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.

HP Designjet 4000/4020 Printer Series Service Manual

1-17

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.

1-18

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.

HP Designjet 4000/4020 Printer Series Service Manual

1-19

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

1-20

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.

HP Designjet 4000/4020 Printer Series Service Manual

1-21

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.

1-22

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

1-23

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

1-24

HP Designjet 4000/4020 Printer Series Service Manual

Troubleshooting

Information on these 3 Calibrations

will be added in Firmware Version 4.x.x.x

In Firmware Version 4.x.x.x the following text will also be added here: "3 Calibrations are not reported within this list: ‘Blue Line Calibration‘, ‘Carriage PCA Setup‘ and ‘Vacuum Fan’."

Calibrations Status

This page contains the following information:

 General Calibrations (performed by Service Engineers).  Media Specific Calibrations (performed by the User).

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.

 Drop Detector relates to the Drop Detector or Service Station

calibration.

 Paper Advance relates to the Service Paper Advance Calibration.  Printhead Alignment relates to the Printhead Alignment which

changes to ‘pending‘ when a Printhead is replaced and the Printhead Alignment has not been performed.

HP Designjet 4000/4020 Printer Series Service Manual

When a component is replaced, the corresponding calibration is NOT automatically set to ‘NOT DONE‘. This is because the Printer does not know that there is a new part installed.

Media Specific Calibrations

This section shows the following for each type of media:

 Color Calibration.  Paper Advance per media type and ‘optimized for‘ Text/drawing and

Graphics.

1-25

Troubleshooting

1-26

HP Designjet 4000/4020 Printer Series Service Manual

System Error Codes 2System Error Codes 1

Introduction 2-2 Continuable and Non-Continuable Error Codes 2-2 System Error Codes and Warnings - Explanation 2-25

HP Designjet 4000/4020 Printer Series Service Manual

2-1

System Error Codes

Code: 0x1901001 Sev e rity: E rro r Priority : 30 0 0 Id: 0x 1 01021 a Description: STRING_POWER_OFF File:

73:03

This is the Code that is required when escalating a problem

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 descriptions and recommended corrective actions. Only try one recommended action at a time and check if the error code has disappeared.

 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.

 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 Internal Error Code and the firmware version. Without this information, HP Support Personnel cannot help you. To view the Internal Error Code, hold the DOWN key and press the CANCEL key at the same when the System Error Code is displayed on the Front Panel.

Continuable and Non-Continuable Error Codes

Some of the Error Codes are continuable, which means you can press 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.

Enter

2-2

Even though the customer can continue working with a Continuable Error Code, an on-site visit should still be planned to troubleshoot the problem.

HP Designjet 4000/4020 Printer Series Service Manual

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

01.0 :03

Error impact I2C channel.

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 System Error continues, replace the Gamut PCI PCA

01.0 :10

Problem with the Gamut PCI PCA.

Try the following:

⇒

Page 8-98.

 Switch the Power OFF from the back of the Printer and disconnect the

Power cord. Reconnect the power cord and power On the Printer.



Replace the Gamut PCI PCA ⇒ Page 8-98.



If the System Error continues, replace

Only replace one component at a time and check if the error has gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

the Main PCA ⇒ Page 8-105.

System Error:

Problem Description:

Corrective Action:

01.1:10

Problem with the PrintMech PCA.

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 cables between the PrintMech PCA and the Gamut PCI

PCA are not damaged and are correctly connected.



Replace the PrintMech PCA



If the System Error continues, replace the Gamut PCI PCA

Only replace one component at a time and check if the error has gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

⇒

Page 8-119.

⇒

Page 8-98.

HP Designjet 4000/4020 Printer Series Service Manual

2-3

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

01.2 :10

ISS PCA faulty - Humidity sensor out of scale or NVM backup 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.



If the System Error continues, replace the Ink Supply Tubes ⇒ Page 8-46.

02:10

Encoder seems to be wrong.

Try the following:

 Check that the Carriage Stopper is correctly installed (Refer to Carriage

Disassembly Instructions ⇒ Page 8-82, Step 16 . ).

 Replace the Carriage Assembly ⇒ Page 8-82.  If the System Error continues, replace the Encoder Strip and Encoder

Sensor ⇒ Page 8-72.

Only replace one component at a time and check if the error has gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

System Error:

Problem Description:

Corrective Action:

02.1:10

Problem with the Carriage PCA.

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 Gamut PCI PCA

Only replace one component at a time and check if the error has gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

⇒

Page 8-98.

2-4

HP Designjet 4000/4020 Printer Series Service Manual

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

03:10

Problem with the Power Supply Unit.

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.

 Perform the Electronics Modules Test (⇒ Page 4-17) to troubleshoot the

problem further.



If the System Error continues, replace the Power Supply Unit

05.1:10

CPU Fan is stopped or burnt.

Try the following:

⇒

Page 8-113.

 Switch the Power OFF from the back of the Printer and disconnect the

Power cord. Reconnect the power cord and power On the Printer.

 Replace the CPU Fan ⇒  If the System Error continues, r

Only replace one component at a time and check if the error has gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

Page 8-107

eplace

the Main PCA ⇒ Page 8-105.

System Error:

Problem Description:

Corrective Action:

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. – 512MB for the HP Designjet 4020.

 Check that the Memory Module is installed correctly.  Try installing the Memory Module in the other Memory slot and check if

the System Error appears.

 If the System Error reappears, r

103.

eplace

the Memory Module ⇒ Page 8-

 If the System Error does NOT reappear, then the original slot could be

faulty. In this case, replace the Main PCA ⇒ Page 8-105.

HP Designjet 4000/4020 Printer Series Service Manual

2-5

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

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.

 If the System Error continues, replace the Hard Disk Drive ⇒ Page 8-107.

06:10

Main NVM failure - not detected, read/write 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.

