HP Designjet 4500, 4520 Printer series (service manual)

Conventions......Page 4
Table of Contents......Page 5
Troubleshooting......Page 7
Performing a Service Test on a Failed Assembly......Page 8
Cover Sensors are not Working......Page 9
Troubleshooting Media Jams/Printhead Crashes......Page 10
Troubleshooting Shutdowns......Page 11
Printhead Crashes/Smears on High Density Prints Using Coated Media......Page 12
Vertical lines are not straight......Page 13
Problems Loading Media into Roll Module 2......Page 15
Problems loading sheet media......Page 18
Using the Power Switch LEDs to Troubleshoot......Page 24
Using the PCA LEDs to Troubleshoot......Page 25
How to Interpret the Service Information Pages......Page 28
Current Media, Printhead and Ink Information......Page 29
Printer Usage Information......Page 31
Event Logs......Page 34
Calibrations Status......Page 35
System Error Codes......Page 37
Continuable and Non-Continuable Error Codes......Page 38
Printer System Error Codes......Page 39
Stacker System Error Codes......Page 72
Stacker System error codes detected by the Stacker.......Page 73
System Error Codes and Warnings - Explanation......Page 78
Ink Supplies Troubleshooting......Page 83
Ink Cartridges......Page 84
Printhead Cleaners......Page 85
General Precautions When Handling Ink Supplies......Page 86
When Should You Replace the Ink Supplies?......Page 87
Obtaining Ink Cartridge Information......Page 88
Obtaining Printhead Information......Page 89
Ink Cartridge Status While Replacing......Page 91
Printhead Status Messages While Replacing......Page 92
Printhead Cleaner Status Messages While Replacing......Page 93
Summary of Solving Ink Supplies Problems......Page 94
Troubleshooting Printhead Error Codes......Page 95
Carriage Interconnect Wiper......Page 96
Warranty Information for Printheads......Page 97
Diagnostic Tests and Utilities......Page 99
Phone Support......Page 100
Entering the Diagnostic Menu......Page 103
1. Scan Axis Test......Page 105
2.1 Media Drive Test......Page 110
2.2 BT Arm Test......Page 122
3. Electronics Module Test......Page 130
4. Carriage Assembly Test......Page 140
5. Sensors Test......Page 141
6. Ink Delivery System Test......Page 149
7. SVS/Aerosol Fan Test......Page 150
8. Air Pump System Test (firmware 10.1.1.4)......Page 151
9. Vacuum Fans Test......Page 153
10.1 Others >>> Bag Broken Recovery......Page 154
10.2 Others >>> IO Information......Page 157
10.3 Others >>> Unit Information......Page 158
10.4 Others >>> Check Ink Supplies......Page 160
10.5 Others >>> Roll Module Config......Page 162
10.6 Others >>> Stacker Test......Page 163
10.7 Others >>> Enable Connectivity......Page 169
11. EEROM Reset......Page 170
12. Set Unit Configuration......Page 172
13. Error 71:19 Recovery......Page 173
14. I/O Tests......Page 175
15. Log Management......Page 177
Entering the Service Utilities Menu......Page 181
1. Turn Drive Roller......Page 183
2. Prime Tubes......Page 185
3. Set SN......Page 189
4. Reset Life Counters......Page 190
5. Diagnostic Print......Page 192
6. Sleep Mode......Page 193
7. Replace Cutter......Page 194
8. Set RTC Clock......Page 195
9. PHC Maintenance......Page 196
10. Media standby behavior......Page 198
11. Backup print mode......Page 200
12. Feed Roller Material Change......Page 201
13. Sanitize Level......Page 203
14. Disk Wipe......Page 205
Service Calibrations......Page 207
Entering the Service Calibrations Menu......Page 209
1. Scan Axis Calibration......Page 210
2. Service Station Calibration......Page 214
3. Paper Advance Calibration......Page 215
4. Drop Detector Calibration......Page 221
5. Line Sensor Calibration......Page 222
6. Vacuum Calibration......Page 226
7. Carriage Setup......Page 227
Print Quality......Page 229
Print Quality Troubleshooting Actions......Page 230
Choosing the Correct Print Quality Settings......Page 231
Considerations for Printing the Diagnostic Print......Page 233
Printing the Service Image Quality Diagnostic Print......Page 234
Diagnostic Part 1: Alignment Test......Page 235
Diagnostic Part 2: Printheads & Paper Advance Test......Page 236
Diagnostic Part 3: Printhead Problems......Page 238
Nozzle Print Test......Page 240
Horizontal Lines Across the Image (Banding)......Page 241
Advanced Banding Troubleshooting for Experts......Page 242
Dark Light Zone Banding (DLZB)......Page 245
Print Banding Plot......Page 246
Force Drop Detection Tool......Page 248
