Cartridge immediately when the printer starts to print again a band will appear in the position where the printing restarted This is because the wet ink interacts with the dried ink on the media causing the band to appear To solve the problem try the following B Do NOT remove the Ink Cartridge while the Printer is Printing Only replace remove Ink Cartridges in between Prints B If the Ink Cartridge was replaced due to the Empty status on the Front Panel then advise the customer to replace the Ink Cartridge when the Very Low status is showing on the Front Panel E Reprint the file without remove the Ink Cartridge 34 Rice Paper not supported Roll length is 34 Non standard and the pinch wheels can t control edge of media causing ink smears and Printhead crashes in middle of prints with or without area fills PRINTER LIMITATION NO SOLUTION AVAILABLE Cut Sheet rice paper loading failure Thin rice paper is sucked into the Center Platen grooves and Linear Blade Ridge This implies that the friction between the Center Platen and the rice paper becomes higher than between the Overdrive wheels
52. Print may look like some of these examples Faulty Replace Faulty Replace Troubleshooting a Faulty Printhead Acceptable If both parts 2 and 3 of the Diagnostic Print show a problem then E Recover the printheads using the option through the Front Panel Ink Menu Printheads Recover Printheads f the problem continues replace the faulty Printhead invent Nozzle Print Test The Nozzle Print Test is part of the Image Quality Service Plot This can only be printed through the Service Utility Menv This test is designed to check if the printhead nozzles print correctly The test prints out every single nozzle of each Printhead No error hiding or Printhead Alignment algorithm is applied For each Printhead you can see both the adjacent and the consecutive nozzles Printhead No 8 Printhead No 6 fe Lia a I PESSET LLENE TEE AGE REE PAT Bie ECE ORE i zr eo bind A AE Dee PUR Crete a Des T a i sui T bis Printhead No 4 Printhead No 2 Printhead No 7 Printhead No 5 WES
53. Printer and disconnect the Power cord Reconnect the power cord and power On the Printer E f the System Error continues replace PCI PCA Page 8 98 System Error 01 0 10 Problem Problem with the Gamut PCI PCA Description 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 E Replace PCI PCA Page 8 98 f the System Error continues replace the PCA Page 8 105 System Error 01 1 10 Problem Problem with the PrintMech Description Corrective Action Try the following B Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer Check that the cables between the PrintMech PCA and the PCI PCA are not damaged and are correctly connected E Replace the PrintMech Page 8 119 W f the System Error continues replace the PCI PCA Page 8 98 System Error 01 2 10 Problem ISS PCA faulty Humidity sensor out of scale or NVM backup failure Description Corrective Action Try the following B Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer f the System Error continues replace the Ink Supply Tubes Page 8 46 System Error 02 10 Problem Encoder s
54. Printer during installation Avoid unnecessary removal of the Ink Cartridges and Printheads When turning off the Printer always use the power Off button on the front panel The Printheads are then stored correctly which prevents them from drying out The Ink Cartridges should never be removed while the printer is printing They should only be removed when the printer is ready for you to replace them The front panel will guide you through the removal and installation procedure General Precautions When Handling Ink Supplies NEC MM Handle the ink supplies with care In particular the Printhead which is a high precision device and must be handled carefully Do not touch the Printhead nozzles Do not put the Printhead down the nozzles Do not be rough when handling the Printheads Always set them down gently Do not drop the Printheads B Proper handling will assure optimum performance throughout the Printhead life The Printhead Cleaner should always be handled and stored upright to avoid a potential spillage of ink Do not touch the end of the Ink Cartridge which is inserted into the printer as there may be a small amount of ink on the connection Avoid storing partially used Ink Cartridges on their ends Priming the Ink System When the customer first receives the printer it is supplied with a set of four Setup Printheads pre installed in the Carriage Assembly Thes
55. Printer will check the PCI PCA and the following messages will be displayed on the Front Panel Checking Gamut PCI Checking ARM Starting Gamut Checking memory Checking memory Il If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 13 A message will appear on the Front Panel asking whether you would like to check the Power Supply Select Yes or No by using the Up and Down keys and press Enter to confirm your selection If you select No the printer skips this test and goes to the next one Press Enter to confirm selection Electronics Module Woo vou want to check the Power Supply Use UP and DOWN keys to select YES Press UP DOWN to change an ENTER tn select 14 Ifyou select Yes the Printer will check the Power Supply Unit and the following messages will be displayed on the Front Panel B Starting Gamut Starting Tests E Set GPIO psu lpm If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 A i Fes ord ies Checking voltage If there is a failure at this point the Front Panel will display System Error Code 03 10 For more information on troubleshooting this er
56. and the paper This effect make it almost impossible to load the rice paper correctly because the Vacuum is too high PRINTER LIMITATION NO SOLUTION AVAILABLE Worm marks on HP Coated media with light area fills Light bands S shaped in Paper axis direction where light area fills are printed causing unacceptable Image Quality defect E Print the Service Configuration Print and check if the level of Humidity is very low below 30 Increasing humidity may help in reducing the severity of the problem invent Solving Media Handling Problems The Front Panel Keeps Indicating that Media Is Misaligned or Incorrectly Positioned Roll media The roll may be loaded the wrong way The paper should load over the roll toward you Check that the paper is correctly loaded onto the spindle E The paper may be loaded at an angle The right hand edge must be aligned with the blue line on the Print Platen Sheet media It must be loaded with the right hand edge against the blue line on the Print Platen The media may be crumpled or warped or may have irregular edges E f hand cut media is used the edges may not form a right angle or they may be rough If possible hand cut media should not be used Only purchased sheet media should be used in the Printer f the overdrive is covered in dust it will have problems picking up the sheet media during the load process Clean the Overdrive using the Turn
57. before powering On the Printer again 3 Incorrect Graphic Language has been set through the Front Panel Make sure that if a MAC OS is being used to print the graphic language setting should be set to Automatic or PostScript 4 Make sure the correct driver has been installed The correct driver can be downloaded from http www hp com go designjet 5 f a Mac OS is being used with either FireWire or USB the data encoding option may need to be changed a Change the data encoding setting through the Front Panel Setup Menu Printing Defaults Menu PS Options Encoding ASCII b Then configure the application to send ASCII data 6 The print job could be waiting for a timeout Check that the file has a proper file terminator If not then wait the specified timeout period f Nesting is turned ON the Printer may be waiting for the specified timeout before printing E f using the Embedded Web Server a print preview may have been requested In this case initiate the print through the Embedded Web Server Pinchwheel Marks when using Glossy Media Description of problem The Pinchwheels mark the glossy media and some waves can be seen in the printed images that have high density area fills This happens when using HP Productivity Photo Gloss media and it can be seen especially at the beginning of the first print job after loading the media the skew check routine moves the media backwards and forwards several times Corr
58. is Service Utilities The following is a list of all internal Service Utilities available in the Printers Instructions for entering the Service Utilities menu are given on Page 4 57 1 Turn Drive Roller Page 4 59 The purpose of this Service Utility is to rotate the Drive Roller and the Overdrive in order to clean them 2 Prime Tubes Page 4 6 The purpose of this Service Utility is to Prime the Tubes when the Ink Tubes are NOT new and they need to be re primed or automatic priming was not completed correctly Set SN Page 4 65 The purpose of this Service Utility is to set the Serial Number of the Printer 4 Reset Life Counters gt Page 4 66 The purpose of this Service Utility is to reset the internal life counters There are two submenus that allow you to E Reset ALL the counters related to a Preventive Maintenance Kit Reset only the counters related to a specific replaced part 9 Diagnostic Print Page 4 68 The purpose of this Service Utility is to print the Diagnostic Print in order to identify image quality problems 6 Sleep Mode Page 4 69 The purpose of this Service Utility is to enable disable the sleep mode so that the Printer is never switched Off automatically if not used for a certain period of time one hour by default 7 Replace Cutter Page 4 70 The purpose of this Service Utility is to move the Carriage to a position where the Cutter can be replaced easily 8 Set RTC Clo
59. is completed the following message will be displayed on the Front Panel Press the Enter key to continue Printhead alignment Calibration successfully completed Press 4 to continue If the Printhead Alignment fails for any reason a warning message will appear on the Front Panel In this case try the following Enter the Front Panel menu and retry the Printhead Alignment If the Alignment completes successfully then perform the Color Calibration E f the Alignment fails again check the Alignment pattern to see if any of the Printheads are printing incorrectly If necessary perform a Printhead Recovery through the Front Panel and retry the Printhead Alignment 0seeclts 9 The Printer will now perform the Color Calibration When the following message appears on the front panel you must select whether you would like to continue with the calibration by pressing the Enter key Press Back or Cancel to exit the calibration Press Cancel or the Line Sensor Calibration ES A Back key Ov 4 ress Enter to Exil 4 5 9 i to proceed Press ENTER to proceed wi Close Loop Color calibration or BACK CANCE 10 Once the Color Calibration is completed the following message will be displayed on the Front Panel Press the Enter key to continue Color calibration Calibration successfully completed All CLC protiles are dele
60. management of EPS PDF or grayscale files If these types of files have to be used try to ensure that the EPS PDF or grayscale images are already in the same color space that is intended to be used later on in Adobe InDesign or QuarkXPress For instance if the final objective is to print the job in a press that follows the SWOP standard at the time of creating the EPS PDF or grayscale the image should be converted into SWOP Print Quality 6 28 Problems with Color Accuracy Spot colors are special premixed inks to be used directly in the press and the best known spot colors are PANTONE colors The PostScript Printer contains an option called Automatic PANTONE Calibration which can easily match most of the PANTONE Solid Coated spot colors When an application sends a PANTONE color to print it sends the PANTONE name together with its own estimate of equivalent CMYK values The Automatic PANTONE Calibration facility recognizes the PANTONE name and converts it CMYK in a way that depends on the printer model and the selected paper type enabling the color to be rendered with greater precision than is possible with the generic CMYK values sent by the application Even when using Automatic PANTONE Calibration it cannot be expected that the printer matches the PANTONE colors exactly The printer is certified by Pantone for some papers but this does not mean that it can reproduce 10096 of t
61. or Cancel to exit the calibration Press Cancel B wes Blue Line Calibration Press Enter ack key ts Exit to proceed Blue Line calibration ar BACK CANCEL to exit 3 A message will appear on the Front Panel requesting you to raise the Media Lever and to place a sheet of white media on the Print Platen aligned with the Blue Line Press the Enter key to continue once the sheet is in placed Please open the cover la Ign eet wit Open the pinch lever and 7 place a sheet on the platen Blue Line without aligned with the right blue covering it line Then close the pinch 9 lever and the Press any key tn continue 4 The Printer will start to calibrate the Blue Line and the following message will be displayed on the Front Panel Blue Line Calibration Blue Line calibrating 5 Once the Blue Line has been calibrated the following message will be displayed on the Front Panel Open the Window and remove the sheet of media that you had placed on the Print Platen Press any key on the Front Panel to continue once the sheet of media has been removed Blue Line Calibration Please open the cover the pinch lever and remove the paper Then close the pinch lever and the cover Press any key to continue 6 The results of the calibration will be displayed on the Front Panel Press any key on the Front Panel to finish the calibration Blue Line Calibration Nominal p
62. purpose of this test is to verify the operation of the following Sensors B Window Sensor Printhead Cleaner PHC Access Door Sensor B Media Lever Sensor B Media Sensor 6 Ink Delivery System Test Page 4 32 The purpose of this test is to verify the operation of the Ink Supply Tubes 7 SVS Aerosol Fan Test Page 4 33 The purpose of this test is to verify the operation of the Service Station and the Aerosol Fan 8 Air Pump System Test Page 4 34 The purpose of this test is to verify the operation of the Air Pressurization System 5 9 Vacuum Fan Test Page 4 36 The purpose of this test is to verify the operation of the Vacuum Fans 10 n 12 13 14 invent Others Page 4 37 This option allows you to E Recover the Printer from Bag Broken error gt Page 4 37 View the information relating to the Page 4 40 View the Firmware Version Part Number Serial Number and PS Unit Configuration Page 4 41 Verify which Ink Cartridges are valid for the purge process and what is their current available ink level Page 4 43 Enable or disable the printer s connectivity dependnig on the customer s security requirments Page 4 45 EEROM Reset Page 4 46 The purpose of this test is to reset the EEROM values Set Unit Configuration Page 4 48 The purpose of this test is to automatically configure the Printer either as Standard or Productivity Error 71 19 Rec
63. screw Type F that secures the Media Lever to the Linkage 5 Remove one T 15 screw Type F that secures the Linkage to the Spring CA 6 Remove one 20 screw that secures the Spring to the Spacer 7 Remove one T20 screw Type O that secures the Media Lever to the Right Trim 8 Remove the Media Lever Assembly from the Printer Q inveni Media Lever Sensor Removal 1 Remove the Right Cover Page 8 6 2 Remove the Rear Door Page 8 16 3 Remove the Right Connector Cover Page 8 18 4 Remove the Service Station Page 8 23 Remove the Front Platen Page 8 127 e m Remove the Media Lever and Linkage Page 8 140 7 Disconnect the Media Lever Sensor cable from the Interconnect PCA 8 Remove five T 15 screws Type B thot secure the Right Trim 9 Carefully remove the Right Trim from the Printer 10 Carefully release the clip securing the Media Lever Sensor from the Right Trim and remove from the locating pins 11 Release the Media Lever Sensor Cable from the four clips on the Vacuum Fan 12 Remove the Media Lever Sensor from the Printer DU Removal and Installation invent Pinchwheel Assembly Removal Remove the Right Cover Page 8 6 Remove the Rear Door Page 8 16 Remove the Service Station Page 8 23 Remove one T 20 screw that secures the Linkage to the Spr
64. settings 2 If not already done so recover the Printheads Ink Menu Printheads Recover Printheads and reprint the image with the same settings as before 3 Try using a heavier paper type When printing dense colors it is recommended to use HP Heavyweight Coated Paper or HP Productivity Gloss 4 If the problem continues Refer to the Advanced Banding Troubleshooting for Experts section on Page 6 17 to troubleshoot the problem further Advanced Banding Troubleshooting for Experts The flowchart on the following pages will help you troubleshoot some of the different banding issues the Print may have If you have a banding issue the main question you should ask is What do you f you see White Lines refer to this page E f you see Dark Lines refer to Page 6 18 E f you see Both White and Dark Lines refer to Page 6 18 If you see White Lines WHITE LINES Are you seeing nozzles out in Part 3 of Image Quality Diagnostic Print Do you see banding white lines all along the customer plot not taking into account the color Media Advance actions Select the correct Print Quality setting Do the nozzles out alternate between one yes and one no in Part 3 see the table on page 6 3 If the problem persists Heavyweight Coated paper should be used If the problem persists perform a Paper Refer to Flowchart BOTH Advance Calibration Dark and White Lines Our printers are ab
65. the sheet 88 degrees clockwise and press ENTER to proceed secs 13 Load the Calibration Pattern following the instructions on the Front Panel Once the Calibration Pattern is loaded correctly the following message will be displayed on the Front Panel Press the Enter key to continue Scan Calibration Pattern Press ENTER to proceed with pattern scanning 14 The Printer will scan the Calibration Pattern which could take several minutes Once the calibration is completed successfully the following message will be displayed on the Front Panel Press the Enter key to continue Paper advance calibration Calibration successfully completed Press to continue If the Paper Advance Calibration fails for any reason a warning message will appear on the Front Panel In this case try the following Check that the Calibration Pattern was not incorrectly cut trimming the actual pattern during the media load process If this is the case perform the Paper Advance Calibration again from step 1 E Perform a Line Sensor Calibration Page 5 16 and then rescan the Calibration pattern E Replace the Line Sensor Page 8 31 If the problem continues replace the Media Axis Motor Page 8 97 invent 15 You will need to re enter the Paper Advance Calibration submenu and scroll to Clean Drive Roller and press Enter Paper Advance Calibration W Calibration Pattern
66. the Boot Up sequence fails because a components has failed to initialize the following explanations will help you to locate the failing component Step Initialization Process BULNEX KERNEL BOOT rc sysinit rerun through initlog E Environmental variables PATH NETWORKING HOSTNAME set Source etc init d functions Fix console loglevel B Mount proc Dismount the initrd if necessary NO Co Configure kernel parameters Set the hostname Initialize USB controller and HID devices Set variables for options to be later used for filesystem check Turn Off DMA on CD ROMs Turn On Hard Disk optimization Perform file system check on root volume Update quotas if fsck was run on root Setup pnp O gt NO oO E ES Ux invent Initialization Process B Remount the root filesystem read write B LVM initialization B Clear mtab E Enter root proc and potentially proc bus usb and devfs into mtab B Remove lib modules preferred and lib modules default Tweak isapnp settings if needed Load sound modules if the need persistent DMA buffers Load modules from etc rc modules 7 W File system check Check filesystems on all volumes found on etc fstab Check remaining quotas other than root Enable local filesystem quotas Configure machine if necessary if the respective configure files exist 2 Reread in network configuration data
67. the Encoder Strip and Encoder Sensor Page 8 72 5 Once the Analog Encoder has been calibrated correctly the following message will appear on the Front Panel Press the Enter key in order to start the media load process Print Calibration Pattern Press ENTER to load paper 6 Load a sheet of HP Productivity Gloss Media that was included in the Paper Advance Calibration Kit Part Number Q1273 60125 following the instructions on the Front Panel If the kit is not available then cut a piece of HP Productivity Gloss Media that is 36 inches wide and at least 45 inches long 7 Once the media is loaded into the Printer the following message will appear on the Front Panel If roll media has been used instead of cut sheet media then you will need to unroll a minimum of 1 meter of media in order to prevent any back tension which could cause any media advance problems Press the Enter key to continue WARNING If roll is used unroll i meter of media to avoid back tension Press ENTER tn proceed with pattern printing 8 The Printer will start to print the Paper Advance Calibration Pattern This could take several minutes during which the following message will be displayed on the Front Panel Paper advance calibration Printing pattern 9 Once the Accuracy Calibration Pattern has been printed successfully the following message will be displayed on the Front panel Press the Enter key to continue
68. the new Carriage into the Printer 2 Make sure the four clips secure the Carriage PCA Removal and Installation DU invent 3 Connect the Line Sensor Cable and the Encoder Sensor Cable to the Carriage PCA 4 Connect the Flex Cables to the Carriage PCA 5 Connect the Trailing Cable to the Carriage PCA E f you cannot connect the Trailing Cable to the new Carriage Assembly because they are incompatible you need to replace the old trailing cable Go to the Trailing Cable Installation procedure on Page 8 33 E f the existing trailing cable can be connected to the new Carriage Assembly go to the next step 8 78 HP Designjet 4000 4020 Printer Series Service Manual Removal and Installation 6 Install the Carriage PCA Cover 7 When everything is connected power ON the Printer Perform the Carriage Setup Utility Reset life counter scan cycles tubes cable Chapter 4 Reset life counter Carriage PCA 8 Install the Printheads once the Utility has been completed successfully HP Designjet 4000 4020 Printer Series Service Manual 8 79 Removal and Installation UJ invent Carriage Flex Cables Removal 1 Remove the Right Cover Page 8 6 2 Press the two side of the Carriage PCA Cover and unclip from the Carriage Assembly 3 Release the ALL the clips securing the Carriage Flex Cables to the Carriage Assembly by pulling upwar
69. the smudging try the following 1 Make sure the environment is not too humid for the Printer 2 Change pure black objects in the image to a dark color e g dark brown so that they will be printed with the colored inks instead of the Black ink 3 HP Heavyweight Coated Paper should be used instead 4 Increase the drying time through the Front Panel Ink Menu Drying Options Drying Time Paper is not Flat Description of problem If the paper does not lie flat when it comes out of the Printer but has shallow waves in it you are likely to see visible defects in the printed image such as vertical stripes This can happen when you use thin paper that becomes saturated with ink Shown below is an example of what you might see if you have problems with the paper not being flat Corrective Action Try using a heavier paper type When printing dense colors it is recommended to use HP Heavyweight Coated Paper or HP Productivity Gloss Make sure that only genuine HP paper is being used Check that the appropriate print quality settings are being used Refer to Page 6 3 for further information on choosing the correct Print Quality settings Check that the environmental conditions temperature humidity are within the temperature humidity range as specified for the Printer refer to the User s Guide for further information Defect Near the of the Print There are two types of defects which affect the
70. will display System Error Code 02 1 10 For more information on troubleshooting this error code refer to Page 2 4 Check also System Error Code 11 10 refer to Page 2 7 or System Error Code 01 1 10 refer to Page 2 3 CA sesctiod ies Unit Hangs Up If no System error code is displayed on the Front Panel but the Printer hangs up and the last message on the Front Panel is Booting up the Carriage it means that the Carriage ASIC could not be detected Troubleshoot this problem in the same way as if System Error Code 02 1 10 had appeared 5 Once the Carriage is booted up the Service Station will be prepared and moved to a safe position so that the Carriage can be moved During this process the following information will be displayed on the Front Panel Starting SVS Motor If there is a failure at this point the Front Panel will display System Error Code 21 12 For more information on troubleshooting this error code refer to Page 2 8 Also try to perform the Service Station Test refer to Page 4 33 Unit Hangs Up If no System error code is displayed on the Front Panel but the Printer hangs up and the last message on the Front Panel is Starting SVS Motor it means that the SVS Motor could not be initialized Troubleshoot this problem in the same way as if System Error Code 21 12 had appeared 6 The Printer will program the duty cycle for the PWM test for the Scan Axis Movement and leave it disabled and the following
71. 0 SG6ABH9014 DJ4500 it will have the old type 15 If the Air Tube has the old type of blue connector on the end disconnect it and remove the blue connector by cutting it off 16 If the Air Tube is new and does not have a blue connector carefully remove the tube see note below Warning Be careful not to cut your hand on sharp surfaces nearby while disconnecting the tube avoid trying to pull the tube off in one go Twisting the tube while pulling will reduce the effort required to disconnect it HP Designjet 4000 4020 Printer Series Service Manual 8 49 invent 17 Twist the 2 latches at the rear of the Ink Cartridge Tube Connector and release the complete assembly 18 Remove the Ink Supply Tubes and Trailing Cable from the Printer 19 Remove the eleven Cable Holders from the two slots of the Ink Tube Carrier CD 20 the Trailing Cable and Power Cable from the Cable Holders Old and New type of Top Crane Covers There are two possible types of Top Crane Cover in the printer the OLD type and the NEW type Removing the trailing cable from the old type 1 Remove one T15 screw from the Top Crane 2 Remove the Trailing Cable and Carriage Power Cable from the groove in the Top Crane Removal ard tslaron Removing the trailing cable from the new type 1 Remove one T15 screw from the Top Crane 2 Remove the Top Crane Cover by unclipping it
72. 1 Install the new Gamut PCI PCA into the Main PCA 2 Install one T 10 screw I that secures the Gamut PCI PCA CA 3 Connect all cables to the PCI 4 Connect the Trailing Cable to the new Gamut PCI PCA 5 Install the conector adaptor if required and then connect the Trailing Cable to the new PCI 6 Install Cover onto the Printer 7 Install three T 15 screws Type that secure the Main PCA cover 9 Install the Left Connector Cover Page 8 19 Install the Rear Door 8 16 Memory Module Removal r E 1 Remove the JetDirect Card if installed 2 Remove three T 15 screws Type that secure the Main PCA cover 3 Remove the Main PCA Cover from the Printer invent 4 Push the Memory Module Connector clips up and down to release the Memory Module 5 Remove the Memory Module from the Printer mrad roten Main PCA Formatter Removal 1 Remove the to PCI Interface Card gt Page 8 96 2 Remove the Gamut PCI PCA Page 8 96 3 Remove the Memory Module Page 8 103 4 Disconnect ALL cables connected to the Main PCA Formatter 5 Remove eight T 10 screws Type I that secure the Formatter UERS POPF FRAP invent 6 Release the plasti
73. 110 CPU Fan is stopped or burnt Try the following B Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer B Replace the CPU Fan Page 8 107 f the System Error continues replace the Page 8 105 05 3 10 Main memory size failure Try the following Check that the minimum amount of memory is intalled correctly 256MB for the HP Designjetjet 4000 512 for the HP Designjet 4020 Check that the Memory Module is installed correctly E Try installing the Memory Module in the other Memory slot and check if the System Error appears If the System Error reappears replace the Memory Module Page 8 103 If the System Error does NOT reappear then the original slot could be faulty In this case replace the Main PCA Page 8 105 System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action invent 06 03 NVM file has bad CRC 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 B If the System Error continues replace the Hard Disk Drive gt Page 8 107 06 10 Main NVM failure not detected read w
74. 20 Printer Series Service Manual ra AAvid Fan Installation 1 Install double sided sticky tape which comes with this kit over the top of the four holes in the corners of the CPU Fan 2 Removing the backing from the double sided sticky tape 3 spacer on each corner of the CPU Fan over the top of the double sided sticky tape invent 4 Make a hole in the four corners of the tape for the screws to pass 5 Install four T10 screws into the CPU Fan and into the Formatter PCA 6 The rest of the installation procedure is the same as the removal procedurem but in reverse Hard Disk Drive HDD Removal E 1 Remove the JetDirect Card if installed 2 Remove three T 15 screws Type A that secure the cover 3 Remove the Main PCA Cover from the Printer Removal and Installation LA inveni 4 Disconnect ALL cables connected to the Hard Disk Drive 5 Remove one 10 screw 1 from the HDD Holder 1111111 6 Slide the Hard Disk Drive upwards and remove from the Printer 8 112 HP Designjet 4000 4020 Printer Series Service Manual CD Power Supply Unit PSU Removal 1 Remove the Right Connector Cover Page 8 18 2 Remove the JetDirect Card if installed 3 Remove three T 15 screws Type that secure the Main PCA cover a Hinc 4 Remove the Main PCA
75. 4 Service Station Calibration 5 8 Paper Advance Calibration 5 9 Drop Detector Calibration 5 15 Line Sensor Calibration 5 16 Platen Blue Line Calibration 5 20 Vacuum Calibration 5 22 Carriage PCA Calibration 5 23 CONN tn BW HP Designjet 4000 4020 Printer Series Service Manual gt Q inveni Service Calibrations The Printer has several calibration procedures that must be performed under certain conditions The following is a list of all internal service calibrations available in the Printers Instructions for entering the service calibrations menu are given on Page 5 3 Scan Axis Calibration Page 5 4 The purpose of this Service Calibration is to carry out a PWM check and calibrate the intensity of the Line Sensor Service Station Calibration Page 5 8 The purpose of this Service Calibration is to calibrate the Drop Detector located in the Service Station in relation to the Carriage Assembly Paper Advance Calibration Page 5 9 The purpose of this Service Calibration is to calibrate the nominal advance of the media This calibration is necessary to control the exact movement of the media in order to avoid print quality problems like banding Drop Detector Calibration Page 5 15 The purpose of this Service Calibration is to calibrate the Drop Detector located in the Service Station in relation to the Carriage Assembly Line Sensor Calibration gt Page 5 16 The purpose of this Se
