For HP Internal Use Only Warranty WARNING ©Copyright Hewlett-Packard Company 2004 The information contained in this document is subject to change without notice. The procedures described in this manual are to be performed by HP-qualified service personnel only. This document contains proprietary information that is protected by copyright. All rights are reserved.
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) 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.
Table of Contents 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 series printers service manual 3
Table of Contents 4 hp designjet 4000 series printers service manual
Troubleshooting 1 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
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.
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.
Troubleshooting The Line Sensor has Problems Detecting Media 1 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.
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.
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.
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.
Troubleshooting Solving Media-Handling Problems The Front Panel Keeps Indicating that Media Is Misaligned or Incorrectly Positioned Roll media The roll may be loaded the wrong way. The paper should load over the roll toward you. Check that the paper is correctly loaded onto the spindle. 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.
Troubleshooting Using the Buzzer at Power-up to Troubleshoot When the Printer is powered up, it doesn’t make a "Beeping Sound" until it is completely powered-up and ready to use. If there is a beep during the power-up sequence, this may signify that there is a problem within the Electronics Module. The following table will help you to use the "Beeping Sound" to diagnose certain problem: Number of Beeps Problem Description Corrective Action 1 Processor absent Replace the Main PCA ⇒ Page 8-74.
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 1-10 30 rc.sysinit rerun through initlog. 29 Environmental variables PATH, NETWORKING, HOSTNAME set.
Troubleshooting Step 18 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. 17 Load modules from /etc/rc.modules. File system check. Add raid devices. 16 Setup Logical Volume Management.
Troubleshooting Step Initialization Process PRINT APPLICATION STARTING POINT 7 IO kernel mode initialization (basically). 6 Printer Application Infrastructure startup. 5 Printer IO startup. 4 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. 1 All subsystems launched.
Troubleshooting Using the Power Switch LEDs to Troubleshoot In certain circumstances, the LEDs located on top of the power switch (located at the rear of the Printer) can help to troubleshoot the Printer. The LEDs can either be ON or Off and using different combinations can indicate different problems: Make sure you look directly at the LEDs and not at an angle.
Troubleshooting 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: 5V 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.
Troubleshooting 1 If the Printer cannot be turned ON: Signal LED on Interconnect PCA LED on PrintMech PCA Power Switch LED Corrective Action Check the connection between the 5Vsb OFF ON Amber PSU and the Interconnect PCA. If connection OK, replace the Interconnect PCA ⇒ Page 8-64. Check the connection between the PSU and the PrintMech PCA. 5Vsb ON OFF Amber Make sure that ALL cables between the PSU and PrintMech are not damaged and are connected correctly.
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 LED on PrintMech PCA Power Switch LED Corrective Action Check the connection between the 5V 24V OFF ON ON Blue ON Blue and Green PSU and the Interconnect PCA. If connection OK, replace the Interconnect PCA ⇒ Page 8-64.
Troubleshooting 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.
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).
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.
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.
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.
Troubleshooting 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).
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.
Troubleshooting Calibrations Status This page contains the following information: General Calibrations (performed by Service Engineers). Media Specific Calibrations (performed by the User). 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’.
System Error Codes 2 1 2 Introduction 2-2 Continuable and Non-Continuable Error Codes 2-2 System Error Codes and Warnings - Explanation 2-25 hp designjet 4000 series printer service manual 2-1
System Error Codes 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.
System Error Codes System Error: 01.0:03 Problem Description: Error impact I2C channel. Corrective Action: Try the following: Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. If the System Error continues, replace the Gamut PCI PCA ⇒ Page 8-69. System Error: 01.0:10 Problem Description: Problem with the Gamut PCI PCA.
System Error Codes System Error: 01.2:10 Problem Description: ISS PCA faulty - Humidity sensor out of scale or NVM backup failure. Corrective Action: Try the following: Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. If the System Error continues, replace the Ink Supply Tubes and Trailing Cable ⇒ Page 8-33. System Error: 02:10 Problem Description: Encoder seems to be wrong.
System Error Codes System Error: 03:10 Problem Description: Problem with the Power Supply Unit. Corrective Action: Try the following: Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. Perform the Electronics Modules Test (⇒ Page 4-17) to troubleshoot the problem further. If the System Error continues, replace the Power Supply Unit ⇒ Page 8-78. System Error: 05.1:10 Problem Description: CPU Fan is stopped or burnt.
System Error Codes System Error: 06:10 Problem Description: Main NVM failure - not detected, read/write failed or readback error. Corrective Action: Try the following: Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. If the System Error continues, replace the Hard Disk Drive ⇒ Page 8-76. System Error: 07:10 Problem Description: Aerosol Fan driver burnt.
System Error Codes System Error: 11:10 Problem Description: Trailing Cable does not seem to be detected. Corrective Action: Try the following: Check that the Trailing Cable is not damaged. Check that the Trailing Cable is correctly connected to the Carriage PCA, Interconnect PCA and to the Gamut PCI PCA. Replace the Gamut PCI PCA ⇒ Page 8-69. Replace the Ink Supply Tubes and Trailing Cable ⇒ Page 8-33. Replace the Carriage PCA ⇒ Page 8-48.
System Error Codes System Error: 21:12 Problem Description: Fail moving Service Station. Corrective Action: Try the following: Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. If the System Error continues, replace the Service Station ⇒ Page 8-23. System Error: 21:13 Problem Description: Problem with the Service Station.
System Error Codes System Error: 24:03 Problem Description: Ink Setup failure (Ink Supply Tubes purge failed). Corrective Action: Try the following: Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. 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.
System Error Codes System Error: 26.2:01 Problem Description: Bad contact detected in ISS slot2 floater. Corrective Action: 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 8-38.
System Error Codes System Error: Problem Description: 27:03 An error has occurred in Printhead detection. Corrective Action: Try the following: Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. Remove the Printheads from the Carriage and reinsert them. Replace the Printheads. Replace the Carriage Flex Cables ⇒ Page 8-51. System Error: 27:14 Problem Description: A wrong Printhead has been detected.
System Error Codes System Error: 29.2:01 Problem Description: Printhead Cleaner not inserted correctly in slot 3. Corrective Action: 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. System Error: 29.
System Error Codes System Error: 29.6:01 Problem Description: Printhead Cleaner not inserted correctly in slot 7. Corrective Action: 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. System Error: 29.7:01 Problem Description: Printhead Cleaner not inserted correctly in slot 8.
System Error Codes System Error: 42:03 Problem Description: Electrical current limit in Scan-Axis Motor. Corrective Action: Try the following: Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. Open the Window and check for any visible obstacles restricting the movement of the Carriage Assembly. If there is a wrinkled mass of media blocking the Carriage Assembly, then clear the obstruction.
System Error Codes System Error: 44:10 Problem Description: Problem with the Aerosol Fan. Corrective Action: Try the following: Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. Check that the 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, replace the Interconnect PCA ⇒ Page 8-64.
System Error Codes System Error: 52:10 Problem Description: Drop Detector switch On/Off failure. Corrective Action: Try the following: Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. Check that the Drop Detector cable is not damaged and is correctly connected to the Service Station cable. Check that the Service Station cable is not damaged and is correctly connected to the Interconnect PCA.
System Error Codes System Error: 56:03 Problem Description: Analog Encoder calibration failed. Corrective Action: Try the following: Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. Replace the Encoder Disc and Sensor ⇒ Page 8-103. If the System Error continues, replace the PrintMech PCA ⇒ Page 8-84. System Error: 56:10 Problem Description: Analog Encoder calibration failed.
System Error Codes System Error: 61:08.1 Problem Description: The file cannot be printed because it is password protected. Corrective Action: Resend the file without password protection. System Error: 63:04 Problem Description: Input/Output problem through the Network Card. Corrective Action: 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.
System Error Codes System Error: 67:04 Problem Description: Input/Output problem through an Firewire Port. Corrective Action: 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, replace the Main PCA ⇒ Page 8-74. System Error: 68:03 Problem Description: Non-critical permanent data was lost.
System Error Codes System Error: 72:04 Problem Description: Generic Firmware error. Corrective Action: Try the following: Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. Check that the Printer has the latest Firmware version. If not, update the Firmware to the latest version. System Error: 73:03 Problem Description: Servo Error.
System Error Codes System Error: 74:04 Problem Description: Old Vacuum Fan detected - upgrade the Firmware. Corrective Action: Try the following: Check that the Printer has the latest Firmware version. If not, update the Firmware to the latest version. System Error: 76:03 Problem Description: Out of Disk space - Data was lost. Corrective Action: Try the following: Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer.
System Error Codes System Error: 79:04 Problem Description: Generic Firmware error. Corrective Action: Try the following: Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. Check that the Printer has the latest Firmware version. If not, update the Firmware to the latest version. System Error: 79.1:04 Problem Description: CDS server lost connection with client.
System Error Codes System Error: 81:10 Problem Description: Fail starting Paper Motor. Corrective Action: 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.
System Error Codes System Error: 86:10 Problem Description: Initializing Scan-Axis Motor failure. Corrective Action: Try the following: Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. Check that the Carriage Belt is correctly installed. Replace the Encoder Strip and Encoder Sensor ⇒ Page 8-45. If the System Error continues, replace the Scan-Axis Motor ⇒ Page 8-59.
System Error Codes System Error: 93:11 Problem Description: Unable to pressurize the IDS. Corrective Action: 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 8-42. If the System Error continues, replace the Ink Supply Tubes and Trailing Cable ⇒ Page 8-33.
System Error Codes The following table explains the XX part of the System Error Code or Warning: Items in red are not applicable to this printer. 2-26 Code Component/System 01.0 01.1 01.2 02 02.1 03 04 05 05.1 05.2 05.3 06 07 08 11 12 13.
System Error Codes Code Component/System 45 51 51.1 52 53 54 55 56 57 58 59 61 61.1 61.2 62 63 63.0 63.1 63.2 64 65 66 67 68 71 72 73 74 75 75.1 75.2 76 77 79 79.
System Error Codes Code Component/System 91 92 93 94 95 96 97 98 Printhead Firing Servicing Ink Pumping Color Calibration Printhead Alignment Image Quality Troubleshooting Paper Advance Calibration Automatic Backup Printmode Enabled The following table explains the YZ part of the System Error Code or Warning: 2-28 Code Recovery Action 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 Replace Reseat/Reconnect/Clean/Adjust (manually) Calibrate/Adjust (using Automatic Process) Power OFF and
,QN 6XSSOLHV 7URXEOHVKRRWLQJ 3 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
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Service Tests and Utilities 4 4 Introduction 4-2 Diagnostics - Self Test 4-2 Service Tests (Diagnostics) 4-3 Entering the Service 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 4-34 9. Vacuum Fans Test 4-35 10.1 Others >>> Bag Broken Recovery 4-36 10.2 Others >>> IO Information 4-39 10.
Service Tests and Utilities Introduction This chapter explains how to use the built-in Service Tests and Service Utilities and what to do if any of the Service Tests fail. If possible, always perform a Service 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.
Service Tests and Utilities Service Tests (Diagnostics) The following is a list of all internal Service Tests available in the Printer. Instructions for entering the Service 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.
Service Tests and Utilities 10 Others ⇒ Page 4-36 This option allows you to: Recover the Printer from a Bag Broken error ⇒ Page 4-36. View the information relating to the IO ⇒ Page 4-39. View the Firmware Version, Part Number, Serial Number and PS Unit Configuration ⇒ Page 4-40. Verify which Ink Cartridges are valid for the purge process and what is their current available ink level ⇒ Page 4-42. 11 EEROM Reset ⇒ Page 4-44 The purpose of this test is to reset the EEROM values.