 If the System Error continues, replace the Hard Disk Drive ⇒ Page 8-107.

07:10

Aerosol Fan driver burnt.

Try the following:



Replace the Interconnect PCA



If the System Error continues, replace the Gamut PCI PCA

⇒

Page 8-93.

⇒

Page 8-98.

System Error:

Problem Description:

Corrective Action:

Only replace one component at a time and check if the error has gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

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.



If the printer emits one or multiple ’beeps’ as the printer turns On, perform

⇒

the procedure ’Using the buzzer at Power-up to Troubleshoot

Page 1- 9 .

 Check that the Front Panel cable is not damaged and is correctly

connected to the Front Panel and to the Interconnect PCA.

 Check that the Memory Module is installed correctly.  Check that the cables between the Interconnect PCA and the Main PCA

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.

2-6

HP Designjet 4000/4020 Printer Series Service Manual

System Error Codes

 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 8-93.

Page 8-98.

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

11 : 1 0

Trailing Cable does not seem to be detected.

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.



Replace the Gamut PCI PCA

⇒

Page 8-98.

 Replace the Trailing Cable ⇒ Page 8-33. 

Replace the Carriage PCA

Only replace one component at a time and check if the error has gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

13 . n :10

Problem starting acumen supplies.

Try the following:

⇒

Page 8-75.

 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.

 Replace the ISS to Cartridge cables ⇒ Page 8-58  Replace the Ink Supply Tubes ⇒ Page 8-33.

System Error:

Problem Description:

Corrective Action:

21: 03

Service Station servo shutdown.

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 System Error continues, replace the Service Station ⇒ Page 8-23. 

Replace the PrintMech PCA



Replace the Interconnect PCA

HP Designjet 4000/4020 Printer Series Service Manual

⇒

Page 8-119.

⇒

Page 8-93.

2-7

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

System Error:

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.

 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.

 If the System Error continues, replace the Service Station ⇒ Page 8-23.

23:10

Problem Description:

Corrective Action:

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 PrintMech PCA.

 Replace the APS Assembly ⇒ Page 8-62.  R

eplace the PrintMech PCA

 If the System Error continues, r

Only replace one component at a time and check if the error has gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

⇒

Page 8-119.

eplace the Gamut PCI PCA

⇒

Page 8-98.

2-8

HP Designjet 4000/4020 Printer Series Service Manual

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective 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:

 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 slot0 floater.

Try the following:

 Remove the Yellow Ink Cartridge and reinstall it in to the Printer.  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.

 Replace the ISS to Cartridge cable (Yellow Ink Cartridge) ⇒ Page 8-58.  Replace the Ink Supply Tubes ⇒ Page 8-33.

System Error:

Problem Description:

Corrective Action:

26.1:01

Bad contact detected in ISS slot1 floater.

Try the following:

 Remove the Magenta Ink Cartridge and reinstall it in to the Printer.  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.



Replace the ISS to Cartridge cable (Magenta Ink Cartridge)

 Replace the Ink Supply Tubes ⇒ Page 8-33.

HP Designjet 4000/4020 Printer Series Service Manual

⇒ Page 8-58

2-9

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

26.2:01

Bad contact detected in ISS slot2 floater.

Try the following:

 Remove the Black Ink Cartridge and reinstall it in to the Printer.  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.



Replace the ISS to Cartridge cable (Black Ink Cartridge)

⇒ Page 8-58

 Replace the Ink Supply Tubes ⇒ Page 8-33.

26.3:01

Bad contact detected in ISS slot3 floater.

Try the following:

 Remove the Cyan Ink Cartridge and reinstall it in to the Printer.  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.



Replace the ISS to Cartridge cable (Cyan Ink Cartridge)

⇒ Page 8-58

 Replace the Ink Supply Tubes ⇒ Page 8-33.

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

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

Firmware 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.

 Replace the Ink Cartridges.

2-10

HP Designjet 4000/4020 Printer Series Service Manual

System Error Codes

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.

 Remove the Printheads from the Carriage and reinsert them.  Replace the Printheads.  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.

 Replace the Printheads.

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

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 Service Station and then close the Printhead Cleaner Access Door.

 Replace the Yellow Printhead Cleaner in 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.

 Replace the Yellow Printhead Cleaner in slot 2 of the Service Station.

HP Designjet 4000/4020 Printer Series Service Manual

2-11

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

29.2:01

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.

 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.

 Replace the Magenta Printhead Cleaner in slot 4 of the Service Station.

29.4:01

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.

 Replace the Black Printhead Cleaner in slot 5 of the Service Station.

System Error:

Problem Description:

Corrective Action:

2-12

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.

 Replace the Black Printhead Cleaner in slot 6 of the Service Station.

HP Designjet 4000/4020 Printer Series Service Manual

System Error Codes

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.

 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

Printhead Cleaner is correctly seated in slot 8 of the Service Station and then close the Printhead Cleaner Access Door.

 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.

 Replace the Media-Axis Motor ⇒ Page 8-91.  If the System Error continues,

replace the PrintMech PCA

⇒

Page 8-119.

System Error:

Problem Description:

Corrective Action:

41:10

Electrical fault 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.

 Check that the Media-Axis Motor cable is not damaged and is correctly

connected to the PrintMech PCA.

 Replace the Media-Axis Motor ⇒ Page 8-91.  If the System Error continues,

HP Designjet 4000/4020 Printer Series Service Manual

replace the PrintMech PCA

⇒

Page 8-119.

2-13

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

42:03

Electrical current limit 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.

 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.

 Replace the Scan-Axis Motor ⇒ Page 8-88.  If the System Error continues,

42:10

Electrical fault in Scan-Axis Motor.

Try the following:

replace the PrintMech PCA

⇒

Page 8-119.

 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 PCA.

 Replace the Scan-Axis Motor ⇒ Page 8-88.  If the System Error continues,

replace the PrintMech PCA

⇒

Page 8-119.