76. 7 4 C5056 A Z50564 C554 5054 C50554 C555 Product 90 90 No 90 HPhNMcSU HPMeoSU HPNMcSOU HPhoSU 90 Printheads Hsen 0 0 0 0 Total Insertions 1 1 1 1 1 1 1 1 Cartridge Section The Ink Cartridges currently being used are not counted Bi This section is split by product name and number for each color we have different Ink Cartridge sizes The sample below does not represent the reality as we only have one size of Black Ink Cartridge 400cc 3 Black Product Name HP No 90 Product Number C5058A Usage 2 Cartridges 3 816380 cc Product Name HP No 90 Product Number 5058 Usage 1 Cartridges 14 144599 cc Preventive Maintenance Section Once the value reaches 100 the corresponding Preventive Maintenance Kit should be used For further details refer to Chapter 9 Preventive Maintenance Preventative maintenance Usage Preventive maintenance kit 1 D Preventive maintenance kit 2 D 0 00000000 res Component Usage One cycle is counted when the Carriage makes one movement to the left of the Printer and then returns to the right B Tube used with non HP ink This is set to Yes as soon as the Printer detects that at least one Ink Cartridge was used with third party ink This cannot be reset to No because it is part of the ISS except when The Ink Supply Tubes are replaced not under warranty The Printer detects tha
77. Assembly omon 1 e Spindle NOT ince Blue Hub 4 hee _ 8 1 Figure 13 Entry Assemblies Miscellaneous Parts Q1273 60097 mn Right Arc Preventive Maintenance Kit Includes Carriage Assembly without Carriage Ink Supply Tubes and Trailing Cable Scan Axis Motor Belt Encoder Strip includes Spring and Nut but does not include Encoder Reader Most Left and Middle Left Spittoons Scraper and the Media Axis Drive Motor Brake with the corresponding support Part 2 Sheets of HP Productivity Gloss Media for EX EN Service Advance Calibration Labels Kit includes the Serial Number Q1273 60130 Label Connector Label and the Main PCA Cover Removal Label 596 3589 Power Cord 2 5 meters Australia Power Cord 2 5 meters for most European Countries Korea Indonesia Portugal 7 Germany Spain France ltaly and Arabic Countries c E Cord 2 5 meters for Singapore BEN Countries and United Kingdom NE 8120 6896 EN Power Cord 2 5 meters for India South Africa Power Cord 2 5 meters for USA Mexico 8121 0917 Canada Taiwan Japan and Arabic Countries 8121 0922 Power Cord 2 5 meters for Brazil Thailand and Philippines 5961 3590 e Cord for Chili Uruguay and rgentina Power Cord 2 3 meters for Chili and 8120 6980 1 Uruguay final cable that is connected to Power Cord
78. B Replace the Ink Supply Tubes Page 8 33 System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action invent 26 2 01 Bad contact detected in ISS slot2 floater Try the following B Remove the Black Ink Cartridge and reinstall it in to the Printer B Replace the Black Ink Cartridge Check that the ISS to Cartridge cable Black Ink Cartridge is not damaged and is correctly connected to the Ink Supply Tubes PCA B Replace ISS to Cartridge cable Black Ink Cartridge Page 8 58 E Replace the Ink Supply Tubes gt Page 8 33 26 3 01 Bad contact detected in ISS slot3 floater Try the following E Remove the Cyan Ink Cartridge and reinstall it in to the Printer B Replace the Cyan Ink Cartridge Check that the ISS to Cartridge cable Cyan Ink Cartridge is not damaged and is correctly connected to the Ink Supply Tubes PCA B Replace ISS to Cartridge cable Cyan Ink Cartridge Page 8 58 B Replace the Ink Supply Tubes Page 8 33 26 n 10 Order of Ink Supplies incorrect Try the following Remove the Ink Cartridges and check that they are the correct ones for this Printer and that they are inserted in the correct position Check that the Printer has the latest Firmware version If not update the Fi
79. Clean out etc w u tmpx files var Reset pam console permissions Cleanup utmp wtmp Delete X locks Delete VNC and X locks Delete Postgres sockets 18 Add raid devices 1 Turn On swap case we swap to files Initialize the Serial Ports SCSI tape has been detected load the st module unconditionally 10 Load usb storage to match most other things If ide scsi is required load it Generate a header that defines the boot kernel Dump the syslog ring in var log dmesg Keep kernel symbols in var log ksyms Create the crash indicator flag to warn on crashes offer fsck with timeout Export this variable BOOT_PART and INSTALL_PART invent Step Initialization Process PRINT APPLICATION STARTING POINT 7 IO kernel mode initialization basically EN Printer Application Infrastructure startup Printer IO startup 4 Front Panel application startup but wait for engine launching i e Front Panel is not cleared yet Engine startup start EE and Mechanical initialization HPGL PS parsers startup All subsystems launched Wait for Front Panel application to clear the Front Panel and start signaling the initialization sequence Corrective Actions for Power Up Problems If the Printer s Power Up process stops when the front panel is displaying the number 17 this indicates that there is a problem with the file system on the Printer s Hard Disk Drive so the Printer is che
80. Clean the exposed part of the wheels with a dry cloth Ideally clean the whole circumference of these wheels you can use Turn Drive Roller Utility on Page 4 69 Applying Oil to the Overdrive Occasionally it maybe necessary to oil the Overdrive in order to stop the rollers squeaking 1 Open the Window 2 There are small holes in the Center Platen beside some of the rollers 3 A bottle of oil is supplied with the Maintenance Kit Insert the pointed end of the bottle into each hole in turn and put three drops into each 4 Be very careful not to spill any oil onto the Center Platen 5 If there is oil on the Center Platen wipe it away with the cloth supplied with the Maintenance Kit 6 Close the Window Lubricating the Carriage Assembly The Carriage Assembly needs to be lubricated occasionally at least once a year so that it can slide easily along the Slider Rod 1 Using the Front Panel in the Printheads menu select Replace printheads now The Carriage Assembly will move to the center of the Printer 2 Open the Window and apply a few drops of oil bottle of oil can be found in the Maintenance Kit to the pads on either side of the Carriage Assembly 3 Apply a few drops of oil directly to the Slider Rod on either side of the Carriage Assembly UJ invent Scheduled Maintenance In some segments of the printer market the customer tends to print more than the maximum number of pri
81. Clear GPIO psu lpm If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 Checking voltage If there is a failure at this point the Front Panel will display System Error Code 03 10 For more information on troubleshooting this error code refer to Page 2 5 Check also System Error Code 01 0 10 refer to Page 2 3 Config GPIO enable If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 3 Alter initializing the Scan Axis system the following message will appear on the Front Panel can Axis Has the carriage supply LED a been switched oan TES Press UP DOWN to change and ENTER to select 4 Open the Window and check that the Carriage power light is ON a faint green light on the carriage PCA Select Yes or No by using the Up and Down keys and press Enter to confirm your selection If you select No at this point the Front Panel will display System Error Code 02 1 10 For more information on troubleshooting this error code refer to Page 2 4 Check also System Error Code 11 10 refer to Page 27 or System Error Code 07 10 refer to Page 2 6 It you select Yes then the Front Panel will display Booting up the Carriage If there is a failure at this point the Front Panel
82. Defaults Menu Graphic Language Refer to the Assembly and Setup Poster and the driver documentation Image is Unexpectedly Rotated PostScript Driver If the output that was expected contains an image that was unexpectedly rotated then try the following to resolve the problem 1 Check the rotate option through the Front Panel Setup Menu Printing Defaults Menu Paper Options Rotate to make sure the rotate option has not been selected 2 For non PostScript files if Nesting is On the pages might be automatically rotated in order to save paper 3 Check also the following options to see if the rotate option has been activated by mistake B Windows Driver Finishing tab Rotate by 90 degrees B Mac OS Driver Finishing panel Rotate by 90 degrees B Embedded Web Server Select Submit Job Rotate UJ invent Print is Distorted or Unintelligible If the output that was expected is distorted or unintelligible then try the following to resolve the problem There might be a problem between the Printer and Computer Check the cable between the computer and the Printer to make sure it is not damaged and is connected correctly If the Front Panel graphic language setting is set to Automatic try choosing a setting specitic to the current requirement e g Select PostScript for PostScript file Depending on the software drivers and RIPs that are being used there are different ways of solving this problem re
83. Drive Roller Service Utility Page 4 59 Troubleshooting Using the Buzzer at Power up to Troubleshoot As the Printer turns On normally it does not make a Beeping Sound until completely initialized If one or muliple beeps are heard during the power up sequence this indicates there is a problem in the Electronics Module The table below troubleshoots the issue using the number of beeps heard Number Problem Corrective Action of Beeps Description between the Power Supply Unit the PCA is correctly connected or is not damaged Replace the Main PCA Page 8 105 Check that the cable between the Power Supply Unit and the Faulty Main Main is correctly connected or is not damaged PCA or PSU Replace the Main PCA Page 8 105 Replace the PSU Page 8 113 Check that the Memory Module is installed correctly Processor absent Installing the Memory Module into the other memory slot and Faulty check if the problem remains Memory It the problem remains replace the Memory Module Page 8 Module 103 It the problem does NOT remain the original slot could be faulty in this case replace the Main PCA Page 8 105 Check that the Front Panel cable is not damaged and is correctly connected between the Front Panel and the Interconnect 4 Front Panel Replace the Front Panel Page 8 20 This functionality is only availble in the HP Designjet 4020 A future firmware release is antici
84. Ink Cartridge Using the front panel detailed information can be checked on the Ink Cartridges Printheads In order to increase printing speed two Printheads are connected to each Ink Cartridge giving eight printheads in total The Printheads are extremely durable and do not need to be replaced every time an Ink Cartridge is replaced They are independent of the Ink Cartridges and will continue giving excellent image quality results even if the Ink Cartridges are low on ink If you notice a decline in print quality such as lines or dots missing from text graphics go to Page 6 16 Troubleshooting Print Quality Problems Printhead Cleaners Each printhead has its own printhead cleaner so there are eight printhead cleaners in the printer Printhead cleaners are used to clean and maintain the printheads to ensure the best possible print quality and to seal the printheads when they are not in use to prevent them from drying out invent General Information About the Ink Supplies Always install the Ink Cartridges Printheads and Printhead Cleaners before the expiration date which is on the packaging Install a new Printhead Cleaner every time you change a Printhead B Allow the Printer and Printhead Cleaners to automatically clean the Printheads Install Ink Cartridges Printheads and Printhead Cleaners in their color coded slots B Follow the instructions on the front panel of the
85. P GL 2 drivers The situation is that you are printing on each printer using the HP GL 2 driver installed for that printer 1 Ensure that both printers have been updated with the latest firmware version 2 Ensure that you have the latest printer driver for both printers The latest versions can be downloaded from http www hp com go designjet 3 Ensure that Color Calibration is turned on Setup Menu Configuration Menu Color calibration On Load both Printers with similar paper types 5 Ensure that the Paper Type setting on the front panel corresponds to the paper that is loaded 6 With the HP GL 2 driver for the HP Designjet 4000 Printer series select the Color tab and set the Color Matching Method to sRGB 7 With the HP GL 2 driver for the HP Designjet 1000 series select the Options tab then Manual Color Color Control Match Screen You should also select the Paper Size tab then Paper Type and select an Enhanced Colors paper type Printing the same HP GL 2 file The situation is that you have produced an HP GL 2 file also known as PLT file using the HP GL 2 driver installed for one printer and you intend to send the same file to both printers 1 Ensure that both printers have been updated with the latest firmware version 2 Ensure that Color Calibration is turned on Setup Menu Configuration Menu Color calibration On 3 Load both Printers with similar paper types 4 Ensure that the Paper Type setting on
86. Printer either as Standard or Productivity Set the Unit Configuration as follows In the Diagnostics Tests submenu scroll to 12 Set Unit Configuration and press Enter B DELIVeElyY Leo 7 S 5 Aeroasol FAN test ses Air Pump System test MG Vacuum FAMs test 18 Others The Printer will start the configuration process and the Front Panel will display the following messages Starting Nvm Getting Part Number will show either Q1273A Q1274A Q1271A Q1272A CM765A CM7664 If there is a failure at this point the Front Panel will display System Error Code 79 03 For more information on troubleshooting this error code refer Page 2 21 The following message will be displayed on the Front Panel Press any key to finish the configuration starting Nym Getting Part Number 012744 Setting new contig STANDARD Press any Key to continue If there is a failure at this point the Front Panel will display System Error Code 79 03 For more information on troubleshooting this error code refer to Page 2 21 4 Once the process is completed OK will be displayed on the Front Panel Set Unit Configuration la ii Fan es 13 71 19 The purpose of this utility is to set the Serial Number and Part Number in case both the Hard Disk Drive and the Ink Supply Tubes are replaced ot the same time Set the Serial Number as follows
87. Replace cutter Set ATC clock rnc Maintenance Media standby behaviour Backup print mode ie Feed Roller change 2 The Printer will display the current status of the Backup Print Mode Use the Up and Down keys to change the status and press the Enter key to select You can press the Cancel key at any time to exit the utility without making any changes Use UP and DOWN keys to change the status Press Enter to go to select 225052 ENABLE Ay Press Cancel to exit Use UP DOWN Keys for selection and ENTERS CANCEL for confirmation 3 The Front Panel will display the Enabled Disabled status of the Backup Print Mode New backup print mode estate DISABLE or 12 Sanitize Level ont ov The purpose of this Service Utility is to set the level of file deletion when ev using the Disk Wipe option described in the next section Perform the Sanitize Level utility as follows 1 In the Service Utilities submenu scroll to Disk Wipe and press Enter set RTC clock WE FHE Maintenance Bir Media standby behaviour Backup print mode Feed Roller change 2 Inthe Disk Wipe submenu scroll to Secure Sanitize and press the Enter key Press Enter to go to next digit Press Cancel to exit Use UP and DOWN keys to go through the digits 3 Use the Up and Dow
88. Sensor Cable from the Vacuum Fan 6 Disconnect both Vacuum Fan cables from the Interconnect PCA Removal and Installation DU invent 7 Remove four T 20 screws Type B that secure the Vacuum Fan to the Printer 8 Remove the Vacuum Fan from the Printer E Paper Advance Calibration Chapter 5 8 28 HP Designjet 4000 4020 Printer Series Service Manual CD Aerosol Fan Removal 1 Remove the Right Cover Page 8 2 Remove the Rear Door Page 8 16 3 Remove the Right Connector Cover Page 8 18 4 Remove the Service Station Page 8 23 5 Unclip the bottom cover from the Aerosol Fan 6 Remove four T 15 screws Type G that secure the Aerosol Fan to the Service Station 7 Remove the Aerosol Fan from the Service Station 8 If necessary remove the Aerosol Fan Filter from the Aerosol Fan invent Removal and Installation Drop Detector Removal 1 Remove the Right Cover Page 8 6 2 Disconnect the Drop Detector Cable from the Service Station Cable 3 Release the Drop Detector Cable from the Service Station 4 Remove one T 8 screw Type K that secures the Drop Detector to the Service Station HP Designjet 4000 4020 Printer Series Service Manual 8 3 5 Remove the Drop Detector from the Printer Drop Detector Calibration gt Chapter 5 CD
89. Service Manual invent For HP Internal Use Only Copyright Hewlett Packard Company 2009 This document contains proprietary information that is protected by copyright rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of Hewlett Packard Company First Edition December 2004 Second Edition April 2005 Third Edition November 2008 Fourth Edition March 2009 Warranty The information contained in this document is subject to change without notice Hewlett Packard makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose Hewlett Packard shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Content Management Department Barcelona Division Hewlett Packard Espanola S A Avda Graells 501 08190 Sant Cugat del Valles Spain WARNING The procedures described in this manual are to be performed by HP qualified service personnel only Electrical Shock Hazard Serious shock hazard leading to death or injury may result if you do not take the following precautions Ensure that the ac power outlet mains has a protective earth ground terminal Disconnect the Printer f
90. Type B that secures the Right Rollfeed Module from the inside 3 9 7 Remove one 20 screw Type one T 15 screw Type G and two T 15 screws Type J that secure the Right Rollfeed Module from the outside 8 Remove the Right Rollfeed Module from the Printer Installation 1 Hold the Right Rollfeed Module as shown keeping your thumb firmly on the Media Tension Mechanism 2 While securely holding the Right Rollfeed Module remove the T 15 screw that secures the Media Tension Mechanism 5565 3 While securely holding the Right Rollfeed Module position the Right Rollfeed on to the Printer and install the T 15 screw that was removed in the previous step 4 Install the remaining screws that were removed during the removal process Removal and Installation LA inveni Right Spindle Lever Removal These instructions explain how to remove a broken Spindle Lever and install a new one 1 Pull out the Media Spindle from the Printer 2 Remove the Spring from the Spindle Lever 3 Remove one 20 screw Type that secures the Spindle Lever 8 162 HP Designjet 4000 4020 Printer Series Service Manual invent 4 Remove the Spindle Lever Installation 1 Position the new Spindle Lever on the Printer 2 Install one T 20 screw Type to secure the Spindle Lever invent 3 Plac
91. Y Who should perform the action 1 digit User or Service Engineer 7 Action to pertorm 1 digit m additional actions information to consider 1 digit Optional e g Non authorized ink was detected PM was triggered or Printhead in out of Warranty O inveni The following table explains the XX part of the System Error Code or Warning Items in red are E Component System not applicable Main ms TERGUM pini or Uu 04 051 05 8 88 ing caste ooo O WecmmdCHhe 3 Service Stofion Spy Staion 39 Frese Sysiom 34 XE 35 3 Cleaner oor 3 Ge Take up Reel B 34 35 QGemowAsemby 38 3 38 39 4 Moor 4p Sci Motor Component Systom 45 8 Window Door Sensor Ca oo o Medi Sensor 54 Finch Sensor a a7 38 59 _ Tanga Interpreting ar 8j ____inpui Ouipur through Parallel Port pcp Cond rough USE Fort 6 __Tapui Onipu rot know what por OO Job Configuration 8 Input Output through FireWire Pot 68 los oF Engine Counters Tracking M
92. according to the part number the Front Panel will display a fail message In this case re enter in to the Diagnostics Tests submenu and use the diagnostic 12 Set Unit Configuration to set the correct configuration refer to Page 4 48 A message will appear on the Front Panel asking whether you would like to check the Interconnect Select Yes or No by using the Up and Down keys and press Enter to confirm your selection If you select No the printer skips this test and goes to the next one Electronics Module Do you want to check the Interconnect Use UP and DOWN keys to select ENTER to select If you select Yes the Printer will check the Interconnect PCA and the following messages will be displayed on the Front Panel Starting CDS Diagnostic Tests and Utilities If there is a failure at this point the Front Panel will display System Error Code 79 03 For more information on troubleshooting this error code refer to Page 2 21 Getting unit config IF the current Part Number is not in the correct 6 character format the Front Panel will display a fail message In this case re enter in to the Diagnostics Tests submenu and use the diagnostic 13 Error 71 19 Recovery to set the correct Serial Number refer to Page 4 49 It the unit configuration is incorrect according to the part number the Front Panel will display a fail message In this case re enter in to the Diag
93. agnostics test The Printer will start the configuration process and the Front Panel will display the following messages Starting Nvm Starting CDS If there is a failure at this point the Front Panel will display System Error Code 79 03 For more information on troubleshooting this error code refer to Page 2 21 Starting Supplies Conf B Starting Gamut CA If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 Starting Pump 5 The Printer will start the test of the pump and the Front Panel will display the following messages Pressuring Current Pressure Holding pressure Current Pressure Depressurizing If there is a failure at this point the front panel will display the following error message Test Failed Replace one cartridge with a new one Press ENTER to continue or CANCEL to abort Remove an ink cartridge and replace it with a new one and press the Enter key to repeat the test If the Air Pump System does not pass the test continue replacing ink cartridges one at a time until it passes 6 When the Air Pump System passes the test the following message is displayed on the front panel press any key to continue Air Pump System Test passed Press any key to continue ca inveni 9 Vacuum Fans Test The purpose of this test is to ve
94. ame HP No 90 Product Number C5064A Serial Number 1289696 15 8 Manufacturer HE Capacity 225 ink Consumed 35 mi Used with non HP Ink no Cartridge Status OK Missing Low Very Low Empty Reseat or Replace B Expiration Date Manufacture date date marked on the actual Ink Cartridge 30 months B Install Date Corresponds to the internal date of the Printer RTC when the Ink Cartridge was installed for the first time Capacity Total capacity of the Ink Cartridge Printer Usage Information This page contains the following information E Printer Usage E Usage per Printhead Slot E Usage per Cartridge Slot B Media Usage per Media B Component Usage Spittoon Usage WB Preventive Maintenance Usage http 15 180 36 190 hp device webAccess servicePlot1b htm Microsoft Internet Explorer provid ew Favorites Tools Help Osx Qi P seach dM Address 15 180 36 190 ho devece webaccess seracePlot ib htm Be usa amp Usage per Cart ridge 1 Yeou 2 Magenta 3 Black 4 Cyan Product Name Product Number Usage Cartridges Cartridges Cartridges Cartridges Media Usage per Media Type Productivty Photo Gloss HP 1 04 21112 8 Bet usage 8 cycles 318 Motor usage 8 cycles 318 Carriage usage 8 cycles 318 Traling cable usage 2 Cycles 318 Tube usage 8 cycles 318 Tube used wth non HP nk No
95. an be sent by e mail from the Web Browser when using the Embedded Web Server File Send Page by E mail You can see the same information through the Front Panel or the Embedded Web Server Current Media Printhead and Ink Information This page contains the following information Current Printer Configuration E Paper Loaded Information Current Printhead Kit Information Current Ink cartridge Information Me QM see De ce J D 32 0 Fme tiim G SaF 5 tee 11 Lih heic mmm ctor nme ae ow amp e Current Media Printhead and Ink Information fe 12 3552 Pleeqetel ly gt 04419006547 frm ant emen A521 eter eb utu 9 5 vg De 350 emp tee Mec art Crest ety Esans Acton Pucer Pur Peper Toss OM eta Semet Prt vrse rem Doya Maze wwe OR 7 4 ON ra Romaneg wete Lega IE Yea o f m Jom E m corey Im m m we m m m pe memesi Sates n re DE mm 77 ert Artest teeth M92 1 tow Cote LI lees owns mowers 79 macer pec et portent vr re v Runt Nut Chota CM ONT Cut ust Sen unter 541235 14 4 14469 119 163 1433163 bap tad VATES tae 099111224 HIDE 144 ace tad Doe ares TOONS OE SO etr aw us ta
96. and there are banding issues that cannot be solved through the standard troubleshooting procedure It is designed to highlight and identify three problems B The advance calibration is not optimized The printhead alignment is not optimized E Nozzles not firing in a printhead How to print the Print Banding Plot 1 in the Service Utilities submenu scroll to Diagnostic Print and press Enter Turn Drive Roller Prime Tubes Bi set sn Reset life counters Sleep mode Benlane cutter O i 2 You will be given three options Use the Arrow keys to select Others and press the Enter key Press Enter to confirm selection X cmd cu Diagnostic Print Image quality user plot i Image quality service plot Use UP and DOWN keys to select 3 You will be given two options Use the Arrow keys to select Print Banding Plot and press the Enter Press Enter to confirm selection Use UP and DOWN keys to select Force Drop Detection Print Banding Plot x 4 Make sure media is loaded the Paper Load Levers are lowered and that the Ink System is correctly installed Press the Enter key to print the Diagnostic Print or press Back Cancel to exit without printing the Diagnostic Print Press Cancel or the Print Banding Plot Back key EH Press Enter ink is ready to Exit to pri
97. bleshooting this error code refer to Page 2 21 8 Once the process is completed OK will be displayed on the Front Panel ii Far ies 14 1 0 Tests The purpose of this test is to check the installed and active Interfaces Perform the I O tests as follows 1 Once the message Ready is displayed on the front panel scroll to the Printer Setup Options icon and press the Enter key HP Designjet 4 lt Fast Ethernet EWS address http NPIGBAOCA7EECFB http 15 23 60 238 2 Once inside the Printer Setup Menus menu press the UP or Down arrow key and the Cancel key together Information menu Configuration menu Printing defaults menu 0 setup Press Cancel You are now in the Service Tools Menu 3 Use the Arrow keys to scroll to the Service Tests menu and press the Enter key Service menu Service utilities M Press Enter Service calibrations or the Back key to Exit Press Cancel inveni 4 Inthe Service Tests submenu scroll to Tests and press Enter Press Enter 5 When the following message appears on the front panel you must select whether you would like to continue with the test by pressing the Enter key Press Back or Cancel to exit the calibration 0 Tests Hardware I O test will be carried out for the installed and active interface Press Ent
98. bly 8 159 Right Spindle Lever 8 162 HP Designjet 4000 4020 Printer Series Service Manual 8 1 Removal ard islaron Introduction This chapter is a step by step guide to the removal and installation of the key components in the printer You may find it useful to tick off the steps as they are performed Use the illustration at each procedure to identify the parts referred to in the text The procedures appear in order of removal So the whole machine can be stripped down by starting at the beginning of this chapter and working through the subsequent procedures Safety Precautions Review WARNING and CAUTION symbols and instructions before you service the printer Follow these warnings and cautions for your protection and to avoid damaging the printer Electrostatic Discharge ESD Precautions To prevent damage to the Printer circuits from high voltage electrostatic discharge ESD 1 2 3 Do not wear clothing that is subject to static build up Do not handle integrated circuits ICs in carpeted areas Do not remove an IC or a printed circuit assembly PCA from its conductive foam pad or conductive packaging until you are ready to install it 4 Ground earth your body while disassembling and working on the Printer After removing a cover from the Printer attach an earthing ground lead between the PCA common and earth ground Touch all tools to earth ground to remove static charges before using them on the Pr
99. c locating pin that secures the Main PCA Formatter 7 Remove the Main PCA Formatter from the Printer CPU Fan Removal r 1 Remove the JetDirect Card if installed 2 Remove three T 15 screws that secure the Main PCA cover 3 Remove the Main PCA Cover from the Printer Removal and Installation DU invent 4 Disconnect the CPU Fan cable from the Formatter PCA 5 Remove four T10 screws from the CPU Fan and remove the Fan 6 Remove the CPU Fan Older printers may have four washers behind it Make sure that the four washers that may be behind the CPU Fan do not fall into the body of the printer when the Fan is removed Place your hand under the Fan as you remove it Discard the four washers as they are no longer required E 90 f E J P Ae PO L d iier Ll Fes en ES B r E 24 The installation procedure for the new CPU fan will depend of the manufacturer of the fan There are two types available Delta Fan Installation 1 Install four cross head screws into the CPU Fan and into the Formatter PCA To ensure the correct orientation of the Delta CPU Fan in the Electronics Module make sure the CE label of the fan faces towards the printer 2 The rest of the installation procedure is the same as the removal procedurem but in reverse 8 108 HP Designjet 4000 40
100. carriage cover and close the window 7 The printer will begin to purge the tubes system 8 Once the tubes system has been purged the following message will instruct you to open the Window 4 02 HP Designjet 4000 4020 Printer Series Service Manual CA 9 When the following message appears on the Front Panel open the Carriage cover and check the window on top of each Setup Printhead If the Ink Supply Tubes have been primed correctly the windows will contain ink If the windows on top of each Setup Printhead does NOT contain ink then you may need to repeat the Prime Tubes process from the beginning Lift printhead cover Remove full setup printheads El Bol Lal LES Remove ALL the Setup Printheads from the Carriage and install the previously removed Printheads 11 Once the Printheads are installed the Front Panel will instruct you to close the Carriage cover and close the Window Close printhead cover and Window a 12 Open the right cover and make sure the Printhead Cleaners are installed in the Service Station 13 The Printer will now perform the Printhead Alignment and the following message will be displayed on the Front Panel To continue with the Printhead Press Enter to confirm selection Alignment select Align now and press the Enter key Aligning printheads now means that the printer may use up to 3m af the roll Use UP and DOWN keys l
101. ce Calibration Only change the paper advance patch if a clear difference in terms of media advance is seen 4 lf the problem persists replace the Printhead that is showing misdirected nozzles invent Lines are Missing or Thinner than Expected Description of problem Shown below is an example of what you might see if you have this problem Corrective Action 1 Check that the line thickness and color settings are correct the application that was used to generate the image 2 Check that the appropriate print quality settings are being used and reprint the image Refer to Page 6 3 for further information on choosing the correct Print Quality settings 3 Recover the Printheads Ink Menu Printheads Recover Printheads and reprint the image 4 Try using a heavier paper type When printing dense colors it is recommended to use HP Heavyweight Coated Paper or HP Productivity Gloss 5 Using Part of the Image Quality Diagnostic Print check if there is a significant amount of nozzles out in the color that is actually causing the problem if see you a problem with the Black color in the customer print then only check the Black printhead in the Image Quality Diagnostic Print If there is a significant amount of nozzles out refer to image 1 on Page 6 19 then replace the faulty Printhead gt O Solid Bands or Lines Printed Over the Image Description of problem This kind of problem can show i