Service Tests and Utilities Entering the Service Tests Menu In order to enter the Service Utility Menu, please refer to the instructions on Page 4-52. 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.
Service Tests and Utilities 4 Once inside the Service Tests Menu use the Arrow keys to scroll through the "Service Tests" selections. Press the Enter key to begin a specific test when the required Service Test is highlighted. Press Enter to confirm selection Use UP and DOWN keys to select The Service Tests work in a special Mode which does NOT require the full Initialization of the Printer.
Service Tests and Utilities ON PH ES RT PO UP 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 System System System Error Error Error Error Code 86:XX. Code 42:XX. Code 73:XX. Codes related to Scan-Axis shutdown or Carriage jam. ALL THE COVER SENSORS ARE DISABLED WHEN IN THE SERVICE TESTS MENU.
Service 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 System Error Code 03:10. For more information on troubleshooting this error code, refer to Page 2-5. Check also System Error Code 01.0:10 (refer to Page 2-3). Config GPIO drv_enable.
Service Tests and Utilities 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.
Service Tests and Utilities 9 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.
Service 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.
Service Tests and Utilities ON PH ES RT PO P U 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 Service Tests submenu, scroll to "2.
Service 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 System Error Code 02.1:10. For more information on troubleshooting this error code, refer to Page 2-4. Check also System Error Code 11:10 (refer to Page 2-7) or System Error Code 01.
Service 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.
Service 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.
Service 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.
Service Tests and Utilities O PH NE S RT PO UP 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 Service Tests submenu, scroll to "3. Electronics Module Test" and press Enter.
Service Tests and Utilities 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.
Service 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. 9 The printer will then check the Serial Number and Part Number and display the information on the Front Panel.
Service Tests and Utilities 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: Press Enter to confirm selection Use UP and DOWN keys to select 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.
Service Tests and Utilities 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.
Service 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. 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 System Error Code 01.0:10 or System Error Code 01.1:10.
Service Tests and Utilities If there is a failure at this point, the Front Panel will display System Error Code 79:03. For more information on troubleshooting this error code, refer to Page 2-21. Getting unit config. If the current Part Number is not in the correct 6 character format, the Front Panel will display a fail message. In this case, re-enter in to the Service Tests submenu and use the diagnostic "13. Error 71:19 Recovery" to set the correct Serial Number (refer to Page 4-47).
Service Tests and Utilities 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.
Service Tests and Utilities If there is a failure at this point, the Front Panel will display System Error Code 02.1:10. For more information on troubleshooting this error code, refer to Page 2-4. Check also System Error Code 11:10 (refer to Page 2-7). 22 A message will appear on the Front Panel asking whether you would like to check the ISS Communication. Select Yes or No by using the Up and Down keys and press Enter to confirm your selection.
Service Tests and Utilities to Page 2-7. Check also System Error Code 01.2:10 (refer to Page 2-4) or System Error Code 01.0:10 (refer to Page 2-3). Getting ISS data. If there is a failure at this point, the Front Panel will display System Error Code 74:00. For more information on troubleshooting this error code, refer to Page 2-20. Checking ISS Ink Sup. If there is a failure at this point, the Front Panel will display System Error Code 26.n:10.
Service Tests and Utilities ON PH ES RT PO UP 4. Carriage Assembly Test The purpose of this test is to verify the operation of the Carriage Assembly. IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE REPLACING THE CARRIAGE ASSEMBLY. IF THIS TEST PASSES, DO NOT REPLACE THE CARRIAGE ASSEMBLY. Perform the Carriage Assembly test as follows: 1 In the Service Tests submenu, scroll to "4. Carriage Assembly Test" and press Enter. Press Enter 2 This test has not yet been implemented.
Service Tests and Utilities O PH NE S RT PO UP 5. Sensors Test The purpose of this test is to verify the operation of the following Sensors: Window Sensor. Printhead Cleaner (PHC) Access Door Sensor. Media Lever Sensor. Media Sensor. IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE REPLACING A RELEVANT SENSOR. IF THIS TEST PASSES, DO NOT REPLACE THE RELEVANT SENSOR. Perform the Sensors test as follows: 1 Before starting, first make sure that: The Window is closed.
Service Tests and Utilities 5 The Window Sensor will be tested first. When the following message is displayed on the Front Panel, open the Window and press any key to continue. 6 If the Window Sensor passes the test, the following message is displayed on the Front Panel. Close the Window and press any key to continue. If the Window Sensor fails the test, the Front Panel will display System Error Code 51:10. For more information on troubleshooting this error code, refer to Page 2-15.
Service Tests and Utilities 9 The Media Lever Sensor will be tested next. When the following message is displayed on the Front Panel, raise the Media Lever and press any key to continue. 10 If the Media Lever Sensor passes the test, the following message is displayed on the Front Panel. Lower the Media Lever and press any key to continue. If the Media Lever Sensor fails the test, the Front Panel will display System Error Code 54:10.
Service Tests and Utilities If there is a failure in reading the GPIO channel, the Front Panel will display System Error Code 01.0:10. For more information on troubleshooting this error code, refer to Page 2-3. Check also System Error Code 07:10 (refer to Page 2-6). 13 Once the test is completed, OK will be displayed on the Front Panel.
Service Tests and Utilities ON PH ES RT PO P U 6. Ink Delivery System Test The purpose of this test is to verify the operation of the Ink Delivery System. Perform the Ink Delivery System test as follows: 1 In the Service Tests submenu, scroll to "6. Ink Delivery System Test" and press Enter. Press Enter 2 This test has not yet been implemented.
Service Tests and Utilities ON PH ES RT PO UP 7. SVS/Aerosol Fan Test The purpose of this test is to verify the operation of the Service Station and the Aerosol Fan. IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE REPLACING THE SERVICE STATION/AEROSOL FAN. IF THIS TEST PASSES, DO NOT REPLACE THE SERVICE STATION/AEROSOL FAN. Perform the SVS/Aerosol Fan test as follows: 1 In the Service Tests submenu, scroll to "7. SVS/Aerosol Fan Test" and press Enter. Press Enter 2 This test has not yet been implemented.
Service Tests and Utilities ON PH ES RT PO UP 8. Air Pump System Test The purpose of this test is to verify the operation of the Air Pressurization System (APS). IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE REPLACING THE APS. IF THIS TEST PASSES, DO NOT REPLACE THE APS. Perform the Air Pump System test as follows: 1 In the Service Tests submenu, scroll to "8. Air Pump System Test" and press Enter. Press Enter 2 This test has not yet been implemented.
Service Tests and Utilities O PH NE S RT PO UP 9. Vacuum Fans Test The purpose of this test is to verify the operation of the Vacuum Fans. IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE REPLACING THE VACUUM FAN. IF THIS TEST PASSES, DO NOT REPLACE THE VACUUM FAN. Perform the Vacuum Fans test as follows: 1 In the Service Tests submenu, scroll to "9. Vacuum Fans Test" and press Enter. Press Enter 2 This test has not yet been implemented.
Service Tests and Utilities ON PH ES RT PO UP 10.1 Others >>> Bag Broken Recovery This option allows to recover the Printer from a Bag Broken error. Perform the Bag Broken Recovery as follows: 1 In the Service Tests submenu, scroll to "10. Others" and press Enter. Press Enter 2 In the Others submenu, scroll to "10.1 Bag Broken Recovery" and press Enter. Press Enter 3 The Printer will start to initialize and the Front Panel will display the following messages: Starting Gamut. Starting TestGPIO.
Service Tests and Utilities If the Bag Broken error is still active even after replacing the faulty Ink cartridge, the Front Panel will display System Error Code 01.2:10. For more information on troubleshooting this error code, refer to Page 2-4. Check also System Error Code 01.0:10 (refer to Page 2-3). 5 If the Printer does not detect that any of the Ink cartridges have a broken bag, then it will read the Acumen of the Ink cartridge to check if there had been an ink short previously.
Service Tests and Utilities 7 If you select Yes, the following message will appear on the Front Panel. Check if the Ink Supply Tubes from the ISS to the Carriage contain visible air. Select Yes or No by using the Up and Down keys and press Enter to confirm your selection. Press Enter to confirm selection Use UP and DOWN keys to select If you select Yes, the Front Panel will display System Error Code 24:10. For more information on troubleshooting this error code, refer to Page 2-9.
Service Tests and Utilities O PH NE S RT PO UP 10.2 Others >>> IO Information This option allows you to view the information relating to the IO. View the IO Information as follows: 1 In the Service Tests submenu, scroll to "10. Others" and press Enter. Press Enter 2 In the Others submenu, scroll to "10.2 IO Information" and press Enter. Press Enter 3 The Printer will start to initialize and the Front Panel will display the following messages: Getting IO Interface. Getting Interface info.
Service Tests and Utilities ON PH ES RT PO UP 10.3 Others >>> Unit Information This option allows you to view the following Printer information: Firmware version. Serial Number. Part Number. PS Language (for HP Designjet 4000PS) View the Unit Information as follows: 1 In the Service Tests submenu, scroll to "10. Others" and press Enter. Press Enter 2 In the Others submenu, scroll to "10.3 Unit Information" and press Enter.
Service Tests and Utilities 4 Once the Unit information is obtained, it is displayed on the Front Panel. Press any key to exit. 5 Once the process is completed, OK will be displayed on the Front Panel.
Service Tests and Utilities ON PH ES RT PO UP 10.4 Others >>> Check Ink Supplies The purpose of this test is to verify which Ink Cartridges are valid for the purge process and what is their current available ink level. Some Ink Cartridges may not be able to be accessed (unable to read the Acumen) if previously there had been a failure (faulty, broken bag, etc...). View the Unit Information as follows: 1 In the Service Tests submenu, scroll to "10. Others" and press Enter.
Service Tests and Utilities 4 Once the Ink Supplies information is obtained, it is displayed on the Front Panel. Press any key to exit. If any part of the Acumen information is invalid, the Front Panel will display System Error Code 74:00. For more information on troubleshooting this error code, refer to Page 2-20. 5 Once the process is completed, OK will be displayed on the Front Panel.
Service Tests and Utilities ON PH ES RT PO UP 11. EEROM Reset The purpose of this diagnostic is to reset the EEROM values. Once the EEROM has been reset, the Printer will act as if it is being started for the first time, except that the Ink Supply Tubes have already been primed. Perform an EEROM Reset as follows: 1 In the Service Tests submenu, scroll to "11. EEROM Reset" and press Enter.
Service Tests and Utilities 4 Once the EEROM has been reset, the following message will appear on the Front Panel. Press any key to continue. After rebooting the Printer, make sure you select Printhead replacement through the Front Panel in order to launch the Printhead calibration. 5 Once the process is completed, OK will be displayed on the Front Panel.
Service Tests and Utilities ON PH ES RT PO UP 12. Set Unit Configuration The purpose of this test is to automatically configure the Printer either as Standard or Productivity. Set the Unit Configuration as follows: 1 In the Service Tests submenu, scroll to "12. Set Unit Configuration" and press Enter. Press Enter 2 The Printer will start the configuration process and the Front Panel will display the following messages: Starting Nvm.
Service Tests and Utilities ON PH ES RT PO UP 13. Error 71:19 Recovery 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. Set the Serial Number as follows: 1 In the Service Tests submenu, scroll to "Error 71:19 Recovery" and press Enter.
Service Tests and Utilities 5 Once the new Serial Number has been entered, the Front Panel will display the Serial Number and Model Number of the Printer. Press the Enter key to confirm the Serial Number or the Cancel key to exit the utility without making any changes. Press Enter to confirm Press Cancel to exit If there is a failure at this point, the Front Panel will display System Error Code 79:03. For more information on troubleshooting this error code, refer to Page 2-21.