System Error:

Problem Description:

Corrective Action:

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.

 Replace the Vacuum Fan ⇒ Page 8-27.  If the System Error continues,

replace the PrintMech PCA

⇒

Page 8-119.

2-14

HP Designjet 4000/4020 Printer Series Service Manual

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

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 PCA.

 Replace the Aerosol Fan ⇒ Page 8-29.  If the System Error continues,

44:11

Aerosol Fan not connected.

Try the following:

replace the Interconnect PCA

⇒

Page 8-93.

 Check that the Aerosol Fan cable is not damaged and is correctly

connected to the Interconnect PCA.

 Replace the Aerosol Fan ⇒ Page 8-29.

51:10

Window Sensor failure.

Corrective Action:

System Error:

Problem Description:

Corrective Action:

Try the following:

 Check that the Window Sensor cable is not damaged and is correctly

connected to the Interconnect PCA.

 Replace the Window Sensor.

51.1:10

PHC Access Door Sensor failure.

Try the following:

 Check that the

correctly connected to the Interconnect PCA

 Replace the

PHC Access Door Sensor cable is not damaged and is

PHC Access Door Sensor

HP Designjet 4000/4020 Printer Series Service Manual

2-15

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

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

connected to the Service Station cable

 Check that the

connected to the Interconnect PCA

Drop Detector cable is not damaged and is correctly

Service Station cable is not damaged and is correctly

 Replace the Drop Detector ⇒ Page 8-31.  R

eplace the Gamut PCI PCA ⇒ Page 8-98.

 If the System Error continues,

Only replace one component at a time and check if the error has gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

53:10

Media Sensor failure.

Try the following:

 Check that the

correctly to the Interconnect PCA

Media Sensor cable is not damaged and is connected

replace the Interconnect PCA ⇒ Page 8-93.

 Replace the Media Sensor ⇒ Page 8-135.

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

2-16

54:10

Media Lever Sensor failure.

Try the following:

 Check that the

connected correctly to the Interconnect PCA

Media Lever Sensor cable is not damaged and is

 Replace the Media Lever Sensor ⇒ Page 8-142.

55:10

Problem with the Line Sensor.

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.

 Replace the Line Sensor ⇒ Page 8-31.  If the System Error continues,

HP Designjet 4000/4020 Printer Series Service Manual

replace the Carriage PCA ⇒ Page 8-75

System Error Codes

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.

 Replace the Encoder Disc and Sensor ⇒ Page 8-137.  If the System Error continues,

56:10

Analog Encoder calibration failed.

Try the following:

replace the PrintMech PCA ⇒ Page 8-119

 Replace the Encoder Disc and Sensor ⇒ Page 8-137.

61: 0 1

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.

System Error:

Problem Description:

Corrective Action:

HP Designjet 4000/4020 Printer Series Service Manual

61: 0 4 .1

The Postscript fonts are missing. Upgrading the Firmware will re-install the fonts.

Perform a full firmware upgrade that includes package ’B’.

2-17

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

61: 0 8 .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.

 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, r

64:04

Input/Output problem through the USB Port.

Try the following:

eplace

the Main PCA ⇒ Page 8-105.

 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.

 Replace the USB card.

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

2-18

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 the file was sent, so the file cannot be printed on the paper type currently loaded.

Try the following:

 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.

HP Designjet 4000/4020 Printer Series Service Manual

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

System Error:

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.

 If the System Error continues, r

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:

eplace

the Main PCA ⇒ Page 8-105.

 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

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

Out of memory failure.

It is recommended that you remove any unnecessary files from the Hard Disk Drive using 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).

You MUST NEVER replace both the Hard Disk Drive and the Ink Supply Tubes at the same time. If both parts need to replaced, you MUST first replace one part and then power ON the Printer until it completely initializes. Then you can power OFF the Printer and replace the other part.

HP Designjet 4000/4020 Printer Series Service Manual

2-19

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

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:

 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.

 Perform the "Scan-Axis" Diagnostic (⇒ Page 4-7) to further troubleshoot

the error code.

 If the System Error continues, perform the "Media Drive" Diagnostic (⇒

Page 4-12) to further troubleshoot the error code.

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

74 :0 0

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:

 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 firmware update file to the Printer.

2-20

HP Designjet 4000/4020 Printer Series Service Manual

System Error Codes

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.  If the System Error continues,

unnecessary files from the Hard Disk Drive using the Web Server

it is recommended that you remove any

 Perform an EEROM Reset (⇒ Page 4-46) and resend the file to the Printer.

77:04

Embedded Web Server internal software 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.

System Error:

Problem Description:

Corrective Action:

79:03

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.

HP Designjet 4000/4020 Printer Series Service Manual

2-21

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

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:

 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.

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.

 Perform the "Media Drive" Diagnostic (⇒ Page 4-12) to further

troubleshoot the error code.



If the System Error continues, replace the Media-Axis Motor ⇒ Page 8-91.

System Error:

Problem Description:

Corrective Action:

2-22

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.

 Perform the "Media Drive" Diagnostic (⇒ Page 4-12) to further

troubleshoot the error code.



If the System Error continues, replace the Media-Axis Motor ⇒ Page 8-91.

HP Designjet 4000/4020 Printer Series Service Manual

System Error Codes

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 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.

 Perform the "Media Drive" Diagnostic (⇒ Page 4-12) to further

troubleshoot the error code.



If the System Error continues, replace the Media-Axis Motor ⇒ Page 8-91.

85:03

Problem finding the Drive Roller zero.

Try the following:

 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. ).

 Perform the "Scan-Axis" Diagnostic (⇒ Page 4-7) to further troubleshoot

the error code.



If the System Error continues,

replace the Scan-Axis Motor ⇒ Page 8-88.