102. ce Station and then close the Printhead Cleaner Access Door B Replace the Yellow Printhead Cleaner slot 1 of the Service Station 29 1 01 Printhead Cleaner not inserted correctly in slot 2 Try the following Open the Printhead Cleaner Access Door and check that the Yellow Printhead Cleaner is correctly seated in slot 2 of the Service Station and then close the Printhead Cleaner Access Door B Replace the Yellow Printhead Cleaner in slot 2 of the Service Station System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action invent 29 2 0 Printhead Cleaner not inserted correctly in slot 3 Try the following Open the Printhead Cleaner Access Door and check that the Magenta Printhead Cleaner is correctly seated in slot 3 of the Service Station and then close the Printhead Cleaner Access Door E Replace the Magenta Printhead Cleaner in slot 3 of the Service Station 29 3 01 Printhead Cleaner not inserted correctly in slot 4 Try the following Open the Printhead Cleaner Access Door and check that the Magenta Printhead Cleaner is correctly seated in slot 4 of the Service Station and then close the Printhead Cleaner Access Door E Replace the Magenta Printhead Cleaner in slot 4 of the Service Station 29 4
103. ceed select Yes or Press Enter to confirm selection No by using the Up and Down keys and press Enter to confirm your selection If you select No the process will end at this point EEROM Reset Wall user information files Will be removed Proceed Use UP and DOWN keys lo select YES Press UP DOWN to change an EMTER tn select 3 f you select Yes the Printer will begin the process to reset the EEROM and the following messages will appear on the Front Panel B Starting Gamut If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 Starting NVM E Setting default config E Restoring tubes state If there is a failure at this point the Front Panel will display System Error Code 79 03 For more information on troubleshooting this error code refer Page 2 21 4 Once the has been reset the following message will appear on the Front Panel Press any key to continue Reset After rebooting there will be printhead error Please select printhead replacement to launch the printhead calibration Press any Key to continue 5 Once the process is completed OK will be displayed on the Front Panel invent 12 Set Unit Configuration The purpose of this test is to automatically configure the
104. ck Page 4 71 The purpose of this Service Utility is to set the Real Time Clock RTC of the Printer 9 PHC Maintenance Page 4 72 The purpose of this Service Utility is to reset the black printhead cleaner once it has been replaced 10 Media standby behavior Page 4 74 This is where you can change the position the media is put when in the standby position 11 Backup Print Mode Page 4 76 The Backup Print mode is a mode that increases the number of passes to O Diagnostic Tests 0 invent 12 13 ensure a consistent level of image quality when there is a significant number of nozzels out in the printheads Sanitize Level Page 4 77 This utility will set one of the three levels of hard disk drive deletion that which is performed by using the Disc Wipe utility described next Disc Wipe Page 4 79 This utility deletes the data on the Printer s Hard Disc Drive Entering the Service Utilities Menu 1 Once the message Ready is displayed on the front panel scroll to the Printer Setup Options icon and press the Enter key Press Enter to confirm selection Use UP and DOWN keys lo select Designjet 4e00ps Fast Ethernet EWS address http NPIGG8ABCATEECFG http 15 23 58 238 2 For Call Agents who will request the user to perform certain Service Utilities once inside the Printer Setup menu press the Down arrow key and the Cance
105. cking the whole file system and making any necessary corrections This problem can arise when there has been a power cut while the Printer was switched On or if there is a physical problem with the Hard Disk Drive Checking the whole file system normally takes about half an hour but could take much longer There is nothing that can be done to speed up the file checking process If you turn Off the Printer during the checking process the file system check will restart whenever you turn it On again If you experience this problem repeatedly when there has been no power cut then this could mean that the Hard Disk Drive is faulty In this case replace the Hard Disk Drive gt Page 8 11 If the printer s start up process stops when the front panel is displaying any number between 1 to 30 then 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 W f the Printer continues to stop during the power up process replace the Hard Disk Drive gt Page 8 111 3 invent Using the Power Switch LEDs to Troubleshoot In certain circumstances the LEDs located on top of the power switch located at the rear of the Printer can help to troubleshoot the Printer The LEDs can either be ON or Off and using different combinations can indicate different problems Make sure you look directly at the LEDs i i the Left and not at an angle
106. ct the correct Print Quality setting see the table on page 6 3 Dark Light Zone Banding actions We strongly recommend using HP media Select the correct Print Quality setting see the table on page 6 3 the problem persists Heavyweight Coated paper should be used Perform a Printhead Recovery if there is a significant amount of nozzles out in Part 3 of the Image Quality Diagnostic Print Perform a Printhead Alignment Ifthe problem persists perform a Paper Advance Calibration If the problem persists replace the Printhead that is showing misdirected nozzles invent Print Quality invent Reference Images for Banding Flowcharts mn Lu HP Designjet 4000 4020 Printer Series Service Manual 6 19 Dark Light Zone Banding DLZB Description of problem Shown below is an example of what you might see if you have this problem is often easier to see the issue at a distance of 50cm than at 10cm Corrective Action 1 Using the Image Quality Diagnostic Print check if there is a significant amount of nozzles out If there is a significant amount of nozzles out refer to image 1 on Page 6 19 then recover the Printheads Ink Menu Printheads Recover Printheads and reprint the image 2 Ifthe problem persists align the Printheads Ink Menu Printheads Align Printheads and reprint the image 3 If the problem persists perform the Paper Advance Calibration Paper Menu Paper Advan
107. d Status Messages While Printing Detailed below are the printhead status messages that may be displayed while printing OK The printhead is operating correctly and will provide an acceptable level of print quality To find more information on the printheads refer to Page 3 7 Obtaining Printhead Information Replace The Printhead is faulty and needs to be replaced before the printer can continue printing If this message continues to appear for example after installing new Printheads try the following 1 Reseat the Printheads and check if the message disappears 2 Remove the Drop Detector and make sure that there are no obstacles inside which are blocking the sensor 3 Print the Diagnostic Print Page 6 6 Check that the Printhead nozzles are firing correctly 4 Perform the Service Station Calibration gt Page 5 8 5 Replace ALL the Printheads Printhead Status Messages While Replacing The following are the Printhead status messages that may be displayed while replacing the Printheads Reseat In this situation select the Printhead replacement option through the Front Panel but do NOT remove the Printheads If this status message continues to appear then remove the Printheads and install them again Remove The Printhead is not a suitable type for use in printing for example a Setup Printhead Missing No Printhead has been detected in that Carriage stall If a Printhead is installed in the Carriage stall when this statu
108. de Holder from the rear of the Printer 2 Using a small flat blade screwdriver unclip the Front Panel Bezel from the Right Cover 3 Remove the Front Panel Bezel from the Right Cover invent 4 Remove two T 15 screws Type G that secure the Front Panel to the Right Cover 5 Open the Printhead Cleaner Door 6 Remove one T 15 screw Type J that secures the Right Cover Removal ard tslaron 7 Open the Window and remove two 15 screws Type J that secure the Right Cover 8 Remove one T 15 screw Type J and one T 20 screw Type A that secure the Right Cover from the rear of the Printer 9 Remove the Right Cover from the Printer ra Left Cover Removal 1 Open the Ink Cartridge Door 2 Remove the Ink Cartridges from the Printer 3 Remove one T 15 screw Type J that secures the Left Cover 4 Open the Window and remove two T 15 Type J screws that secure the Left Cover 5 Remove one T 15 screw Type J and one T 20 screw Type that secure the Left Cover 6 Remove the Left Cover from the Printer Removal and Installation Top Cover Removal Switch off the product and remove the power cable 1 Remove the Right Cover Page 8 2 Remove the Left Cover Page 8 9 3 Release the three clips securing the Ink Supply Tubes and the Trailing Cable to the Top Cover
109. dge replacement while printing 1 7 34 Rice Paper not supported 1 7 Cut Sheet rice paper loading failure 1 7 Worm marks on HP Coated media with light area fills 1 7 Solving Media Handling Problems 1 8 Using the Buzzer at Power up to Troubleshoot 1 9 Using the Power up Sequence to Troubleshoot 1 11 Using the Power Switch LEDs to Troubleshoot 1 14 Using the PCA LEDs to Troubleshoot 1 15 How to Interpret the Service Information Pages 1 18 Guide to Troubleshooting the Printer Introduction This chapter will guide you through the relevant steps to take when troubleshooting the printer Troubleshooting System Error Codes Chapter 2 System Error Codes contains a list of system error codes and their respective descriptions and recommended corrective actions Only try one recommended action at a time and check if the error code has disappeared If you have an error code which is not documented in this Service Manual or you have an error which you cannot resolve then report the error to the HP Response Center or the nearest HP Support Office When reporting the error have the following information ready Model and Serial Number of the printer Which firmware revision the printer is using See Note below Check firmware in Utilities Statistics Code rev B The complete error number See Note below B The Service Configuration Print The Current configuration sheet Which software application the customer is usi
110. ds 4 Disconnect the Flex Cables from the Carriage PCA 8 80 HP Designjet 4000 4020 Printer Series Service Manual mora tation 5 Remove eight T 8 screws Type L that secure the Carriage Flex Cables to the Carriage Assembly 6 Open the Carriage Cover and remove ALL the Printheads from the Carriage Assembly 7 Remove the Carriage Flex Cable from the Printer invent Carriage Assembly Removal Remove the Right Cover Page 8 6 Remove the Left Cover Page 8 9 Remove the Encoder Strip Page 8 72 honc Move the Carriage Assembly to the extreme right of the Printer Ul Press the two side of the Carriage PCA Cover and unclip from the Carriage Assembly 6 Disconnect the Trailing Cable from the Carriage PCA CD 7 Open the Carriage Cover and remove ALL the Printheads from the Carriage Assembly 8 Remove five T 15 screws G that secure the Ink Supply Tubes to the Carriage Assembly 9 Remove the Ink Supply Tubes from the Carriage Assembly and safely place to one side of the Printer Removal ard tslaron 10 Disconnect the Aerosol Fan Tube from the Chassis 11 Remove one T 15 screw Type A that secures the Belt Tensioner to the Chassis 12 Move the Carriage Assembly slightly away from the right Scan Axis Bracket CD 13 Release the Carriage Belt the Scan Axis Motor on the left hand side of th
111. ds amp Paper Advance Test This test is designed to check whether the Printheads and the Paper Advance Mechanism are working correctly This part of the Image Quality Test should not be used to check for color consistency or accuracy Banding If the Printer is experiencing a banding problem you will see repetitive horizontal bands within the printed image Banding can appear as follows E E d Light Bands Dark Bands z Gradual Wave Effect Troubleshooting Banding Problems It banding does not occur in ALL the colors then it is more than likely a Printhead problem In this case try the following 1 Check that the appropriate print quality settings are being used Refer to Page 6 3 for further information on choosing the correct Print Quality settings 2 Recover the printheads using the option through the Front Panel Ink Menu Printheads Recover Printheads Reprint the Diagnostic Print or the print file and if the problem persists As there are two Printheads for each color check exactly which Printhead is causing the problem Page 6 9 B If the problem continues replace the faulty Printhead It banding does occur in ALL the colors then it is more than likely a Paper Advance problem E If the bands are light it means that the paper has advanced too much B If the bands are dark it means that the paper hasn t advanced enough B n high quality modes graininess in ALL col
112. e Printer 14 Remove four T 20 screws Type that secure the right Scan Axis Bracket 15 Remove the right Scan Axis Bracket from the Printer invent 16 Remove the Carriage Stopper Screw 25 from the Chassis 17 Remove the Carriage Stopper from the Printer 18 Slide the Carriage Assembly including the belt to the right and out of the Printer 19 If the Carriage Assembly is to be replaced make sure that you remove the Belt the Carriage PCA Encoder and Line Sensors and the Cutter Assembly in order to install them on the new Carriage Assembly E Reset life counter Carriage ME Chapter 4 Scan Axis Calibration gt Chapter 5 E Service Station Calibration gt Chapter 5 E Line Sensor Calibration gt Chapter 5 Belt Assembly Removal Remove the Right Cover Page 8 6 Remove the Left Cover Page 8 9 Remove the Top Cover Page 8 11 Remove the Encoder Strip Page 8 72 Remove the Carriage Assembly Page 8 82 m Release the Belt from the bottom of the Carriage Assembly E Reset life counter scan cycles belt gt Chapter 4 Scan Axis Motor Removal 1 Remove the Right Cover Page 8 6 2 Remove the Left Cover Page 8 9 3 Remove the Rear Door gt Page 8 16 4 Remove the Left Connector Cover Page 8 19 5 Remove one T 15 screw that secures the Belt
113. e 23 10 For more information on troubleshooting this error code refer to Page 2 8 7 Ifyou select Yes the following message will appear on the Front Panel Check if the Ink Supply Tubes from the ISS to the Carriage contain visible air Select Yes or No by using the Up and Down keys and press Enter to confirm your selection Press Enter to confirm selection Bag Broken Recovery Do Tubes from Iss to Carriage contain visible air Use UP and DOWN keys to select Press UP DOWN to change an ENTER to select If you select Yes the Front Panel will disolay System Error Code 24 10 For more information on troubleshooting this error code refer to Page 2 9 8 Ifyou select No the following message will appear on the Front Panel You can now remove the Broken Bag condition causing the initial problem Select Yes or No by using the Up and Down keys and press Enter to confirm your selection Use UP and Gy f H DOWN keys to select Press Enter to confirm selection a Bag Broken Recovery Boo you want to remove the broken bag condition n 9 f you select Yes the following messages will appear on the Front Panel Start Supplies Conf If there is a problem at this stage the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3
114. e Sensor position to Black Printhead It will print a line of black dots and then scan them 7 Once the Line Sensor has been calibrated the results will be displayed on the Front Panel Press Enter to finish the calibration or press Back or Cancel to exit the calibration Y Offset Range 38 to 59 Y Offset got 43 Offset Range z4 to 24 Dffset got 14 SWS Offset 1 5 to 1058 SVS Offset got 944 Press any Key to continue 8 The Printer will now perform the Printhead Alignment When the following message appears on the front panel you must select whether you would like to continue with the calibration by pressing the Enter key Press Back or Cancel to exit the calibration Press Cancel Or the l o Scan Axis Calibration 9 4 1 to Exit F e Ww to proceed Pen Alignment calibration BACK CAMCEL to exit Press Enter 17 NX Press EMTER tn proceed with 9 Before continuing with the Printhead Alignment the following message will be displayed on the Front Panel To continue with the Printhead Alignment select Align now and press the Enter key Press Enter to confirm selection Aligning printheads now means that the printer may use up to 3m af the roll Use UP and O align now DOWN keys OaAutomatically align O continue without aligning to select
115. e Setup Printheads are used for the priming of the tubes in the modular ink delivery system The customer must not remove the Setup Printheads from the Carriage without following the procedures in the Setup Guide When the Printer is powered ON for the first time the Printer will automatically perform the priming process Without the priming process the customer will NOT be able to use the Printer Why does the Printer require priming The Tubes System is empty when the customer receives the Printer The Tubes System has to be pressurized and filled with ink ejecting any air bubbles When Should You Replace the Ink Supplies When to change the ink supplies is mostly determined by you with guidance from the front panel In conjunction with the messages displayed in the front panel and the message explanations in this chapter you will be able to choose for yourself when is the right time to change the ink supplies The Printer will also display the ink level and will tell you when the ink supply is low on ink This means you have constantly updated information about the ink supplies Printhead life is anticipated to be 1000ml or twelve months in the printer whichever occurs first provided that the printhead is used under normal operating conditions using HP Ink Cartridges only and its install before date has not lapsed However results vary depending on the print quality setting being used invent Obtaining I
116. e customer then reprint it using the Best print quality setting Lines are Blurred Ink Bleeds from Lines Description of problem This problem is often caused by the ink soaking into the paper making the lines blurred and fuzzy This could be because of the humidity in the air Corrective Action 1 Print in a less humid environment 2 using a heavier paper type such as HP Heavyweight Coated Paper Glossy Photo Paper types are especially difficult to dry Take extra care with them 3 Make sure that the paper type selected in the Front Panel is the same as the paper type loaded into the Printer 4 Increase the drying time through the Front Panel Ink Menu Drying Options Drying Time 5 Allow the prints time to dry separately do NOT cover or stack them Problems with Color Accuracy There are two basic requirements for color accuracy 1 Ensure that the paper type being used has been color calibrated which will give color consistency from print to print and from Printer to Printer 2 Select suitable options in the application refer to the User s Guide for more information If PostScript is not being used remember that the printer may be configured to use one of its internal pen palettes instead of the software s palette which is the default Color accuracy using EPS or PDF images in page layout applications Page layout applications such as Adobe InDesign and QuarkXPress do not support color
117. e following message is displayed on the Front Panel Press any key to continue Sensors Test of Paper sensor PASS Press any key to continue If the Media Lever Sensor fails the test the Front Panel will display System Error Code 53 10 For more information on troubleshooting this error code refer to Page 2 16 Check also System Error Code 07 10 refer to Page 2 6 CA If there is a failure reading the GPIO channel the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 Check also System Error Code 07 10 refer Page 2 6 13 Once the test is completed OK will be displayed on the Front Panel Sensors eu our ort 1 invent 6 Ink Delivery System Test The purpose of this test is to verify the operation of the Ink Delivery System Perform the Ink Delivery System test as follows In the Diagnostics Tests submenu scroll to 6 Ink Delivery System Test and press Enter Scan Axis test Media Drive test Electronics module test Carriage assembly test Sensors test Ink Delivery system tes Co T co 2 This test has not yet been implemented ii Ford ies NS 7 SVS Aerosol Fan Test The purpose of this test is to verify the operation of the Service Station and the Aerosol Fan Perform SVS Aerosol Fan tes
118. e latest Firmware version not update the Firmware to the latest version 2 Try rotating the print by 90 180 or 270 degrees 3 Since this problem is only seen when printing thin lines try to avoid printing thin lines whenever possible 4 To decrease the probability of having the Inter Swath Decap issue a black frame around the print should be added 5 Switch to the Best print quality setting and turn Off the Maximum Detail option in the Driver Paper Expansion Paper Advance Description of problem When printing high density area fills on a paper based media the media will expand As the media expands it can create bandings between each swath The banding is mainly noticeable when printing high density area fills while using the Fast print quality setting and with the optimized for drawings text setting activated As the quantity of ink is higher in this area the paper expands more and can cause dark banding As the quantity of ink is lower in this area the paper does not expand more WE and some white banding can appear Corrective Action If the image has been printed using the Fast print quality setting then reprint it using the Normal or Best print quality setting and activate the optimized for images option Try using a heavier paper type such as HP Heavyweight Coated Paper or HP Productivity Gloss Check that the environmental conditions temperature humidity are
119. e obstacles restricting the movement of the Drive Roller If there is a wrinkled mass of media inside the paper path lift the Pinchwheels using the Media Lever and clear the obstruction E Perform the Media Drive Diagnostic Page 4 12 to further troubleshoot the error code f the System Error continues replace the Media Axis Motor Page 8 91 85 03 Problem finding the Drive Roller zero Try the following E Perform the Media Drive Diagnostic Page 4 12 to further troubleshoot the error code 86 01 Carriage servo shutdown Try the following Open the Window and check for any visible obstacles restricting the movement of the Carriage Assembly If there is a wrinkled mass of media inside the paper path lift the Pinchwheels using the Media Lever and clear the obstruction Check that the Carriage Stopper is correctly installed Refer to Carriage Disassembly Instructions Page 8 82 Step 16 B Perform the Scan Axis Diagnostic Page 4 7 to further troubleshoot the error code f the System Error continues replace Scan Axis Motor Page 8 88 86 03 Scan Axis length test failure Try the following E Perform the Scan Axis Diagnostic Page 4 7 to further troubleshoot the error code System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action
120. e the sleep mode so ev that the Printer is never switched Off automatically if not used for a certain period of time one hour by default Perform the Sleep Mode utility as follows 1 In the Service Utilities submenu scroll to Sleep Mode and press Enter Press Enter Reset Life counters Diagnostic Print 2 When the following message appears on the front panel use the Up and Down arrow keys to either disable or enable the sleep mode Press the Press Enter or Cancel to confirm Enter or Cancel key to confirm the selection 2 Sleep mode Tm Enable sleep mode 3 _ C J Use UP and DOWN keys to enable or disable the sleep mode ENABLE 53 Use UP DOWN Keys for selection and EMTER CANCEL for confirmation If the current sleep mode cannot be read it could point to a possible Firmware error Once the selection is confirmed the Front Panel will display the new sleep mode state New Sleep mode state ENABLE If the current sleep mode cannot be set it could point to a possible Firmware error 4 If the utility exits correctly OK will be displayed on the Front Panel invent or 7 Replace Cutter We 5 The purpose of this Service Utility is to move the Carriage to a position where the Cutter can be replaced easily Perform the Replace Cutter utility as follows 1 In the Se
121. e the spring on the top hook 4 Stretch the spring and loop the spring on the bottom hook 5 Check that the Spindle Lever is installed correctly as shown here Preventive Maintenance Moisture on the Printer 9 2 Noisy Carriage Bushing 9 2 Belt Swelling 9 2 Cleaning the Printer 9 2 General Cleaning 9 2 Cleaning the Drive Roller and Overdrive 9 3 Cleaning the Center Platen 9 3 Applying Oil to the Overdrive 9 5 Lubricating the Carriage Assembly 9 5 Scheduled Maintenance 9 6 Level of Printer Usage 9 6 HP Designjet 4000 4020 Printer Series Service Manual 9 1 invent Preventive Maintenance Moisture on the Printer Users should use the Printer in an environment between 20 and 80 relative humidity To recover from moisture condensation turn the Printer Off and using the main roller as a reference wait until the Printer is completely dry before using it again Noisy Carriage Bushing To prevent noisy movement of the carriage remove aluminum or dust particles from the bushing at the back of the carriage and from the slider path along which the bushing moves Belt Swelling To prevent new belts from swelling incorrectly keep them in their bags with dissicant until you need to install them Cleaning the Printer To maintain the Printer in good operating condition keep it free of dust accumulation ink and other contamination Cleaning intervals are determined by the Printer environ
122. ead hp no 90 is recommended The product number of the Printhead The serial number of the Printhead The current status of the printhead How much ink has been fired consumed by the printhead Note It is possible for a printhead to consume more than one Ink Cartridge The current status of the Printhead Cleaner The current warranty status of the Printhead Status Bars OK Low Very Low Empty Missing Reseat Replace Unknown Ink Supplies Troubleshooting Ink Cartridge Status Messages The front panel displays four horizontal bars These bars represent how much ink is remaining in the Ink Cartridges as ink is used up the bars get shorter in length To see how much ink is remaining go to the Ink Cartridge Information submenu See Page 3 6 Obtaining Ink Cartridge Information Ink Cartridge Status While Printing The Ink Cartridge is operating correctly and no action is required The Low message is an early warning sign and it is advisable that new supplies should be obtained of that particular color The amount of ink remaining in the Ink Cartridge depends on it s capacity but there is approximately 14 of ink available for the user When the Very Low message is displayed overnight printing should not be attempted Changing the Ink Cartridge is strongly recommended to prevent the printer from stopping halfway through a print There is approximately 8 of ink available for the use
123. ead health values within the service print current information 2 Look at the nozzle patterns on part 3 of the user s image quality plot If the health of a printhead is low five for example and there are no specific nozzle defects from part 3 of the image quality print this may point to a false drop detection Running this tool will force a drop detection The root causes of this issue may come from an incorrect detection of failed nozzles by the drop detector In order to fix this it may have to be run up to four times if it is still failing the drop detector may be faulty or incorrectly calibrated Some things to check that can improve image quality If all the test patterns from the Diagnostic Print are correct and you still experience Image Quality problems here are some of the more likely causes to check The print mode used in your printer is not right for the image you are printing this is defined by the printer s front panel menu selections E Make sure that the paper type selected in the Front Panel is the same as the paper type loaded into the Printer B Non HP driver B The RIP If you are using one The software applications you are using Print Quality General Advice 1 To achieve the best performance from the printer only genuine HP accessories and supplies should be used 2 Make sure that the paper type selected in the Front Panel is the same as the paper type loaded into the P
124. ective Action 1 If an image is to be printed that has high density area fills advance the media so that the problem is greatly reduced 2 Reprint the image the problem will be reduced VLS 1 Pass Printmodes Description of problem In certain circumstances the lines are not straight when using 1 pass printmodes There are several factors that explain why vertical line straightness VLS in 1 pass printmodes are above acceptability threshold Printhead Alignment residual error Printing on paper type different from the one used to perform the Printhead Alignment Some level of theta Z coming from the stabilization area after a media load approximately 3 meters of paper Shown below is an example of what you might see if you have this problem Check that the appropriate print quality settings are being used Refer to Page 6 3 for further information on choosing the correct Print Quality settings Corrective Action Roll paper usually gives better vertical lines than a single sheet of the same type of paper If sheet paper must be used then it is recommended to use the Best print quality setting Try using a heavier paper type such as HP Heavyweight Coated Paper or HP Productivity Gloss Align the Printheads Ink Menu Printheads Align Printheads Print Quality VLS in First 3 Meters after a Media Load Description of problem In order to ensure that the user can load the media in
125. ecure Sanitizing Erase meets the US Department of Defense 5220 22 m requirements for clearing and sanitization of the hard disk Press the Enter key to confirm the level of sanitization or the Cancel key to exit the utility without making any changes or the Back key to modify again Time taken to finish security delete The amount of time taken to finish the erase disc procedure will depend on the level of file deletion selected In the case of the HP Designjet 4520 the erase disc procedure can also be selected from the WebJetAdmin which takes slightly longer The table below shows the time taken to finsh the procedure for the two security levels and from the Front Panel or WebJetAdmin DJ4020 only HP Designjet 4500 HP Designjet 4020 40GB HDD 160GB HDD Front Panel Front Panel Webjet Admin Secure Sanitize Level Mode lt 1 pass gi pass Mode Press Enter to confirm ei Fad ies or 13 Disk Wipe ont ov The purpose of this Service Utility is to erase the hard disk according to the ert directive DoD 5220 22 M The printer s hard disk is used as a temporary storage area for print jobs The Disk Wipe utility can erase the information from the hard disk to prevent unauthorized access Perform the Disk Wipe utility as follows 1 In the Service Utilities submenu scroll to Disk Wipe and press Enter Set RTC clock