Service Tests and Utilities O PH NE S RT PO UP I/O Tests The purpose of this test is to check the installed and active I/O Interfaces. Perform the I/O tests as follows: 1 Once the message "Ready" is displayed on the front-panel, scroll to the "Printer Setup Options" icon and press the Enter key. Press Enter 2 Once inside the "Printer Setup Menus" menu, press the UP or Down arrow key and the Cancel key together. You are now in the Service Tools Menu.
Service Tests and Utilities 5 When the following message appears on the front panel, you must select whether you would like to continue with the test by pressing the Enter key. Press Back or Cancel to exit the calibration. Press Cancel or the Back key to Exit Press Enter to proceed 6 The Printer will get information on the I/O Interfaces. Once the information has been read, the following message will be displayed on the Front Panel.
Service Tests and Utilities Service Utilities The following is a list of all internal Service Utilities available in the Printers. Instructions for entering the Service Utilities menu are given on Page 4-52. 1 Turn Drive Roller ⇒ Page 4-54 The purpose of this Service Utility is to rotate the Drive Roller and the Overdrive in order to clean them.
Service Tests and Utilities Entering the Service Utilities Menu 1 Once the message "Ready" is displayed on the front-panel, scroll to the "Printer Setup Options" icon and press the Enter key. Press Enter to confirm selection Use UP and DOWN keys to select 2 For Call Agents who will request the user to perform certain Service Utilities, once inside the "Printer Setup" menu, press the Down arrow key and the Cancel key together. You are now in the Service Tools Menu.
Service Tests and Utilities 4 Use the Arrow keys to scroll to the "Service Utilities" menu and press the Enter key. Press Enter to confirm selection Use UP and DOWN keys to select 5 Use the Arrow keys to scroll through the "Service Utilities" selections and press the Enter key to begin a specific operation when the required Service Utility is highlighted.
Service Tests and Utilities O PH NE S RT PO UP 1. Turn Drive Roller The purpose of this Service Utility is to rotate the Drive Roller and the Overdrive in order to clean them. REMOVE THE MEDIA BEFORE PERFORMING THIS OPERATION. OPEN THE WINDOW OF THE PRINTER AND ACTIVATE THE WINDOW SENSOR (USING A PIECE OF PAPER) BEFORE PERFORMING THIS SERVICE UTILITY. Perform the Turn Drive Roller utility as follows: 1 In the Service Utilities submenu, scroll to "Turn Drive Roller" and press Enter.
Service Tests and Utilities 3 The Drive Roller begins to turn slowly and the following message is displayed on the Front Panel: 4 Refer to the Cleaning Instructions on Page 9-3. 5 Once you have finished cleaning the Drive Roller and the Overdrive, press the Cancel key to finish the utility. 6 If the utility exits correctly, OK will be displayed on the Front Panel. PLEASE REMEMBER TO REMOVE THE PIECE OF PAPER FROM THE WINDOW SENSOR BEFORE CLOSING THE WINDOW AS THIS COULD DAMAGE THE WINDOW AND THE SENSOR.
Service Tests and Utilities 2. Prime Tubes The purpose of this Service Utility is to Prime the Tubes when the Ink Tubes are NOT new and they need to be re-primed or automatic priming was not completed correctly. Make sure that NEW Ink Cartridges are installed or that the ink volume remaining in the Ink cartridges is below 88% before starting to prime the tubes. If you do not comply, you will get a warning message.
Service Tests and Utilities 4 Once the Printer has rebooted, the Front Panel will instruct you to open the Window and remove ALL the Printheads installed in the Carriage. 5 Once ALL the Printheads have been removed, the Front Panel will instruct you to install the Setup Printheads into the Carriage. Make sure you install the Setup Printheads in stalls 1, 3, 5 and 7. 6 Once all the Setup Printheads are installed, the following message will appear on the front panel.
Service Tests and Utilities 9 When the following message appears on the Front Panel, open the Carriage cover and check the window on top of each Setup Printhead. If the Ink Supply Tubes have been primed correctly, the windows will contain ink. If the windows on top of each Setup Printhead does NOT contain ink, then you may need to repeat the Prime Tubes process from the beginning. 10 Remove ALL the Setup Printheads from the Carriage and install the previously removed Printheads.
Service Tests and Utilities 14 Once the Printhead Alignment is completed, the following message will be displayed on the Front Panel. Press the Enter key to continue.
Service Tests and Utilities 3. Set SN The purpose of this Service Utility is to set the Serial Number of the Printer. Perform the Set SN utility as follows: 1 In the Service Utilities submenu, scroll to "Set SN" and press Enter. Press Enter 2 The Printer will display the current Serial Number and the new Serial Number of the Printer. Use the Up and Down keys to go through the digits and press the Enter key to go to the next digit.
Service Tests and Utilities 4. Reset Life Counters The purpose of this Service Utility is to reset the internal life counters. There are two submenus that allow you to: Reset ALL the counters related to a Preventive Maintenance Kit (PMK). Reset only the counters related to a specific replaced part. ALWAYS RESET THE LIFE COUNTER OF A CORRESPONDING PART AFTER REPLACING IT.
Service Tests and Utilities 3 Once you have selected a Life Counter to reset, the following message will be displayed on the Front Panel. Press the Enter key to reset the selected Life Counter or press Back/Cancel to exit without resetting the Life Counter. Press Cancel or the Back key Press Enter If the Usage Counter information cannot be read, the Front Panel will display "Unable to get usage counter". This could point to a possible Firmware error.
Service Tests and Utilities ON PH ES RT PO UP 5. Diagnostic Print The purpose of this Service Utility is to print the Diagnostic Print in order to identify image quality problems. Print the Diagnostic Print as follows: 1 In the Service Utilities submenu, scroll to "Diagnostic Print" and press Enter. Press Enter 2 You will be given an option to either print the "Image Quality User Plot" or the "Image Quality Service Plot".
Service Tests and Utilities ON PH ES RT PO UP 6. Sleep Mode The purpose of this Service Utility is to enable/disable the sleep mode so that the Printer is never switched Off automatically if not used for a certain period of time (one hour by default). Perform the Sleep Mode utility as follows: 1 In the Service Utilities submenu, scroll to "Sleep Mode" and press Enter.
Service Tests and Utilities O PH NE S RT PO UP 7. Replace Cutter The purpose of this Service Utility is to move the Carriage to a position where the Cutter can be replaced easily. Perform the Replace Cutter utility as follows: 1 In the Service Utilities submenu, scroll to "Replace Cutter" and press Enter. Press Enter 2 When the following message appears on the front panel, you must select whether you would like to continue with replacing the Cutter by pressing the Enter key.
Service Tests and Utilities O PH NE S RT PO UP 8. Set RTC Clock The purpose of this Service Utility is to set the Real Time Clock of the Printer. Perform the Set RTC Clock utility as follows: 1 In the Service Utilities submenu, scroll to "Set RTC Clock" and press Enter. Press Enter 2 The Printer will display the current time and the new time. Use the Up and Down keys to go through the digits and press the Enter key to go to the next digit.
Service Tests and Utilities O PH NE S RT PO UP 9. Carriage Setup The purpose of this Service Utility is to reset the ink short thresholds after replacing the Carriage PCA. From Firmware Version 4.x.x.x, "Carriage Setup" will be moved from Service Utilities to the Service Calibrations section. Perform the Carriage Setup utility as follows: 1 In the Service Utilities submenu, scroll to "Carriage Setup" and press Enter.
Service Tests and Utilities 4-68 hp designjet 4000 series printer service manual
Service Calibrations 5 5 Service Calibrations 5-2 Entering the Service Calibrations Menu 5-3 1. Scan Axis Calibration 5-4 2. Service Station Calibration 5-8 3. Paper Advance Calibration 5-9 4. Drop Detector Calibration 5-15 5. Line Sensor Calibration 5-16 6. Platen Blue Line Calibration 5-20 7. Vacuum Calibration 5-22 8.
Service Calibrations Service Calibrations The Printer has several calibration procedures that must be performed under certain conditions. REMEMBER THAT CERTAIN CALIBRATIONS ARE REQUIRED EVEN IF AN ASSEMBLY HAS BEEN DISASSEMBLED TO GAIN ACCESS TO ANOTHER ASSEMBLY OR COMPONENT. The following is a list of all internal service calibrations available in the Printers. Instructions for entering the service calibrations menu are given on Page 5-3.
Service Calibrations Entering the Service Calibrations Menu 1 Once the message "Ready" is displayed on the front-panel, scroll to the "Printer Setup Options" icon and press the Enter key. Press Enter 2 Once inside the "Printer Setup Menus" menu, press the UP or Down arrow key and the Cancel key together. You are now in the Service Tools Menu. Press UP OR DOWN Press Cancel 3 Use the Arrow keys to scroll to the "Service Calibrations" menu and press the Enter key.
Service Calibrations 1. Scan Axis Calibration The purpose of this Service Calibration is to carry out a PWM check, calibrate the intensity of the Line Sensor and calibrate the Line Sensor position to the Black Printhead. Perform the Scan Axis Calibration whenever: Carriage is disassembled or replaced. Encoder Strip is disassembled or replaced. Center Platen is disassembled or replaced.
Service Calibrations 3 If media is not loaded, the following message appears on the front panel. Load media in to the Printer and start again from step 1. Before continuing, the Printer will check the following: The Media Lever is in the lowered position. The correct paper type is loaded (check list on previous page). The correct paper size (minimum paper size 24 inches).
Service Calibrations 6 The Printer will start to calibrate the Line Sensor position to the Black Printhead. It will print a line of black dots and then scan them: 7 Once the Line Sensor has been calibrated, the results will be displayed on the Front Panel. Press Enter to finish the calibration or press Back or Cancel to exit the calibration. 8 The Printer will now perform the Printhead Alignment.
Service Calibrations 10 Once the Printhead Alignment is completed, the following message will be displayed on the Front Panel. Press the Enter key to continue. If the Printhead Alignment fails for any reason, a warning message will appear on the Front Panel. In this case, try the following: Enter the Front Panel menu and retry the Printhead Alignment. If the Alignment completes successfully, then perform the Color Calibration.
Service Calibrations 2. Service Station Calibration The purpose of this Service Calibration is to calibrate the Service Station in relation to the Carriage Assembly. Perform the Service Station Calibration whenever: Carriage Assembly is disassembled or replaced. Service Station is disassembled or replaced. Perform the Service Station Calibration as follows: 1 In the Service Calibrations submenu, scroll to "Service Station Calibration" and press Enter.
Service Calibrations This Calibration will be available from FW Version 3.x.x.x 3. Paper Advance Calibration The purpose of this Service Calibration is to calibrate the nominal advance of the media. This calibration is necessary to control the exact movement of the media in order to avoid print quality problems like banding. In order to perform this Calibration, you should order the Paper Advance Calibration Kit (Part Number Q1273-60125) which contains two sheets of HP Productivity Gloss Media.
Service Calibrations 2 In the Paper Advance Calibration submenu, scroll to "Print Calibration Pattern" and press Enter. Press Enter 3 When the following message appears on the front panel, you must select whether you would like to continue with the calibration by pressing the Enter key. Press Back or Cancel to exit the calibration.
Service Calibrations 5 Once the Analog Encoder has been calibrated correctly, the following message will appear on the Front Panel. Press the Enter key in order to start the media load process. 6 Load a sheet of HP Productivity Gloss Media that was included in the Paper Advance Calibration Kit (Part Number Q1273-60125) following the instructions on the Front Panel. If the kit is not available, then cut a piece of HP Productivity Gloss Media that is 36 inches wide and at least 45 inches long.
