HP Designjet 4000, 4020 service manual

For HP Internal Use Only

©Copyright Hewlett-Packard Company 2009

This document contains proprietary information that is protected by copyright. All 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.

WARNI NG

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 from 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.

WARNI NG

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.

Content Management Department, Barcelona Division, Hewlett-Packard Espanola, S.A. Avda. Graells, 501 08190 Sant Cugat del Valles Spain

Safety Symbols

General definitions of safety symbols are given immediately after the table of contents.

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 (Model 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.

HP Designjet 4000/4020 Printer Series Service Manual

Table of Contents 1

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

HP Designjet 4000/4020 Printer Series Service Manual

Table of Contents

HP Designjet 4000/4020 Printer Series Service Manual

Troubleshooting 1

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 Cartridge 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

HP Designjet 4000/4020 Printer Series Service Manual

1-1

Troubleshooting

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.

 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.).

When reporting the System Error Code, make sure that you supply the full Error Code and the firmware version. Without this information, HP Support Personnel cannot help you.

Performing a Service Test on a Failed Assembly

If 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.

If the test on that component/assembly passes, you should NOT replace it.

For information on the Service Tests and how to use them see Chapter 4 - Diagnostic Tests and Utilities.

1-2

HP Designjet 4000/4020 Printer Series Service Manual

Troubleshooting

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.

Remember that certain Calibrations are required even if an Assembly has been disassembled to gain access to another Assembly or Component.

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 the 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

⇒ Page 4-17.

Test

Cover Sensors are not Working

1 Perform the Sensors Test ⇒ Page 4-28.

2 Check if the cable for the faulty sensor is not damaged and is connected

correctly.

3 Replace the faulty Sensor.

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1-3

Troubleshooting

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.

2 Excessive ink deposits on the Platen surface can fool the sensor by reflecting

the light. Clean the Center Platen.

3 The Line Sensor is not calibrated correctly. Perform the Line Sensor

Calibration ⇒ Page 5-16.

4 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

1-6

refer to Page

The failure modes "media jam" and "head crash" are grouped together because in many cases a 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.

1 Did the media jam occur when loading media?

 If the client has had media jams, it is common for pieces of media to get

stuck in the media path. Clear the media path.

When clearing a media jam, sometimes media is stuck in the paper path. To clear this, you must lift the Pinchwheel Lever and insert thicker media into the paper path to push out the media that is still stuck there.

2 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.

3 Check that the Vacuum Fan works correctly.

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HP Designjet 4000/4020 Printer Series Service Manual

Troubleshooting

Troubleshooting Shutdowns

If a 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.

In each case, make sure that you power OFF the printer before attempting any procedures to resolve the problem.

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 paper 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

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 Oil along the complete axis of the Slider Rods.

After applying the Oil, perform the Scan-Axis Test

⇒ Page 8-91.

⇒ 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.

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1-5

Troubleshooting

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:

 Ink Smearing on the Media.  Printhead crashes 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:

1. 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:

 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.

2. 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 Limiting is

OFF, turn it ON.

 Never use HP Coated Media for High Density prints. As a substitute use

HP Heavy Coated Media.

1-6

HP Designjet 4000/4020 Printer Series Service Manual

Troubleshooting

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:

 Do NOT remove the Ink Cartridge while the Printer is Printing. Only

replace/remove Ink Cartridges in between Prints.

 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.

 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 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.

 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.

The media is causing the problem and NOT the Printer. Do not attempt to try and replace Printer parts to solve this problem.

HP Designjet 4000/4020 Printer Series Service Manual

1-7

Troubleshooting

Solving Media-Handling Problems

The Front Panel Keeps Indicating that Media Is Misaligned or Incorrectly Positioned

Roll media

Sheet 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.  The paper may be loaded at an angle. The right-hand edge must be

aligned with the blue line on the Print Platen.

Ensure that the paper is wrapped tightly on the roll. This is a very important step to remember because if this is not done, the media may be loaded at an angle, causing the media to be rejected.

 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.  If 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.

 If 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 Drive Roller Service Utility

⇒ Page 4-59.

1-8

HP Designjet 4000/4020 Printer Series Service Manual

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

of Beeps

4Front Panel

Problem

Description

Processor absent

Faulty Main PCA or PSU

Faulty Memory Module

Faulty PCI Card

BIOS Damaged

Main PCA damaged

Hard Disk Drive damaged or missing

Corrective Action

 Check the cable between the Power Supply Unit and the Main

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

Main PCA is correctly connected or is not damaged.

 Replace the Main PCA ⇒ Page 8-105.  Replace the PSU ⇒ Page 8-113.

 Check that the Memory Module is installed correctly.  Installing the Memory Module into the other memory slot and

check if the problem remains.

 If the problem remains r

103.

eplace

the Memory Module ⇒ Page 8-

 If 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 PCA.

 Replace the Front Panel ⇒ Page 8-20

This functionality is only availble in the HP Designjet 4020. A future firmware release is anticipated to give this funcionality to the HP Designjet 4000.