126. eems to be wrong Description Corrective Action Try the following Check that the Carriage Stopper is correctly installed Refer to Carriage Disassembly Instructions Page 8 82 Step 16 E Replace the Carriage Assembly Page 8 82 f the System Error continues replace the Encoder Strip and Encoder Sensor Page 8 72 System Error 02 1 10 Problem Problem with the Carriage PCA Description 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 Check that the Trailing Cable is not damaged Check that the Trailing Cable is correctly connected to the Carriage PCA Interconnect PCA and to the Gamut PCI PCA Replace the Carriage PCA Page 8 75 If the System Error continues replace the PCI PCA gt Page 8 98 System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action 03 10 Problem with the Power Supply Unit Try the following B Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer Perform the Electronics Modules Test Page 4 17 to troubleshoot the problem further f the System Error continues replace the Power Supply Unit Page 8 113 05
127. el CM766A For information about using these printers refer to the corresponding User and Quick Reference Guides Readership The procedures described in this Service Manual are to be performed by HP Certified service personnel only Part Numbers Part Numbers for Printer options accessories and service parts are located in Chapter 7 Conventions A small arrow is used to indicate other parts of the Service Manual where you can find information related to the topic you are consulting Table of Contents Troubleshooting 1 1 System Error Codes 2 1 Ink Supplies Troubleshooting 3 1 Service Tests and Utilities 4 1 Service Calibrations 5 1 Print Quality 6 1 Parts and Diagrams 7 1 Removal and Installation 8 1 Preventive Maintenance 9 1 Troubleshooting HP Designjet 4000 4020 Printer Series Service Manual Introduction 1 2 Troubleshooting System Error Codes 1 2 Performing a Service Test on a Failed Assembly 1 2 Performing the Necessary Service Calibrations 1 3 Solving Print Quality Problems 1 3 The Printer does not Power ON 1 3 The Printer Continuously Rejects Printheads 1 3 Cover Sensors are not Working 1 3 The Line Sensor has Problems Detecting Media 1 4 Troubleshooting Shutdowns 1 5 Vacuum suction much lower at high altitudes 1 6 Banding at variable extreme environmental conditions 1 6 Printhead Crashes Smears on High Density Prints Using Coated Media 1 6 Banding due to Ink Cartri
128. emory Management eerie Firmware Motor Control Functions 75 Frenne Meiionanes 7 ENGNEEEAE 1 1 __ m O Media Cor 8 SmgeShedFedhng 84 Feeding 85 Medians Encoder Reading 86 8 Encoder Reading Component Systom 96 nage Qualiy Toubleshooting 38 Automatic Backup Printmode Enabled The following table explains the YZ part of the System Error Code or Warning 00 epe Reseat Reconnect Clean Adjust manually Possible for Calibrate Adjust using Automatic Process Power OFF and Restart the Printer perform Upgrade System Firmware action Upgrade Driver or Computer Software 06 Add Accessory 08 Send Plot Again 09 Wrong Part Installed Replace 11 Reseat Reconnect Clean Adjust manually m p qualifie evird inveni Ink Supplies Troubleshooting What are Ink Supplies 3 2 Ink Cartridges 3 2 Printheads 3 3 Printhead Cleaners 3 3 General Information About the Ink Supplies 3 4 General Precautions When Handling Ink Supplies 3 4 Priming the Ink System 3 5 When Should You Replace the Ink Supplies 3 5 Obtaining Ink Cartridge Information 3 6 Obtaining Printhead Information 3 7 Ink Cartridge Status Messages 3 9 Ink Cartridge Status While Printing 3 9 Ink Cartridge Status While Replacing 3 9 Printhead Status Messages While P
129. er to proceed Press ENTER to proceed or BACK CANMCEL to exit 6 The Printer will get information on the I O Interfaces Once the information has been read the following message will be displayed on the Front Panel Press any key to continue with the test Interface select AUTO Active interface FAST ETH Active int installed YES Active int state UP Press any key to continue This screens shows which interface is currently installed and active If a connection is made to the active interface the Active int MAC state will be displayed as UP otherwise it will displayed as DOWN 7 Ifan active interface is installed the Printer will test the active interface and if it passes it will display the following message on the Front Panel I H test for FAST ETH interface has passed 8 Once the process is completed OK will be displayed on the Front Panel ii Far ies o 15 Log Management ont 5 Log files are files which capture specific information about the status of the ev printer as it processes a job these files can later be used to help troubleshoot system errors for example the 79 04 system error Its designed so that you can see what the printer s process was leading up to the system error To Enable logs perform the following procedure 1 Once the message Ready is displayed on the front panel scroll to the Printer Setup Options icon and press the Enter key
130. er path lift the Pinch wheels using the Media Load Handles and clear the obstruction 2 If this shutdown happens at the end of a Roll of Media it could be because the media is stuck firmly to the Roll Lift the Pinch wheels using the Media load Handles and pull the media clear 3 Replace media spindle if broken 4 Replace the Media Axis Motor Page 8 91 Printhead Path When a shutdown occurs in the Printhead path you will get the message Switch Power Off Check Printhead Path The will be a number which will give an indication on where the failure occurred PWM Shutdown 1 and Energy Shutdown 3 1 Clean Slider Rods and Apply along the complete axis of the Slider Rods After applying the Oil perform the Scan Axis Test gt Page 4 7 and check that the values are within the given limits 2 Replace the Scan Axis Motor Page 8 88 Velocity Shutdown 2 1 Open the Window and check for any visible obstacles restricting the movement of the Carriage Assembly Try and move the Carriage Assembly manually checking for smooth and free movement 2 Check that the Encoder Strip is clean If necessary clean Encoder Strip using a damp cloth UJ invent Vacuum suction much lower at high altitudes At altitudes above 3 000 meters the vacuum force holding down the media will be lower therefore the media will not be held in place properly causing B Ink Smearing on the Media Printhead crash
131. es against the Media Cut Sheet loading problems high probability Roll Media loading problems low probability PRINTER LIMITATION NO SOLUTION AVAILABLE Banding at variable extreme environmental conditions Since the Accuracy Calibration has been done at normal environmental conditions printing in extreme environmental conditions will cause banding because the advance of the Drive Roller does not correspond to the same conditions that the calibration was done in To solve the problem try the following Perform the Accuracy Calibration in the new environmental conditions Refer to the User s Guide Printhead Crashes Smears on High Density Prints Using Coated Media High density prints can cause cockle mainly on HP Coated Media This causes two main problems Cockling in the borders Because the printer places too much ink on the Coated Media the borders of the print become raised causing the Printhead to crash against the media To solve the problem try the following B Change the paper margins to 15mm either in the Front Panel or in the Driver If the customer is printing PostScript images send them a PPD file containing the extended margins of 15mm Cockling within the print If the Printer places too much ink within the print the media starts to ripple causing the Printhead to smear against the media To solve the problem try the following Check in the Front Panel if Ink Limiting is ON or OFF If Ink
132. ete Carriage Assembly Page 8 82 Ink Supply Tubes and Trailing Cable Page 8 33 Scan Axis Motor Page 8 88 Belt Assembly Page 8 87 Most Left Spittoons Page 8 70 Middle Left Spittoons Page 8 71 Scraper located on the Service Station You must also clean the holes in the Service Station which are located under the Black Printhead Cleaners About this Edition This is the 4th edition of this Service Manual March 2009 models Q1273A Q1274A CM765A CM766A Ist edition HP Designjet 4000 Printers Series Service Manual models Q1273A Q 12744 December 2004 2nd edition HP Designjet 4000 Printers Series Service Manual models Q1273A Q 12744 April 2005 3rd edition HP Designjet 4000 Printers Series Service Manual models Q1273A Q 12744 November 2005
133. ey to continue A minimum of 256 megabytes of memory must be installed in the Printer If not the Front Panel will display System Error Code 05 3 10 For more information on troubleshooting this error code refer to Page 2 5 7 A message will appear on the Front Panel asking whether you would like to check the Printer Configuration Select Yes or No by using the Up and Down keys and press Enter to confirm your selection If you select No the printer skips this test and goes to the next one Press Enter to confirm selection Electronics Module Wo vou want to check the Printer Configuration Use UP and DOWN keys lo select YES Press UP DOWN to change an ENTER tn select CA sessctiod is 8 Ifyou select Yes the Printer will start the CDS and the following information will be displayed on the Front Panel Starting CDS If there is a failure at this point the Front Panel will display System Error Code 79 03 For more information on troubleshooting this error code refer to Page 2 21 9 The printer will then check the Serial Number and Part Number and display the information on the Front Panel Press any key to continue the test Electronics Module serial Number SG460351 9801 Press any Key to continue IF the Serial Number or the Part Number cannot be read the Front Panel will display System Error Code 74 00 For more information on troubleshooting this e
134. failure at this point the Front Panel will display System Error Code 74 00 For more information on troubleshooting this error code refer Page 220 4 Once the Unit information is obtained it is displayed on the Front Panel Press any key to exit invent FW version GW 3 1 1 2 Serial Number 564831981 Part Number 1 2744 PS Language Roman Press any key to finish 5 Once the process is completed OK will be displayed on the Front Panel owt 1 10 4 Others gt gt gt Check Ink Supplies The purpose of this test is to verify which Ink Cartridges are valid for the purge process and what is their current available ink level Some Ink Cartridges may not be able to be accessed unable to read the Acumen if previously there had been a failure faulty broken bag etc View the Unit Information as follows In the Diagnostics Tests submenu scroll to 10 Others and press Enter Sensors test Ink Delivery system test EE S S Aerosol FAM test Air Pump System test Vacuum FANS test EN GO om on Others io Bag Broken Recovery 18 2 ID Information 18 3 unit Information ME18 4 Check Ink Supplies 3 The Printer will start to initialize and the Front Panel will display the following messages B Starting Gamut If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this e
135. fer to the relevant Vendor s User Documentation for further information Print is a Mirror Image of the Original It the output that was expected is a mirror image of the original image then try the following to resolve the problem Check the mirror option through the Front Panel Setup Menu Printing Detaults Menu Paper Options Mirror to make sure the rotate option has not been selected Check also the following options to see if the mirror option has been activated by mistake B Windows Driver Finishing tab Mirror Image B Mac OS Driver Finishing panel Mirror Image B Embedded Web Server Select Submit Job Mirror One Image Overlaps Another on the Same Sheet If the output that was expected contains an image that overlaps another on the same sheet then try the following to resolve the problem The Timeout setting may be too long Decrease the I O timeout setting Setup Menu I O Setup IO Timeout and then send the file again No Output from the Printer If a file is sent to the Printer but no output is printed then try the following to resolve the problem 1 Check that the power cable is correctly connected and that the Printer is switched On Check that all communication cables are correctly connected 2 Strong Electromagnetic fields or electrical disturbances may be affecting the Printer In this case power Off the Printer and wait until the electromagnetic environment has returned to normal
136. fernt types of APS assembly To know which one to install you must first check the serial number of the printer you are working on If the printer you are working on has one of the following serial numbers E before SG6A9H900 Z go to step 1 on this page If the printer you are working on has one of the following serial numbers E SG6A9H900Z cr alter proceed to Page 8 67 1 Remove the Left Cover Page 8 9 2 Remove the Left Connector Cover Page 8 19 3 Remove the ISS gt Page 8 60 4 Release the Air Tube from the slot in the Ink Supply Station CA 5 Unclip the APS Assembly Bracket from the Ink Supply Station 6 Remove the APS Assembly Bracket from the Ink Supply Station Installation for printers with the serials numbers before SG6A9H900Z and SG6ABH9014 The tubes are setup to be installed on newer printers Before attempting to install the APS Assembly you will need to change this setup to be compatible with the older type of printer 1 Remove the APS and Valve from the metal bracket wexsodeuan 2 Remove the tube from the Valve and the Tube Connector 3 Connect the small tube that comes with this kit to the Valve and the Tube Connector 4 Remove the short tube without the blue connector the Tube Connector feedadvslaion 5 Connect the long tube with the blue connector to the Tube Connector 6 Install the APS and the Valve into t
137. from 3 latches located underneath 3 Remove the Top Crane Cover 4 Remove the Trailing Cable and Carriage Power Cable from the groove in the Top Crane Installation of the new Trailing Cable 1 Mark on the Trailing Cable 42 about 65mm from the neck of the connectors using a marker pen 2 Install the new Trailing Cable into the Top Crane invent 3 Align the marking of the Trailing Cable with the screw area as indicated by the two arrows 4 Install the Carriage Power Cable into the Top Crane 5 Ensure the Power Cable and the Trailing Cable are at the same length CA Installing the Trailing Cable into the old type of Top Crane Cover 6 Install the securing Cable Bracket in place 7 Install one T 15 screw into the Cable Bracket and secure the cables Go to step10 Installing the trailing cable into the new type of Top Crane Cover 8 Install the Top Crane Cover invent m 9 Secure the cables with one T15 screw 10 Insert the Trailing Cable and Power Cable into the first Cable Holder 11 Insert the Cable Holder through the two slots of the new Ink Tube Carrier 12 Insert the Trailing Cable into all the Cable Holders and insert all the Cable Holders into the slots of the Ink Tube Carrier 13 Install the Ink Supply Tubes Trailing Cable and Carriage Power Supply Cable into the Printer The rest
138. gt Image quality user plot Use UP and me Image quality service plat Wr others DOWN keys to select 3 Make sure media is loaded the Pinch Lever is lowered and that the Ink System is correctly installed Press the Enter key to print the Diagnostic Print or press Back Cancel to exit without printing the Diagnostic Print Press Cancel or the check that media is loaded E Back key pinch lever is closed and Press Enter ink is ready to Exit to print Proceed 7 Press ENTER to accept or BACK CANCEL to exit 4 The selected Diagnostic Print will now be printed o m Diagnostic Part 1 Alignment Test This test is designed to check any color to color and bi directional misalignment the printer may have 4I S AG 1 If the Printer is experiencing horizontal misalignment problems Alignment Test will show something like this 2 Ifthe Printer is experiencing vertical misalignment problems the Alignment Test will show something like this UJ invent 3 If the Printer is experiencing bi directional misalignment problems the Alignment Test will show something like this Perform a Printhead Alignment using the same paper type with which you were experiencing unacceptable image quality if feasible some paper types are not suitable for Printhead Alignment Corrective Action Diagnostic Part 2 Printhea
139. he bracket that comes with this kit 7 Install the APS Assembly onto the underside of the Ink Supply Station invent 8 Install the tube with the blue connector into the slot in the Ink Supply Station 9 Connect the tube with the blue connector to the Ink Supply Tubes Be caretull not to cut your hand on any sharp surfaces Install the ISS Page 8 60 Tl Install the Left Connector Cover Page 8 19 12 Install the Left Cover Page 8 9 CA Removal for printers with the serial numbers SG6A9H900Z and SG6ABH9014 and onwards 1 Remove the Left Cover Refer to Service Manual 2 Remove the Left Connector Cover Refer to Service Manual 3 Remove the ISS Refer to Service Manual 4 Remove the screw that secures the APS Assembly to the Side Plate E 25 07 11 35 5 Remove the APS Assembly L 25 07 11 35 Removal ard tslaron Installation for printers with the serial numbers SG6A9H900Z and SG6ABH9014 and onwards The installation procedure is the same as the removal in reverse on this type of printer Included below are the most important steps of the installtion procedure for the new style APS 1 The APS Assembly that comes with this kit is already setup to be installed on printers with serial number SG6A9H900Z and SG6ABH9014 and after You will not need to change this setup to install it on printers with this range of
140. he Front Panel cable is not damaged 5 Replace the Power Supply Unit Page 8 113 The Printer Continuously Rejects Printheads 1 Clean the flex contacts on the Printhead and in the Carriage Assembly using the Carriage Interconnect Wiper Refer to Chapter 3 and try again 2 If ALL the Printheads are rejected the status message on the Front Panel does NOT show OK for ALL the Printheads then perform the Electronic Systems Test gt Page 4 17 Cover Sensors are not Working 1 Perform the Sensors Test gt Page 4 28 2 Check if the cable for the faulty sensor is not damaged and is connected correctly 3 Replace the faulty Sensor O inveni The Line Sensor has Problems Detecting Media Check the type of media that is being used since the Line sensor may have problems detecting transparent media or some types of Non HP media Try loading white HP media in to the Printer and check if the Line sensor detects it Excessive ink deposits on the Platen surface can fool the sensor by reflecting the light Clean the Center Platen The Line Sensor is not calibrated correctly Perform the Line Sensor Calibration Page 5 16 The Line Sensor is damaged or faulty Replace the Line Sensor Page 8 124 Troubleshooting Media Jams Printhead Crashes If using HP Coated Media when problem occurred please also refer to Page 7 6 The failure modes media jam and head crash are grouped together because in many cases a
141. he PANTONE colors Using Automatic PANTONE Calibration the best choice In order to use Automatic PANTONE Calibration an application that recognizes the PANTONE colors and a calibrated PostScript Printer is needed The Automatic PANTONE Calibration facility emulates PANTONE Solid Coated colors only suffix C Other PANTONE colors will be printed using the CMYK values sent by the application Converting PANTONE colors manually If a non PostScript Printer is being used or if an application such as Adobe Photoshop is being used that does not send the name of the PANTONE color to the Printer then the Automatic PANTONE Calibration will not be available Instead if required each PANTONE color has to be manually converted to CMYK values in the application using tables produced especially for the printer and paper type It the application has a facility to convert PANTONE colors to CMYK values automatically it probably does not take into account the type of Printer or paper type so better results will be achieved with a manual conversion using the tables A PANTONE calibrated color chart in EPS TIFF and PDF format can also be obtained which can be convenient if the application being used has an eyedropper tool with which colors can be picked up from an imported graphic Tips Automatic PANTONE Calibration works with PostScript printers only E Ensure that Automatic PANTONE Calibration is turned on in the driver Some appl
142. iage assembly test to select 4 5 Sensors test 6 Ink Delivery system test WWwC Aerncnl l FAM tect ei Fs and ies oor 1 Scan Axis Test The purpose of this test is to diagnose a failure in the operation of components related to the Scan Axis You must perform the Scan Axis Test after System Error Code 86 XX System Error Code 42 XX System Error Code 73 XX m System Error Codes related to Scan Axis shutdown or Carriage jam Perform the Scan Axis test as follows 1 in the Diagnostics Tests submenu scroll to 1 Scan Axis test and press Enter 1 2 Media Drive test 3 Electronics module test 4 Carriage assembly test 5 amp sensors test Ink Delivery system test Ae POA 2 The Printer will start to initialize the Scan Axis system and the Front Panel will display the following information B Starting Gamut Starting Tests PWM Starting Tests E Set GPIO psu lpm If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 Checking voltage If there is a failure at this point the Front Panel will display System Error Code 03 10 For more information on troubleshooting this error code refer to Page 2 5 Check also System Error Code 01 0 10 refer to Page 2 3 id Utilities invent B
143. ications may not support PANTONE colors fully for example Photoshop 7 0 does not send the PANTONE Color with its name it sends only the CMYK values from its standard table Some colors may be out of gamut and impossible to match precisely with your Printer and paper type HP Designjet 4000 4020 Printer Series Service Manual La Print Quality nw 1 Color Matching Between Different HP Designjet Printers It an image is printed on two different Printer models for instance on an HP Designjet 4000 Printer series and an HP Designjet 1000 Printer series you may find that the colors of the two prints do not match well Matching two printing devices that use different ink chemistry paper chemistry and Printheads is unlikely to be completely successful The information provided here is the best way to emulate one Printer with another Even so the end result may not be a perfect match Printing via separate PostScript drivers The situation is that you are printing on each printer using the PostScript driver installed for that printer In this example we are using an HP Designjet 4000 Printer series and an HP Designjet 1000 Printer series 1 Ensure that both printers have been updated with the latest firmware version 2 Ensure that you have the latest printer driver for both printers The latest versions can be downloaded from http www hp com go designjiet 3 Ensure that Color Calibration is turned on Setup Menu Configurat
144. information will be displayed on the Front Panel Prog slow PWM scan Moving carriage middle E Prog fast PWM scan If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 7 The Carriage will be moved to the middle of the Center Platen If there is a failure in moving the Carriage the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 8 The printer will now check that it can read the Encoder Strip When the following message appears on the Front Panel open the Window and press the Up key to move the Carriage to the left and the Down key to move the Carriage to the right Make sure that you move the Carriage in both directions and check that the Carriage actually moves when a key is pressed Use the Up key a to move the axis X m rriage to Checking encoder readings A Y Please Keep nut from platen N nz Left Zone and press UP clef ti DOWN right to Bmove the carriage Use the Down Remaining movements 16 Last movement eu lo move the Carriage to the Left If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 If the Carriage only moves in one direction
145. ing 5 Remove one 1 20 screw that secures the Cam to the Cam Lever 6 Insert a plastic stud in to each Pinchwheel Subassembly the Plastic Studs can be found in the replacement Pinchwheel Assembly kit HP Designjet 4000 4020 Printer Series Service Manual 8 145 invent 7 Remove two 20 screws from each Pinchwheel Subassembly a 90 degree angle screwdriver is included with the replacement Pinchwheel Assembly 8 Remove the complete Pinchwheel Assembly including the Cam and Cam Lever from the Printer CD Removing individual Pinchwheels 1 To remove an individual Pinchwheel push apart the metal part that secures the pinchwheels and then pull out the individual Pinchwheel Removal and Installation inveni Important Information on Installation of Pinchwheels The Pinchwheel Assembly contains 3 white Pinchwheels and several black Pinchwheels The black Pinchwheels are symmetrical so can be installed without any problems BUT the white Pinchwheels are NOT symmetrical so it is VERY IMPORTANT to install them correctly using the following illustration Check the orientation of the Pinchwheel before installing 8 148 HP Designjet 4000 4020 Printer Series Service Manual CA Center Guide Removal 1 Remove the Right Cover Page 8 2 Remove the Left Cover Page 8 9 3 Remove the Right Connector Cover Page 8 18 4 Rem
146. ing 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 Assembly If there is a wrinkled mass of media blocking the Carriage Assembly then clear the obstruction B Replace the Scan Axis Motor Page 8 88 W If the System Error continues replace the PrintMech gt Page 8 119 42 10 Electrical fault in Scan Axis Motor 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 Check that the Scan Axis Motor cable is not damaged and is correctly connected to the PrintMech B Replace the Scan Axis Motor Page 8 88 B If the System Error continues replace the PrintMech PCA Page 8 119 43 10 Vacuum Fan has stopped functioning 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 Check that the Vacuum Fan cables are not damaged and are correctly connected to the Interconnect PCA Also check that the cables between the Interconnect PCA and the PrintMech PCA are not damaged and are correctly connected B Replace the Vacuum Fan Page 8 27 If the System Error continues replace the PrintMech PCA Page 8 119 inven
147. ing the Web Server 71 04 Out of memory failure It is recommended that you remove any unnecessary files from the Hard Disk Drive using the Web Server 71 19 Default Serial Number found in the main and backup NVM It seems that both the Ink Supply Tubes and Hard Disk Drive have been replaced together Try the following Perform the Error 71 19 Recovery Service Utility refer to Chapter 4 System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action invent 72 04 Generic Firmware error 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 Check that the Printer has the latest Firmware version If not update the Firmware to the latest version 73 03 Servo Error Try the following B Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer Check that the Printer has the latest Firmware version If not update the Firmware to the latest version E Perform the Scan Axis Diagnostic gt Page 4 7 to further troubleshoot the error code If the System Error continues perform the Media Drive Diagnostic gt Page 4 12 to f
148. inter After removing any PCA from the Printer place it on a conductive foam pad or into its conductive packaging to prevent ESD damage to any ICs on the PCA CD Required Tools The following tools are required to disassemble and repair the Printer Sz 3 3 Long Torx Screwdriver with i i i i the indicated attachments 110 T20 T15L 1 Small flat blade screwdriver Screw Types Type Torx Length mm Head Thread Type Part Number eme OS 08 ene me 70 o gt m NER RNC em Ls pw nm o Ce omen Lm mr e Jem _ L3 3e oo 3 98 e eme e ee DEMONS a pe poe p o poe 0515 2521 C607120025 0624 1062 C284720018 0515 2916 0515 1916 Removal and Installation DU invent Window Removal 1 Open the Window 2 Unclip the Window hinges from the Top Cover 3 Remove the Window from the Printer 8 4 HP Designjet 4000 4020 Printer Series Service Manual ames roten Installation of New Window 1 Identify the two ends of the Window Hinge four in total one end is clipped to the Window and the other to the Top Cover 2 Slide the Window Hinges on to the Window 3 Clip the Window Hinges to the Top Cover Removal and tslaron Right Cover Removal 1 Unclip the Quick Reference Gui
149. inter cannot print the Information Pages are still accessible through the Embedded Web Server Wu 1 NPDancATEECFHB 15 23 50 235 Printer Statue UJ HP Designjet 4000 Ready Errore Firmware Internalenor Media sage Date 1 eot Fw 3332 Cet Son 11 530200 Fen 25 2006 322 Fa remy i Bot c S2 11 530299 Feb 25 2005 3 22 BM 1 amp 159 34 3178994 Mv 26 1137 1 Bot 134343 Dinit 317099 shi Pre 10 2004 421 Help liek 1 24 34 3 Uxbabatece Daa som 10 3545 AME 5 1 BA 134343 0214010008 D DODDUOR Cet 27 2004 2 31 Mirari mag a thet OOS Cet Zi 2 17 PM Ire m 1 miia Aj303 413 017080006 73082 Cx 27 2004 2 304 links LIP Derz Ser astecriee lusor Main Characteristics Each Service Information page fits on a sheet of A4 A size media so that it can be faxed if necessary Only available in English except the current information page From the Front Panel you can choose to print ALL pages or just select the specific pages that are needed If ALL pages are printed Nesting is turned ON automatically and turned OFF once all the pages have been printed Nesting cannot be mixed with other jobs in the queue Each page can be printed from the Web browser when using the Embedded Web Server Each page c
150. ion Menu Color calibration On 4 Load both Printers with similar paper types 5 Ensure that the Paper Type setting on the front panel corresponds to the paper that is loaded 6 Print the image on the HP Designjet 1000 Printer series using the normal settings 7 Now prepare to print the same image on the HP Designjet 4000 Printer series 8 In the application set the color space of the image to emulate the HP Designjet 1000 Printer series and the specific paper type that you used in that printer The data sent to the driver must be already converted to this emulation color space which is a CMYK color space refer to the application s online help for information on how to do this In this way the 4000 series will emulate the colors that the 1000 series can produce when printing on that paper type 9 n the PostScript driver for the HP Designjet 4000 Printer series go to the Color Management section and set the CMYK input profile to the same HP Designjet 1000 Printer series color space that was selected in the application the emulation color space When trying to emulate another printer CMYK colors should always be used not RGB Set the rendering intent to Relative Colorimetric or to Absolute Colorimetric if the whiteness of the paper needs to be emulated 11 Print the image on the HP Designjet 4000 Printer series HP Designjet 4000 4020 Printer Series Service Manual 6 29 UJ invent Printing via separate H
151. is designed to check if the printhead nozzles print correctly Considerations for Printing the Diagnostic Print 1 The IQ Diagnostic Print prints in and B sizes so you must have media loaded roll or sheet that is this size or larger 2 Use the same type of media that the customer was using when they found the image quality problem 3 Ifthe customer is using non HP media and after the Image Quality Test you still have the same image quality problems change to genuine HP media and repeat the Image Quality Test 4 f you do not see any problems with the Image Quality Test then the problem may not be with the printer itself The problem may be with the RIP or the driver for example However if you do see problems with the Image Quality Test then continue with the following procedures which will help you to diagnose the problem KJ Printing the Service Image Quality Diagnostic Print 1 In the Service Utilities submenu scroll to Diagnostic Print and press Enter Press Enter Turn Drive Raller Prime Tubes Set SN Reset life counters 2 You will be given an option to either print the Image Quality User Plot or the Image Quality Service Plot Use the Arrow keys to make the selection and press the Enter key to start printing the required Diagnostic Print Press Enter to confirm selection 4 ep eem vom Diagnostic Print M LA