System Error:

Problem Description:

Corrective Action:

86:03

Scan-Axis length test failure.

Try the following:

 Perform the "Scan-Axis" Diagnostic (⇒ Page 4-7) to further troubleshoot

the error code.

HP Designjet 4000/4020 Printer Series Service Manual

2-23

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

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.  Replace the Encoder Strip and Encoder Sensor ⇒ Page 8-72. 

If the System Error continues,

86:11

Scan-Axis length too short.

Try the following:

replace the Scan-Axis Motor ⇒ Page 8-88.

 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.

 Replace the Encoder Strip and Encoder Sensor ⇒ Page 8-72.

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

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:

 It 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 Printer 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.

2-24

HP Designjet 4000/4020 Printer Series Service Manual

System Error Codes

System Error:

Problem Description:

Corrective Action:

System Error:

Problem Description:

Corrective Action:

93:11

Unable to pressurize the IDS.

Try the following:

 Remove ALL the Ink Cartridges and reinstall them one by one in to the

Printer.

 Replace the Ink Cartridges.  Replace the APS Assembly ⇒ Page 8-62.  If the System Error continues, replace the Ink Supply Tubes ⇒ Page 8-33.

98:02 (this error code will be logged in the system but will not actually appear on the Front Panel)

Switching to lower performance due to Printhead quality.

Try the following:

 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.

 XX: Service Part (2 digits).  n: Service Part Index (if more than one used in the product) - Optional.

– e.g. Identify the Ink Supply (color and number).

 Y: Who should perform the action (1 digit) - (User or Service Engineer).  Z: Action to perform (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.

HP Designjet 4000/4020 Printer Series Service Manual

2-25

System Error Codes

Items in red are not applicable to this printer.

The following table explains the

Code Component/System

01.0 Main PCA/Electronics Module (Gamut)

01.1 Add-on Electronics Module (Printmech)

01.2 ISS Electronics Module 02 Carriage

02.1 Carriage PCA 03 Power Supply Unit 04 Network Card 05 Formatter

05.1 Fan of the Formatter

05.2 Processor of the Formatter

05.3 Memory of the Formatter 06 Hard Disk Drive 07 Interconnect PCA 08 Front Panel

11 Trailing Cable

12 Ca rr i a g e Fl ex Ci r cu it

13.n Cable from cartridge n to ISS PCA

17 Interconnect Cable 21 Se rv ic e St at ion 22 Ink Supply Station 23 Pressure System (APS) 24 Ink Delivery Tubes 25 Spittoon

26n Ink Cartridge (color n) 27n Printhead (color n) 28n Setup Printhead (color n) 29n Printhead Cleaner (color n)

31 C u t t e r

32 Take-up Reel 33 Sheet Feeder 34 Dryer/Blower 35 Cleanout Assembly 36 Duplexer 37 ARSS/Rollfeed

38 Output Tray 39 Paper Loading Failure 41 Pa pe r- Ax is Mo t o r 42 Scan-Axis Motor 43 Vacuum Fan 44 Aerosol Fan

part of the System Error Code or Warning:

2-26

HP Designjet 4000/4020 Printer Series Service Manual

System Error Codes

Code Component/System

45 Back Tension Motor 51 Window/Door Sensor

51.1 Service Station Door Sensor 52 Drop Detector 53 Media Sensor 54 Pinch-Arm Sensor 55 Line Sensor 56 Drive Roller Encoder Sensor

57 Ink Leak Detector

58 Color Sensor

59 Media Type Sensor

61 Language Interpreting

61.1 PS F on t s M i s s i n g

61.2 File with Passwords cannot be Printed

62 Input/Output through Parallel Port

63 Input/Output through LAN Card

63.0 Input/Output through Integrated LAN Card

63.1 Input/Output through add-on JetDirect LAN Card

63.2 Input/Output through add-on Gigabit LAN Card 64 Input/Output through USB Port 65 Input/Output (not know what port) 66 Print Job Configuration 67 Input/Output through FireWire Port 68 Loss of Engine Counters Tracking 71 Memory Management 72 Generic Firmware 73 Motor Control Functions 74 Firmware Upgrade 75 Preventive Maintenance

75.1 Preventive Maintenance Kit #1

75.2 Preventive Maintenance Kit #2 76 Dis k Ful l 77 WebAccess Application 79 Assertion (Uncontrollable Firmware Error)

79.1 Warning (Uncontrollable Recoverable Firmware Error) 81 Media Advance 81 Media Cut 83 Single-Sheet Feeding 84 Roll Feeding 85 Media-Axis Encoder Reading 86 Carriage Movement 87 Scan-Axis Encoder Reading

HP Designjet 4000/4020 Printer Series Service Manual

2-27

System Error Codes

Code Component/System

91 Printhead Firing 92 Servicing 93 Ink Pumping 94 Color Calibration 95 Printhead Alignment 96 Image Quality Troubleshooting 97 Paper Advance Calibration 98 Automatic Backup Printmode Enabled

The following table explains the YZ part of the System Error Code or Warning:

Code Recovery Action Response

00 Replace 01 Reseat/Reconnect/Clean/Adjust (manually) 02 Calibrate/Adjust (using Automatic Process) 03 Power OFF and Restart the Printer 04 Upgrade System Firmware 05 Upgrade Driver or Computer Software 06 Add Accessory 07 Escalate 08 Send Plot Again 09 Wrong Part Installed 10 Repl ac e

11 Reseat/Reconnect/Clean/Adjust (manually) 12 Calibrate/Adjust (using Automatic Process) 13 Po we r O F F 14 Upgrade System Firmware 15 Upgrade Driver or Computer Software 16 Add Accessory 17 E sc a la t e 18 S en d P lo t A ga in 19 Wrong Part Installed

Possible for customer to

perform

action

hp qualified

personnel

assistance

required

2-28

HP Designjet 4000/4020 Printer Series Service Manual

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 Printing 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 W i per 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

Ink Supplies Troubleshooting

Ink Cartridges

Printhead Cleaners

Printheads

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 cm³, and the black cartridge has a capacity of 400 cm³. It is also possible to buy and use color cartridges with a capacity of 400 cm³.