 Replace the Main PCA ⇒ Page 8-105

 Remove the Main PCA Cover and (with the Printer switched

On) check the HDD is turning (feel it turning when you touch it or at least hear it turning). If the HDD is not turning, then it could be damaged, replace the HDD

⇒ Page 8 - 111 .

 Ensure ALL cables are connected to the HDD and are not

damaged.



Replace the HDD ⇒ Page 8-111

 Replace the Main 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 Main PCA 107 .

⇒ Page 8-

 Check that the cables between the Interconnect PCA and the Main PCA are not damaged and

HP Designjet 4000/4020 Printer Series Service Manual

1-9

Troubleshooting

are correctly connected.

 Check that the cable between the Power Supply Unit and the Main PCA is not damaged and is

correctly connected.

 Replace the Interconnect PCA  Replace the Gamut PCA

⇒

Page 8-98

⇒

Page 8-93

1-10

HP Designjet 4000/4020 Printer Series Service Manual

Troubleshooting

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 the BootUp 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

30 rc.sysinit rerun through initlog.



Environmental variables PATH, NETWORKING, HOSTNAME set.

 Source /etc/init.d functions.

 Fix console loglevel.

 Mount /proc.  Dismount the initrd, if necessary.  Configure kernel parameters.

27 Set the system clock.

26 Load keymap.

25 Load system font.

24 Start up swapping.

 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

21 Perform file system check on root volume.

20 Update quotas if fsck was run on root

19 Setup pnp

HP Designjet 4000/4020 Printer Series Service Manual

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Troubleshooting

Step Initialization Process

 Remount the root filesystem read-write.  LVM initialization.  Clear mtab.  Enter root, /proc and (potentially /proc/bus/usb and devfs

into mtab.

 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.

 File system check.  Add raid devices.

 Setup Logical Volume Management.

 Check filesystems on all volumes found on /etc/fstab.

15 Mount local filesystems.

14 Check remaining quotas other than root.

13 Enable local filesystem quotas.

 Configure machine if necessary (if the respective configure

files exist).

 Reread in network configuration data.

 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.  Turn On swap in case we swap to files.

 Initialize the Serial Ports.  If a SCSI tape has been detected, load the st module

unconditionally.

 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.

1-12

8 Export this variable BOOT_PART and INSTALL_PART.

HP Designjet 4000/4020 Printer Series Service Manual

Troubleshooting

Step Initialization Process

PRINT APPLICATION STARTING POINT

7 IO kernel mode initialization (basically).

6 Printer Application Infrastructure startup.

5Printer IO startup.

Front Panel application startup (but wait for engine launching,

i.e. Front Panel is not cleared yet).

3 Engine startup, start EE and Mechanical initialization.

2 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

1 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 checking 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

⇒ Page 8 - 111 .

2 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.



If the Printer continues to stop during the power-up process, replace the Hard Disk Drive ⇒ Page 8 - 111 .

HP Designjet 4000/4020 Printer Series Service Manual

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Troubleshooting

Amber is on the Left Blue is in the center Green is on the Right

Make sure you look directly at the LEDs and not at an angle.

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:

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).

 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 (+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

Blue

LED

Status

ON OFF

ON OFF Green (flashing) Initializing

ON ON Green Ready (but not printing)

ON ON Green Printing or preparing to print

OFF ON Any Not possible

ON ON

PSU

Green

LED

Status

Left LED (on

Front Panel)

Status

Red (Front Panel Black)

Printer Status

Standby (with Embedded Web Server up and running)

Not possible

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HP Designjet 4000/4020 Printer Series Service Manual

Troubleshooting

5Vsb

24V

Interconnect PCA

5V - Comes from the PSU after the fuse on Interconnect PCA. Used to power On Front Panel

and some Interconnect Electronics. 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.

PrintMech PCA

5Vsb - Comes from the PSU after the fuse on PrintMech PCA.

3V3

ERIDANI

24V

VPOWER2

VAUX

VAN

5SB

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 - Is 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.

Using the PCA 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:

HP Designjet 4000/4020 Printer Series Service Manual

1-15

Troubleshooting

1 If the Printer cannot be turned ON:

Signal LED on

Interconnect

PCA

5Vsb OFF ON Amber

5Vsb ON OFF Amber

5Vsb OFF OFF

LED on

PrintMech

PCA

Power Switch

LED

Amber

or no

LED

Corrective Action

 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 PCA.

 Make sure that ALL cables between

the PSU and PrintMech are not damaged and are 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 If the Printer starts (after having pressed the ON button on the Front Panel)

but the front Panel remains black:

Signal LED on

Interconnect

PCA

5V OFF ON Blue

5V ON ON Blue

LED on

PrintMech

PCA

Power Switch

LED

Corrective Action

 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 the Front Panel

⇒ Page 8-93 and

⇒ Page 8-20.

