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HP Designjet 4000 and 4020 Printer Series Service Manual and Parts Manual

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SERVICE MANUAL TABLE OF CONTENTS

1 Troubleshooting
Introduction
Troubleshooting System Error Codes
Performing a Service Test on a Failed Assembly
Performing the Necessary Service Calibrations
Solving Print Quality Problems
The Printer does not Power ON
The Printer Continuously Rejects Printheads
Cover Sensors are not Working
The Line Sensor has Problems Detecting Media
Troubleshooting Shutdowns
Vacuum suction much lower at high altitudes
Banding at variable extreme environmental conditions
Printhead Crashes/Smears on High Density Prints Using Coated Media
Banding due to Ink Cartridge replacement while printing
34″ Rice Paper not supported
Cut Sheet rice paper loading failure
Worm marks on HP Coated media with light area fills
Solving Media-Handling Problems
Using the Buzzer at Power-up to Troubleshoot
Using the Power-up Sequence to Troubleshoot
Using the Power Switch LEDs to Troubleshoot
Using the PCA LEDs to Troubleshoot
How to Interpret the Service Information Pages

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

3 Ink Supplies Troubleshooting
What are Ink Supplies?
General Information About the Ink Supplies
General Precautions When Handling Ink Supplies
Priming the Ink System
When Should You Replace the Ink Supplies?
Obtaining Ink Cartridge Information
Obtaining Printhead Information
Ink Cartridge Status Messages
Ink Cartridge Status While Printing
Ink Cartridge Status While Replacing
Printhead Status Messages While Printing
Printhead Status Messages While Replacing
Printhead Cleaner Status Messages While Printing
Printhead Cleaner Status Messages While Replacing
Summary of Solving Ink Supplies Problems
Troubleshooting Printhead Error Codes
Carriage Interconnect Wiper
Warranty Information for Ink Supplies
Warranty Information for Printheads

4 Service Tests and Utilities
Introduction 4-2
Diagnostics Tests 4-3
Service Utilities

5 Service Calibrations
Entering the Service Calibrations Menu

6 Print Quality
Print Quality
How to Use the Service Image Quality Diagnostic Print
Troubleshooting Print Quality Problems

7 Parts and Diagrams
Printer Support
Center Covers
Electronics Module
Right Hand Cover
Left Hand Cover
Right Hand Assemblies
Left Hand Assemblies
Carriage Assembly
Scan-Axis Assemblies
Drive Roller and Media-Axis Motor
Paper Path Assemblies
Center Guide and Pinchwheel Assembly
Media Entry Assemblies
Miscellaneous Parts

8 Removal and Installation
Introduction
Screw Types
Window
Right Cover
Left Cover
Top Cover
Rear Door
Right Connector Cover
Left Connector Cover
Front Panel
Service Station
Vacuum Fan
Aerosol Fan
Drop Detector
Trailing Cables
Ink Supply Tubes
ISS to Cartridge Cables
Cutter Assembly
Ink Supply Station (ISS)
APS Assembly
Most Left Spittoons
Middle Left Spittoons
Encoder Strip and Encoder Sensor
Carriage PCA
Carriage Flex Cables
Carriage Assembly
Belt Assembly
Scan-Axis Motor
Media-Axis Motor
Interconnect PCA
EIO to PCA Interface Card 8
Gamut PCI PCA
Memory Module
Main PCA Formatter
CPU Fan
Hard Disk Drive (HDD)
Power Supply Unit (PSU)
PrintMech
Formatter Battery
Line Sensor Assembly
Media Deflector
Front Platen
Center Platen
Cartridge Trays
Input Roller
Media Sensor
Encoder Disc and Sensor
Media Lever Assembly
Media Lever Sensor
Pinchwheel Assembly
Center Guide
Drive Roller
Right Rollfeed Module Assembly
Right Spindle Lever

9 Preventive Maintenance
Moisture on the Printer
Noisy Carriage Bushing
Belt Swelling
Cleaning the Printer
General Cleaning
Cleaning the Drive Roller and Overdrive
Cleaning the Center Platen
Applying Oil to the Overdrive
Lubricating the Carriage Assembly
Scheduled Maintenance
Level of Printer Usage

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