152. ity problems refer to Page 6 16 invent Choosing the Correct Print Quality Settings The following table shows suggested print quality settings and paper types for various different kind of prints assuming that roll paper is being used If sheet paper is being used it is recommended to set print quality to Best Print content Image quality settings Paper types front panel Print Optimized Maximum quality for detail Lines draft Fast Drawings text Lines Drawings Bright White text Bond Paper S ey Translucent materials iH RM Coated Paper gree Bright White Bond Paper Translucent materials Coated Paper Bright White Bond Paper Lines and Drawings area fills text Translucent materials Coated Paper Heavyweight Coated Paper Productivity Photo Gloss Image quality settings Paper types front panel Print Optimized Maximum quality for detail Lines and Best Drawings On Coated Paper Images text Heavyweight Coated Paper i Productivity Photo T Gloss In store Normal Off Coated Paper advertising Heavyweight Coated Paper Productivity Photo Gloss Renderings Best Off Heavyweight Coated Paper Productivity Photo Gloss Photographs Best Off Productivity Photo Gloss Print content How to Use the Service Image Quality Diagnostic Print What is the Service Image Quality Diagnostic Print The Printer contains an interna
153. ize Level 4 77 13 Disk Wipe 4 79 gt WN OANA BW HP Designjet 4000 4020 Printer Series Service Manual 41 Introduction This chapter explains how to use the Diagnostics Tests and Service Utilities and what to do if any of the tests fail Diagnostics Self Test Initialization Sequences Whenever the Printer is switched ON it automatically performs a series of internal self tests and mechanical initialization sequences If any of the parts fail a system error will appear and you should consult Chapter 2 System Error Codes CA sessctiod Uie Diagnostics Tests The following is a list of all internal Diagnostics Tests available in the Printer Instructions for entering the Diagnostics Tests menu are given on Page 4 5 1 Scan Axis Test gt Page 4 7 The purpose of this test is to verify the operation of components related to the Scan Axis 2 Media Drive Test Page 4 12 The purpose of this test is to verify the operation of components related to the Media Axis 3 Electronics System Page 4 17 The purpose of this test is to verity the operation of the Main PCA Formatter Printer Configuration Gamut PCI Power Supply Unit PrintMech Interconnect Carriage Communication ISS Communication 4 Carriage Assembly Test Page 4 27 The purpose of this test is to verify the operation of the Carriage Assembly 9 Sensors Test Page 4 28 The
154. l Image Quality Test which helps you to diagnose the possible source of any image quality defects The Service IQ Diagnostic Print is available in two options 1 Image Quality User plot This can be printed either through the normal front panel menu or through the Service Utility Menu a If the Image Quality Diagnostic Print is printed through the Service Utility Menu you will not be prompted to select optimized for drawings text or optimized for images The Printer will automatically take the settings that have already been selected in Setup Menu Printing Defaults Menu Image Quality Optimized for b Ifthe Image Quality Diagnostic Print is printed through the standard menu Setup Menu Information Menu Internal Prints Print Image Diagnostics you will be prompted to select drawings text or images It is recommended to print the Diagnostic Print using this option The Image Quality User Plot print is divided in to three parts as follows B Alignment Test This test is designed to check any color to color and bi directional misalignment the printer may have Printheads and Paper Advance test This test is designed to check whether the Printheads and the Paper Advance Mechanism are working correctly Printhead Problems The purpose of this test is to identify which Printhead is faulty 2 Image Quality Service Plot This can only be printed through the Service Utility Menu This print contains the Printhead Nozzles test which
155. l key together You are now in the Service Tools Menu Configuration menu _ MiPrinting defaults menu 0 setup Press DOWN Press Cancel key 3 For On Site Engineers once inside the Printer Setup menu press the Up arrow key and the Cancel key together You are now in the Service Tools Menu Press UP key Information menu configuration menu Printing defaults menu 0 setup Press Cancel key invent 4 Use the Arrow keys to scroll to the Service Utilities menu and press the Enter key Press Enter to confirm selection Service menu Service utilities Use UP and DOWN keys to select Service calibrations Service tests 5 Use the Arrow keys to scroll through the Service Utilities selections and press the Enter key to begin a specific operation when the required Service Utility is highlighted Press Enter to confirm selection Service utilities Torn Drive Roller Prime Tubes Set SH Reset life counters Diagnostic Print Sleep mode 2 cutter Use UP and DOWN keys lo select invent grow Diagnostic Tests and Utilities 1 Turn Drive Roller The purpose of this Service Utility is to rotate the Drive Roller and the Overdrive in order to clean them Perform the Turn Drive Roller utility as follows In the Service Utilities submenu
156. le Main i Includes Processor amp Main Includes Processor amp Main x Formatter Includes Processor amp Heatsink DJ4020 Q1273 60298 PCI PCA Q1273 69298 Gamut PCI PCA Refurbished Q1273 60269 Printmech PCA 91273 69269 69269 Printmech PCA Refurbished Hard Disk Drive Includes Holder and Hard Disk Drive Includes Holder and mE E screws DJ4000 Refurbished Hard Disk Drive Includes Holder and r screws DJ4020 01273 60251 Power Supply Unit GWm us Power Supply Uni Refurbished 8 1 9 973508 1 Ei earne Modde sony 10 Q1273 60230 Electronics Module Cables Kit 11 01273 60272 Electronics Module Metal Parts Kit 2 05680 60001 PCI USB 13 05679 60001 BEEN Gigabit Ethernet PCI Card invent Figure 3 Electronics Module Right Hand Cover _ 1 omas 1 gh ond Corbito Dos _ gt WM 3 amano _ 1 Front FonPaneBezel Bezel ien mei Access Door Printhead Access Door for HP Q1273 60295 Designjet 4000ps includes nce and Pantone Logo Printhead I Access Door for HP Printhead M Access Door for HP EE Designjet 4020ps NEM Q1273 60143 EN vg Reference Guide Holder DJ4000 Left Hand Cover Q1273 60053 Left Hand Cover without Door Q1273 60096 Left Hand Trim Q1273 60293 Cartridge Access Door
157. le to achive optimal Image Quality performance even with some nozzles out see image 3 on page 6 16 Bubbles actions Are you seeing white banding somewhere in Part 2 of the Image Select the correct Print Quality setting Quality Diagnostic Print and it matches with the color where you see the table on page 6 3 are seeing nozzles out Ifthe problem persists perform a Printhead recovery Activating the intensive checking option in the front panel will guarantee print quality performance while continuing to see the problem Ifthe problem persists replace the faulty Printhead Are there a significant amount of nozzles out See image 2 on page 6 16 Nozzles out actions Select the correct Print Quality setting see the table on page 6 3 Perform a Printhead recovery Ifthe problem persists replace the faulty Printhead yes yes Nozzles out actions Select the correct Print Quality setting see the table on page 6 3 If the problem persists perform a Printhead recovery If you see Dark Lines DARK LINES Do you see dark lines all along the custom er plot Refer to Flowchart BOTH Dark and W hite Lines Media Advance actions Select the correct Print Quality setting see the table on page 6 3 We strongly recommend using HP media Ifthe problem persists Heavyweight Coated paper should be used Ifthe problem persists perform a Paper Advance Calibration Note 1 How lo
158. lem since this is a permanent problem and eventually degrades the life of the Printhead Corrective Action 1 Replace the Yellow Printhead and the Black Printhead Cleaner Satellites Black Lines Description of problem In certain prints black text and lines have a fuzzy or shadow effect This problem is more likely to be seen when printing CAD data at high Carriage Speeds when printing on Plain Paper using the fast print quality setting Shown below is an example of what you might see if you have this problem Ay m umm m vr e 4 Corrective Action 1 If the image has been printed using the Fast print quality setting then reprint it using the Normal or Best print quality setting 2 Ifthe image needs to be printed using the Fast print quality setting then try turning On the Maximum Detail option in the Driver Parts and Diagrams Printer Support Q1271 60454 Foot Assembly Q1271 60183 legs Assembly Q1271 60456 X Brace Assembly Q1271 60457 Bin Assembly 014000 06651 60260 Bin Assembly DJ4020 Hardware Kit Includes screws for Legs EN _ _ AssemblyyDJ4000 Hardware Kit Includes screws for Legs Assembly DJ4020 invent Figure 1 Printer Support Center Covers Q1273 60105 Left Connector Cover Q1273 60106 ot 4 ic Connector Cover invent Figure 2 Center Covers Electronics Modu
159. ll through the Service Calibrations selections and press the Enter key to begin a specific operation when the required Service Calibration is highlighted Service Calibrations DU invent 1 Scan Axis Calibration The purpose of this Service Calibration is to carry out a PWM check calibrate the intensity of the Line Sensor and calibrate the Line Sensor position to the Black Printhead Perform the Scan Axis Calibration whenever Carriage is disassembled or replaced Encoder Strip is disassembled or replaced Center Platen is disassembled or replaced Perform the Scan Axis Calibration as follows 1 In the Service Calibrations submenu scroll to Scan Axis Calibration and press Enter Paper advance calibration Drop Detector calibration Line Sensar calibration Platen blue line calib Emm um calihratinn 2 When the following message appears on the front panel you must select whether you would like to continue with the calibration by pressing the Enter key Press Back or Cancel to exit the calibration Press Cancel iot Scan Axis Calibration Press Enter ack key ic But to proceed Press ENTER to proceed with Scan Axis calibration or BACKS CANCEL to exit 5 4 HP Designjet 4000 4020 Printer Series Service Manual 3 If media is not loaded the following message appears on the front panel Load media in to the Printer and start again f
160. llowing messages Detecting Bag Broken If the Printer does not detect that any of the Ink cartridges have a broken bag then the message ink short detected on supplies will be displayed on the Front Panel If there is a problem while reading the Bag Broken signal the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 Check also System Error Code 01 2 10 refer to Page 2 4 If the Printer detects that one or more of the Ink Cartridges have a broken bag then the message Please replace one of the defective cartridges O 1 2 or 3 and press any key to continue will be displayed on the Front Panel In this case remove the faulty Ink Cartridge as indicated by the Front Panel and install a new Ink Cartridge If the Bag Broken error is still active even after replacing the faulty Ink cartridge the Front Panel will display System Error Code 01 2 10 For more information on troubleshooting this error code refer to Page 2 4 Check also System Error Code 01 0 10 refer to Page 2 3 5 f the Printer does not detect that any of the Ink cartridges have a broken bag then it will read the Acumen of the Ink cartridge to check if there had been an ink short previously During this check the Front Panel will display the following messages Starting AcumenSupplies Getting ISS data If the Printer does not detect that any of the Ink
161. m Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action 56 03 Analog Encoder calibration failed 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 E Replace the Encoder Disc and Sensor gt Page 8 137 m If the System Error continues replace the PrintMech PCA gt Page 8 119 56 10 Analog Encoder calibration failed Try the following E Replace the Encoder Disc and Sensor gt Page 8 137 61 01 The file format is incorrect and the Printer cannot process the job 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 Check the graphic language setting of the Printer Refer to the User s Guide Resend the file to the Printer Check that the Printer has the latest Firmware version If not update the Firmware to the latest version 61 04 1 The Postscript fonts are missing Upgrading the Firmware will re install the fonts Perform a full firmware upgrade that includes package B System Error Problem Description Corrective Action System Error Problem Description Corrective Action
162. media jam causes the media to lift up into the Carriage path and cause a Printhead crash thus causing many media jam failures to be reported as head crashes Did the media jam occur when loading media B f the client has had media jams it is common for pieces of media to get stuck in the media path Clear the media path Is the customer using non HP media The use of non HP media can easily be the cause of media jams and head crashes especially head crashes because HP media is specially formulated to avoid cockle one of the primary causes of head crashes If the media is not HP approved advise the customer to use HP media and check to see if the problem is now solved Check that the Vacuum Fan works correctly Troubleshooting Shutdowns If shutdown occurs you will get the message Switch Power Off followed by Check Printhead Cleaner Path Check Paper Path Check Printhead Path followed by 1 2 or 3 A shutdown in each path will require different steps to resolve the problem as explained as follows Printhead Cleaner Path 1 Open the right door of the printer and check for any visible obstacles restricting the movement of the Service Station Manually move the Service Station checking for smooth and free movement Paper Path 1 Open the Window and check for any visible obstacles restricting the movement of the Drive Roller If there is a wrinkled mass of media inside the pap
163. ment and by the types of Printer supplies used General Cleaning Proper general cleaning should include the following Blow away dust accumulation with compressed air if available Clean the outer surface of the Printer with a damp sponge or cloth Use a mild soap and water solution if necessary Do not use abrasive cleaners 3 Wipe the Printer dry with a soft lint free cloth 0 tesserae Cleaning the Drive Roller and Overdrive 1 Perform the Turn Drive Roller Utility Refer to Page 4 69 2 Open the window and apply any common household cleaning solution water based only to a soft lint free rag and apply it to the Drive Roller and Overdrive surface while it is rotating Make sure that you thoroughly clean the Drive Roller and Overdrive surface 3 Press Enter when you have completed the cleaning procedure 4 Allow the Drive Roller to dry before loading media in to the Printer Cleaning the Center Platen It is recommended to clean the Center Platen on a regular basis at least every few months or when required as follows 1 Unload any media loaded from the Printer 2 Open the Window and with a dry brush remove ink deposits from the Cutter Groove and the Center Platen surface Cutter Groove Center Platen Surface Usea clean absorbent lint free cloth dampened with Isopropyl Alcohol not supplied in the Maintenance Kit to wipe loosened ink deposits from the Center Platen 5
164. movement done is more than 100 encoder units in absolute value If the movement done is less than 100 encoder units then open the Window and check for any visible obstacles restricting the movement of the Drive Roller or the Overdrive Assembly If the Encoder Units is less than 100 the Printer will request you to follow these instructions a Manually load a sheet of paper in to the Printer an A4 sheet b The Printer will test the Media Drive moving in an open loop Perform a visual check during the test The Front Panel will ask you if the paper moved or not If the paper moved the Front Panel will display System Error Code 56 10 For more information on troubleshooting this error code refer to Page 2 17 If the paper did not move the Front Panel will display System Error Code 41 10 For more information on troubleshooting this error code refer to Page 2 13 d FAIL message will be displayed on the Front Panel and the test will be terminated at this point iar aon is 8 The Printer will now check the Media Drive servo system and the following messages will be displayed on the Front Panel Starting Paper Motor B Off On Paper Motor Starting Paper Axis If there is a failure at this point the Front Panel will display System Error Code 81 10 For more information on troubleshooting this error code refer to Page 223 Calib Analog Encoder If there is a failure at this point the Fron
165. n If you select No the printer skips this test and goes to the next one Do you want to check the Formatter Use UP and DOWN keys to select YES Press UP DOWN to change an ENTER tn select If you select Yes the printer will get the CPU information and display the information on the Front Panel Press any key to continue the test CPU information Processor GenuineIntel CPU family 15 model 2 Intel CeleraoncR 1999 793 Fress any key to continue invent 4 The printer will now get the Main Board MB information and display the information on the Front Panel Press any key to continue the test Main Board information Temp sws CPU amb eo 354 00 50 ae VOUT q1 5 1 9 2 5 3 3 1 515 1 754 2 552 3 352 volt i5 12 wWccpa H p9zB 11 8 5 1 500 Press any to continue 5 The printer will now get the CPU Fan Speed and display the information on the Front Panel Press any key to continue the test Electronics Module CPU Fan speed 5229 Press any Key to continue If the CPU Fan Speed is less than 2500 the Front Panel will display System Error Code 05 1 10 For more information on troubleshooting this error code refer to Page 2 5 6 The printer will now calculate the amount of memory installed and display the information on the Front Panel Press any key to continue the test Electronics Module Main memory size 256MB Press any K
166. n EEROM Reset Page 4 46 and resend the file to the Printer 77 04 Embedded Web Server internal software error Try the following B Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer Check that the Printer has the latest Firmware version If not update the Firmware to the latest version 79 03 Generic Firmware error Try the following B Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer Check that the Printer has the latest Firmware version If not update the Firmware to the latest version System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action invent 79 04 Generic Firmware error 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 Check that the Printer has the latest Firmware version If not update the Firmware to the latest version 79 1 04 CDS server lost connection with client Try the following B Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printe
167. n as double lines Corrective Action 1 The easiest solution is to select the Extended Margins option in the driver the Embedded Web Server or the Front Panel This means that the area of the paper affected by the problem at the top of the page will no longer be used Problems with Stepped Lines Description of problem When you look at the image you have printed there are stepped lines in the borders of arrows and diagonal lines The lines should be straight with no stepping Shown below is an example of what you might see if you have problems with Stepped Lines Corrective Action 1 If the image has been printed using the Normal or Fast print quality setting and it is not acceptable to the customer then reprint it using the Best print quality setting 2 Turn On the Maximum Detail option in the Driver 3 The problems may be inherent in the image that you are trying to print Try to improve the image with the application that generated the file Lines are Printed Double or in Wrong Colors Description of problem This problem can have various visible symptoms as shown below Colored lines are Borders of colored printed double in blocks are wrongly E lines are different colors colored wavy or E Corrective Action 1 Align the Printheads Ink Menu Printheads Align Printheads 2 Ifthe image has been printed using the Normal or Fast print quality setting and it is not acceptable to th
168. n keys to select the deletion security level of the print files on the HDD Unsecure Mode default All pointers to print information are erased The actual print information residing on the hard disk is NOT erased and it will remain on the hard disk until the disk space it occupies is needed for new print jobs The new print job information overwrites the old information While the information remains on the disk it is difficult for most people to access it but it may be accessed using software specifically designed for that purpose This is the normal method in which files are erased from most computer systems it is the fastest method but the least secure 1 Pass Mode a fast level of file deletion All pointers to print information are erased and the actual print information is immediately overwritten with a fixed character pattern This method is slower than the unsecure method faster method but more secure However it may still be possible to access fragments of the erased information by using special tools to detect residual magnetic traces 5 Pass Mode the most secure level of deletion All pointers to print information are erased and the actual print information is immediately and repetitively overwritten using an algorithm designed to gt Pass Thr 13min 3hrs 43min 3hrs 45min Mode Press Cancel to exit invent eliminate any residual traces This is the slowest method but the most secure S
169. nd remove the blue connector by cutting it off 16 If the Air Tube is new and does not have a blue connector carefully remove the tube see note below Warning Be careful not to cut your hand on sharp surfaces nearby while disconnecting the tube avoid trying to pull the tube off in one go Twisting the tube while pulling will reduce the effort required to disconnect it HP Designjet 4000 4020 Printer Series Service Manual CA 17 Twist the 2 latches at the rear of the Ink Cartridge Tube Connector and release the complete assembly T MA e 5 aN We 18 Remove the Ink Supply Tubes Trailing Cable and Carriage Power Cable from the Printer 19 Remove the eleven Cable Holders from the two slots of the Ink Tube Carrier Removal and tslaron O 20 Remove the Trailing Cable and Power Cable from the Cable Holders Old and New type of Top Crane Covers There are two possible types of Top Crane Cover in the printer the OLD type and the NEW type Removing the trailing cable from the old type 1 Remove one T15 screw from the Crane 2 Remove the Trailing Cable and Carriage Power Cable from the groove in the Top Crane mera tation Removing the trailing cable from the new type 1 Remove one T15 screw from the Top Crane 2 Remove the Top Crane Cover by unclipping it from 3 latches located underneath 3 Remove the Top Crane Cover
170. ng name version etc Performing a Service Test on a Failed Assembly It possible always perform a Service Test on the component assembly that you are about to replace just to make sure that is the component assembly that has failed For information on the Service Tests and how to use them see Chapter 4 Diagnostic Tests and Utilities Performing the Necessary Service Calibrations Is the printer calibrated correctly after replacing a component For information on the Service Calibrations and how to use them see Chapter 5 Service Calibrations Solving Print Quality Problems Whenever a Print Quality problem appears it is advisable to print the Diagnostic Print to help diagnose the problem The Diagnostic Print will help you differentiate between possible printhead errors and other problems such as incorrect front panel selection driver or RIP configuration or mechanical problems For information on solving Print Quality problems see Chapter 6 Print Quality The Printer does not Power ON 1 Check that the power cord is connected correctly to the Printer and to the Power Socket 2 Check that the Power Switch on the BACK of the Printer is in the ON position 3 Check to see if any of the LEDs on the Power Switch are On If any of the LEDs are On then refer to Page 1 14 for more information 4 Check that the Front Panel Cable is correctly connected to the Electronics Module Also make sure that t
171. ng have you had media loaded There is a specific problem when printing with a brand new unit using Heavyweight Coated paper It is normal to see dark lines for the first few meters of paper After printing for a while the paper advance should be stabilized and optimal print IQ should be achieved without any further actions Note 2 Were you previously printing using Glossy paper and now you have started printing using Bond paper The first few meters of the plot being printed on Bond paper may have dark lines if the paper previously used was glossy After a few plots this problem will disappear without any further actions If you see Both White and Dark Lines BOTH DARK and Are you seeing a frequential banding composed by a darker WHITE LINES zone and a lighter zone See image 4 on page 6 16 Are you seeing dark lines in some areas and white lines in others Or are you seeing either dark or white lines but not all along the plot Are you seeing white lines but only in some areas of the plot probably containing the same based color Are you printing a high ink density plot Or are you printing a plot that contains both high ink es Do you see ing Wh Refer to Flowchart es a WHITE LINES This problem mainly occurs after inserting new Printheads specially cyan or when loading Heavyweight Coated paper for the first few meters density areas and low ink density areas Media Expansion actions Sele
172. nk Cartridge Information 1 Scroll to the Ink Menu icon and press Enter Press Enter to confirm selection Use UP and DOWN keys to select Ug Ba Se Press Enter to confirm selection Printheads Use UP and Ink cartridges Drying options DOWN keys to select 3 Inthe Ink Cartridges submenu scroll to Ink cartridge information and press Enter Press Enter to confirm selection Use UP and DOWN keys lo select 4 In the Ink Cartridge Information submenu scroll to the Ink Cartridge that you want information on and press Enter Press Enter to confirm selection yellow ink cartridge X PF 3 3 U se UP and gyoMagenta ink cartridge _ Au Pm DOWNI keys Black ink cartridge to select Cyan ink cartridge tes Troubleshooting 5 The front panel displays information on the selected Ink Cartridge Product name HP No Se Product number C50654 Serial number 1116688 29 Status OF Ink level 379 ml Capacity 468 ml Manufacturer HP Warranty status In warranty The information supplied is The make of the Ink Cartridge hp 90 is recommended The product number of the Ink Cartridge The serial number of the Ink Cartridge The current status of the Ink Cartridge The current ink level of the ink cartridge in milliliters Original capacity of the ink cartridge in milliliters The manufacturer of
173. nostics Tests submenu and use the diagnostic 12 Set Unit Configuration to set the correct configuration refer to Page 4 46 Starting Tests If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 Checking GPIO channels At this stage the Printer reads and checks the default GPIO values in the Interconnect PCA when all the cables are connected and all the sensors give the default value or the current state The results will be displayed on the Front Panel and you can press any key to scroll through the information Electronics Module Electronics Module Revision Id 1 OK Pinch Lever OK Revision Id 2 DK BT Standby DK Revision Id 3 OK Sheet Sensoar 1 0K Window Sensor a D Back Channel Sensori DK sv5 Door amp Feed Pinch Lever 8 Media Sensor OK Feed Pinch Lever 1 DK Press any Key to continue Press any Key to continue 1 OF 1 0K FM Check Cable DD Goods Media Jam Sensor amp D Press any key to continue Press any key to continue Items marked with an asterisk are not important and can be ignored If any of the channels cannot be read the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 It any of the read values do not match the expected default
174. nt 7 Press ENTER to accept or BACK CANCEL to exit 5 The Print Banding Plot will now be printed Troubleshooting using the Print Banding Plot If there is dark or white banding along all of the colors in the area marked a perform the Media Calibration If this fails perform the service advance media calibration use the kit Q1273 60296 which contains HP Universal Photo Gloss media for the calibration f there is dark or white banding along at least one of the colors in the area marked b perform the Printhead Alignment If this does not solve the problem remove and install a new Carriage Assembly E f there is white banding with at least one color of the area marked perform a Printhead Check Use the thresholds mentioned earliar after having printed the Image Quality Print If the nozzles are deteriorating remove and replace the defective printhead The numbers 1 8 on the print banding plot represent the printheads in the printer The print banding plot is printed in FAST mode so the quality of the image is not as good as the other print modes It must only be used for troubleshooting the three issues mentioned above Force Drop Detection Tool This tool can to be used when part 3 of the image quality print looks ok but there are persistent image quality issues that point to defective printhead s How to detect this issue 1 Look at the printh
175. nters Reset Maintenance Kit usage Reset usage counters a If you select to reset the Life Counter for ALL the parts related to a Preventive Maintenance Kit PMK you will be given an option to reset the Life Counter of Preventive Maintenance Kit 1 PMK1 Preventive Maintenance Kit 2 PMK2 b If you select to reset the Life Counter a particular part you will be given an option to reset the Life Counter of the Scan Axis Motor Trailing Cable and Tubes Carriage Belt Carriage Bushing Most Left Spittoon Middle Left Spittoon Spittoons ii Fs ard ies 3 Once you have selected a Life Counter to reset the following message will be displayed on the Front Panel Press the Enter key to reset the selected Life Counter or press Back Cancel to exit without resetting the Life Counter Press Cancel or the Back key Reset Bushings Usage Carriage bushings 6 Reset this life counter Press ENTER to accept or BACKS CANCEL to exit If the Usage Counter information cannot be read the Front Panel will display Unable to get usage counter This could point to a possible Firmware error 4 If the utility exits correctly OK will be displayed on the Front Panel Reset Bushings Usage invent o 5 Diagnostic Print ont 5 The purpose of this Service Utility is to print the Diagnostic Print
176. nthead Cleaner is correctly seated in slot 8 of the Service Station and then close the Printhead Cleaner Access Door B Replace the Cyan Printhead Cleaner in slot 8 of the Service Station 41 03 Electrical current limit in Media Axis Motor 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 Drive Roller If there is a wrinkled mass of media inside the paper path lift the Pinchwheels using the Media Lever and clear the obstruction B Replace Media Axis Motor Page 8 91 If the System Error continues replace the PrintMech Page 8 119 41 10 Electrical fault in Media Axis Motor Try the following B Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer Check that the Media Axis Motor cable is not damaged and is correctly connected to the PrintMech PCA B Replace Media Axis Motor Page 8 97 If the System Error continues replace the PrintMech PCA Page 8 119 System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action invent 42 03 Electrical current limit in Scan Axis Motor Try the follow