All these Ink cartridges are physically the same size, only the internal capacity varies.

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 highquality printing results even when the ink levels are getting low.

The front panel displays the status of the Ink Cartridge. Using the front panel, detailed information can be checked on the Ink Cartridges.

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Ink Supplies Troubleshooting

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.

Whenever a new Printhead is bought, it will come with a new Printhead Cleaner. When a Printhead is replaced, the Printhead Cleaner should be replaced at the same time. Leaving the old Printhead Cleaner in the Printer will shorten the new Printhead's life and possibly damage the Printer.

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.

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Ink Supplies Troubleshooting

General Information About the Ink Supplies

For optimum results from the printer and modular ink delivery system always follow these guidelines when handling 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.  Allow the Printer and Printhead Cleaners to automatically clean the

Printheads.

 Install Ink Cartridges, Printheads and Printhead Cleaners in their color-

coded slots.

 Follow the instructions on the front panel of the 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

Do not touch, wipe or attempt to clean the printhead nozzles. This can damage the printhead.

 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 on the nozzles.  Do not be rough when handling the Printheads. Always set them down

gently.

 Do not drop the Printheads.  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.

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HP Designjet 4000/4020 Printer Series Service Manual

Ink Supplies Troubleshooting

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. These 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.

If the Printing Printheads are installed in the carriage during the priming process, they will be rejected and the front panel will show a warning message.

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.

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3-5

Ink Supplies Troubleshooting

Press Enter to

confirm selection

Use UP and

DOWN keys

to select

Press Enter to

confirm selection

Use UP and

DOWN keys

to select

Press Enter to

confirm selection

Use UP and

DOWN keys

to select

Press Enter to

confirm selection

Use UP and

DOWN keys

to select

Obtaining Ink Cartridge Information

1 Scroll to the Ink Menu icon and press Enter.

2 In the Ink Menu submenu, scroll to "Ink cartridges" and press Enter.

3 In the Ink Cartridges submenu, scroll to "Ink cartridge information" and press

Enter.

4 In the Ink Cartridge Information submenu, scroll to the Ink Cartridge that you

want information on and press Enter.

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Ink Supplies Troubleshooting

Press Enter to

confirm selection

Use UP and

DOWN keys

to select

Press Enter to

confirm selection

Use UP and

DOWN keys

to select

5 The front panel displays information on the selected Ink Cartridge.

The information supplied is:

 The make of the Ink Cartridge (hp no.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 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.

2 In the Ink Menu submenu, scroll to "Printheads" and press Enter.

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Ink Supplies Troubleshooting

Press Enter to

confirm selection

Use UP and

DOWN keys

to select

Press Enter to

confirm selection

Use UP and

DOWN keys

to select

3 In the Printheads submenu, scroll to "Printhead information" and press

Enter.

4 In the Printhead Information submenu, scroll to the Printhead that you want

information on and press Enter.

5 The front panel displays information on the selected printhead.

The information supplied is:

 The make of the printhead (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 warranty status of the Printhead.  The current status of the Printhead Cleaner.

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Ink Supplies Troubleshooting

Ink Cartridge Status Messages

Status Bars 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

OK The Ink Cartridge is operating correctly and no action is required.

Low 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.

Very Low 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 user.

Empty 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:

Missing The Ink Cartridge has not been installed or is installed incorrectly. The Printer

will not print until ALL Ink Cartridges have been installed correctly.

Reseat The Ink Cartridge is having continuity problems. Try removing the Ink

Cartridge from the Printer and inserting it in again.

Replace The Ink Cartridge is faulty and needs to be replaced before the printer can

continue printing.

Unknown 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:

1 Reseat the Ink Cartridge.

2 If reseating does not resolve the status message, replace the Ink Cartridge.

3 If the Status messages continue to appear, even after replacing the Ink

Cartridge, replace the Ink Supply Tubes ⇒ Page 8-33.

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Ink Supplies Troubleshooting

Printhead 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 ⇒ 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 status 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.

If all 8 Printheads are installed but have the Status message "Missing", it is possible that the Carriage Assembly is faulty.

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HP Designjet 4000/4020 Printer Series Service Manual

Ink Supplies Troubleshooting

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 with Printhead

A new Printhead has been installed without installing a new 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 must 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.

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Ink Supplies Troubleshooting

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 during the priming process, the Setup Printheads are installed in the Carriage. If the printing Printheads are installed in the carriage during the priming process, they will be rejected and the front panel will show a warning message.



Check that the protective tape has been removed from the printhead.

 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 ⇒ Page 3-14.

 Replace the Printhead with a new one.

You Cannot Insert the Ink Cartridge Into the Printer

1 Ensure that you have the correct hp no.90 Ink Cartridge.

2 Ensure that the Ink Cartridge is the correct color for that slot.

3 Ensure that the Ink Cartridge is the correct orientation, with the color coded

label at the top.

Never clean inside the Ink Cartridge slots as this can cause damage to the Printer.