Service Calibrations If the Paper Advance Calibration fails for any reason, a warning message will appear on the Front Panel. In this case, try the following: Retry the Paper Advance Calibration. If necessary, perform a Printhead Recovery through the Front Panel and retry the Calibration. Remove the pattern from the printer and leave it to dry for a few minutes before continuing with the Calibration. MAKE SURE NO MEDIA IS LOADED INTO THE PRINTER BEFORE STARTING TO SCAN THE CALIBRATION PATTERN.
Service Calibrations Only scan the Calibration Pattern in the Printer that was used to actually print it. Using the Calibration in a different Printer could cause it to experience media advance problems. After scanning the Calibration Pattern, it should be discarded. When Loading the Calibration Pattern, use the Cutter blade on the Print Platen to align the edge of the sheet.
Service Calibrations 15 You will need to re-enter the Paper Advance Calibration submenu and scroll to "Clean Drive Roller" and press Enter. Press Enter 16 When the following message appears on the front panel, you must select whether you would like to continue with the cleaning of the Drive Roller by pressing the Enter key. Press Back or Cancel to exit the calibration. Press Cancel or the Back key to Exit Press Enter to proceed 17 The Printer will begin the Drive Roller Cleaning procedure.
Service Calibrations 4. Drop Detector Calibration The purpose of this Service Calibration is to calibrate the Drop Detector (located in the Service Station) in relation to the Carriage Assembly. Perform the Drop Detector Calibration whenever: Drop Detector is disassembled or replaced. Perform the Drop Detector Calibration as follows: 1 In the Service Calibrations submenu, scroll to "Drop Detector Calibration" and press Enter.
Service Calibrations 5. Line Sensor Calibration The purpose of this Service Calibration is to calibrate the intensity of the line sensor in the Carriage PCA. An incorrect calibration can result in edgedetection failures during media loading and incorrect reading of prints that are used for alignment or calibration. Perform the Line Sensor Calibration whenever: Edge detect procedure fails during media loading. Carriage is disassembled or replaced. Line Sensor is disassembled or replaced.
Service Calibrations 3 If media is not loaded, the following message appears on the front panel. Load media in to the Printer and start again from step 1. Before continuing, the Printer will check the following: The Media Lever is in the lowered position. The correct paper type is loaded (check list on previous page). The correct paper size (minimum paper size 24 inches).
Service Calibrations 6 Once the Line Sensor has been calibrated, the results will be displayed on the Front Panel. Press Enter to finish the calibration or press Back or Cancel to exit the calibration. 7 The Printer will now perform the Printhead Alignment. When the following message appears on the front panel, you must select whether you would like to continue with the calibration by pressing the Enter key. Press Back or Cancel to exit the calibration.
Service Calibrations 9 The Printer will now perform the Color Calibration. When the following message appears on the front panel, you must select whether you would like to continue with the calibration by pressing the Enter key. Press Back or Cancel to exit the calibration. Press Cancel or the Back key to Exit Press Enter to proceed 10 Once the Color Calibration is completed, the following message will be displayed on the Front Panel. Press the Enter key to continue.
Service Calibrations This Calibration will be available from FW Version 3.x.x.x 6. Platen Blue Line Calibration The purpose of this Service Calibration is to calibrate the blue line which is marked on the Print Platen. Make sure you unload media before performing this calibration. Perform the Platen Blue Line Calibration whenever: Center Platen is disassembled or replaced. Perform the Platen Blue Line Calibration as follows: 1 In the Service Calibrations submenu, scroll to "Platen blue line calib.
Service Calibrations 4 The Printer will start to calibrate the Blue Line and the following message will be displayed on the Front Panel. 5 Once the Blue Line has been calibrated, the following message will be displayed on the Front Panel. Open the Window and remove the sheet of media that you had placed on the Print Platen. Press any key on the Front Panel to continue once the sheet of media has been removed. 6 The results of the calibration will be displayed on the Front Panel.
Service Calibrations This Calibration will be available from FW Version 3.x.x.x 7. Vacuum Calibration The purpose of this Service Calibration is to set the default nominal and real values of the Vacuum Fan Assembly. This Service Calibration should ONLY be performed when the Vacuum Fan Assembly has been replaced. Perform the Vacuum Calibration as follows: 1 In the Service Calibrations submenu, scroll to "Vacuum Calibration" and press Enter.
Service Calibrations O PH NE S RT PO UP 8. Carriage Setup The purpose of this Service Calibration is to reset the ink short thresholds after replacing the Carriage PCA. From Firmware Version 4.x.x.x, "Carriage Setup" will be moved from Service Utilities to the Service Calibrations section. Perform the Carriage Setup as follows: 1 In the Service Calibrations submenu, scroll to "Carriage Setup" and press Enter.
Service Calibrations 5-24 hp designjet 4000 series printer service manual
3ULQW 4XDOLW\ 6 Print Quality 6-2 Print Quality Troubleshooting Actions 6-2 Choosing the Correct Print Quality Settings 6-3 How to Use the Service Image Quality Diagnostic Print 6-5 What is the Service Image Quality Diagnostic Print? 6-5 Considerations for Printing the Diagnostic Print 6-5 Printing the Service Image Quality Diagnostic Print 6-6 Diagnostic Part 1: Alignment Test 6-7 Diagnostic Part 2: Printheads & Paper Advance Test 6-8 Diagnostic Part 3: Printhead Problems 6-9 Nozzle Print Test 6-11 No Pr
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3ULQW 4XDOLW\ ,I \RX VHH 'DUN /LQHV DARK LINES Do you see dark lines all along the customer plot? no Refer to Flowchart BOTH (Dark and White Lines) yes / no yes Media Advance actions: - Select the correct Print Quality setting (see the table on page 6-3). - We strongly recommend using HP media. - If the problem persists, Heavyweight Coated paper should be used. - If the problem persists, perform a Paper Advance Calibration.
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Parts and Diagrams 7 7 Printer Support 7-2 Center Covers 7-4 Electronics Module 7-6 Right Hand Cover 7-8 Left Hand Cover 7-10 Right Hand Assemblies 7-12 Left Hand Assemblies 7-14 Carriage Assembly 7-16 Scan-Axis Assemblies 7-18 Drive Roller and Media-Axis Motor 7-20 Paper Path Assemblies 7-22 Center Guide and Pinchwheel Assembly 7-24 Media Entry Assemblies 7-26 Miscellaneous Parts 7-28 hp designjet 4000 series printer service manual 7-1
Parts and Diagrams Printer Support Printer Support Reference on Drawing HP Part Number Quantity 1 Q1271-60454 2 Foot Assembly 2 Q1271-60455 2 Legs Assembly 3 Q1271-60456 1 X-Brace Assembly 4 Q1271-60457 1 Bin Assembly - Q1271-60458 1 Hardware Kit (Includes screws for Legs Assembly) 5 Q1271-60459 2 Leg Cover 7-2 Description/Comments hp designjet 4000 series printer service manual
1 5 2 3 4 Parts and Diagrams Figure 1: Printer Support hp designjet 4000 series printer service manual 7-3
Parts and Diagrams Center Covers Center Covers Reference on Drawing HP Part Number Quantity 1 Q1273-60057 1 Window 2 Q1273-60052 1 Top Cover 3 Q1273-60107 1 Rear Door 4 Q1273-60105 1 Left Connector Cover 5 Q1273-60106 1 Right Connector Cover 6 Q1273-60072 1 Window Sensor 7-4 Description/Comments hp designjet 4000 series printer service manual
1 6 5 2 4 3 Parts and Diagrams Figure 2: Center Covers hp designjet 4000 series printer service manual 7-5
Parts and Diagrams Electronics Module Electronics Module Reference on Drawing HP Part Number Quantity Description/Comments 1 Q1273-60043 1 Main PCA Formatter (Includes Processor & Heatsink) Q1273-69043 1 Main PCA Formatter (Includes Processor & Heatsink) - Refurbished Q1273-60074 1 Gamut PCI PCA Q1273-69074 1 Gamut PCI PCA - Refurbished Q1273-60055 1 Printmech PCA Q1273-69055 1 Printmech PCA - Refurbished Q1273-60044 1 Hard Disk Drive (Includes Holder and screws) Q1273-69044 1 H
9 6 1 8 2 7 11 3 4 5 10 Parts and Diagrams Figure 3: Electronics Module hp designjet 4000 series printer service manual 7-7
Parts and Diagrams Right Hand Cover Right Hand Cover Reference on Drawing HP Part Number Quantity 1 Q1273-60054 1 Right Hand Cover (without Door) 2 Q1273-60095 1 Right Hand Trim 3 Q1273-60045 1 Front Panel (Includes Cable) 4 Q1273-60101 1 Front Panel Bezel 5 Q1273-60090 1 Printhead Cleaner Access Door (for hp designjet 4000) Q1273-60129 1 Printhead Cleaner Access Door (for hp designjet 4000ps) (includes Adobe and Pantone Logo) 6 Q1273-60092 1 Push-Push Mechanism 7 Q1273-60088
2 5 3 4 6 1 7 Parts and Diagrams Figure 4: Right Hand Cover hp designjet 4000 series printer service manual 7-9
Parts and Diagrams Left Hand Cover Left Hand Cover Reference on Drawing HP Part Number Quantity 1 Q1273-60053 1 Left Hand Cover (without Door) 2 Q1273-60096 1 Left Hand Trim 3 Q1273-60091 1 Cartridge Access Door 4 Q1273-60092 1 Push-Push Mechanism 7-10 Description/Comments hp designjet 4000 series printer service manual
1 4 3 2 Parts and Diagrams Figure 5: Left Hand Cover hp designjet 4000 series printer service manual 7-11
Parts and Diagrams Right Hand Assemblies Right Hand Assemblies Reference on Drawing HP Part Number Quantity 1 Q1273-60046 1 Service Station (Includes Drop Detector) 2 Q1273-60047 1 Aerosol Fan Assembly 3 Q1273-60048 1 Vacuum Fan Assembly 4 Q1273-60066 1 Drop Detector 5 Q1273-60067 1 Service Station Cable (Includes Printhead Cleaner Door Switch) 6 Q1273-60084 1 Aerosol Filter 7 Q1273-60086 1 Right Bracket 7-12 Description/Comments hp designjet 4000 series printer service man
3 5 4 2 6 1 7 Parts and Diagrams Figure 6: Right Hand Assemblies hp designjet 4000 series printer service manual 7-13
Parts and Diagrams Left Hand Assemblies Left Hand Assemblies Reference on Drawing HP Part Number Quantity 1 Q1273-60049 1 Ink Supply Station (without APS) 2 Q1273-60068 1 Air Pressurization Pump (APS) 3 Q1273-60102 4 Cartridge Trays 4 Q1273-60085 1 Left Bracket 5 Q1273-60117 1 ISS to Cartridge Cable 6 Q1273-60099 1 Most Left Spittoons 7 Q1273-60100 1 Middle Left Spittoons 7-14 Description/Comments hp designjet 4000 series printer service manual
4 5 7 6 2 1 3 Parts and Diagrams Figure 7: Left Hand Assemblies hp designjet 4000 series printer service manual 7-15