177. nts that the throughput allows exceeding by far the limit of the design When this happens the customer runs into print quality problems and continuous Printer failures The purpose of scheduled preventive maintenance is to avoid these failures ensuring a good performance during all the product life Level of Printer Usage Normal printer use means 6 000 000 Carriage Cycles which corresponds to approximately 100 000 AO prints on average Under normal usage conditions it will be approximately 5 years before the printer needs maintenance If the printer is used more than the normal usage conditions then it will need maintenance service much more frequently One of the EEROM counters is assigned to counting the number of carriage cycles When certain components of the Printer exceed this amount the front panel displays the following message Maintenance 1 required The following message is triggered depending on the total quantity of ink spitted in each Spittoon Maintenance 2 required Once one of the maintenance advised messages is displayed the preventive maintenance kit must be used to replace the most worn parts of the printer Use the Removal and Installation Chapter of this Service Manual as a guide to replace the necessary parts The following PM Kit covers both Maintenance advised messages Preventive Maintenance Kit Part Number Q1273 60061 This Preventive Maintenance Kit contains the following components Compl
178. o select MO Align now MeO Automatically align O Continue without aligning 14 Once the Printhead Alignment is completed the following message will be displayed on the Front Panel Press the Enter key to continue Printhead alignment Calibration successfully completed invent Press 4 to continue 3 Set SN The purpose of this Service Utility is to set the Serial Number of the Printer Perform the Set SN utility as follows 1 In the Service Utilities submenu scroll to Set SN and press Enter Press Enter 2 The Printer will display the current Serial Number and the new Serial Number of the Printer Use the Up and Down keys to go through the digits and press the Enter key to go to the next digit You can press the Cancel key at any time to exit the utility without making any changes Press Enter to go to next digit Set Serial Number We current unit SN 56463191M unit SH 5048631901 Use UP and DOWN keys to go through the digits Use UP DOWN to scroll to move cursor ENTER to confirm or CANCEL to exit Press Cancel to exit If the Serial Number or the Part Number cannot be read the Front Panel will display System Error Code 74 00 For more information on troubleshooting this error code refer to Page 2 20 3 the new Serial Number has been entered the Front Panel will dis
179. of the installation procedure is the same as the removal procedure but in reverse Removal and Installation inveni ISS to Cartridge Cables Removal 1 Remove the Left Cover Page 8 4 2 Disconnect the ISS to Cartridge Cable from the ISS PCA 3 Release the clips securing the ISS to Cartridge Cable 4 Remove the ISS to Cartridge Cable from the Printer HP Designjet 4000 4020 Printer Series Service Manual 8 58 inven Cutter Assembly Removal Select Replace Cutter from Service Menu refer to Chapter 4 and follow the instructions on the Front Panel 2 Open the Window secures the Cutter Assembly to the Carriage Assembly Removal and Installation D inveni Ink Supply Station ISS Removal 1 Remove the Left Cover Page 8 4 2 Remove the Left Connector Cover Page 8 19 3 Disconnect the Electrical Cable from the rear of the Ink Cartridge Tube Connector 4 Disconnect the Air Tube from the Ink Supply Tubes 5 Twist the 2 latches at the rear of the Ink Cartridge Tube Connector and release the complete assembly 8 60 HP Designjet 4000 4020 Printer Series Service Manual CD 6 Disconnect the two Ink Supply Station cables from the PrintMech PCA 7 Release the Ink Supply Station from the Chassis 8 Remove the Ink Supply Station from the Printer invent APS Assembly Removal There are two dif
180. on Back key proceed ee to proceed Press ENTER to proceed with Drop Detector calibration BACK CAMCEL to exit 3 The Printer will start to calibrate the Service Station Once the Service Station has been calibrated the results will be displayed on the Front Panel Press any key on the Front Panel to finish the calibration Seryice Station Calibration DD Offset Range 9 to 86 4 Once the calibration is completed OK will be displayed on the Front Panel 0st 3 Paper Advance Calibration The purpose of this Service Calibration is to calibrate the nominal advance of the media This calibration is necessary to control the exact movement of the media in order to avoid print quality problems like banding Perform the Service Accuracy Calibration whenever Banding is detected in prints Drive Roller is disassembled or replaced E Paperaxis Assembly is disassembled or replaced The Paper Advance Calibration is split into three parts and should always be done in this order 1 Print Calibration Pattern The Printer first calibrates the Analog Encoder and then prints the Paper Advance Calibration pattern 2 Scan Calibration Pattern The Printer scans the Paper Advance Calibration pattern in order to calibrate the nominal advance of the media 3 Clean Drive Roller After loading media that the customer will use the Printer prepares the media path to prevent any future advance problems
181. onics Should be ON at the same time as Blue Power Switch LED 5Vsb Comes from the PSU after the fuse on Interconnect PCA Used to power On the Printer from the Front Panel Should be ON at the same time as Blue or Amber Power Switch LED 24V Comes from the PSU after the fuse on Interconnect PCA Used to power the Carriage PCA Should be ON at the same time as Green Power Switch LED 5Vsb Comes from the PSU after the fuse on PrintMech 3V3 Comes from the Power Supply Unit 5V Comes from the Power Supply Unit ERIDANI Specific power line from PSU which powers ERIDANI chip after a fuse on PrintMech 24V Comes from the PSU after a fuse on the PrintMech PCA VPOWER2 Comes from the PSU 42V after a fuse on the PrintMech PCA VAUX Comes from the PSU 12V after a fuse on the PrintMech VAN 5 generated in the PrintMech PCA reference tension is generated from ERIDANI IC The value is around 5V If this LED is not ON and the others are ON this indicates that there is high probability that the PrintMech PCA is defective invent 1 If the Printer cannot be turned ON LED on LED on Corrective Action Interconnect PrintMech PCA PCA Check the connection between the PSU and the Interconnect PCA If connection OK replace the Interconnect PCA Page 8 93 Check the connection between the PSU and the PrintMech Make sure that ALL cables between the PSU and PrintMech are not damaged and a
182. onnection OK run the Electronics Module Test to further diagnose the problem Check the connection between the PSU and the PrintMech If connection OK run the Electronics Module Test to further diagnose the problem 4 Onthe PrintMech if the 3V3 LED is ON 5V LED is ON ERIDANI LED is ON VAUX LED is ON and the VAN LED is OFF then try the following Run the Electronics Module Test to further diagnose the problem E Replace the PrintMech PCA Page 8 119 5 If the Power Switch LED is Green and the 3V3 LED is ON 5V LED is ON ERIDANI LED is ON VAUX LED is ON VAN LED is ON and the VPOWER2 LED is OFF then try the following Check the connection between the PSU and the PrintMech Run the Electronics Module Test to further diagnose the problem E Replace the PrintMech Page 8 119 EWS Event Log Page Advanced Button UJ invent How to Interpret the Service Information Pages The Service Information Pages contain the following information Current Information E Printer Usage Information B Event Logs Calibration Status B Network and Configuration It is possible to print the Service Information Pages either through the Front Panel or through the Embedded Web Server E Front Panel Setup menu gt Information Menu Internal Prints gt Print Service Information B Embedded Web Server Information Event Log Advanced Even the Pr
183. ont Panel will display System Error Code 03 10 For more information on troubleshooting this error code refer to Page 2 5 Check also System Error Code 01 0 10 refer to Page 2 3 CA Config GPIO drv enable If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 Booting up the Carriage If there is a failure at this point the Front Panel will display System Error Code 02 1 10 For more information on troubleshooting this error code refer to Page 2 4 Check also System Error Code 11 10 refer to Page 2 7 or System Error Code 01 1 10 refer to Page 2 3 Unit Hangs Up If no System error code is displayed on the Front Panel but the Printer hangs up and the last message on the Front Panel is Booting up the Carriage it means that the Carriage ASIC could not be detected Troubleshoot this problem in the same way as if System Error Code 02 1 10 had appeared 3 The Printer will now check the revision of the PCA and the following message will be displayed on the Front Panel Checking rev The value for the PCA revision must be more than 0 625V if not the Front Panel will display System Error Code 01 1 10 For more information on troubleshooting this error code refer to Page 2 3 4 The Printer will program the duty cycle for the PWM test for the Media Drive Movement and leave it disabled and
184. onverted to binary number 1000000000001 So using the table above the error code means FAILS LOGICAL V FAILS CONTINUITY and MISMATCH UJ invent Carriage Interconnect Wiper Whenever you replace the Printhead check the empty slots to see if they need cleaning In extreme circumstances when a Printhead is inserted it is possible that the Printer will not recognize it due to the build up of ink on the electrical connection between the Printhead and the Carriage Assembly Included with the HP Designjet Printer is a Carriage Interconnect Wiper This tool is provided in a separate package It also contains replacement sponges and an instruction sheet This tool should be used for cleaning the electrical interconnects of both the Carriage Assembly and the Printhead If the front panel displays the message Reseat or Replace next to the offending printhead try cleaning the flex circuits of the Carriage and the Printheads Warranty Information for Ink Supplies Ink Cartridge The warranty for the Ink Cartridges will end when one of the following OCCUIS 24 months from the date of manufacture or When the advertised deliverable ink is reached 225ml 7 6 oz or 400ml 13 5 oz or When the user confirms that they have used non hp ink in empty over ride mode The actual end of warranty date is printed on the supply label Warranty Information for Printheads Ink Cartridge The
185. oor sensor PASS close the right Press any key to continue It the PHC Access Door Sensor fails the test the Front Panel will display System Error Code 51 1 10 For more information on troubleshooting this error code refer to Page 2 15 Check also System Error Code 07 10 refer to Page 2 6 UJ invent 9 The Media Lever Sensor will be tested next When the following message is displayed on the Front Panel raise the Media Lever and press any key to continue Sensors Test af Pinchwheel Lewer sensor Please raise the lever Press any Key to continue If the Media Lever Sensor passes the test the following message is displayed on the Front Panel Lower the Media Lever and press any key to continue Sensors Test of Pinchwheel Lewer sensor PASS Please lower the Lever Press any Key to continue If the Media Lever Sensor fails the test the Front Panel will display System Error Code 54 10 For more information on troubleshooting this error code refer to Page 2 16 Check also System Error Code 07 10 refer to Page 2 6 11 The Media Lever Sensor will be tested next When the following message is displayed on the Front Panel raise the Media Lever and remove the Media from the Printer and press any key to continue Sensors Test of Paper sensor Please remove the paper and Lower the lever Press any Key to continue 12 If the Media Lever Sensor passes the test th
186. order to pr identify image quality problems Print the Diagnostic Print as follows 1 In the Service Utilities submenu scroll to Diagnostic Print and press Enter Service utilities Sleep mode Renlare cuttar 2 You will be given three options B image Quality User Plot B image Quality Service Plot Others which includes the Print Banding Plot and the Force Drop Detection print 3 Use the Arrow keys to make the selection and press the Enter key to start printing the required Diagnostic Print Press Enter to confirm selection X ES mun mmn o ma Diagnostic Print Image quality user plot mi P NM lt E U se UP an d Image quality service plot DOWN keys We others to select 4 Make sure media is loaded the Pinch Lever is lowered and that the Ink System is correctly installed Press the Enter key to print the Diagnostic Print or press Back Cancel to exit without printing the Diagnostic Print Press Cancel or the Guat ity print Face 1 ol Back key Press Enter to Exit eo to print Proceed 7 Press ENTER to accept or BACK CANCEL to exit 5 The selected Diagnostic Print will now be printed For further information on troubleshooting Image Quality problems refer to Chapter 6 ei Fs and ies 6 Sleep Mode The purpose of this Service Utility is to enable disabl
187. orientation of the paper is the same as that assumed by the software The front panel Printing defaults menu gt Paper options gt Rotate option changes both the orientation of a print and the orientation of the page It is possible that a rotated image on a roll may be slightly clipped in order to retain the correct page size The page may have been rotated from portrait to landscape on a paper size that is not wide enough f necessary change the printable area in the software Other Possible Explanation Some applications such as Adobe Photoshop Adobe Illustrator and CorelDRAW use an internal 16 bit coordinate system which means that they cannot handle an image of more than 32 768 pixels If you try to print an image larger than this from these applications the bottom of the image will be clipped In this case the only way to print the whole image is to reduce the resolution so that the whole image requires fewer than 32 768 pixels The HP GL 2 printer driver contains an option called Compatibility with 16 bit applications which can be used to reduce the resolution of such images automatically This option can be found by clicking the Troubleshooting button in the driver s Services tab HP Designet 400p HPGLZ REL Properties fx Papeu Qualty Ettects Finishing Cole Services Savei Hi Sun OF memes SE ajx C M Compab ly with 1604 applications SendJob a Process n
188. ors can indicate problems either with alignment or Paper Advance In order to solve any of these problems try the following 1 Check that the appropriate print quality settings are being used 2 Ifthe customer is using low quality paper try recommending better quality paper preferable HP paper Printer performance can only be guaranteed by using recommended papers 3 Perform the Paper Advance Calibration using the same type of paper that will be used for the final print Diagnostic Part 3 Printhead Problems If part 2 revealed a Printhead problem then the purpose of part is to identify exactly which Printhead is faulty Each rectangle in this part is identified with the number of the Printhead that produced it It ALL the Printheads are printing perfectly part 3 of the Diagnostic print will look like this MH Maa EHE EL HG on co wv 1 6 a The following example shows an imperfect Printhead number 4 that is still suitable for printing It is not damaged enough to warrant a replacement because the Printer can compensate for a number of faulty nozzles Analyzing Printhead Nozzles Do not expect perfection because even if there are only a few missing lines the Printer can compensate for this so there is no need to replace the Printhead Up close the rectangle printed by a faulty Printhead in part 3 of the Diagnostic
189. osition 87687 Allowed margin 4 Real position B717 Press any key to finish 7 Once the calibration is completed OK will be displayed on the Front Panel invent 7 Vacuum Calibration The purpose of this Service Calibration is to set the default nominal and real values of the Vacuum Fan Assembly Perform the Vacuum Calibration as follows 1 In the Service Calibrations submenu scroll to Vacuum Calibration and press Enter X125 LALIHI ALIUN Service Station calibration Paper advance calibration Drop Detector calibration Line Sensor calibration Flaten blue line calib 2 When the following message appears on the front panel you must select whether you would like to continue with the calibration by pressing the Enter key Press Back or Cancel to exit the calibration Press Cancel or the Back key to Exit vacuum Calibration Please run this utility only in case that the fan box has been replaced Press Enter to proceed Press ENTER tn proceed with Vacuum calibration or BACK CANCEL to exit 3 The Printer will set the default nominal and real values of the Vacuum Fan vacuum Calibration Setting default vacuum nominal values 4 Once the calibration is completed OK will be displayed on the Front Panel 5c or 8 Carriage PCA Calibration ont ov The purpose of this Service Calibration is to re
190. ove the Left Connector Cover Page 8 19 5 Remove the Service Station Page 8 23 6 Remove the Ink Supply Station Page 8 60 7 Remove the Media Sensor 8 142 8 Disconnect ALL the cables connected to the Interconnect PCA and the Gamut PCI PCA 9 Disconnect ALL the cables connected to the invent 10 Remove four T 20 screws Type B that secure the Electronics Module lu c F E CE i LLL B B d 11 Remove the Electronics Module from the Printer 12 Remove one T 15 screw Type E that secures the Center Guide from underneath the Printer CD 13 Remove two T 15 screws Type E that secure the Center Guide from the left hand side of the Printer 14 Remove one T 15 screw Type E and two T 20 screws Type that secure the Center Guide from the right hand side of the Printer 15 Remove the Center Guide from the Printer Removal ard tslaron Drive Roller Removal 10 12 Remove the Right Cover Page 8 6 Remove the Left Cover Page 8 9 Remove the Right Connector Cover Page 8 18 Remove the Left Connector Cover Page 8 19 Remove the Service Station Page 8 23 Remove the Ink Supply Station Page 8 60 Remove the Media Axis Motor Page 8 9 Remove the Encoder Disc and Sensor Page 8 137 Remove the Media Lever A
191. overy Page 4 49 The purpose of this utility is to set the Serial Number and Part Number in case both the Hard Disk Drive and the Ink Supply Tubes are replaced at the same time I O Tests Page 4 51 The purpose of this test is to check the installed and active Interfaces invent Entering the Diagnostics Tests Menu 1 Make sure the printer is switched OFF from the power switch on the front of the printer and NOT from the power switch on the back of the printer 2 For Call Agents who will request the User to Perform certain troubleshooting action hold the Down arrow key and the Cancel key down and switch the printer ON using the front power switch Wait until you hear one usually after 5 seconds before releasing ALL 3 keys Hold DOWN Hold Cancel gt m m mme n key key 3 For On Site Engineers hold the Up arrow key and the Cancel key down and switch the printer ON using the front power switch Wait until you hear one beep usually after 5 seconds before releasing ALL 3 keys Hold UP key Hold Cancel key ca inveni 4 Once inside the Diagnostics Tests Menu use the Arrow keys to scroll through the Diagnostics Test selections Press the Enter key to begin a specific test when the required test is highlighted Press Enter to confirm selection Scan Axis test A Use UP and 2 Media Drive test um 3 Electronics module te om DOWN keys 1 Carr
192. pated to give this funcionality to the HP Designjet 4000 5 Fauty PCI E Replace the Page 8 105 Card BIOS Replace the PCA Page 8 105 Damaged Main PCA B Replace the Page 8 105 damaged B Remove the PCA Cover and with the Printer switched On check the HDD is turning feel it turning when you touch it Hard Disk or at least hear it turning If the HDD is not turning then it Drive could be damaged replace the HDD Page 8 111 damaged B Ensure ALL cables are connected to the HDD and are not missing damaged E Replace the HDD Page 8 111 B Replace the PCA Page 8 105 If the printer is turned On and the Power switch Amber LED is On but the printer turns itself Off after a few seconds during the initialization sequence replace the CPU fan on the Page 8 107 Check that the cables between the Interconnect and the are not damaged and HP Designjet 4000 4020 Printer Series Service Manual 1 9 invent are correctly connected Check that the cable between the Power Supply Unit and the Main PCA is not damaged and is correctly connected B Replace the Interconnect Page 8 93 E Replace Gamut PCA Page 8 98 Using the Power up Sequence to Troubleshoot When the Printer is powered up it performs the Boot UP sequence which initializes the major components of the Printer If for some reason
193. play the Serial Number and Model Number of the Printer Press the Enter key to confirm the Serial Number or the Cancel key to exit the utility without making any changes or the Back key to modify again CR ecc C 9 may Set Serial Number New serial number Ni E 564831901 A Press Enter Froduct Number M7 Hm 01274 JJ to confirm Press ENTER to confirm BACK to modify CANCEL exit Press Cancel to exit 4 Ifthe new Serial Number cannot be set the Front Panel will display System Error Code 74 00 For more information on troubleshooting this error code refer to Page 2 20 5 If the utility exits correctly OK will be displayed on the Front Panel 1 invent 4 Reset Life Counters The purpose of this Service Utility is to reset the internal life counters There are two submenus that allow you to E Reset ALL the counters related to a Preventive Maintenance Kit PMK Reset only the counters related to a specific replaced part Perform the Reset Life Counters utility as follows In the Service Utilities submenu scroll to Reset Life Counters and press Enter Diagnastic Print Sleep mode Benlace cutter 2 You will be given an option to either reset the Life Counter for ALL the parts related to a Preventive Maintenance Kit PMK or to just reset the Life Counter for a particular part Reset life cou
194. r Check that the Printer has the latest Firmware version If not update the Firmware to the latest version 81 01 Paper servo shutdown Try the following Open the Window and check for any visible obstacles restricting the movement of the Drive Roller If there is a wrinkled mass of media inside the paper path lift the Pinchwheels using the Media Lever and clear the obstruction E Perform the Media Drive Diagnostic Page 4 12 to further troubleshoot the error code f the System Error continues replace the Media Axis Motor Page 8 91 81 03 It was impossible to correctly stop the servo before setting the encoder position Try the following Open the Window and check for any visible obstacles restricting the movement of the Drive Roller If there is a wrinkled mass of media inside the paper path lift the Pinchwheels using the Media Lever and clear the obstruction E Perform the Media Drive Diagnostic Page 4 12 to further troubleshoot the error code f the System Error continues replace the Media Axis Motor Page 8 91 invent System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action 81 10 Fail starting Paper Motor Try the following Open the Window and check for any visibl
195. r The printer will stop and will not be able to continue printing until a new Ink Cartridge has been installed If this occurs halfway through printing an image you should check the quality of this image as stopping mid plot can affect the print It would be recommended to reprint the image once a new Ink Cartridge has been installed Ink Cartridge Status While Replacing The printer can report the following status messages while the Ink Cartridge is being replaced The Ink Cartridge has not been installed or is installed incorrectly The Printer will not print until ALL Ink Cartridges have been installed correctly The Ink Cartridge is having continuity problems Try removing the Ink Cartridge from the Printer and inserting it in again The Ink Cartridge is faulty and needs to be replaced before the printer can continue printing The Ink Cartridge installed is not approved but the user has confirmed that he is using refilled or non hp Ink Cartridges Refer to the User s Guide for further information regarding using refilled or non hp approved Ink Cartridges The main actions for all 4 status messages is as follows Reseat the Ink Cartridge If reseating does not resolve the status message replace the Ink Cartridge It the Status messages continue to appear even after replacing the Ink Cartridge replace the Ink Supply Tubes Page 8 33 HP Designjet 4000 4020 Printer Series Service Manual 3 9 UJ invent Printhea
196. r from the Printer 10 Remove the two small Platen Gears by releasing the clips Tl Remove two 20 screws that secure the Gear Bracket 12 Remove the Gear Bracket from the Printer 13 Remove 79 T 10 screws Type C that secure the Center Platen Removal and Installation n 9 d 5 E 7 Hm e Installation of the Foams invent 14 Remove the Center Platen from the Printer E Paper Advance Calibration Chapter 5 Before installing the Center Platen make sure you check the foams that are stuck on the Vacuum Beam These foams should ONLY be changed if they are damaged In the circumstance where they do need to be changed use the following illustrations to guide you 8 132 Foams will need to be trimmed when stuck to the Vacuum Beam HP Designjet 4000 4020 Printer Series Service Manual LCA Removal and Installation Cartridge Trays Removal 1 Open the Ink Cartridge Door 2 Release the Tray Lever of the required color and pull out the Tray Remove the Ink Cartridge if installed 3 Press down on the Tray clip and pull the Tray completely out of the Printer HP Designjet 4000 4020 Printer Series Service Manual 8 133 invent Input Roller Removal 1 Raise the left and right levers to release the Input Roller 2 Pull out the Input Roller from the Printer
197. r is damaging the Printhead If after replacing the Printhead a third time it is found to be defective again you may need to troubleshoot the Carriage Flex Cables or the Carriage PCA System Error 93 11 Problem Unable to pressurize the IDS Description Corrective Action Try the following E Remove ALL the Ink Cartridges and reinstall them one by one in to the Printer B Replace the Ink Cartridges B Replace the APS Assembly gt Page 8 62 f the System Error continues replace the Ink Supply Tubes Page 8 33 System Error 98 02 this error code will be logged in the system but will not actually appear on the Front Panel Problem Switching to lower performance due to Printhead quality Description Corrective Action Try the following B Try a Printhead recovery on the Printheads Replace the faulty Printhead You may have to print the Image Quality Diagnostics print in order to identify the faulty Printhead System Error Codes and Warnings Explanation System Error Codes explain which component system is failing and what action should be taken to resolve the problem System Error Codes are displayed directly on the front panel but can also be seen on the Information Page and have been defined in the format XX YZ or XX n YZ m B XX Service Part 2 digits E n Service Part Index if more than one used in the product Optional e g Identify the Ink Supply color and number
198. r priming the following message will appear on the Front Panel Replace the installed Ink Cartridges with Ink Cartridges that are new or contain less than 88 of ink Press any key to finish the utility ES Some the current ink supplies are not valid for purge 8 1 2 3 Please replace them by valid cartridges for purge and start again Press any key to finish 3 When the following message appears on the front panel you must select whether you would like to continue with the procedure by pressing the Enter key in which case the Printer will reboot Press Back or Cancel to exit the procedure at this point Press Cancel or the Back key to Exit Prime Tubes ithe system is going to reboot After then the Press Enter to proceed procedure for priming the tubes will start automatically Press ENTER to proceed or BACK CANMCEL to exit Diagnostic Tests and Utilities LA 4 Once the Printer has rebooted the Front Panel will instruct you to open the Window and remove ALL the Printheads installed in the Carriage Lift printhead cover Remove printheads 5 Once the Printheads have been removed the Front Panel will instruct you to install the Setup Printheads into the Carriage Make sure you install the Setup Printheads in stalls 1 3 5 and 7 6 Once all the Setup Printheads are installed the following message will appear on the front panel Close the
199. re connected correctly Check the connection between the PSU and the PrintMech PCA and Interconnect PCA If connection OK check that power reaches the PSU check the power outlet If power reaches PSU replace the PSU Page 8 113 2 Ifthe Printer starts after having pressed the ON button on the Front Panel but the front Panel remains black Corrective Action Interconnect Check the connection between the PSU and the Interconnect PCA If connection OK replace the Interconnect PCA Page 8 93 Check the connection between the Front Panel and the Interconnect PCA If connection OK replace the Interconnect PCA Page 8 93 and the Front Panel gt Page 8 20 invent 3 The Printer is up and running or may have a System Error at the end of the power up sequence For the Carriage PCA connection perform the Scan Axis Test gt Page 4 7 LED on LED on Corrective Action Interconnect PrintMech PCA PCA Check the connection between the PSU and the Interconnect PCA If connection OK replace the Interconnect PCA Page 8 93 Check the System Error that is produced and run the corresponding Diagnostic Test either Scan Axis or Media Axis Test Check the connection between the PSU and the PrintMech PCA and Interconnect PCA If connection OK run the Electronics Module Test to further diagnose the problem Check the connection between the PSU and the Interconnect PCA If c
200. re information on troubleshooting this error code refer to Page 2 3 Before starting to test the sensors the following message will be displayed Press any key to continue Test of sensors Default conditions are Window Closed Right Door Closed Pinch Wheel Down Paper Loaded Press any key to continue CA 5 Window Sensor will be tested first When the following message is displayed on the Front Panel open the Window and press any key to continue Sensors Test of Window sensor Please open the cover Press any Key to continue 6 Ifthe Window Sensor passes the test the following message is displayed on the Front Panel Close the Window and press any key to continue Sensors Test of Window sensor PASS Please close the cover Press any Key to continue If the Window Sensor fails the test the Front Panel will display System Error Code 51 10 For more information on troubleshooting this error code refer to Page 2 15 Check also System Error Code 07 10 refer to Page 2 6 7 The PHC Access Door Sensor will be tested next When the following message is displayed on the Front Panel open the PHC Access Door and press any key to continue Sensors Press any Key to continue 8 Ifthe PHC Access Door Sensor passes the test the following message is displayed on the Front Panel Close the PHC Access Door and press any key to continue Sensors Test of Access D
201. riage If there is a failure at this point the Front Panel will display System Error Code 02 1 10 For more information on troubleshooting this error code refer to Page 2 4 Check also System Error Code 11 10 refer to Page 27 or System Error Code 01 0 10 refer to Page 2 3 Checking Carriage rev CA sessions Ulis If there is a failure at this point the Front Panel will display System Error Code 02 1 10 For more information on troubleshooting this error code refer to Page 2 4 Check also System Error Code 11 10 refer to Page 2 7 22 message will appear on the Front Panel asking whether you would like to check the ISS Communication Select Yes or No by using the Up and Down keys and press Enter to confirm your selection If you select No the printer skips this test and goes to the next one Press Enter to confirm selection Electronics Module Do you want to check the 155 Communication Use UP and DOWN keys to select YES 23 Ifyou select Yes the Printer will check the ISS Communication and the following information will be displayed on the Front Panel Starting Gamut If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 Checking ISS PCA rev The value for the ISS PCA revision must be more than 0 625V if not the Front Panel will display Sys