Print Quality General Advice......Page 249
Lines are Missing or Thinner than Expected......Page 250
Solid Bands or Lines Printed Over the Image......Page 251
Print Smudges when Touched......Page 252
Paper is not Flat......Page 253
Defect Near the Top of the Print......Page 254
Lines are Printed Double or in Wrong Colors......Page 255
Problems with Color Accuracy......Page 256
Problems with PANTONE Color Accuracy......Page 257
Color Matching Between Different HP Designjet Printers......Page 258
Problems with Image Clipping......Page 261
Output Only Contains a Partial Print......Page 262
Image is Unexpectedly Rotated (PostScript Driver)......Page 263
One Image Overlaps Another on the Same Sheet......Page 264
Pinchwheel Marks when using Glossy Media......Page 265
VLS in 1 Pass Printmodes......Page 266
Bubbles (Only occurs in Cyan, Magenta and Yellow)......Page 267
Black Printhead: Decap Problem......Page 268
Paper Expansion - Paper Advance (PEPA)......Page 269
Ink Contamination on Yellow Printhead......Page 270
Satellites in Black Lines......Page 271
Stacker......Page 273
Removal and Installation......Page 327
Electrostatic Discharge (ESD) Precautions......Page 330
Screw Types......Page 331
Removal......Page 332
Installation of New Window......Page 333
Removal......Page 334
Removal......Page 337
Removal......Page 340
Removal......Page 342
Removal......Page 344
Removal......Page 349
Removal......Page 351
Removal......Page 352
Removal......Page 353
Removal......Page 356
Removal of the Service Station Scraper......Page 359
Removal......Page 360
Removal......Page 362
Removal......Page 364
Removal......Page 366
Removal......Page 379
Removal......Page 391
Removal......Page 392
Removal......Page 393
Removal......Page 395
Installation for printers with the serials numbers before SG6ABH9014......Page 396
Removal for printers with the serial numbers SG6ABH9014 and onwards......Page 400
Installation for printers with the serial numbers SG6ABH9014 and onwards......Page 401
Removal......Page 403
Removal......Page 404
Removal......Page 405
Removal......Page 408
Installation......Page 410
Removal......Page 413
Removal......Page 415
Removal......Page 420
Removal......Page 421
Removal......Page 424
Removal......Page 426
Removal......Page 429
Removal......Page 431
Removal......Page 436
Removal......Page 438
Removal......Page 440
Delta Fan Installation......Page 441
AAvid Fan Installation......Page 442
Removal......Page 444
Removal......Page 446
Removal......Page 452
Removal......Page 455
Removal......Page 457
Removal......Page 459
Removal......Page 461
Removal......Page 463
Removal......Page 466
Installation of the Foams......Page 469
Removal......Page 470
Removal......Page 472
Removal......Page 473
Removal......Page 475
Removal......Page 478
Removal......Page 481
Removal......Page 484
Removal......Page 486
Installation of the Drive Roller......Page 490
Removal......Page 493
Removal......Page 495
Removal......Page 497
Removal......Page 502
Removal......Page 504
Removing the Spindle Support......Page 505
Removing the obsoleted parts......Page 506
Installation......Page 508
Removal......Page 509
Removal......Page 514
Removal......Page 516
Removal......Page 520
Removal......Page 525
Removal......Page 526
Removal......Page 530
Removal......Page 533
Removal......Page 535
Removal......Page 537
Removal......Page 539
Removal......Page 540
Removal......Page 544
Removal......Page 548
Removal......Page 555
Installation......Page 560
Removal......Page 561
Removal......Page 566
Removal......Page 569
Removal......Page 570
Removal......Page 575
Removal......Page 577
Removal......Page 579
Removal......Page 581
Removal......Page 582
Removal......Page 583
Removal......Page 587
Removal......Page 590
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Removal......Page 593
Removal......Page 602
Removal......Page 604
Removal......Page 606
Removal......Page 609
Removal......Page 614
Removal......Page 616
Removal......Page 618
Removal......Page 620
Removal......Page 622
Removal......Page 625
Removal......Page 627
Removal......Page 629
Removal......Page 631
Removal......Page 633
Removal......Page 634
Removal......Page 637
Removal......Page 642
Removal......Page 647
Removal......Page 649
Preventive Maintenance......Page 657
General Cleaning......Page 658
Cleaning the Center Platen......Page 659
Lubricating the Carriage Assembly......Page 661
Level of Printer Usage......Page 662