Parts and Diagrams Carriage Assembly Carriage Assembly Reference on Drawing HP Part Number Quantity Description/Comments 1 Q1273-60051 1 Carriage Assembly (does not include Cutter, Carriage PCA, Encoder and Line Sensors) 2 Q1273-60062 1 Cutter Assembly 3 Q1273-60063 1 Line Sensor 4 - 1 Encoder Sensor (this sensor is included within the Encoder Strip and Encoder Sensor Kit, pn Q1273-60070) 5 Q1273-60111 1 Setup Printhead Kit 6 Q1273-60115 1 Carriage Flex Cables 7 Q1273-60116 1
Parts and Diagrams 6 3 7 4 5 2 6 1 Figure 8: Carriage Assembly hp designjet 4000 series printer service manual 7-17
Parts and Diagrams Scan-Axis Assemblies Scan-Axis Assemblies Reference on Drawing HP Part Number Quantity 1 Q1273-60050 1 Ink Supply Tubes and Trailing Cable 2 Q1273-60069 1 Belt and Tensioner Assembly 3 Q1273-60071 1 Scan-Axis Motor 4 Q1273-60070 1 Encoder Strip and Encoder Sensor Kit 5 Q1273-60108 5 Ink Supply Tubes Clips 6 Q1273-60112 2 Rear Tube Brackets 7-18 Description/Comments hp designjet 4000 series printer service manual
6 1 5 2 3 4 Parts and Diagrams Figure 9: Scan-Axis Assemblies hp designjet 4000 series printer service manual 7-19
Parts and Diagrams Drive Roller and Media-Axis Motor Drive Roller and Media-Axis Motor Reference on Drawing HP Part Number Quantity 1 Q1273-60039 1 Drive Roller 2 Q1273-60094 1 Drive Roller Encoder Kit 3 Q1273-60087 1 Gears and Drive Roller Brake Kit 4 Q1273-60037 1 Media-Axis Motor 5 Q1273-60137 1 Carriage Stopper (includes Carriage Stopper Screw and Media-Axis Motor Bracket) 7-20 Description/Comments hp designjet 4000 series printer service manual
3 4 1 5 2 Parts and Diagrams Figure 10: Drive Roller and Media-Axis Motor hp designjet 4000 series printer service manual 7-21
Parts and Diagrams Paper Path Assemblies Paper Path Assemblies Reference on Drawing HP Part Number Quantity 1 Q1273-60041 1 Center Platen 2 Q1273-60060 1 Front Platen 3 Q1273-60058 1 Input Roller 4 Q1273-60103 2 Input Roller Levers 5 Q1273-60073 1 Media Deflectors Kit 7-22 Description/Comments hp designjet 4000 series printer service manual
4 3 5 2 1 Parts and Diagrams Figure 11: Paper Path Assemblies hp designjet 4000 series printer service manual 7-23
Parts and Diagrams Center Guide and Pinchwheel Assembly Center Guide and Pinchwheel Assembly Reference on Drawing HP Part Number Quantity 1 Q1273-60059 1 Center Guide 2 Q1273-60040 1 Complete Pinchwheels Assembly - Q1273-60104 1 Pinchwheels Kit (only contains the wheels) 3 Q1273-60082 1 Media Lever Sensor 4 Q1273-60093 1 Media Lever Assembly 5 Q1273-60079 1 Media Sensor 7-24 Description/Comments hp designjet 4000 series printer service manual
5 2 1 3 4 Parts and Diagrams Figure 12: Center Guide and Pinchwheel Assembly hp designjet 4000 series printer service manual 7-25
Parts and Diagrams Media Entry Assemblies Media Entry Assemblies Reference on Drawing HP Part Number Quantity 1 Q1273-60080 1 Left Roll Module Assembly 2 Q1273-60081 1 Right Roll Module Assembly (Also includes Right Spindle Lever p/n Q1273-60136) 3 Q1273-60121 1 42" Spindle (does NOT include Blue Hub) 4 C6090-60105 1 Blue Hub 5 C6090-60112 1 3" Spindle Adaptors 6 Q1273-60136 1 Right Spindle Lever 7-26 Description/Comments hp designjet 4000 series printer service manual
4 5 1 6 3 2 Parts and Diagrams Figure 13: Media Entry Assemblies hp designjet 4000 series printer service manual 7-27
Parts and Diagrams Miscellaneous Parts Arc Assemblies Reference on Drawing HP Part Number Quantity 1 Q1273-60097 1 Right Arc 2 Q1273-60098 1 Left Arc 7-28 Description/Comments - Q1273-60061 1 Preventive Maintenance Kit (Includes Carriage Assembly (without Carriage PCA), Ink Supply Tubes and Trailing Cable, ScanAxis Motor, Belt, Encoder Strip (includes Spring and Nut but does not include Encoder Reader), Most Left and Middle Left Spittoons), Scraper and the Media-Axis Drive Motor Brake (with
2 1 Parts and Diagrams Figure 14: Arc Assemblies hp designjet 4000 series printer service manual 7-29
Parts and Diagrams 7-30 hp designjet 4000 series printer service manual
Removal and Installation 8 8 Introduction 8-2 Screw Types 8-3 Window 8-4 Right Cover 8-6 Left Cover 8-9 Top Cover 8-11 Rear Door 8-16 Right Connector Cover 8-18 Left Connector Cover 8-19 Front Panel 8-20 Service Station 8-23 Vacuum Fan 8-27 Aerosol Fan 8-29 Drop Detector 8-31 Ink Supply Tubes and Trailing Cable 8-33 ISS to Cartridge Cables 8-38 Cutter Assembly 8-39 Ink Supply Station (ISS) 8-40 APS Assembly 8-42 Most Left Spittoons 8-43 Middle Left Spittoons 8-44 Encoder Strip and Encoder Sensor 8-45 Car
Removal and Installation Introduction This chapter is a step by step guide to the removal and installation of the key components in the printer. You may find it useful to tick off the steps as they are performed. Use the illustration at each procedure to identify the parts referred to in the text. The procedures appear in order of removal. So the whole machine can be stripped down by starting at the beginning of this chapter and working through the subsequent procedures.
Removal and Installation Required Tools The following tools are required to disassemble and repair the Printer. Long Torx Screwdriver with the indicated attachments Small flat-blade screwdriver Screw Types Type Torx Length (mm) Head Type Thread Type Part Number A T-20 17 Pan Taptite 0515-1743 B T-20 10 Pan Taptite 0515-2282 C T-10 7.0 Pan Machined 0515-4613 D T-8 5.5 Pan Taptite 0515-2850 E T-15 - Pan - C3180-20001 F T-15 9.5 Pan Plastite 0515-2981 G T-15 12.
Removal and Installation Window Removal Switch off the product and remove the power cable. 1. Open the Window. 2. Unclip the Window hinges from the Top Cover. Since the hinges are very hard to unclip, it is recommended that you use a screwdriver or other tool to forcefully unclip the Window hinges from the Top Cover. 3. Remove the Window from the Printer.
Removal and Installation Installation of New Window Top Cover 1. Identify the two ends of the Window Hinge (four in total) - one end is clipped to the Window and the other to the Top Cover. Window 2. Slide the Window Hinges on to the Window. 3. Clip the Window Hinges to the Top Cover. Since the hinges are very hard to clip, you will need to forcefully clip the Window hinges to the Top Cover.
Removal and Installation Right Cover Removal Switch off the product and remove the power cable. 1. Unclip the Quick reference Guide Holder from the rear of the Printer. 2 1 2. Using a small flat-blade screwdriver, unclip the Front Panel Bezel from the Right Cover. 3. Remove the Front Panel Bezel from the Right Cover.
Removal and Installation 4. Remove two T-15 screws (Type G) that secure the Front Panel to the Right Cover. 5. Open the Printhead Cleaner Door. 6. Remove one T-15 screw (Type J) that secures the Right Cover.
Removal and Installation 7. Open the Window and remove two T-15 screws (Type J) that secure the Right Cover. Type J 8. Remove one T-15 screw (Type J) and one T-20 screw (Type A) that secure the Right Cover from the rear of the Printer. Type A 9. Remove the Right Cover from the Printer. When installing the Right Cover, make sure you leave the Printhead Cleaner Door open, otherwise you could damage the Printhead Cleaner Door Sensor.
Removal and Installation Left Cover Removal Switch off the product and remove the power cable. 1. Open the Ink Cartridge Door. 2. Remove the Ink Cartridges from the Printer. 3. Remove one T-15 screw (Type J) that secures the Left Cover.
Removal and Installation 4. Open the Window and remove two T-15 (Type J) screws that secure the Left Cover. Type J 5. Remove one T-15 screw (Type J) and one T-20 screw (Type A) that secure the Left Cover. Type A 6. Remove the Left Cover from the Printer.
Removal and Installation Top Cover Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Left Cover ⇒ Page 8-9. 3. Release the three clips securing the Ink Supply Tubes and the Trailing Cable to the Top Cover. 4. Release the Ink Supply Tubes and Trailing Cable from the clip underneath the Top Cover. 5. Remove the Ink Supply Tubes and Trailing Cable from within the Top Cover and lay them on the Print Platen.
Removal and Installation 6. Remove one T-10 (Type I) screw that secures the ESD Strip to the Top Cover (on the left hand side of the Printer). 7. Disconnect the ESD Strip from the Top Cover. 8. Remove three T-15 screws (Type G) that secure the Rear Door. Each screw includes a washer (part number 3050-1267).
Removal and Installation 9. Open the Rear Door. 10. Remove four T-15 screws (Type H) that secure the Top Cover from the rear of the Printer. 11. Using a flat-head screwdriver, release the Top Cover from the right hand side of the Printer.
Removal and Installation 12. Release the Top Cover from the rear of the Printer. 13. Raise the right hand side of the Top Cover and pull out to the right. 1 2 If a NEW Top Cover is to be installed, take note of the following instructions before assembling the Top Cover on to the Printer: 1. Position the Metallic Support on to the Top Cover.
Removal and Installation 2. Lock the Metallic Support on to the Top Cover. 3. Install the T-20 screw that secures the Metallic Support to the Top Cover. 4. Remove the Window (⇒ Page 8-4) from the old Top Cover and install it on the new Top Cover. When installing the Ink Supply Tubes and Trailing Cable on to the Top Cover, take note of the of the two red marks on the Ink Supply Tubes.
Removal and Installation Rear Door Removal Switch off the product and remove the power cable. 1. Remove three T-15 screws (Type G) from the Rear Door. Each screw includes a washer (part number 3050-1267). 2. Open the Rear Door slightly (as shown). 3. To release the right hand hinge of the Rear Door, move the Rear Door to the right and then towards you.
Removal and Installation 4. To release the left hand hinge of the Rear Door, move the Rear Door to the right and then bend the hinge slightly (as shown). 1 2 5. Remove the Rear Door from the Printer.
Removal and Installation Right Connector Cover Removal Switch off the product and remove the power cable. 1. Remove the Rear Door ⇒ Page 8-16. 2. Remove two T-20 screws (Type B) from the Right Connector Cover. 3. Remove the Right Connector Cover from the Printer.
Removal and Installation Left Connector Cover Removal Switch off the product and remove the power cable. 1. Remove the Rear Door ⇒ Page 8-16. 2. Remove two T-20 screws (Type B) from the Left Connector Cover. 3. Remove the Left Connector Cover from the Printer.
Removal and Installation Front Panel Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Rear Door ⇒ Page 8-16. 3. Remove the Right Connector Cover ⇒ Page 8-18. 4. Disconnect the Front Panel Cable from the Interconnect PCA. 5. Disconnect the Ferrite clip (located on the rear of the Electronics Module) from the front of the Printer.
Removal and Installation 6. Move the Front Panel Cable (including the ferrite) out of the Electronics Module. 7. Release the Front Panel Cable from the Right Arc. 8. Disconnect the Ferrite clip from the Right Arc.
Removal and Installation 9. Remove two T-15 screws (Type G) that secure the Front Panel to the Printer. 10. Remove the Front Panel from the Printer.