202. rify the operation of the Vacuum Fans 1 In the Diagnostics Tests submenu scroll to Vacuum Fans Test and press Enter Diagnostics menu a Leese Carriage assembly test Sensors test Ink Delivery system test S 5 Aerosol FAN test Air Pump System test 9 Vacuum FANS test co c 2 This test has not yet been implemented CD ei Fs ard ies por 10 1 Others gt gt gt Bag Broken Recovery This option allows to recover the Printer from a Bag Broken error Perform the Bag Broken Recovery as follows 1 In the Diagnostics Tests submenu scroll to 10 Others and press Enter 5 Sensors test WG Ink Delivery system test gt SvS aerosol FAN test 9 1 Pump System test Vacuum FANS test 2 In the Others submenu scroll to 10 1 Bag Broken Recovery and press Enter 10 1 Bag Broken Recovery lt 19 2 Information 10 3 Unit Information 18 4 Check Ink Supplies 3 The Printer will start to initialize and the Front Panel will display the following messages B Starting Gamut Starting TestCPIO If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 4 The Printer will now detect for a broken bag in the Ink cartridges and the Front Panel will display the fo
203. rinter 3 Roll paper usually gives better Print Quality than a single sheet of the same type of paper 4 When single sheets are being used it is recommended to use the Best print quality setting 5 The most appropriate print quality settings must be used for the current purpose You are most likely to see print quality problems while using the Fast print quality setting 6 n order to achieve the best print quality at the expense of speed always set Printhead Monitoring to Intensive 7 Check that the environmental conditions temperature humidity are within the temperature humidity range as specified for the Printer refer to the User s Guide for further information 8 Remember that certain print quality problems can be solved by E Recovering the Printheads Ink Menu Printheads Recover Printheads Aligning the Printheads Ink Menu Printheads Align Printheads E Performing the Paper Advance Calibration Paper Menu Paper Advance Calibration invent Troubleshooting Print Quality Problems Horizontal Lines Across the Image Banding Description of problem When you look at the image you have printed there are horizontal lines across the image Shown below is an example of what you might see if you have this problem Corrective Action 1 Check that the appropriate print quality settings are being used and reprint the image Refer to Page 6 3 for further information on choosing the correct Print Quality
204. rinting 3 10 Printhead Status Messages While Replacing 3 10 Printhead Cleaner Status Messages While Printing 3 11 Printhead Cleaner Status Messages While Replacing 3 11 Summary of Solving Ink Supplies Problems 3 12 Troubleshooting Printhead Error Codes 3 13 Carriage Interconnect Wiper 3 14 Warranty Information for Ink Supplies 3 15 Warranty Information for Printheads 3 15 HP Designjet 4000 4020 Printer Series Service Manual 3 1 What are Ink Supplies For each of the four ink colors used in the printer there are three separate components The Printhead and the Printhead Cleaner are supplied together and the Ink Cartridge is supplied separately All of these components are called Ink Supplies Ink Cartridges The printer s four Ink Cartridges provide yellow magenta black and cyan ink to the Printheads The color Ink Cartridges supplied with the printer have a capacity of 225 cm and the black cartridge has a capacity of 400 cm It is also possible to buy and use color cartridges with a capacity of 400 cm8 The Ink Cartridges for the hp designjet 4000 series printers require no maintenance or cleaning As long as each Ink Cartridge is inserted correctly into its slot the ink will flow to the Printheads Because the Printheads control the amount of ink transferred to the page you will continue to see high quality printing results even when the ink levels are getting low The front panel displays the status of the
205. rite failed or readback error 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 B f the System Error continues replace the Hard Disk Drive Page 8 107 07 10 Aerosol Fan driver burnt Try the following E Replace the Interconnect Page 8 93 E f the System Error continues replace PCI PCA Page 8 98 08 11 Problem with the Front Panel 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 E If the printer emits one or multiple beeps as the printer turns On perform the procedure Using the buzzer at Power up to Troubleshoot 1 9 Check that the Front Panel cable is not damaged and is correctly connected to the Front Panel and to the Interconnect Check that the Memory Module is installed correctly Check that the cables between the Interconnect and the are not damaged and are correctly connected Check that the cables between the Hard Disk Drive and the Power Supply Unit and the Main PCA are not damaged and are correctly connected Check that the cable between the Power Supply Unit and the is not damaged and is correctly connected E Replace the Interconnect Page 8 93 E Replace the Gam
206. rmware to the latest version 26 14 A wrong Ink Cartridge has been detected Try the following Remove the Ink Cartridges and check that they are the correct ones for this Printer Check that the Printer has the latest Firmware version If not update the Firmware to the latest version E Replace the Ink Cartridges invent System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action 27 03 An error has occurred in Printhead detection 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 E Remove the Printheads from the Carriage and reinsert them E Replace the Printheads E Replace the Carriage Flex Cables Page 8 79 27 14 A wrong Printhead has been detected Try the following Remove the Printheads and check that they are the correct ones for this Printer Check that the Printer has the latest Firmware version If not update the Firmware to the latest version E Replace the Printheads 29 0 01 Printhead Cleaner not inserted correctly in slot 1 Try the following Open the Printhead Cleaner Access Door and check that the Yellow Printhead Cleaner is correctly seated in slot 1 of the Servi
207. rom step 1 Paper not detected Please Load media and start again Before continuing the Printer will check the following B The Media Lever is in the lowered position B The correct paper type is loaded check list on previous page The correct paper size minimum paper size 24 inches It these conditions are not met a warning will be displayed on the Front Panel and you will need to restart the Calibration from step 1 4 The Printer will start to check the PWM Once the PWM has been checked the results will be displayed on the Front Panel Press Enter to continue or press Back or Cancel to exit the calibration avg range 6 to 90000 avg got 31640 3 min diff limit 2088 min diff got 8792 Press ENTER to continue or BACK CANCEL to exit 5 The Printer will start to calibrate the Line Sensor Once the Line Sensor has been calibrated the results will be displayed on the Front Panel Press Enter to continue or press Back or Cancel to exit the calibration Scan Axis Calibration VBLACK VWHITE RANGE B 866 750 950 839 750 950 0 857 750 950 862 750 950 Press ENTER to continue or BACK CANCEL to exit If the values are not within the range specified an error will appear on the Front Panel In this case try the following B Try the Scan Axis Calibration again B Replace the Line Sensor Page 8 31 6 The Printer will start to calibrate the Lin
208. rom the power source prior to performing any maintenance Prevent water or any other liquids from running onto electrical components or circuits or through openings in the enclosure Electrostatic Discharge Refer to the beginning of Chapter 4of this manual for precautions you should take to prevent damage to the Printer circuits from electrostatic discharge Safety Symbols General definitions of safety symbols are given immediately after the table of contents WARNING The Warning symbol calls attention to a procedure practice or the like which if not correctly performed or adhered to could result in personal injury Do not proceed beyond a Warning symbol until the indicated conditions are fully understood and met CAUTION The Caution symbol calls attention to an operating procedure practice or the like which if not correctly performed or adhered to could result in damage to or destruction of part or all of the product Do not proceed beyond a Caution symbol until the indicated conditions are fully understood and met Service Manual HP Designjet 4000 4020 Printer series invent invent Using this Manual Purpose This Service Manual contains information necessary to test calibrate and service HP Designjet 4000 printer Model Q1273A HP Designjet 4000ps printer Model Q1274A HP Designjet 4020 printer Model CM765A HP Designjet 4020ps printer Mod
209. ror code refer to Page 2 5 B Clear GPIO psu lpm If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 Checking voltage If there is a failure at this point the Front Panel will display System Error Code 03 10 For more information on troubleshooting this error code refer to Page 2 5 Starting CDS If there is a failure at this point the Front Panel will display System Error Code 79 03 For more information on troubleshooting this error code refer to Page 2 21 15 message will appear on the Front Panel asking whether you would like to check the PrintMech Select Yes or No by using the Up and Down keys and press Enter to confirm your selection If you select No the printer skips this test and goes to the next one Press Enter to confirm selection Electronics Module you want to check the PrintMech Use UP and DOWN keys to select YES Press UP DOWN to change an ENTER tn select 16 Ifyou select Yes the Printer will check the PrintMech and the following messages will be displayed on the Front Panel B Starting Gamut Starting Tests If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 Checking rev The
210. rrently this will show not available all the time since the media length tracking function in not available Troubleshooting 0 invent 1 Yelow In warranty yes Printhead heath 10 0 10 Error D Code 0 Cleaner Status Working Cleaner replaced with printhead Yes Product Number C5057A Product Name HP No 80 Serial Number 16445235 14 E ink Used 6 mi Usage Time 561842 h Maximum Recovery Levet 1 B Printhead Status OK Missing Reseat Replace or Remove B Expiration Date Manufacture date date marked on the actual Printhead 24 months B Used with non HP ink Can be reset to NO only when a new Printhead has been installed and neither the Ink Tubes nor the Ink Cartridges have been marked as Used with non HP ink Yes Warranty spent Percentage 76 versus 1000ml B Scan Axis Shutdown Corresponds to a media jam 1 Yelow In warranty yes Printhead Status Working Error ID Code 0 Cleaner Status Working B Printhead Health This represents the number of nozzles out of service during the last drop detection that was performed Number of Nozzles Out lt 5 gt or 5 and lt 10 gt 10 lt 20 gt 20 lt 30 gt or 30 and lt 50 gt or 50 and lt 70 gt or 70 and lt 100 gt 100 lt 150 gt 150 lt 200 gt or 200 and lt 400 or 400 EE Status Working Product N
211. rror code refer to Page 2 3 Starting AcumenSupplies If there is a problem while reading the Acumen the Front Panel will display System Error Code 26 n 10 For more information on troubleshooting this error code refer to Page 2 10 Check also System Error Code 13 n 10 refer to Page 2 7 System Error Code 01 2 10 refer to Page 2 4 or System Error Code 01 0 10 refer to Page 2 3 B Reading Ink Supplies If there is a failure at this point the Front Panel will display the message Replace failing ink supplies after running this utility Yellow Magenta Black or Cyan a invent 4 Once the Ink Supplies information is obtained it is displayed on the Front Panel Press any key to exit Check Ink Supplies Y DK purge NO NO NO NO Purge done TES TES TES YES Ink X O94 094 093 95 Ink 3 8 370 373 388 Press any key to finish If any part of the Acumen information is invalid the Front Panel will display System Error Code 74 00 For more information on troubleshooting this error code refer to Page 2 20 5 Once the process is completed OK will be displayed on the Front Panel Check Ink Supplies or 10 5 Others gt gt gt Enable Connectivity This option allows you to enable or disable connectivity depending on the security requirements of the user 1 In the Diagnostics submenu scroll to 10 Others and press Enter Diagnostics menu 4
212. rror code refer to Page 220 If the Serial Number does not have assigned a correct 10 character format or the Part number does not have assigned a correct 6 character format a fail message will appear on the Front Panel In this case re enter in to the Diagnostics Tests submenu and use the diagnostic 13 Error 71 19 Recovery to set the correct Serial Number refer to Page 4 49 The Printer will now check the unit configuration whether it is Standard or Productivity and the Part Number and display the information on the Front Panel Press any key to continue the test Electronics Module Unit config STANDARD Part Number 12 74 Press any Key to continue If the unit configuration is incorrect according to the part number the Front Panel will display a fail message In this case re enter in to the Diagnostics Tests submenu and use the diagnostic 12 Set Unit Configuration to set the correct configuration refer to Page 4 48 11 message will appear on the Front Panel asking whether you would like to check the Gamut Select Yes or No by using the Up and Down keys and press Enter to confirm your selection If you select No the printer skips this test and goes to the next one Press Enter to confirm selection ibo you want to check the aamut Use UP and DOWN keys to select YES Fress UP DOWN to change an ENTER to select 12 If you select Yes the
213. rvice Calibration is to calibrate the intensity of the Line Sensor An incorrect calibration can result in edge detection failures during media loading and incorrect reading of prints that are used for alignment or calibration Platen Blue Line Calibration Page 5 20 The purpose of this Service Calibration is to calibrate the blue line which is marked on the Print Platen Vacuum Calibration gt Page 5 22 The purpose of this Service Calibration is to set the default nominal and real values of the Vacuum Fan Carriage Setup Page 5 23 The purpose of this Service Calibration is to reset the ink short thresholds after replacing the Carriage scs Entering the Service Calibrations Menu 1 Once the message Ready is displayed on the front panel scroll to the Printer Setup Options icon and press the Enter key HP Designjet 4 lt Fast Ethernet EWS address http NPIGBAOCA7EECFB 4 16 25 68 239 2 Once inside the Printer Setup Menus menu press the UP or Down arrow key and the Cancel key together You are now in the Service Tools Menu Information menu Configuration menu Printing defaults menu 0 setup Press Cancel 3 Use the Arrow keys to scroll to the Service Calibrations menu and press the Enter key Service tests Service mmu Service utilities j Press Enter service calibrations mne e oe 4 Use the Arrow keys to scro
214. rvice Utilities submenu scroll to Replace Cutter and press Enter Reset life counters Diagnostic Print Sleep mode Replace cutter service utilities etc m TOT LI ROLLEI A i gt B qus ABEL Press Enter Lai di 2 When the following message appears on the front panel you must select whether you would like to continue with replacing the Cutter by pressing the Enter key Press Back or Cancel to exit the utility Press Cancel B cutter Press Enter E to replace SM the Cutter Press EMTER tn proceed with cutter replacement ar BACK CANMCEL to exit 3 The Carriage will move to the Cutter replacement position and the following message will be displayed on the Front Panel After a few seconds the Printer will begin to shutdown The system is shutting down After then switch off the printer with the back switch Then replace the cutter and switch an the unit again 4 Before replacing the Cutter make sure that you switch the Printer OFF from the rear 8 Set Clock The purpose of this Service Utility is to set the Real Time Clock of the Printer Perform the Set RTC Clock utility as follows 1 In the Service Utilities submenu scroll to Set Clock and press Enter agir nuc ruscs Set SN life counters Diagnostic Print Sleep mode Replace cutter poet RTC clock
215. s and recommended corrective actions Only try one recommended action at a time and check if the error code has disappeared If you have an error code which is not documented in this Service Manual or you have an error which you cannot resolve then report the error to the HP Response Center or the nearest HP Support Office When reporting the error have the following information ready Model and Serial Number of the printer Which firmware revision the printer is using See Note below Check firmware in Setup Menu Information Menu Show Printer Information B The complete error number See Note below The Service Configuration Print The Current configuration sheet Which software application the customer is using name version etc This is the Code that is required when escalating a problem Continuable and Non Continuable Error Codes Some of the Error Codes are continuable which means you can press Enter on the front panel and continue working with the Printer Non Continuable Error Codes do not allow you to continue working with the Printer in this case power the Printer OFF and ON again and see if the System Error disappears If the Error Code reappears then the Printer requires an on site visit in order to resolve the problem o m System Error 01 0 03 Problem Error impact I2C channel Description Corrective Action Try the following Switch the Power OFF from the back of the
216. s message is shown 1 Reseat the Printhead making sure it is installed correctly 2 Clean the Carriage and Printhead flex circuits using the Carriage Interconnect Wiper Page 3 14 3 Replace the Printhead 4 Perform the Electronic Systems Test Page 4 17 Printhead Cleaner Status Messages While Printing Detailed below are the Printhead Cleaner status messages that may be displayed while printing OK The Printhead Cleaner is operating correctly and no action is required End of Life The Printhead Cleaner has reached the end of it s life and should be replaced Printhead Cleaner Status Messages While Replacing The following are the Printhead Cleaner status messages that may be displayed while replacing the Printheads Reseat Cleaner In this situation remove the Printhead Cleaner and install it again Wrong Stall The Printhead Cleaner has been installed in the incorrect place Remove the Printhead Cleaner and check that it is installed in the correct stall of the Service Station Missing The Printhead Cleaner has not been installed or is installed incorrectly The Printer will not print until ALL Printhead Cleaners have been installed correctly Not replaced A new Printhead has been installed without installing a new Printhead with Printhead Cleaner that came with it Make sure a new Printhead Cleaner is installed everytime you replace a Printhead If a Printhead Cleaner needs to be removed or reseated you mu
217. scription Corrective Action System Error Problem Description Corrective Action invent 52 10 Drop Detector switch On Off failure 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 Check that the Drop Detector cable is not damaged and is correctly connected to the Service Station cable Check that the Service Station cable is not damaged and is correctly connected to the Interconnect E Replace the Drop Detector Page 8 31 Replace the PCI PCA Page 8 98 If the System Error continues replace the Interconnect Page 8 93 53 10 Media Sensor failure Try the following Check that the Media Sensor cable is not damaged and is connected correctly to the Interconnect PCA B Replace the Media Sensor Page 8 135 54 10 Media Lever Sensor failure Try the following Check that the Media Lever Sensor cable is not damaged and is connected correctly to the Interconnect PCA E Replace the Media Lever Sensor Page 8 142 55 10 Problem with the Line Sensor Try the following B Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer B Replace the Line Sensor Page 8 31 If the System Error continues replace the Carriage Page 8 75 invent Syste
218. serial number 2 When connecting the Air Tube to the Ink Supply Tubes be carefull not to cut your hand on sharp surfaces While connecting the tube avoid trying to push the tube on in one go Twisting the tube while pushing will reduce the effort required to connect it 3 When installing the new APS Assembly orientate the assembly as shown so the cables cannot touch the side plate CA 4 Use the photo shown here as a guide for routing the cables once the APS Assembly has been installed on the side 23 07 Wai Removal and tslaron Most Left Spittoons Removal Remove the Left Cover Page 8 9 Remove one T 15 screw Type that secures the Most Left Spittoons to the Ink Supply Station 3 Remove the Most Left Spittoons from the Printer E Reset life counter most left spittoon gt Chapter 4 0000000000000 Middle Left Spittoons Removal 1 Open the Window 2 Remove one T 10 screw Type C that secures the Middle Left Spittoons 3 Remove the Middle Left Spittoons from the Printer E Reset life counter mid left spittoon gt Chapter 4 Removal ard tslaron Encoder Strip and Encoder Sensor Removal 1 Remove the Right Cover Page 8 6 2 Remove the Left Cover gt Page 8 9 3 Uncap the Carriage Assembly by manually pulling out the Printhead Cleaner tray 4 Move the Carriage Assembly out of the Service Station
219. set the ink short thresholds ev after replacing the Carriage Perform the Carriage Setup as follows 1 In the Service Calibrations submenu scroll to Carriage Setup and press Enter 2 When the following message appears on the front panel you must select whether you would like to continue with the Carriage Setup by pressing Enter Press Back or Cancel to exit the utility Press Cancel or the Back key to Exit Press Enter to proceed Press ENTER to proceed wi ink short threshold reset Por BACKY CANCEL to exit If the Ink Short Thresholds have been reset correctly the following message will be displayed on the Front Panel Press any key to exit Ink short thresholds have been reset If any of the Printhead ink short thresholds cannot be reset or if the Printheads info cannot be accessed it could point to a possible Firmware error 4 Ifthe utility exits correctly OK will be displayed on the Front Panel Print Quality Print Quality 6 2 Print Quality Troubleshooting Actions 6 2 Choosing the Correct Print Quality Settings 6 3 How to Use the Service Image Quality Diagnostic Print 6 5 What is the Service Image Quality Diagnostic Print 6 5 Considerations for Printing the Diagnostic Print 6 5 Printing the Service Image Quality Diagnostic Print 6 6 Diagnostic Part 1 Alignment Test 6 7 Diagnostic Part 2 Printheads amp Paper Advance Test 6 8 Diagnostic Part
220. splayed on the Front Panel Press Enter to continue or press Back or Cancel to exit the calibration Line Sensor Calibration VBLACK VWHITE RANGE 864 750 950 839 750 950 868 750 950 B 0 G Bof 750 950 Fress ENTER to continue BACK CANCEL to exit If the values are not within the range specified an error will appear on the Front Panel In this case try the following B Try the Scan Axis Calibration again B Replace the Line Sensor Page 8 31 5 The Printer will start to calibrate the Line Sensor position to the Black Printhead It will print a line of black dots and then scan them invent 6 Once the Line Sensor has been calibrated the results will be displayed on the Front Panel Press Enter to finish the calibration or press Back or Cancel to exit the calibration Y Offset Range 38 to 59 Y Offset got 43 Offset Range 24 to 24 Dffset got 14 SVS Offset 1 5 to 1058 SVS Offset got 944 Press any key to exit 7 The Printer will now perform the Printhead Alignment When the following message appears on the front panel you must select whether you would like to continue with the calibration by pressing the Enter key Press Back or Cancel to exit the calibration Press Cancel or the Back key Press Enter E Exil to proceed Press ENTER to proceed wit Pen Alignment calibration cor BACK CANCEL to exit 8 Once the Printhead Alignment
221. ssembly Page 8 140 Remove the Media Sensor Page 8 142 Remove the Center Guide Page 8 149 Remove two T 10 screws that secure the Drive Roller Gear CA 13 Remove the Drive Roller Gear the Printer 14 Remove one T 20 screw Type B that secures the cover on the right hand side of the Printer 15 Remove the Cover 16 Remove two 20 screws Type B that secure the cover on the left hand side of the Printer 17 Remove the Cover 18 Remove three T 20 screws Type B that secure the Media Axis Motor Bracket to the sideplate DU Removal and Installation invent 19 Remove two T 20 screws Type A that secure the Media Axis Motor Bracket to the Chassis 20 Remove the Media Axis Motor Bracket from the Printer 21 Remove the Drive Roller by sliding it to the right then downwards and then out of the Printer I b wu cc CCCCEE Paper Advance Calibration Chapter 5 HP Designjet 4000 4020 Printer Series Service Manual 8 155 Removal and tslaron Installation of the Drive Roller When installing the Drive Roller several different datums have to be met in order to ensure that the Drive Roller has no axial play Use the following illustrations to ensure that ALL the datums are met Media Axis Motor Bracket Media Axis Motor Bracket Drive Roller Bearing Sideplate 1 Datum between Media Axis Motor
222. st first start the Printhead Replacement process Open the window when prompted to do so by the front panel If the front panel shows the Printheads with no Printhead blinking you do not need to touch the Printheads Just close the window again and the Printer will proceed to Printhead Cleaner replacement gt Q Nae N Summary of Solving Ink Supplies Problems Most of the problems that you could encounter when working with the ink supplies are solved with guidance from the front panel A full list of front panel messages are supplied in the User s Guide Problems reseating the printhead If you have inserted the printhead into the printhead carriage assembly and the printer does not BEEP try the following steps Check that the protective tape has been removed from the printhead E Insert the Printhead into the Carriage Assembly but this time correctly close the cover using the latch Clean the electrical contacts on both the printheads and the printhead Carriage Assembly using the carriage interconnect wiper gt Page 3 14 E Replace the Printhead with a new one You Cannot Insert the Ink Cartridge Into the Printer Ensure that you have the correct hp no 90 Ink Cartridge Ensure that the Ink Cartridge is the correct color for that slot Ensure that the Ink Cartridge is the correct orientation with the color coded label at the top You Cannot Insert the Printhead Into the Printer Ensure that you have
223. submenu scroll to Line Sensor Calibration and press Enter can axis calibration Press Enter Service Station calibration M MM Press Enter Paper advance calibration Drop Detector calibration Line Sensor calibration Platen blue line calib Emm warm ca1i1hratinn 2 When the following message appears on the front panel you must select whether you would like to continue with the calibration by pressing the Enter key Press Back or Cancel to exit the calibration Press Cancel or the Back key Press Enter ic Exit to proceed Press ENTER to proceed with Line Sensor calibration ar BACK CANCEL to exit 5 16 HP Designjet 4000 4020 Printer Series Service Manual 3 If media is not loaded the following message appears on the front panel Load media in to the Printer and start again from step 1 Line Sensor Calibration Paper not detected Please Load media and start again Before continuing the Printer will check the following B The Media Lever is in the lowered position The correct paper type is loaded check list on previous page The correct paper size minimum paper size 24 inches If these conditions are not met a warning will be displayed on the Front Panel and you will need to restart the Calibration from step 1 4 The Printer will start to calibrate the Line Sensor Once the Line Sensor has been calibrated the results will be di
224. t System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action 44 10 Problem with the Aerosol Fan 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 Check that the Aerosol Fan cable is not damaged and is correctly connected to the Interconnect E Replace the Aerosol Fan Page 8 29 f the System Error continues replace the Interconnect Page 8 93 44 11 Aerosol Fan not connected Try the following Check that the Aerosol Fan cable is not damaged and is correctly connected to the Interconnect B Replace the Aerosol Fan Page 8 29 5110 Window Sensor failure Try the following Check that the Window Sensor cable is not damaged and is correctly connected to the Interconnect PCA E Replace the Window Sensor 51 110 PHC Access Door Sensor failure Try the following Check that the Access Door Sensor cable is not damaged and is correctly connected to the Interconnect PCA B Replace the PHC Access Door Sensor System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem De
225. t gt gt Unit Information eur uont This option allows you to view the following Printer information Y E Firmware version B Serial Number B Part Number B PS Language for HP Designjet 4000PS View the Unit Information as follows 1 In the Diagnostics Tests submenu scroll to 10 Others and press Enter 4 Ldll laye dgosullLyY Leoe Sensors test Ink Delivery system tes 5 Press Enter Nc HER svs Aerosol FAN test 8 g Pump System test Vacuum FANS test Others 10 1 Bag Broken Recovery 18 2 10 Information 19 Unit Information x _ 18 4 Check Ink Supplies Press Enter 3 The Printer will start to initialize and the Front Panel will display the following messages B Starting Nvm Getting FW version Getting Serial Number Getting Part Number If there is a failure at this point the Front Panel will display System Error Code 79 03 For more information on troubleshooting this error code refer Page 2 21 If the Serial Number does not have assigned a correct 10 character format or the Part number does not have assigned a correct 6 character format fail message will appear on the Front Panel In this case re enter in to the Diagnostics Tests submenu and use the diagnostic 13 Error 71 19 Recovery to set the correct Serial Number refer to Page 4 49 Getting PS Language for HP Designjet 4000PS If there is a
226. t Panel will display System Error Code 56 03 For more information on troubleshooting this error code refer to Page 2 17 Once the Analog Encoder calibration is completed the Front Panel will display the results ES Analog Encoder results CHANNEL GAIN OFFSET ads 818 B ad 019 Press BACK CAMCEL to reject or ENTER to accept Acceptable values are Gain between 3 and 31 Offset between 12 and 25 If the results are acceptable press Enter If the results are unacceptable then press the Back Cancel key and the Front Panel will display System Error Code 56 10 For more information on troubleshooting this error code refer to Page 2 17 Starting Media Path If there is a failure at this point the Front Panel will display System Error Code 81 10 For more information on troubleshooting this error code refer to Page 223 B Homing and repeat test If there is a failure at this point the Front Panel will display System Error Code 56 10 For more information on troubleshooting this error code refer to Page 2 17 9 The Printer will now check the Media Drive PWM You must load media in to the Printer and press any key to continue the test raise the pinch Load the paper roll and lower the pinch lever Press any key to proceed invent 10 When the PWM check is being performed the following message will be displayed on the Front Panel B PWM test with paper 11 Once