You Cannot Insert the Printhead Into the Printer

1 Ensure that you have the correct hp no.90 Printhead.

2 Ensure that the printhead is the correct color for that slot.

3 Ensure that the printhead is in the correct orientation.

4 Ensure that the protective cap is removed from the Printhead.

You Cannot Insert the Printhead Cleaner Into the Printer

1 Ensure that you have the correct hp no.90 printhead cleaner.

2 Ensure that the printhead cleaner is the correct color for that slot.

3 Ensure that the printhead cleaner is in the correct orientation.

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HP Designjet 4000/4020 Printer Series Service Manual

Ink Supplies Troubleshooting

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 (0 or 1). When the value of the error code is reported as 0, it means that the Printhead is working correctly:

Bit Meaning Bit Meaning

1st FAILS_LOGICAL_V 11th BAD_ACUMEN_ACCESS

2nd FAILS_CONTINUITY 12th WRONG_MODEL

3rd SHUTDOWN 13th MISMATCH 4th FAILS_VPP 14th CSDATA_NOT_RESPONDING 5th TEMP_EXTREMELY_HIGH 15th CSDATA_TRANSMIT_ERROR 6th TEMP_EXTREMELY_LOW 16th FAILS_ENERGY_CALIBRATION 7th TEMP_TOO_HIGH 17th EMPTY_DUMMY 8th TEMP_TOO_LOW 18th FULL_DUMMY 9th BAD_ACUMEN_INFO 19th END_OF_LIFE

10th NO_PEN 20th OUT_OF_WARRANTY

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 converted to binary number 10000000000011. So using the table above, the error code means "FAILS_LOGICAL_V", "FAILS_CONTINUITY" and "MISMATCH".

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3-13

Ink Supplies Troubleshooting

Carriage Interconnect Wiper

The Carriage Interconnect Wiper is part of the Maintenance Kit which can be ordered using Part Number Q1271-60420. All the instructions needed to use the Carriage Interconnect Wiper will be packaged with the kit.

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.

Do not touch, wipe or attempt to clean the printhead nozzles. This can damage the printhead and reduce print quality.

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HP Designjet 4000/4020 Printer Series Service Manual

Ink Supplies Troubleshooting

Warranty Information for Ink Supplies

Ink Cartridge

The warranty for the Ink Cartridges will end when one of the following occurs:

 24 months from the date of manufacture

 When the advertised deliverable ink is reached (225ml/7.6 oz or

400ml/13.5 oz)

 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 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

 When 1000ml/33.8 oz of HP original ink has been consumed by the

Printhead

 When the user confirms that they have used non-hp ink in empty over-ride

mode.

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Ink Supplies Troubleshooting

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HP Designjet 4000/4020 Printer Series Service Manual

Diagnostic Tests and Utilities

Introduction 4-2

Diagnostics - Self Test 4-2 Diagnostics Tests 4-3

Entering the Diagnostics Tests Menu 4-5

1. Scan Axis Test 4-7

2. Media Drive Test 4-12

3. Electronics Module Test 4-17

4. Carriage Assembly Test 4-27

5. Sensors Test 4-28

6. Ink Delivery System Test 4-32

7. SVS/Aerosol Fan Test 4-33

8. Air Pump System Test (firmware 10.1.1.4) 4-34

9. Vacuum Fans Test 4-36

10.1 Others >>> Bag Broken Recovery 4-37

10.2 Others >>> IO Information 4-40

10.3 Others >>> Unit Information 4-41

10.4 Others >>> Check Ink Supplies 4-43

10.5 Others >>> 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

1. Turn Drive Roller 4-59

2. Prime Tubes 4-61

3. Set SN 4-65

4. Reset Life Counters 4-66

5. Diagnostic Print 4-68

6. Sleep Mode 4-69

7. Replace Cutter 4-70

8. Set RTC Clock 4-71

9. PHC Maintenance 4-72

10. Media standby behavior 4-74

11. Backup print mode 4-76

12. Sanitize Level 4-77

13. Disk Wipe 4-79

HP Designjet 4000/4020 Printer Series Service Manual

4-1

Diagnostic Tests and Utilities

Introduction

This chapter explains how to use the Diagnostics Tests and Service Utilities and what to do if any of the tests fail.

If possible, always perform a Diagnostics Test on the component that you are about to replace, just to make sure that is the component that has failed. If the test on that component passes, there is no need to replace it.

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.

Phone Support

In certain circumstances, a Call Agent can try and troubleshoot the Printer by requesting the Customer to perform a Diagnostics Test via the phone. Using this process, it can be determined whether the Printer requires any on-site maintenance.

Remember that the Key combination for the Customer to Enter the Diagnostics Tests and Utilities is different from the one that the Customer Engineer will use.

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HP Designjet 4000/4020 Printer Series Service Manual

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 ⇒ 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 verify the operation of the:

 Main PCA (Formatter).  Printer Configuration.  Gamut PCI PCA.  Power Supply Unit.  PrintMech.  Interconnect PCA.  Carriage Communication.  ISS Communication.

Diagnostic Tests and Utilities

4 Carriage Assembly Test ⇒ Page 4-27

The purpose of this test is to verify the operation of the Carriage Assembly.

5 Sensors Test ⇒ Page 4-28

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.  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 (APS).

9 Vacuum Fan Test ⇒ Page 4-36

The purpose of this test is to verify the operation of the Vacuum Fans.

HP Designjet 4000/4020 Printer Series Service Manual

4-3

Diagnostic Tests and Utilities

10 Others ⇒ Page 4-37

This option allows you to:

 Recover the Printer from a Bag Broken error ⇒ Page 4-37.  View the information relating to the IO ⇒ 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

11 EEROM Reset ⇒ Page 4-46

The purpose of this test is to reset the EEROM values.

12 Set Unit Configuration ⇒ Page 4-48

The purpose of this test is to automatically configure the Printer either as Standard or Productivity.

13 Error 71:19 Recovery ⇒ 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.

14 I/O Tests ⇒ Page 4-51

The purpose of this test is to check the installed and active I/O Interfaces.

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HP Designjet 4000/4020 Printer Series Service Manual

Diagnostic Tests and Utilities

Hold Cancel

key

Switch Printer ON

PPO

Hold DOWN

key

Hold Cancel

key

Switch Printer ON

N-

EPA

Hold UP key

Entering the Diagnostics Tests Menu

In order to enter the Service Utility Menu, please refer to the

4-57

instructions on Page

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 beep (usually after 5 seconds) before releasing ALL 3 keys.