Removal and Installation Service Station Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Rear Door ⇒ Page 8-16. 3. Remove the Right Connector Cover ⇒ Page 8-18. 4. Disconnect the cable from the Printhead Cleaner Door Switch. 5. Disconnect the Service Station and Aerosol Fan Cables from the Interconnect PCA.
Removal and Installation 6. Uncap the Carriage Assembly by manually pulling out the Printhead Cleaner tray. 7. Move the Carriage Assembly out of the Service Station. 8. Remove four T-15 screws (Type J) that secure the Service Station to the Chassis. When removing the screws, please be very careful NOT to damage the Encoder Strip.
Removal and Installation 9. Disconnect the Aerosol Fan Tube from the Chassis. 10. Remove the Service Station from the Printer. After installing the NEW Service Station, make sure you perform the following Service Utility: Reset Counter PHC spittoon ⇒ Chapter 4. After installing the NEW Service Station, make sure you perform the following Service Calibration: Service Station Calibration ⇒ Chapter 5.
Removal and Installation Removal of the Service Station Scraper 1. Release the clip securing the Scraper to the Service Station. 2. Remove the Scraper from the Service Station.
Removal and Installation Vacuum Fan Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Rear Door ⇒ Page 8-16. 3. Remove the Right Connector Cover ⇒ Page 8-18. 4. Remove the Service Station ⇒ Page 8-23. 5. Release the Pinchwheel Lever Sensor Cable from the Vacuum Fan. 6. Disconnect both Vacuum Fan cables from the Interconnect PCA.
Removal and Installation 7. Remove four T-20 screws (Type B) that secure the Vacuum Fan to the Printer. 8. Remove the Vacuum Fan from the Printer. After installing the NEW Vacuum Fan, make sure you perform the following Service Calibration: Paper Advance Calibration ⇒ Chapter 5. Cable 2 When connecting the Vacuum Fan cables to the Interconnect PCA, make sure you connect the cable with the label marked Vacuum Fan 1 to connector 1 and the cable with the label marked Vacuum Fan 2 to connector 2.
Removal and Installation Aerosol Fan Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Rear Door ⇒ Page 8-16. 3. Remove the Right Connector Cover ⇒ Page 8-18. 4. Remove the Service Station ⇒ Page 8-23. 5. Unclip the bottom cover from the Aerosol Fan. 6. Remove four T-15 screws (Type G) that secure the Aerosol Fan to the Service Station.
Removal and Installation 7. Remove the Aerosol Fan from the Service Station. 8. If necessary, remove the Aerosol Fan Filter from the Aerosol Fan.
Removal and Installation Drop Detector Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Disconnect the Drop Detector Cable from the Service Station Cable. 3. Release the Drop Detector Cable from the Service Station. 4. Remove one T-8 screw (Type K) that secures the Drop Detector to the Service Station.
Removal and Installation 5. Remove the Drop Detector from the Printer. 1 2 8-32 After installing the NEW Drop Detector, make sure you perform the following Service Calibration: Drop Detector Calibration ⇒ Chapter 5.
Removal and Installation Ink Supply Tubes and Trailing Cable Removal Switch off the product and remove the power cable. You MUST NEVER replace both the Hard Disk Drive and the Ink Supply Tubes and Trailing Cable 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. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Left Cover ⇒ Page 8-9. 3.
Removal and Installation 8. Press the two side of the Carriage PCA Cover and unclip from the Carriage Assembly. 1 1 2 9. Disconnect the Trailing Cable from the Carriage PCA. 10. Open the Carriage Cover and remove ALL the Printheads from the Carriage Assembly.
Removal and Installation 11. Remove five T-15 screws (Type G) that secure the Ink Supply Tubes to the Carriage Assembly. 12. Remove one T-20 screw (Type B) from each plastic holder at the rear of the Printer. 13. Disconnect the Electrical Cable from the rear of the Ink Cartridge Tube Connector.
Removal and Installation 14. Disconnect the Air Tube from the Ink Supply Tubes. 1 2 15. Twist the 2 latches at the rear of the Ink Cartridge Tube Connector and release the complete assembly. 16. Remove the Ink Supply Tubes and Trailing Cable from the Printer.
Removal and Installation Installation of the Ink Supply Tubes and Trailing Cable After installing the NEW Ink Supply Tubes and Trailing Cable, make sure you perform the following Service Utility: Reset life counter scan cycles tubes/ cable ⇒ Chapter 4. When installing the Ink Supply Tubes and Trailing Cable on to the Top Cover, take note of the of the two red marks on the Ink Supply Tubes.
Removal and Installation ISS to Cartridge Cables Removal Switch off the product and remove the power cable. 1. Remove the Left Cover ⇒ Page 8-4. 2. Disconnect the ISS to Cartridge Cable from the ISS PCA. 3. Release the clips securing the ISS to Cartridge Cable. 4. Remove the ISS to Cartridge Cable from the Printer.
Removal and Installation Cutter Assembly Removal 1. Select "Replace Cutter" from Service Menu (refer to Chapter 4) and follow the instructions on the Front Panel. 2. Open the Window. 3. Remove one T-15 screw (Type G) that secures the Cutter Assembly to the Carriage Assembly. 4. Slide the Cutter Assembly to the left and remove from the Printer.
Removal and Installation Ink Supply Station (ISS) Removal Switch off the product and remove the power cable. 1. Remove the Left Cover ⇒ Page 8-4. 2. Remove the Left Connector Cover ⇒ Page 8-19. 3. Disconnect the Electrical Cable from the rear of the Ink Cartridge Tube Connector. 4. Disconnect the Air Tube from the Ink Supply Tubes. 1 2 5. Twist the 2 latches at the rear of the Ink Cartridge Tube Connector and release the complete assembly.
Removal and Installation 6. Disconnect the two Ink Supply Station cables from the PrintMech PCA. 7. Release the Ink Supply Station from the Chassis. 8. Remove the Ink Supply Station from the Printer.
Removal and Installation APS Assembly Removal 1. Remove the Left Cover ⇒ Page 8-4. 2. Remove the Left Connector Cover ⇒ Page 8-19. 3. Remove the ISS ⇒ Page 8-40. 4. Release the Air Tube from the Slot in the Ink Supply Station. 5. Unclip the APS Assembly from the Ink Supply Station. 6. Remove the APS Assembly from the Ink Supply Station.
Removal and Installation Most Left Spittoons Removal Switch off the product and remove the power cable. 1. Remove the Left Cover ⇒ Page 8-9. 2. Remove one T-15 screw (Type G) that secures the Most Left Spittoons to the Ink Supply Station. Use a Screwdriver with a small head so that the screw can be removed easily. 3. Remove the Most Left Spittoons from the Printer.
Removal and Installation Middle Left Spittoons Removal Switch off the product and remove the power cable. 1. Open the Window. 2. Remove one T-10 screw (Type C) that secures the Middle Left Spittoons. 3. Remove the Middle Left Spittoons from the Printer. After installing the NEW Middle Left Spittoons, make sure you perform the following Service Utility: Reset life counter mid left spittoon ⇒ Chapter 4.
Removal and Installation Encoder Strip and Encoder Sensor Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Left Cover ⇒ Page 8-9. 3. Uncap the Carriage Assembly by manually pulling out the Printhead Cleaner tray. 4. Move the Carriage Assembly out of the Service Station. 5. Remove one T-10 screw (Type I) that secures the Encoder Strip on the right hand side of the Printer.
Removal and Installation 6. Release the Encoder Strip from the locating pins on the right hand side of the Printer. 7. Release the Spring Clip from the Bracket on the left hand side of the Printer. 1 2 8. Pull the Encoder Strip out of the left hand side of the Printer. 9. Remove the Carriage PCA ⇒ Page 8-48.
Removal and Installation 10. Remove one T-8 (Type L) screw that secures the Encoder Sensor to the Carriage Assembly. 11. Remove the plastic cover from the Encoder Sensor. 12. Remove the Encoder Sensor from the Printer. After installing the NEW Encoder Strip and Encoder Sensor, make sure you perform the following Service Calibration: Scan-Axis Calibration ⇒ Chapter 5.
Removal and Installation Carriage PCA Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Press the two side of the Carriage PCA Cover and unclip from the Carriage Assembly. 1 1 2 3. Disconnect the Trailing Cable from the Carriage PCA. 4. Release the ALL the clips, securing the Carriage Flex Cables to the Carriage PCA, by pulling upwards.
Removal and Installation 5. Disconnect the Flex Cables from the Carriage PCA. 6. Disconnect the Line Sensor Cable and the Encoder Sensor Cable from the Carriage PCA. 7. Push inwards the four clips that secure the Carriage PCA.
Removal and Installation 8. Remove the Carriage PCA from the Printer. Once you have installed a NEW Carriage PCA, you MUST perform the following steps to ensure that the Printer will function correctly: 1. Power ON the Printer. 2. Execute the "Carriage Setup" Utility from the Service Utility Menu (Refer to Chapter 4 for more information). 3. Install the Printheads once the Utility has been completed successfully. 4. Reset life counter Carriage PCA ⇒ Chapter 4.
Removal and Installation Carriage Flex Cables Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Press the two side of the Carriage PCA Cover and unclip from the Carriage Assembly. 1 1 2 3. Release the ALL the clips, securing the Carriage Flex Cables to the Carriage Assembly, by pulling upwards. 4. Disconnect the Flex Cables from the Carriage PCA.
Removal and Installation 5. Remove eight T-8 screws (Type L) that secure the Carriage Flex Cables to the Carriage Assembly. 6. Open the Carriage Cover and remove ALL the Printheads from the Carriage Assembly. 7. Remove the Carriage Flex Cable from the Printer.
Removal and Installation Carriage Assembly Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Left Cover ⇒ Page 8-9. 3. Remove the Encoder Strip ⇒ Page 8-45. 4. Move the Carriage Assembly to the extreme right of the Printer. 5. Press the two side of the Carriage PCA Cover and unclip from the Carriage Assembly. 1 2 1 6. Disconnect the Trailing Cable from the Carriage PCA.
Removal and Installation 7. Open the Carriage Cover and remove ALL the Printheads from the Carriage Assembly. 8. Remove five T-15 screws (Type G) that secure the Ink Supply Tubes to the Carriage Assembly. 9. Remove the Ink Supply Tubes from the Carriage Assembly and safely place to one side of the Printer.
Removal and Installation 10. Disconnect the Aerosol Fan Tube from the Chassis. 11. Remove one T-15 screw (Type A) that secures the Belt Tensioner to the Chassis. 12. Move the Carriage Assembly slightly away from the right Scan-Axis Bracket.
Removal and Installation 13. Release the Carriage Belt from the ScanAxis Motor on the left hand side of the Printer. 14. Remove four T-20 screws (Type N) that secure the right Scan-Axis Bracket. Note that these are Chassis screws and in normal circumstances should NEVER be removed, but in this case we need to remove them in order to remove the Carriage Assembly. 15. Remove the right Scan-Axis Bracket from the Printer.
Removal and Installation 16. Remove the Carriage Stopper Screw (T-25) from the Chassis. 17. Remove the Carriage Stopper from the Printer. 18. Slide the Carriage Assembly (including the belt) to the right and out of the Printer. 19. If the Carriage Assembly is to be replaced, make sure that you remove the Belt, the Carriage PCA, Encoder and Line Sensors and the Cutter Assembly (in order to install them on the new Carriage Assembly).
Removal and Installation Belt Assembly Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Left Cover ⇒ Page 8-9. 3. Remove the Top Cover ⇒ Page 8-11. 4. Remove the Encoder Strip ⇒ Page 8-45. 5. Remove the Carriage Assembly ⇒ Page 853. 6. Release the Belt from the bottom of the Carriage Assembly. After installing the NEW Belt Assembly, make sure you perform the following Service Utility: Reset life counter scan cycles belt ⇒ Chapter 4.