227. t as follows 1 in the Diagnostics Tests submenu scroll to 7 SVS Aerosol Fan Test and press Enter Carriage assembly test sensors test Ink Delivery system tes svs hero sal FAN test 1 old AXIS CES i x j p Media Drive test a u Press Enter Electronics module test A ls EE 2 This test has not yet been implemented invent 8 Air Pump System Test firmware 10 1 1 4 The purpose of this test is to verify the operation of the Air Pressurization System APS Perform the Air Pump System test as follows In the Diagnostics Tests submenu scroll to 8 Air Pump System Test and press Enter a Seo LI Ivi 3 Electranics module test _ M4 Carriage assembly test WHS sensors test 6 7 Ink Delivery system tes SyS Aernsnl FAN test 18 Air Pump System test 2 A message will appear on the Front Panel asking whether you would like to check run the diagnostic 93 11 Select Yes or No by using the Up and Down keys and press Enter to confirm your selection Press Enter to confirm selection LX Use UP and DOWN keys select 3 If you select Yes the printer will display the following message ensure all the ink are installed correctly and press any key to continue air Pump System all the ink cartridges Press ENTER key to start the di
228. t the Ink Cartridge being used no longer uses third party ink Component Usage Bett usage cycles 2075 Maotorusadge Xcyclesy 2075 Carriage usage cycles 2075 Trailing cable usage cycles 2075 usage cycles 2075 Tube uzed with non HP ink Spittoon Section This section contains information on the different Spittoons located in the Printer Sphioon Usage Lert te Right Spittoon 1 0 00 cc Spittoon2 0 00 Spittoon 3 0 00 cc Spitteon 4 0 00 Black clearer spittoon 1 0 48 cc Black cleaner spittoon 2 0 45 cc Black Cleaner Spittoon 1 UJ invent Event Logs This page contains the following information Last 20 System Error Codes which prevented the Printer from booting Last 20 System Warnings which did not prevent the Printer from booting but which required the user to acknowledge the problem Printhead Error log Event Logs Ones Mew 200 Produci eee HP 4000 Sota SGSNSTITM e vernon MN 3112 Produc S r O tens every Code tena YN Version Med Dis Due 1 zevere 600 01001000 Ww 3112 1 50029 cpp 006 20020225 2 severe 8801 0780110001 ONA 11 530299 CarriageServoddetior 1537 2050925 3 arven ThBABEFACF 3 17104 Common opp fod 20041125 s severe AJNI jrm Scans eatis cpp tes 241110 severe ThA UDAD ACC A 121043
229. ted so you will need to perform Color Calibration again for every new media that is loaded in to the Printer Press 4 to continue If the Color Calibration fails for any reason a warning message will appear on the Front Panel In this case try the following E Enter the Front Panel menu and retry the Color calibration B If the Calibration fails again check the Calibration pattern to see if any of the Printheads are printing incorrectly If necessary perform a Printhead Recovery through the Front Panel and retry the Calibration 11 Once the complete Line Sensor calibration is completed successfully OK will be displayed on the Front Panel Line Sensor Calibration Service Calibrations invent 6 Platen Blue Line Calibration The purpose of this Service Calibration is to calibrate the blue line which is marked on the Print Platen Perform the Platen Blue Line Calibration whenever Center Platen is disassembled or replaced Perform the Platen Blue Line Calibration as follows 1 In the Service Calibrations submenu scroll to Platen blue line calib and press Enter Scan Axis calibration Service Station calibration Paper advance calibration Drop Detector calibration Line Sensor calibration Platen blue line calib Eee 2 When the following message appears on the front panel you must select whether you would like to continue with the calibration by pressing the Enter key Press Back
230. tem Error Code 01 2 10 For more information on troubleshooting this error code refer to Page 2 4 Check also System Error Code 01 0 10 refer to Page 2 3 If there is a problem in reading the values the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 24 When the Front Panel displays the following message open the Ink Cartridge Door and check that all the Ink cartridges are correctly installed Press any key to continue Please check that all ink 4 supplies are inserted in the correct position Press any Key to continue 25 The Printer will continue with the ISS Communication test and the following messages will be displayed on the Front Panel Starting ISS Ink Sup If there is a failure at this point the Front Panel will display System Error Code 13 n 10 For more information on troubleshooting this error code refer invent to Page 2 7 Check also System Error Code 01 2 10 refer to Page 2 4 or System Error Code 01 0 10 refer to Page 2 3 Getting ISS data If there is a failure at this point the Front Panel will display System Error Code 74 00 For more information on troubleshooting this error code refer to Page 220 Checking ISS Ink Sup If there is a failure at this point the Front Panel will display System Error Code 26 n 10 For more information on troubleshooting this error code refer to Page 2
231. ter invent Removal and Installation PrintMech PCA Removal 1 Remove the Left Connector Cover Page 8 19 2 Remove three T 15 screws Type that secure the PSU cover 3 Remove the PSU Cover from the Printer 4 Disconnect ALL cables the PrintMech PCA HP Designjet 4000 4020 Printer Series Service Manual 8 119 5 Remove two 15 screws Type B that secure the PrintWech Cover 6 Slide the PrintMech Cover out of the Printer 7 Remove eight T 10 screws Type 1 that secure the PrintMech PCA 8 Remove PrintMech from the Printer Formatter Battery Removal r E 1 Remove the JetDirect Card if installed 2 Remove three T 15 screws Type that secure the cover 3 Remove the Main PCA Cover from the Printer 4 Push the clip down and release the battery from the Main PCA Push here to release battery Removal and Installation DU invent Line Sensor Assembly Removal 1 Remove the Right Cover Page 8 6 2 Press the two side of the Carriage PCA Cover and unclip from the Carriage Assembly 3 Release the clip and disconnect the Line Sensor cable from the Carriage PCA 4 Remove one T 15 screw Type G that secures the Line Sensor to the carriage Assembly 8 124 HP Designjet 4000 4020 Printer Series Service Manual CA
232. the file was sent so the file cannot be printed on the paper type currently loaded Try the following E Resend the file to be printed on the current paper type Change the paper type to the type that was loaded when the file was originally sent System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action 67 04 Input Output problem through an Firewire Port Try the following Check that the Firewire cable is correctly connected to the Printer Check that the Printer has the latest Firmware version If not update the Firmware to the latest version B f the System Error continues replace the Main PCA Page 8 105 68 03 Non critical permanent data was lost This does not prevent the Printer to work only that internal life counters will not be recorded until the Printer is restarted Try the following B Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer Check that the Printer has the latest Firmware version If not update the Firmware to the latest version 71 03 Out of memory failure It is recommended that you remove any unnecessary files from the Hard Disk Drive us
233. the Ink Cartridge hp is recommended The current warranty status of the Ink Cartridge Obtaining Printhead Information 1 Scroll to the Ink Menu icon and press Enter Press Enter to confirm selection aE na T use UP and Cy DOWN keys to select Press Enter to confirm selection Use UP and DOWN keys to select Ink cartridges Drying options invent In the Printheads submenu scroll to Printhead information and press Enter Press Enter to confirm selection Use UP and DOWN keys to select Recover printheads Align printheads Calibrate color Replace printheads now 4 In the Printhead Information submenu scroll to the Printhead that you want information on and press Enter Press Enter to confirm selection Printhead information Yellow printhead 1 me 1 i 4 p t Use UP and vellow printhead 2 1 i Jp Nw DOWNI keys Magenta printhead 3 to select Magenta printhead 4 Black printhead 5 Black printhead Lovan nrintheand 7 5 The front panel displays information on the selected printhead Product name HP 98 Product number C5057A Serial number 16455695 33 Printhead status DK Ink fired 3 ml Warranty status In warranty Cleaner status DK The information supplied is The make of the printh
234. the PWM check is done the results will be displayed on the Front Panel Press any key to finish the test avg 16000 To 2806000 PWM avg got 16993 8 Speed error limit 48 Speed error got 25 StDev 1 00 To 850 08 StDbewv got 349 51 Press any key to finish If there is a failure at this point the Front Panel will display WARMIMG High Frictian avg 160600 2888068 avg got 13300 0 Speed error top limit 48 speed error got 208 StDev 1 86 5650 00 StDey got 128 53 Press any key finish 12 Once the test is completed OK will be displayed on the Front Panel e T sot ev 1 2 Press Enter to confirm selection 3 3 Electronics Module Test The purpose of this test is to diagnose a failure in the operation of the Components of the Electronics Module Electronics Module to Carriage and ISS Communication Perform the Electronics Module test as follows In the Diagnostics Tests submenu scroll to 3 Electronics Module Test and press Enter Scan Axis test 2 Media Drive test 3 Electronics module test 4 Carriage assembly test 5 sensors test 5 Ink Delivery system tes 1 FAM tect A message will appear on the Front Panel asking whether you would like to check the Formatter Select Yes or No by using the Up and Down keys and press Enter to confirm your selectio
235. the correct hp no 90 Printhead Ensure that the printhead is the correct color for that slot Ensure that the printhead is in the correct orientation Ensure that the protective cap is removed from the Printhead You Cannot Insert the Printhead Cleaner Into the Printer Ensure that you have the correct hp no 90 printhead cleaner Ensure that the printhead cleaner is the correct color for that slot Ensure that the printhead cleaner is in the correct orientation Troubleshooting Printhead Error Codes The Printhead Error Codes can be found on the Service Information Print Setup Menu Information Menu Internal Prints Print Service Information Current Information The actual error code is a decimal number and it has to be converted to a binary number before it can be used In order to convert the decimal error code to a binary error code you can use a calculator For example if you had the error code 4099 you would enter 4099 as a decimal number and then select the binary option which would give you a binary number of 1000000000011 The following table explains the meaning of the different bits O or 1 When the value of the error code is reported as O it means that the Printhead is working correctly _ Meaning Bit Meaning The binary number needs to be read from right to left so that the 1st bit corresponds to the right one of the binary number For example the error code 4099 is c
236. the following message will be displayed on the Front Panel Prog slow PWM paper If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 5 Before continuing the following message will appear on the Front Panel Remove the media if it is still loaded and make sure you stay out of the Print Platen area if the Window is open al Please remove the media for testing and keep out from the platen zone Press any Key to continue UJ invent 6 The Printer will now test the Media Drive moving in an open loop in one direction and the following message will be displayed on the Front Panel Press any key to continue the test Checking Open Loop ROLL Movement done 31298 Press any Key to continue Check that the movement done is more than 100 encoder units in absolute value If the movement done is less than 100 encoder units then open the Window and check for any visible obstacles restricting the movement of the Drive Roller or the Overdrive Assembly In this case press any key to finish the test The Printer will now test the Media Drive moving in an open loop in the opposite direction and the following message will be displayed on the Front Panel Press any key to continue the test EE Checking Open Loop UNRDLL Movement done 38441 Press any key to continue Check that the
237. the front panel corresponds to the paper that is loaded 5 f you have an 1 2 file produced for an HP Designjet 1000 Printer series and you want to print it on an HP Designjet 4000 Printer series proceed as follows using the Embedded Web Server or the front panel E Using the Embedded Web Server in the Color Management section of the Submit Job page set the Input Profiles RGB to None Native E Using the front panel Enter the Setup Menu then Printing defaults menu gt Color Options gt RGB Input Profile None Native For other HP Designjet Printers set both printers to match the screen colors sRGB if selectable as when printing with separate HP GL 2 drivers Problems with Image Clipping This normally indicates a discrepancy between the actual printable area on the loaded paper and the printable area as understood by the software Check the actual printable area for the paper size that is loaded printable area paper size margins The Windows HP GL 2 driver displays the printable area in the Paper Quality tab Check what the software understands to be the printable area which it may call printing area or imageable area For example some software applications assume standard printable areas that are larger than those used in this Printer E f a very long image needs to be printed on a roll check that the software is capable of printing an image of that size Check that the
238. to the Printer with an acceptable success rate the Printer allows the media to be loaded with a certain level of skew This initial skew gets automatically corrected as the media is advanced there is a transition area where the media rotates until the skew gets corrected and the paper stabilizes The media rotation in the transition zone is what actually creates the vertical line straightness problem Corrective Action Make sure that the media is loaded as straight as possible Use the blue line of the Print Platen to align the edge of the media correctly An alternative way of loading media is to align the media with the end of the overdrive This way media waste will be minimized and it will also reduce media load problems Check that the appropriate print quality settings are being used Refer to Page 6 3 for further information on choosing the correct Print Quality settings Roll paper usually gives better vertical lines than a single sheet of the same type of paper If sheet paper must be used then it is recommended to use the Best print quality setting Try using a heavier paper type such as HP Heavyweight Coated Paper or HP Productivity Gloss Align the Printheads Ink Menu Printheads Align Printheads Bubbles Only occurs in Cyan Magenta and Yellow Description of problem The bubbles problem is normally seen as banding white lines and the severity is quite different depending on the amount of nozzles out Correcti
239. top of the Print Soft Landing B Avioneta Soft Landing Description of problem There is a type of defect that affects only the top of the print within 5 5 cm 2 17 inches of the leading edge of the paper You may see a thin or thick band of inconsistent color This problem is caused because of the different grains that each Printhead has Shown below is an example of what you might see if you have this problem Corrective Action 1 The easiest solution is to select the Extended Margins option in the driver the Embedded Web Server or the Front Panel This means that the area of the paper affected by the problem at the top of the page will no longer be used If using the Extended Margins option is not possible the try the following E Recover the Printheads Ink Menu Printheads Recover Printheads Align the Printheads Ink Menu Printheads Align Printheads E Perform the Paper Advance Calibration Paper Menu Paper Advance Calibration 2 Check that the appropriate print quality settings are being used Refer to Page 6 3 for further information on choosing the correct Print Quality settings Avioneta Description of problem The Vacuum suction varies depending on the amount of media covering the printzone The Vacuum suction increases as the beginning of the media advances over the printzone and this causes the Avioneta defect This defect mainly affects CAD plots during the first swath and is seen as roughness or eve
240. tself in several different ways A thick colored band Thinner colored bands Discontinued colored blocks Thin lines ITTA Corrective Action Clean the electrical connections of the Printhead that seems to be responsible for the problem in this example the Magenta Printhead is responsible Recover the Printheads Ink Menu Printheads Recover Printheads Reprint the image with the same settings as before If the problem continues replace the Printhead that seems to be causing the problem If you are not sure which Printhead is responsible use the Image Quality Diagnostic Print to identify it Problems with Graininess Description of problem Shown below is an example of what you might see if you have problems with graininess Corrective Action 1 Follow the general advice given on Page 6 15 2 Align the Printheads Ink Menu Printheads Align Printheads 3 Ifthe image has been printed using the Normal or Fast print quality setting and it is not acceptable to the customer then reprint it using the Best print quality setting 4 If the problem continues perform the Paper Advance Calibration Print Smudges when Touched Description of problem The black ink pigment can smudge when touched by a finger or a pen This is particularly noticeable on the following materials Vellum Translucent Bond B Films Productivity Photo Paper E Natural Tracing Paper To reduce
241. up print mode Feed Roller change 2 There are three different standby behaviors to choose from E Remain at standby This is the default behavior B Unload If the media has been at the standby position for more than 260 hours the printer will unload the following types of media Coated Heavy weight Coated Super Heavyweight Coated Any Gloss Trim after resume If the media has been at the standby position for more than 260 hours the first 20cm will be trimmed before printing on the following types of media Coated Heavy weight Coated Super Heavyweight Coated Any Gloss Use the Up and Down keys to select the Media Standby Behavior and press the Enter key CD ei Ford ies 3 Once the new Media Standby Behavior has been selected the Front Panel displays the following Media standby behaviour n New media standbs behaviour TRIM AFTER RESUME invent 11 Backup print mode we The purpose of this Service Utility is to set the Backup Print Mode of the Printer The Backup Print mode is a mode that increases the number of passes to ensure a consistent level of image quality when there is a significant number of nozzels out in the printheads Change the backup print mode as follows 1 In the Service Utilities submenu scroll to Backup Print Mode and press Enter service utilities Wr steep
242. urther troubleshoot the error code 74 00 Failed getting Part Number Serial Number 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 Check that the Printer has the latest Firmware version If not update the Firmware to the latest version 74 01 Error uploading firmware update file Try the following B Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer E Resend the firmware update file to the Printer invent System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action 74 04 Old Vacuum Fan detected upgrade the Firmware Try the following Check that the Printer has the latest Firmware version If not update the Firmware to the latest version 76 03 Out of Disk space Data was lost 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 Resend the file to the Printer f the System Error continues it is recommended that you remove any unnecessary files from the Hard Disk Drive using the Web Server E Perform a
243. ut Page 8 98 System Error 11 10 Problem Trailing Cable does not seem to be detected Description Corrective Action Try the following Check that the Trailing Cable is not damaged Check that the Trailing Cable is correctly connected to the Carriage PCA Interconnect PCA and to the Gamut PCI PCA E Replace PCI PCA gt Page 8 98 E Replace the Trailing Cable Page 8 33 E Replace the Carriage Page 8 75 System Error 13 n 10 Problem Problem starting acumen supplies Description Corrective Action Try the following B Remove ALL Ink Cartridges and reinstall them in the Printer Check that the ISS to Cartridge cables are not damaged and are correctly connected to the Ink Supply Tubes PCA E Replace the ISS to Cartridge cables Page 8 58 B Replace the Ink Supply Tubes Page 8 33 System Error 21 03 Problem Service Station servo shutdown Description Corrective Action Try the following B Switch the Power OFF from the back of the Printer and disconnect the Power cord Reconnect the power cord and power On the Printer If the System Error continues replace the Service Station Page 8 23 E Replace the PrintMech PCA Page 8 119 E Replace the Interconnect Page 8 93 System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action
244. utput Only Contains a Partial Print It the output that was expected only contains a partial image then try the following to resolve the problem 1 Was the Cancel key pressed before all the data was received by the Printer If so send the file again and make sure that the Cancel key is not pressed 2 Thel O Timeout setting may be too short Increase timeout setting Setup Menu I O Setup IO Timeout and then send the file again 3 There might be a problem between the Printer and Computer Check the cable between the computer and the Printer to make sure it is not damaged and is connected correctly 4 Make sure that the software settings are correct for the current page size e g long axis prints 5 If network software is being used make sure it has not timed out 6 32 HP Designjet 4000 4020 Printer Series Service Manual Image is One Portion of the Printing Area If the output that was expected only contains an image in one portion of the Print Area then try the following to resolve the problem 1 Check to see if a too small a page size has been selected in the application 2 Check to see if the application is set to print the image in only one portion of the page If the problem continues then the cause could be software printer incompatibility Check to see if the software is configured correctly for the Printer Try changing the Graphic Language through the Front Panel Setup Menu Printing
245. value for the PCA revision must be more than 0 625V if not the Front Panel will display System Error Code 01 1 10 For more information on troubleshooting this error code refer to Page 2 3 confirm selection 17 18 B Clear GPIO psu lpm If there is a failure at this point the Front Panel will display System Error Code 01 0 10 For more information on troubleshooting this error code refer to Page 2 3 Disable Vacuum Fans Checking Vacuum Fans B Enable Vacuum Fans Checking Vacuum Fans B Disable Vacuum Fans If there is a failure at this point the Front Panel will display either System Error Code 01 0 10 or System Error Code 01 1 10 For more information on troubleshooting either of these error codes refer to Page 2 3 Starting CDS If there is a failure at this point the Front Panel will display System Error Code 79 03 For more information on troubleshooting this error code refer to Page 2 21 Getting unit config If the Part Number cannot be read the Front Panel will display System Error Code 74 00 For more information on troubleshooting this error code refer to Page 2 20 IF the current Part Number is not in the correct 6 character format the Front Panel will display a fail message In this case re enter in to the Diagnostics Tests submenu and use the diagnostic 13 Error 71 19 Recovery to set the correct Serial Number refer to Page 4 49 If the unit configuration is incorrect
246. ve Action 24 03 Ink Setup failure Ink Supply Tubes purge failed 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 Try purging the Ink Supply Tubes again once the Printer has been rebooted Install new Ink Cartridges in to the Printer and try purging the Printer again 24 10 Broken bag detected in Ink Cartridge Try the following B Remove the Ink Cartridges and check for ink leakage in the ISS area Perform the Bag Broken Recovery Diagnostic Page 4 37 to further troubleshoot the error code 26 0 01 Bad contact detected in ISS slotO floater Try the following E Remove the Yellow Ink Cartridge and reinstall it in to the Printer B Replace the Yellow Ink Cartridge Check that the ISS to Cartridge cable Yellow Ink Cartridge is not damaged and is correctly connected to the Ink Supply Tubes PCA E Replace the ISS to Cartridge cable Yellow Ink Cartridge Page 8 58 B Replace the Ink Supply Tubes Page 8 33 26 1 01 Bad contact detected in ISS slot floater Try the following E Remove the Magenta Ink Cartridge and reinstall it in to the Printer B Replace the Magenta Ink Cartridge Check that the ISS to Cartridge cable Magenta Ink Cartridge is not damaged and is correctly connected to the Ink Supply Tubes PCA E Replace ISS to Cartridge cable Magenta Ink Cartridge Page 8 58
247. ve Action Check that the appropriate print quality settings are being used Refer to Page 6 3 for further information on choosing the correct Print Quality settings Recover the Printheads Ink Menu Printheads Recover Printheads Turn Printhead Monitoring to Intensive to guarantee consistent quality while using the Best print quality setting Replace the faulty Printhead HP Designjet 4000 4020 Printer Series Service Manual 6 37 invent Black Printhead Decap Problem Description of problem When the Black Printhead does not fire any ink during one swath but only prints at the end of the swath a thin vertical line a defect can be seen Some information to take into consideration The part of the thin line which is before the black box is of much better quality compared to the part which has not been printed for at least the last 37 5 inches 95 3 cm B The longer the Black Printhead is not printing the more visible the defect will be The defect is not seen with thicker lines B If the Black Printhead is not printing at the beginning of the print e g no black frame around the print the defect can be worse This specific defect is called Inter Swath When the Black Printhead is printing at the beginning of the swath e g when there is a black frame around the print the specific decap defect is called Intra Swath Decap Corrective Action 1 Check that the Printer has th
248. warning means that there is a mechanical problem in the Printer Encoder Strip friction Carriage Belt Slider Rod etc Press any key to continue with the PWM test The Printer will now start to initialize the Scan Axis servo and the Front Panel will display the following information B Starting Carriage Motor Off On Carriage Motor Doing right side bump Doing a left side bump Exit bump position If there is a failure at this point the Front Panel will display System Error Code 86 10 For more information on troubleshooting this error code refer Page 224 The Printer checks the complete length of the Scan Axis and displays the result on the Front Panel The length has to be between 1158629 and 1164616 can Axis Checking scan axis length Total length 1152384 Press any Key to continue CA If it is shorter it means that there is an obstacle blocking the Scan Axis path and the Front Panel will display System Error Code 86 11 For more information on troubleshooting this error code refer to Page 2 24 If the length is longer it means that the carriage has a datum broken or the Carriage Stopper is not installed and the Front Panel will display System Error Code 02 10 For more information on troubleshooting this error code refer to Page 2 4 12 The Printer will now check the Scan Axis PWM and the following information will be displayed on the Front Panel Starting Scan Axis
249. warranty for the Printheads will end when one of the following occurs 24 months from the date of manufacture that is printed on the Printhead or B When 1000ml 33 8 oz of HP original ink has been consumed by the Printhead or When the user confirms that they have used non hp ink in empty over ride mode Diagnostic Tests and Utilities Introduction 4 2 Diagnostics Self Test 4 2 Diagnostics Tests 4 3 Entering the Diagnostics Tests Menu 4 5 Scan Axis Test 4 7 Media Drive Test 4 12 Electronics Module Test 4 17 Carriage Assembly Test 4 27 Sensors Test 4 28 Ink Delivery System Test 4 32 SVS Aerosol Fan Test 4 33 Air Pump System Test firmware 10 1 1 4 4 34 Vacuum Fans Test 4 36 10 1 Others gt gt gt Bag Broken Recovery 4 37 10 2 Others gt gt gt IO Information 4 40 10 3 Others gt gt gt Unit Information 4 41 10 4 Others gt gt gt Check Ink Supplies 4 43 10 5 Others gt gt gt Enable Connectivity 4 45 11 EEROM Reset 4 46 12 Set Unit Configuration 4 48 13 Error 71 19 Recovery 4 49 14 I O Tests 4 51 15 Log Management 4 53 Service Utilities 4 55 Entering the Service Utilities Menu 4 57 Turn Drive Roller 4 59 Prime Tubes 4 61 Set SN 4 65 Reset Life Counters 4 66 Diagnostic Print 4 68 Sleep Mode 4 69 Replace Cutter 4 70 Set Clock 4 71 PHC Maintenance 4 72 10 Media standby behavior 4 74 11 Backup print mode 4 76 12 Sanit
250. we We facet loot gt ox 1 m e z m Tee Mr ans dee pun Uema Leone Lee 1 Leer isa 17 200 2 gt EL LJ 22 ow ute p nei weg rg Reel wen a ue Pr ofa Ste hunder 20096 11 4 Gis 2943112 204 U8 184 20045413 Seat Jl apr an Dem 70000117 Dez gt Cechy ze mea exe 225 Ltd n ue Mo vet n tem jo rmm The first two lines are available at the beginning of each Service Information Page and contains standard information like Service ID Firmware version Items of Interest The items explained below are useful to know Current Media Printhead and Ink Information Oste 766 22 2003 Product Name WP Oesgnet 400003 Serai Number 506441190060447 Fermo art A 131311 Product counter 012744 ZervceD 14112 Language fagh Memory Sce 254 MB 42008 Current Temperate 266 C 2C Caren 5 15 000270 Pacer Pal Red Paper Loaded Status OK 5 Bert iste miyet Paper Meca Wem 1068 mm 1 42 06 mches Meda Length ecl Temperature and Humidity The sensors are located on the ISS at the top of the Ink Cartridges B Active Paper Path Whether Roll or Cut Sheet is currently loaded B Remaining Media Length Cu
251. within the temperature humidity range as specified for the Printer refer to the User s Guide for further information Do NOT perform the Paper Advance Calibration as this will recenter the actual advance factor BUT won t prevent the differential banding due to paper expansion Bidirectional Offset Light Color Density Areas Description of problem There seems to be a slight Bidirectional offset when printing light color density areas in lines or drawings This happens when printing on Plain Paper using the Fast print quality setting with the Maximum Detail option switched Shown below is an example of what you might see if you have this problem X 1 s T 3 n E A 2 2 Ay J i A A E d 6 4 S Corrective Action If the image has been printed using the Fast print quality setting then reprint it using the Normal or Best print quality setting Avoid printing light density areas lines especially grays Turn On the Maximum Detail option in the Driver Ink Contamination on Yellow Printhead Description of problem In certain circumstances the Yellow Printhead is cross contaminated by aerosol coming from the Black Printhead This occurs when the aerosol removal system in the Service Station ceases to work When this problem occurs you will actually see nozzles out and misdirected In this situation Printhead Recovery will not help to resolve the prob

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