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.

HP Designjet 4000/4020 Printer Series Service Manual

4-5

Diagnostic Tests and Utilities

Press Enter to

confirm selection

Use UP and

DOWN keys

to select

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.

The Diagnostics Tests work in a special Mode which does NOT require the full Initialization of the Printer. Therefore it is important that once you have finished with the Diagnostics Tests, you MUST power OFF the Printer and Power ON again before trying to print.

In some cases a quick press of a button may not be recognized by the Printer. When pressing a button, be sure to press it deliberately and all the way to the bottom of its travel.

If the Printer hangs up during a test, switch the Printer OFF and restart from step 1.

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HP Designjet 4000/4020 Printer Series Service Manual

Press Enter

Diagnostic Tests and Utilities

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.  System Error Codes related to Scan-Axis shutdown or Carriage jam.

ALL THE COVER SENSORS ARE DISABLED WHEN IN THE DIAGNOSTIC TESTS MENU. IF THE CARRIAGE IS MOVING IT WILL NOT STOP IF THE WINDOW IS OPENED, SO BE VERY CAREFUL NOT TO PUT YOUR HANDS INSIDE.

IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE REPLACING ANY COMPONENT OF THE SCAN-AXIS.

Perform the Scan Axis test as follows:

Perform this test with the Printheads and the Tubes System installed in order to get values that can be compared correctly.

1 In the Diagnostics Tests submenu, scroll to "1. Scan Axis test" and press

Enter.

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 GPIO.  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

Code 03:10

to Page 2-5. Check also

. For more information on troubleshooting this error code, refer

System Error Code 01.0:10

System Error

(refer to Page 2-3).

HP Designjet 4000/4020 Printer Series Service Manual

4-7

Diagnostic Tests and Utilities

 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

Code 03:10

to Page 2-5. Check also

 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.

3 After initializing the Scan-Axis system, the following message will appear on

the Front Panel.

System Error

. For more information on troubleshooting this error code, refer

System Error Code 01.0:10

(refer to Page 2-3).

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

Code 02.1:10

to Page 2-4. Check also

System Error Code 07:10

If you select Yes, then the Front Panel will display:

. For more information on troubleshooting this error code, refer

System Error Code 11:10

(refer to Page 2-6).

System Error

(refer to Page 2-7) or

 Booting up the Carriage.

If there is a failure at this point, the Front Panel will display

Code 02.1:10

to Page 2-4. Check also

System Error Code 01.1:10

. For more information on troubleshooting this error code, refer

System Error Code 11:10

(refer to Page 2-3).

System Error

(refer to Page 2-7) or

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HP Designjet 4000/4020 Printer Series Service Manual

Diagnostic Tests and Utilities

Use the Up key

to move the

Carriage to

the Left

Use the Down

key to move

the Carriage

to the Left

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

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

6 The Printer will program the duty cycle for the PWM test for the Scan-Axis

Movement and leave it disabled and the following information will be displayed on the Front Panel:

- If no System error code is displayed on the Front Panel but

System Error Code 21:12

had appeared

 Prog slow PWM scan.  Moving carriage middle.  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.

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 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.

key to move the Carriage to the left and the

Down

key to move the

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, troubleshoot the problem as System Error Code 01.1:10 (refer to Page 2-3).

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4-9

Diagnostic Tests and Utilities

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.

If 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 2-7) 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 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.

10 The Printer will now start to initialize the Scan-Axis servo and the Front Panel

will display the following information:

 Starting Carriage Motor.  Off/On Carriage Motor.  Doing a 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

to Page 2-24.

The Printer checks the complete length of the Scan-Axis and displays the result on the Front Panel. The length has to be between

11 5 8 6 2 9

and

1164616

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HP Designjet 4000/4020 Printer Series Service Manual

Diagnostic Tests and Utilities

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.

Make sure you keep your hands away from the Print Platen as the Carriage will be moving at high speed and you could injure yourself or damage the Carriage Assembly.

12 The Printer will now check the Scan-Axis PWM and the following information

will be displayed on the Front Panel:

 Starting Scan Axis.  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

to Page 2-24.

13 The Printer will test the PWM at 61 ips and display the results on the Front

Panel.

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:

 If 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.

 If 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.

HP Designjet 4000/4020 Printer Series Service Manual

4-11

Diagnostic Tests and Utilities

Press Enter

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:XX.  System Error Code 41:XX.  System Error Code 73:XX.

IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE REPLACING ANY COMPONENT OF THE MEDIA-AXIS.

Perform the Paper Axis test as follows:

1 In the Diagnostics Tests submenu, scroll to "2. Media Drive test" and press

Enter.

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 GPIO.  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).

 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).

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HP Designjet 4000/4020 Printer Series Service Manual

Diagnostic Tests and Utilities

 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

Code 02.1:10

to Page 2-4. Check also

System Error Code 01.1:10 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:

. For more information on troubleshooting this error code, refer

System Error Code 11:10

(refer to Page 2-3).

System Error

(refer to Page 2-7) or

 Checking PCA 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 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.

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4-13

Diagnostic Tests and Utilities

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:

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.

7 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:

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.

c 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 A "FAIL" message will be displayed on the Front Panel and the test will be

terminated at this point.

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Diagnostic Tests and Utilities

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.  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 2-23.

 Calib. Analog Encoder.

If there is a failure at this point, the Front 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:

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 2-23.

 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.

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4-15

Diagnostic Tests and Utilities

10 When the PWM check is being performed, the following message will be

displayed on the Front Panel:

 PWM test with paper.

11 Once the PWM check is done, the results will be displayed on the Front

Panel. Press any key to finish the test:

If there is a failure at this point, the Front Panel will display:

12 Once the test is completed, OK will be displayed on the Front Panel.

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HP Designjet 4000/4020 Printer Series Service Manual

Press Enter

Press Enter to

confirm selection

Use UP and

DOWN keys

to select

Diagnostic Tests and Utilities

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.