Removal and Installation Scan-Axis Motor Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Left Cover ⇒ Page 8-9. 3. Remove the Rear Door ⇒ Page 8-16. 4. Remove the Left Connector Cover ⇒ Page 8-19 5. Remove one T-15 screw that secures the Belt Tensioner to the Chassis. 6. Move the Carriage Assembly slightly away from the right Scan-Axis Bracket.
Removal and Installation 7. Release the Carriage Belt from the ScanAxis Motor on the left hand side of the Printer. 8. Disconnect the Scan-Axis Motor cable from the PrintMech PCA. 9. Release the Scan-Axis Motor cable from the clips on the chassis.
Removal and Installation 10. Remove two T-20 screws (Type A) that secure the Scan-Axis Motor. Make sure you hold the Scan-Axis Motor securely when removing the screws. 11. Remove the Scan-Axis Motor from the Printer. After installing the NEW Scan-Axis Motor, make sure you perform the following Service Utility: Reset life counter scan motor ⇒ Chapter 4.
Removal and Installation Media-Axis Motor Removal Switch off the product and remove the power cable. 1. Remove the Rear Door ⇒ Page 8-16. 2. Remove the Left Connector Cover ⇒ Page 8-19. 3. Disconnect the Media-Axis Motor cable from the PrintMech PCA. 4. Remove two T-15 screws (Type R) that secure the Media-Axis Motor. 5. Loosen two T-20 screws (Type B) that secure the Media-Axis Motor Bracket.
Removal and Installation 6. Remove the Media-Axis Motor from the Printer. When reinstalling the parts, make sure you apply the grease (included with the support part) to the gears. After installing the NEW MediaAxis Motor, make sure you perform the following Service Calibration: Paper Advance Calibration ⇒ Chapter 5.
Removal and Installation Interconnect PCA Removal Switch off the product and remove the power cable. 1. Remove the Rear Door ⇒ Page 8-16. 2. Remove the Left Connector Cover ⇒ Page 8-19. 3. Remove the JetDirect Card (if installed). 4. Remove three T-15 screws (Type A) that secure the Main PCA cover. 5. Remove the Main PCA Cover from the Printer.
Removal and Installation 6. Remove six T-10 screws (Type I) that secure the Interconnect PCA Cover. 7. Remove the Interconnect PCA Cover from the Printer. 8. Disconnect ALL cables from the Interconnect PCA.
Removal and Installation 9. Remove five T-10 screws (Type I) that secure the Interconnect PCA. 10. Remove the Interconnect PCA from the Printer.
Removal and Installation EIO to PCA Interface Card Removal Switch off the product and remove the power cable. 1. Remove the JetDirect Card (if installed). 2. Remove three T-15 screws (Type A) that secure the Main PCA cover. 3. Remove the Main PCA Cover from the Printer.
Removal and Installation 4. Remove one T-10 screw (Type I) that secures the Interface Card. 5. Disconnect the Interface Card from the Main PCA and remove from the Printer.
Removal and Installation Gamut PCI PCA Removal Switch off the product and remove the power cable. 1. Remove the Rear Door ⇒ Page 8-16. 2. Remove the Left Connector Cover ⇒ Page 8-19. 3. Remove the JetDirect Card (if installed). 4. Remove three T-15 screws (Type A) that secure the Main PCA cover. 5. Remove the Main PCA Cover from the Printer.
Removal and Installation 6. Disconnect the Trailing Cable from the Gamut PCI PCA. 7. Disconnect ALL cables connected to the Gamut PCI PCA 8. Remove one T-10 screw (Type I) that secures the Gamut PCI PCA.
Removal and Installation 9. Disconnect the Gamut PCI PCA from the Main PCA and remove from the Printer.
Removal and Installation Memory Module Removal Switch off the product and remove the power cable. 1. Remove the JetDirect Card (if installed). 2. Remove three T-15 screws (Type A) that secure the Main PCA cover. 3. Remove the Main PCA Cover from the Printer.
Removal and Installation 4. Push the Memory Module Connector clips up and down to release the Memory Module. 5. Remove the Memory Module from the Printer.
Removal and Installation Main PCA Formatter Removal Switch off the product and remove the power cable. Do NOT remove the Fan or the Processor (located under the Fan) from the Main PCA Formatter - The Fan and the Processor are part of the Main PCA Formatter support part and should be replaced as one assembly. 1. Remove the EIO to PCI Interface Card ⇒ Page 8-67. 2. Remove the Gamut PCI PCA ⇒ Page 8-69. 3. Remove the Memory Module ⇒ Page 8-72. 4. Disconnect ALL cables connected to the Main PCA Formatter. 5.
Removal and Installation 6. Release the plastic locating pin that secures the Main PCA Formatter. 7. Remove the Main PCA Formatter from the Printer. When installing the Main PCA Formatter, make sure that you first locate it on the plastic locating pin and then install the screws.
Removal and Installation Hard Disk Drive (HDD) Removal Switch off the product and remove the power cable. 1. Remove the JetDirect Card (if installed). 2. Remove three T-15 screws (Type A) that secure the Main PCA cover. 3. Remove the Main PCA Cover from the Printer.
Removal and Installation 4. Disconnect ALL cables connected to the Hard Disk Drive. 5. Remove one T-10 screw (Type I) from the HDD Holder. 6. Slide the Hard Disk Drive upwards and remove from the Printer. It is not necessary to remove the screws securing the HDD inside the metal casing. 1 2 After installing the NEW HDD, make sure you perform the following User Calibrations: Printhead Alignment. Paper Advance Calibration. Color Calibration.
Removal and Installation Power Supply Unit (PSU) Removal Switch off the product and remove the power cable. 1. Remove the Right Connector Cover ⇒ Page 8-18. 2. Remove the JetDirect Card (if installed). 3. Remove three T-15 screws (Type A) that secure the Main PCA cover. 4. Remove the Main PCA Cover from the Printer.
Removal and Installation 5. Remove three T-15 screws (Type A) that secure the PSU cover. 6. Remove the PSU Cover from the Printer. 1 2 7. Disconnect the Power Supply and Interconnect cables from the PrintMech PCA.
Removal and Installation 8. Remove six T-10 screws (Type I) that secure the Interconnect PCA Cover. 9. Remove the Interconnect PCA Cover from the Printer. 10. Disconnect one cable from the Interconnect PCA.
Removal and Installation 11. Disconnect two cables from the Main PCA. 12. Disconnect one cable from the Gamut PCA. 13. Disconnect one cable from Hard Disk Drive.
Removal and Installation 14. Bend the edge of the Cable Support Bracket so that it can be released. 15. Move the Cable Support Bracket to the left to release it from the Electronics Module. 16. Lower the Cable Support Bracket so that the cables can be accessed.
Removal and Installation 17. Release the Power Supply Cable from the Cable Support Bracket. 18. Remove four T-10 screws (Type I) that secure the Power Supply Unit. 19. Route the cables through the hole in the Electronics Module and remove the Power Supply Unit from the Printer.
Removal and Installation PrintMech PCA Removal Switch off the product and remove the power cable. 1. Remove the Left Connector Cover ⇒ Page 8-19. 2. Remove three T-15 screws (Type A) that secure the PSU cover. 3. Remove the PSU Cover from the Printer. 1 2 4. Disconnect ALL cables from the PrintMech PCA.
Removal and Installation 5. Remove two T-15 screws (Type B) that secure the PrintMech Cover. 6. Slide the PrintMech Cover out of the Printer. 7. Remove eight T-10 screws (Type I) that secure the PrintMech PCA.
Removal and Installation 8. Remove the PrintMech PCA from the Printer.
Removal and Installation Formatter Battery Removal Switch off the product and remove the power cable. 1. Remove the JetDirect Card (if installed). 2. Remove three T-15 screws (Type A) that secure the Main PCA cover. 3. Remove the Main PCA Cover from the Printer.
Removal and Installation 4. Push the clip down and release the battery from the Main PCA.
Removal and Installation Line Sensor Assembly Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Press the two side of the Carriage PCA Cover and unclip from the Carriage Assembly. 1 2 1 3. Release the clip and disconnect the Line Sensor cable from the Carriage PCA. 4. Remove one T-15 screw (Type G) that secures the Line Sensor to the carriage Assembly.
Removal and Installation 5. Remove the Line Sensor from the Carriage Assembly. After installing the NEW Line Sensor, make sure you perform the following Service Calibrations: Line Sensor Calibration ⇒ Chapter 5.
Removal and Installation Media Deflector Removal Switch off the product and remove the power cable. 1. Remove one T-20 screw (Type B) that secures the Media Deflector that needs to be replaced. 2. Release the clip securing the Media Deflector. 3. Remove the Media Deflector (slide upwards first) from the Printer.
Removal and Installation Front Platen Removal Switch off the product and remove the power cable. 1. Open the Window. 2. Remove three T-15 screws and two crosshead screws that secure the Front Platen. 3. Release the clip on the left hand side of the Front Platen.
Removal and Installation 4. Pull out the left hand side of the Front Platen. 5. Slide the Front Platen to the Left and then remove from the Printer. 1 2 If a NEW Front Platen is to be installed, make sure that you first remove ALL 3 Media Deflectors (⇒ Page 8-91) from the OLD Front Platen and install them on the New Front Platen.
Removal and Installation Center Platen Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Left Cover ⇒ Page 8-9. 3. Remove the Top Cover ⇒ Page 8-11. 4. Remove the Service Station ⇒ Page 8-23. 5. Remove the Middle Left Spittoons ⇒ Page 8-44. 6. Remove one T-15 screw (Type P) that secures the Center Platen Gear. 7. Remove the Center Platen Gear from the Printer.
Removal and Installation 8. Remove one T-15 screw that secures the small Gear. 9. Remove the small Gear from the Printer. 10. Remove the two small Platen Gears by releasing the clips.
Removal and Installation 11. Remove two T-20 screws (Type Q) that secure the Gear Bracket. 12. Remove the Gear Bracket from the Printer. 13. Remove 79 T-10 screws (Type C) that secure the Center Platen.
Removal and Installation 14. Remove the Center Platen from the Printer. Make sure you take note of the positions of the Foams located underneath the center Platen. When reinstalling the parts, make sure you apply the grease (included with the support part) to the gears. After installing the NEW Center Platen, make sure you perform the following Service Calibration: Paper Advance Calibration ⇒ Chapter 5.
Removal and Installation Cartridge Trays Removal Switch off the product and remove the power cable. 1. Open the Ink Cartridge Door. 2. Release the Tray Lever of the required color and pull out the Tray. Remove the Ink Cartridge if installed. 3. Press down on the Tray clip and pull the Tray completely out of the Printer. Note that each Cartridge Tray is different even though they look very similar.
Removal and Installation Input Roller Removal Switch off the product and remove the power cable. 1. Raise the left and right levers to release the Input Roller. 2. Pull out the Input Roller from the Printer.
Removal and Installation Push-Push Mechanism Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-4 or the Left Cover ⇒ Page 8-4 depending on which Push-Push Mechanism you want to replace. 2. Open the Ink Cartridge or the Printhead Cleaner Door (depending on which cover you have removed). 3. Squeeze the release clips from inside the Cover. 4. Push the Push-Push Mechanism through the hole to remove.
Removal and Installation Media Sensor Removal Switch off the product and remove the power cable. 1. Remove the Rear Door ⇒ Page 8-16. 2. Remove the Right Connector Cover ⇒ Page 8-18. 3. Disconnect the Media Sensor cable from the Interconnect PCA. 4. Release the Media Sensor cable from the clip located on the Electronics Module. 5. Unclip the Media Sensor from the Center Guide.