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HP Designjet 4000/4020 Printer Series Service Manual

Troubleshooting

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 ScanAxis Test

⇒ Page 4-7:

Signal LED on

Interconnect

PCA

5V OFF ON Blue

24V ON ON

24V OFF OFF

24V OFF ON

LED on

PrintMech

PCA

Power Switch

LED

Blue and

Green

Blue and

Green

Blue and

Green

Corrective Action

 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 connection OK, run the Electronics

Module Test to further diagnose the problem.

24V ON OFF

4 On the PrintMech PCA, 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.  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 PCA.  Run the Electronics Module Test to further diagnose the problem.  Replace the PrintMech PCA ⇒ Page 8-119.

Blue and

Green

 Check the connection between the

PSU and the PrintMech PCA.

 If connection OK, run the Electronics

Module Test to further diagnose the problem.

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Troubleshooting

EWS Event Log Page -

Advanced Button

How to Interpret the Service Information Pages

The Service Information Pages contain the following information:

 Current Information.  Printer Usage Information.  Event Logs.  Calibration Status.  Network and I/O Configuration.

It is possible to print the Service Information Pages either through the Front Panel or through the Embedded Web Server:

 Front Panel: Setup menu ⇒ Information Menu ⇒ Internal Prints ⇒ Print

Service Information.

 Embedded Web Server: Information ⇒ Event Log ⇒ Advanced

Even the Printer cannot print, the Information Pages are still accessible through the Embedded Web Server.

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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 can 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.

HP Designjet 4000/4020 Printer Series Service Manual

Troubleshooting

Current Media, Printhead and Ink Information

This page contains the following information:

 Current Printer Configuration.  Paper Loaded Information.  Current Printhead Kit Information.  Current Ink cartridge Information.

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:

 Temperature and Humidity: The sensors are located on the ISS PCA

(at the top of the Ink Cartridges).

 Active Paper Path: Whether Roll or Cut Sheet is currently loaded.  Remaining Media Length: Currently this will show "not available" all

the time since the media length tracking function in not available.

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Troubleshooting

 Printhead Status: ’OK’, ’Missing’, ’Reseat’, ’Replace’ or ’Remove’.  Expiration Date: Manufacture date (date marked on the actual

Printhead) + 24 months.

 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 (%) versus 1000ml.  Scan Axis Shutdown: Corresponds to a media jam.

 Printhead Health: This represents the number of nozzles out of service

during the last drop detection that was performed.

Number of Nozzles Out Printhead Health

< 5 10

> or = 5 and < 10 9

> or = 10 and < 20 8

> or = 20 and < 30 7

> or = 30 and < 50 6

> or = 50 and < 70 5

> or = 70 and < 100 4

> or = 100 and < 150 3

> or = 150 and < 200 2

> or = 200 and < 400 1

> or = 400 0

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HP Designjet 4000/4020 Printer Series Service Manual

Troubleshooting

 Cartridge Status: ’OK’, ’Missing’, ’Low’, ’Very Low’, ’Empty’, ’Reseat’

or ’Replace’.

 Expiration Date: Manufacture date (date marked on the actual Ink

Cartridge) + 30 months.

 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:

 Printer Usage.  Usage per Printhead Slot.  Usage per Cartridge Slot.  Media Usage per Media Type.  Component Usage.  Spittoon Usage.  Preventive Maintenance Usage.

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Troubleshooting

Media Used Sections

 Total media used in the Printer.

 Media used for each media type.

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.

 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 (0).

Cartridge Section

The Ink Cartridges currently being used are not counted.

 This section is split by product name and number for each color as 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).

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.

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HP Designjet 4000/4020 Printer Series Service Manual

Troubleshooting

Black Cleaner Spittoon #1

Black Cleaner Spittoon #2

Spittoon #1 Spittoon #2

Spittoon #3 Spittoon #4

Component Usage

One cycle is counted when the Carriage makes one movement to the left of the Printer and then returns to the right.

 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 EEROM), except when:

– The Ink Supply Tubes are replaced (not under warranty). – The Printer detects that the Ink Cartridge being used no longer uses

third-party ink.

Spittoon Section

This section contains information on the different Spittoons located in the Printer.

HP Designjet 4000/4020 Printer Series Service Manual

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Troubleshooting

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.

System/Warning Error

 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)).

 Media Usage (in square meters) and Date (from the Printer’s Internal

Clock (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 (’0’ represents

the current Printhead used).



Status

’8’ = Remove.



% Ink Used



Error Code

Printhead has been replaced.



Max Recovery

– 0: No manual Printhead recovery has been performed on the Printhead. – 1 or higher: At least one Printhead recovery has been performed.

: ’0’ = Working, ’1’ = No Pen Detected, ’2’ = Replace, ’4’ = Reseat,

: Percentage of the Warranty life (1000cc).

: Specific error code generated by the Printer when the

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HP Designjet 4000/4020 Printer Series Service Manual

+ 393 hidden pages