This test does not test the EIO Card or the Hard Disk Drive.

Perform the Electronics Module test as follows:

1 In the Diagnostics Tests submenu, scroll to "3. Electronics Module Test" and

press Enter.

2 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 selection. If you select No, the printer skips this test and goes to the next one:

3 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:

HP Designjet 4000/4020 Printer Series Service Manual

4-17

Diagnostic Tests and Utilities

Press Enter to

confirm selection

Use UP and

DOWN keys

to select

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:

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:

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:

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:

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Diagnostic Tests and Utilities

8 If you 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.

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:

If the Serial Number or the Part Number cannot be read, the Front Panel will display this error code, refer to Page 2-20.

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).

10 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:

System Error Code 74:00

. For more information on troubleshooting

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).

HP Designjet 4000/4020 Printer Series Service Manual

4-19

Diagnostic Tests and Utilities

Press Enter to

confirm selection

Use UP and

DOWN keys

to select

Press Enter to

confirm selection

Use UP and

DOWN keys

to select

11 A 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:

12 If you select Yes, the Printer will check the Gamut PCI PCA and the

following messages will be displayed on the Front Panel:

 Checking Gamut PCI.  Checking ARM Gamut.  Starting Gamut.  Checking Gamut memory I.  Checking Gamut memory II.

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:

14 If you select Yes, the Printer will check the Power Supply Unit and the

following messages will be displayed on the Front Panel:

 Starting Gamut.  Starting Tests GPIO.  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.

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HP Designjet 4000/4020 Printer Series Service Manual

Diagnostic Tests and Utilities

Press Enter to

confirm selection

Use UP and

DOWN keys

to select

 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.

 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 A 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:

16 If you select Yes, the Printer will check the PrintMech and the following

messages will be displayed on the Front Panel:

 Starting Gamut.  Starting Tests GPIO.

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 PCA 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.

HP Designjet 4000/4020 Printer Series Service Manual

4-21

Diagnostic Tests and Utilities

Press Enter to

confirm selection

Use UP and

DOWN keys

to select

 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.  Enable Vacuum Fans.  Checking Vacuum Fans.  Disable Vacuum Fans.

If there is a failure at this point, the Front Panel will display either

Error Code 01.0:10

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).

System Error Code 01.1:10

System

. For more

4-22

17 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:

18 If you select Yes, the Printer will check the Interconnect PCA and the

following messages will be displayed on the Front Panel:

 Starting CDS.

HP Designjet 4000/4020 Printer Series Service Manual

Diagnostic Tests and Utilities

* Items marked with an asterisk are not important and can be ignored.

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).

 Starting Tests GPIO.

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.

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.

If any of the read values do not match the expected default, 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

Diagnostic Tests and Utilities

Press Enter to

confirm selection

Use UP and

DOWN keys

to select

19 A 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:

20 If you select Yes, the following message will appear on the Front Panel:

21 Open the Window and check that the Carriage power light is ON (a green

faint 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 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 Carriage.

If there is a failure at this point, the Front Panel will display

Code 02.1:10

to Page 2-4. Check also

System Error Code 01.0:10

. For more information on troubleshooting this error code, refer

System Error Code 11:10

(refer to Page 2-3).

System Error

(refer to Page 2-7) or

4-24

 Checking Carriage rev.

HP Designjet 4000/4020 Printer Series Service Manual

HP Designjet 4000, 4020 service manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Purpose

Readership

Part Numbers

Conventions

Table of Contents

Troubleshooting 1

Introduction

Troubleshooting System Error Codes

Performing a Service Test on a Failed Assembly

Performing the Necessary Service Calibrations

Solving Print Quality Problems

The Printer does not Power ON

The Printer Continuously Rejects Printheads

Cover Sensors are not Working

The Line Sensor has Problems Detecting Media

Troubleshooting Media Jams/Printhead Crashes

Troubleshooting Shutdowns

Vacuum suction much lower at high altitudes

Banding at variable extreme environmental conditions

Printhead Crashes/Smears on High Density Prints Using Coated Media

Banding due to Ink Cartridge replacement while printing

34" Rice Paper not supported

Cut Sheet rice paper loading failure

Worm marks on HP Coated media with light area fills

Solving Media-Handling Problems

Using the Power-up Sequence to Troubleshoot

Using the Power Switch LEDs to Troubleshoot

Using the PCA LEDs to Troubleshoot

How to Interpret the Service Information Pages

Current Media, Printhead and Ink Information

Printer Usage Information

Event Logs

Calibrations Status

System Error Codes 2System Error Codes 1

Introduction

Continuable and Non-Continuable Error Codes

System Error Codes and Warnings - Explanation

Ink Supplies Troubleshooting

Ink Cartridges

What are Ink Supplies?

Printheads

Printhead Cleaners

General Information About the Ink Supplies

General Precautions When Handling Ink Supplies

Priming the Ink System

When Should You Replace the Ink Supplies?

Obtaining Ink Cartridge Information

Obtaining Printhead Information

Ink Cartridge Status Messages

Ink Cartridge Status While Printing

Ink Cartridge Status While Replacing

Printhead Status Messages While Printing

Printhead Status Messages While Replacing

Printhead Cleaner Status Messages While Printing

Printhead Cleaner Status Messages While Replacing

Summary of Solving Ink Supplies Problems

Troubleshooting Printhead Error Codes

Carriage Interconnect Wiper

Warranty Information for Ink Supplies

Warranty Information for Printheads

Diagnostic Tests and Utilities

Diagnostics - Self Test

Phone Support

Entering the Diagnostics Tests Menu

1. Scan Axis Test

2. Media Drive Test

3. Electronics Module Test