Removal and Installation 6. Pull the cable through the hole and remove the Media Sensor from the Printer.
Removal and Installation Encoder Disc and Sensor Removal Switch off the product and remove the power cable. Please handle the Encoder Disc very carefully since any finger prints, scratches or stains could cause the Printer to malfunction. 1. Remove the Left Cover ⇒ Page 8-9. 2. Remove the Rear Door ⇒ Page 8-16. 3. Remove the Left Connector Cover ⇒ Page 8-19. 4. Remove the Ink Supply Station ⇒ Page 840. 5. Disconnect the Encoder Sensor cable from the PrintMech PCA. 6.
Removal and Installation 7. Release the Encoder Sensor cable from the clip located on the Encoder Disc Cover. 8. Unclip the Encoder Disc Cover and remove from the Printer. 9. Remove one T-8 screw (Type D) that secures the Encoder Sensor to the Chassis.
Removal and Installation 10. Remove the Encoder Sensor from the Printer. 11. Carefully peel the Encoder Disc from the Drive Roller.
Removal and Installation Media Lever Assembly Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Rear Door ⇒ Page 8-16. 3. Raise the Media Lever. 4. Remove one T-15 screw (Type F) that secures the Media Lever to the Linkage. 5. Remove one T-15 screw (Type F) that secures the Linkage to the Spring.
Removal and Installation 6. Remove one T-20 screw (Type A) that secures the Spring to the Spacer. 7. Remove one T-20 screw (Type O) that secures the Media Lever to the Right Trim. 8. Remove the Media Lever Assembly from the Printer.
Removal and Installation Media Lever Sensor Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Rear Door ⇒ Page 8-16. 3. Remove the Right Connector Cover ⇒ Page 8-18. 4. Remove the Service Station ⇒ Page 8-23. 5. Remove the Front Platen ⇒ Page 8-92. 6. Remove the Media Lever and Linkage ⇒ Page 8-106. 7. Disconnect the Media Lever Sensor cable from the Interconnect PCA. 8. Remove five T-15 screws (Type B) that secure the Right Trim.
Removal and Installation 9. Carefully remove the Right Trim from the Printer. 10. Carefully release the clip securing the Media Lever Sensor from the Right Trim and remove from the locating pins. 1 2 11. Release the Media Lever Sensor Cable from the four clips on the Vacuum Fan.
Removal and Installation 12. Remove the Media Lever Sensor from the Printer.
Removal and Installation Pinchwheel Assembly Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Rear Door ⇒ Page 8-16. 3. Remove the Service Station ⇒ Page 8-23. 4. Remove one T-20 screw that secures the Linkage to the Spring. 5. Remove one T-20 screw that secures the Cam to the Cam Lever. 6. Insert a plastic stud in to each Pinchwheel Subassembly (the Plastic Studs can be found in the replacement Pinchwheel Assembly kit).
Removal and Installation 7. Remove two T-20 screws (Type M) from each Pinchwheel Subassembly (a 90 degree angle screwdriver is included with the replacement Pinchwheel Assembly). 8. Remove the complete Pinchwheel Assembly (including the Cam and Cam Lever) from the Printer. Before installing the NEW Pinchwheel Assembly, insert the plastic studs in to each Pinchwheel subassembly. This will make it easier to install the complete Pinchwheel Assembly.
Removal and Installation Removing individual Pinchwheels 1. To remove an individual Pinchwheel, push apart the metal part that secures the pinchwheels and then pull out the individual Pinchwheel.
Removal and Installation Important Information on Installation of Pinchwheels The Pinchwheel Assembly contains 3 white Pinchwheels and several black Pinchwheels.
Removal and Installation Center Guide Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Left Cover ⇒ Page 8-9. 3. Remove the Right Connector Cover ⇒ Page 8-18. 4. Remove the Left Connector Cover ⇒ Page 8-19. 5. Remove the Service Station ⇒ Page 8-23. 6. Remove the Ink Supply Station ⇒ Page 840. 7. Remove the Media Sensor ⇒ Page 8-108. 8. Disconnect ALL the cables connected to the Interconnect PCA and the Gamut PCI PCA. 9.
Removal and Installation 10. Remove four T-20 screws (Type B) that secure the Electronics Module. 11. Remove the Electronics Module from the Printer. 12. Remove one T-15 screw (Type E), that secures the Center Guide, from underneath the Printer.
Removal and Installation 13. Remove two T-15 screws (Type E), that secure the Center Guide, from the left hand side of the Printer. 14. Remove one T-15 screw (Type E) and two T-20 screws (Type A), that secure the Center Guide, from the right hand side of the Printer. Type E Type A 15. Remove the Center Guide from the Printer.
Removal and Installation Drive Roller Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Left Cover ⇒ Page 8-9. 3. Remove the Right Connector Cover ⇒ Page 8-18. 4. Remove the Left Connector Cover ⇒ Page 8-19. 5. Remove the Service Station ⇒ Page 8-23. 6. Remove the Ink Supply Station ⇒ Page 840. 7. Remove the Media-Axis Motor ⇒ Page 862. 8. Remove the Encoder Disc and Sensor ⇒ Page 8-103. 9. Remove the Media Lever Assembly ⇒ Page 8-106. 10.
Removal and Installation 13. Remove the Drive Roller Gear from the Printer. 14. Remove one T-20 screw (Type B) that secures the cover on the right hand side of the Printer. 15. Remove the Cover.
Removal and Installation 16. Remove two T-20 screws (Type B) that secure the cover on the left hand side of the Printer. 17. Remove the Cover. 18. Remove three T-20 screws (Type B) that secure the Media-Axis Motor Bracket to the sideplate.
Removal and Installation 19. Remove two T-20 screws (Type A) that secure the Media-Axis Motor Bracket to the Chassis. 20.Remove the Media-Axis Motor Bracket from the Printer. 21. Remove the Drive Roller by sliding it to the right, then downwards and then out of the Printer. 1 2 When reinstalling the parts, make sure you apply the grease (included with the support part) to the gears.
Removal and Installation Installation of the Drive Roller When installing the Drive Roller, several different datums have to be met in order to ensure that the Drive Roller has no axial play. Use the following illustrations to ensure that ALL the datums are met: Media-Axis Motor Bracket Drive Roller Bearing Sideplate 1 2 1. Datum between Media-Axis Motor Bracket and Drive Roller Bearing 1 2. Datum between Media-Axis Motor Bracket and Sideplate 3 3.
Removal and Installation To make sure that ALL the datums are met when installing the Media-Axis Motor Bracket, make sure you follow these instructions: 1. Place the Media-Axis Motor Bracket in the correct position on the Printer. Make sure you keep it pushed down (as shown in the illustration) until the first screw has been installed and fully tightened. 2. Install the first screw (T-15) in the position shown. Make sure you tighten the screw fully so that the Media-Axis Motor Bracket cannot be moved. 3.
Removal and Installation 4. Install the remaining two screws (T-15) that secure the Media-Axis Motor Bracket.
Removal and Installation Right Rollfeed Module Assembly Removal Switch off the product and remove the power cable. 1. Remove the Right Cover ⇒ Page 8-6. 2. Remove the Service Station ⇒ Page 8-23. 3. Remove the Vacuum Fan ⇒ Page 8-27. 4. Remove the Input Roller ⇒ Page 8-99. 5. Remove the Media Spindle (if installed). 6. Remove one T-15 screw (Type B) that secures the Right Rollfeed Module from the inside. Type G Type B 7.
Removal and Installation 8. Remove the Right Rollfeed Module from the Printer. Installation Follow these instructions for the correct installation of a NEW Right Rollfeed Module Assembly: 1. Hold the Right Rollfeed Module as shown, keeping your thumb firmly on the Media Tension Mechanism. 2. While securely holding the Right Rollfeed Module, remove the T-15 screw that secures the Media Tension Mechanism.
Removal and Installation 3. While securely holding the Right Rollfeed Module, position the Right Rollfeed on to the Printer and install the T-15 screw that was removed in the previous step. 4. Install the remaining screws that were removed during the removal process.
Removal and Installation Right Spindle Lever Removal These instructions explain how to remove a broken Spindle Lever and install a new one. 1. Pull out the Media Spindle from the Printer. 2. Remove the Spring from the Spindle Lever. 3. Remove one T-20 screw (Type O) that secures the Spindle Lever.
Removal and Installation 4. Remove the Spindle Lever. Installation 1. Position the new Spindle Lever on the Printer. 2. Install one T-20 screw (Type O) to secure the Spindle Lever.
Removal and Installation 3. Place the spring on the top hook. 4. Stretch the spring and loop the spring on the bottom hook. 5. Check that the Spindle Lever is installed correctly as shown here.
Preventive Maintenance 9 9 Moisture on the Printer 9-2 Noisy Carriage Bushing 9-2 Belt Swelling 9-2 Cleaning the Printer 9-2 General Cleaning 9-2 Cleaning the Drive Roller and Overdrive 9-3 Cleaning the Center Platen 9-3 Applying Oil to the Overdrive 9-5 Lubricating the Carriage Assembly 9-5 Scheduled Maintenance 9-6 Level of Printer Usage 9-6 hp designjet 4000 series printer service manual 9-1
Preventive Maintenance Preventive Maintenance Moisture on the Printer Users should use the Printer in an environment between 20% and 80% relative humidity. To recover from moisture condensation, turn the Printer Off, and, using the main roller as a reference, wait until the Printer is completely dry before using it again.
Preventive Maintenance Cleaning the Drive Roller and Overdrive If ink is spilled on the Overdrive, remove the ink immediately. Due to the ink's reflectance, ink on the Overdrive can disrupt the Printer's edge-sensing function. To remove any ink from the Overdrive, perform the following procedure: Prevent water or other liquids from running onto electrical components or circuits, or through openings in the Electronics Module. 1 Perform the Turn Drive Roller Utility (Refer to Page 4-63).
Preventive Maintenance 3 Use a clean, absorbent lint-free cloth, dampened with Isopropyl Alcohol (not supplied in the Maintenance Kit), to wipe loosened ink deposits from the Center Platen. Do NOT use commercial cleaners or abrasive cleaners. Do NOT wet the Center Platen directly because you will leave too much moisture behind. Do NOT wet the rubber wheels at all (not even with the cloth). 4 Clean the Cutter ramp with the damp cloth. 5 Clean the exposed part of the wheels with a dry cloth.
Preventive Maintenance Applying Oil to the Overdrive Occasionally, it maybe necessary to oil the Overdrive in order to stop the rollers from squeaking: 1 Open the Window. 2 There are small holes in the Center Platen beside some of the rollers. 3 A bottle of oil is supplied with the Maintenance Kit. Insert the pointed end of the bottle into each hole in turn, and put three drops into each. 4 Be very careful not to spill any oil onto the Center Platen.
Preventive Maintenance Scheduled Maintenance In some segments of the printer market, the customer tends to print more than the maximum number of prints that the throughput allows, exceeding by far the limit of the design. When this happens the customer runs into print quality problems and continuous Printer failures. The purpose of scheduled preventive maintenance is to avoid these failures ensuring a good performance during all the product life.
About this Edition This is the 2nd edition of this Service Manual 1st edition, titled hp designjet 4000 series printers service manual (models Q1273A/Q1274A) December 2004 2nd edition, titled hp designjet 4000 series printers service manual (models Q1273A/Q1274A) April 2005
What’s in this Service Manual This manual contains information necessary to test, calibrate and service: - hp designjet 4000 (model Q1273A) - hp designjet 4000ps (model Q1274A) For information about using these printers, refer to the corresponding User and Quick Reference Guides. The procedures described in this manual are to be performed by HP-qualified Service Personnel only.
