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HP Designjet 4000 Service Manual - Page 308

Main PCA Formatter, Removal

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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. Remove eight T-10 screws (Type I) that secure the Main PCA Formatter. 8-74 hp designjet 4000 series printer service manual

Section	Page
Purpose	4
Readership	4
Part Numbers	4
Conventions	4
Table of Contents	5
Troubleshooting	7
Introduction	8
Troubleshooting System Error Codes	8
Performing a Service Test on a Failed Assembly	8
Performing the Necessary Service Calibrations	9
Solving Print Quality Problems	9
The Printer does not Power ON	9
The Printer Continuously Rejects Printheads	9
Cover Sensors are not Working	9
The Line Sensor has Problems Detecting Media	10
Troubleshooting Media Jams/Printhead Crashes	10
Troubleshooting Shutdowns	11
Vacuum suction much lower at high altitudes	12
Banding at variable extreme environmental conditions	12
Printhead Crashes/Smears on High Density Prints Using Coated Media	12
Banding due to Ink Cartridge replacement while printing	13
34\	13
Cut Sheet rice paper loading failure	13
Worm marks on HP Coated media with light area fills	13
Solving Media-Handling Problems	14
Using the Buzzer at Power-up to Troubleshoot	15
Using the Power-up Sequence to Troubleshoot	16
Using the Power Switch LEDs to Troubleshoot	19
Using the PCA LEDs to Troubleshoot	20
How to Interpret the Service Information Pages	23
Current Media, Printhead and Ink Information	24
Printer Usage Information	26
Event Logs	29
Calibrations Status	30
System Error Codes	31
Introduction	32
Continuable and Non-Continuable Error Codes	32
System Error Codes and Warnings - Explanation	55
Ink Supplies Troubleshooting	59
What are Ink Supplies?	60
Ink Cartridges	60
Printheads	61
Printhead Cleaners	61
General Information About the Ink Supplies	62
General Precautions When Handling Ink Supplies	62
Priming the Ink System	63
When Should You Replace the Ink Supplies?	63
Obtaining Ink Cartridge Information	64
Obtaining Printhead Information	65
Ink Cartridge Status Messages	67
Ink Cartridge Status While Printing	67
Ink Cartridge Status While Replacing	67
Printhead Status Messages While Printing	68
Printhead Status Messages While Replacing	68
Printhead Cleaner Status Messages While Printing	69
Printhead Cleaner Status Messages While Replacing	69
Summary of Solving Ink Supplies Problems	70
Troubleshooting Printhead Error Codes	71
Carriage Interconnect Wiper	72
Warranty Information for Ink Supplies	73
Warranty Information for Printheads	73
Service Tests and Utilities	75
Diagnostics - Self Test	76
Phone Support	76
Entering the Service Tests Menu	79
1. Scan Axis Test	81
2. Media Drive Test	86
3. Electronics Module Test	91
4. Carriage Assembly Test	101
5. Sensors Test	102
6. Ink Delivery System Test	106
7. SVS/Aerosol Fan Test	107
8. Air Pump System Test	108
9. Vacuum Fans Test	109
10.1 Others >>> Bag Broken Recovery	110
10.2 Others >>> IO Information	113
10.3 Others >>> Unit Information	114
10.4 Others >>> Check Ink Supplies	116
11. EEROM Reset	118
12. Set Unit Configuration	120
13. Error 71:19 Recovery	121
I/O Tests	123
Entering the Service Utilities Menu	126
1. Turn Drive Roller	128
2. Prime Tubes	130
3. Set SN	134
4. Reset Life Counters	135
5. Diagnostic Print	137
6. Sleep Mode	138
7. Replace Cutter	139
8. Set RTC Clock	140
9. Carriage Setup	141
Service Calibrations	143
Entering the Service Calibrations Menu	145
1. Scan Axis Calibration	146
2. Service Station Calibration	150
3. Paper Advance Calibration	151
4. Drop Detector Calibration	157
5. Line Sensor Calibration	158
6. Platen Blue Line Calibration	162
7. Vacuum Calibration	164
8. Carriage Setup	165
Print Quality	167
Print Quality Troubleshooting Actions	168
Choosing the Correct Print Quality Settings	169
What is the Service Image Quality Diagnostic Print?	171
Considerations for Printing the Diagnostic Print	171
Printing the Service Image Quality Diagnostic Print	172
Diagnostic Part 1: Alignment Test	173
Diagnostic Part 2: Printheads & Paper Advance Test	174
Diagnostic Part 3: Printhead Problems	175
Nozzle Print Test	177
No Printing Defects Found in the Diagnostic Print	178
Print Quality General Advice	178
Horizontal Lines Across the Image (Banding)	179
Advanced Banding Troubleshooting for Experts	180
Dark Light Zone Banding (DLZB)	183
Lines are Missing or Thinner than Expected	184
Solid Bands or Lines Printed Over the Image	185
Problems with Graininess	186
Print Smudges when Touched	186
Paper is not Flat	187
Defect Near the Top of the Print	188
Problems with Stepped Lines	189
Lines are Printed Double or in Wrong Colors	189
Lines are Blurred (Ink Bleeds from Lines)	190
Problems with Color Accuracy	190
Problems with PANTONE Color Accuracy	191
Color Matching Between Different HP Designjet Printers	192
Problems with Image Clipping	194
Image is Completely Blank	195
Output Only Contains a Partial Print	195
Image is in One Portion of the Printing Area	196
Image is Unexpectedly Rotated (PostScript Driver)	196
Print is Distorted or Unintelligible	197
Print is a Mirror Image of the Original	197
One Image Overlaps Another on the Same Sheet	197
No Output from the Printer	198
Pinchwheel Marks when using Glossy Media	198
VLS in 1 Pass Printmodes	199
VLS in First 3 Meters after a Media Load	200
Bubbles (Only occurs in Cyan, Magenta and Yellow)	200
Black Printhead: Decap Problem	201
Paper Expansion - Paper Advance (PEPA)	202
Bidirectional Offset in Light Color Density Areas	203
Ink Contamination on Yellow Printhead	203
Satellites in Black Lines	204
Parts and Diagrams	205
Removal and Installation	235
Introduction	236
Safety Precautions	236
Electrostatic Discharge (ESD) Precautions	236
Required Tools	237
Screw Types	237
Window	238
Removal	238
Installation of New Window	239
Right Cover	240
Removal	240
Left Cover	243
Removal	243
Top Cover	245
Removal	245
Rear Door	250
Removal	250
Right Connector Cover	252
Removal	252
Left Connector Cover	253
Removal	253
Front Panel	254
Removal	254
Service Station	257
Removal	257
Removal of the Service Station Scraper	260
Vacuum Fan	261
Removal	261
Aerosol Fan	263
Removal	263
Drop Detector	265
Removal	265
Ink Supply Tubes and Trailing Cable	267
Removal	267
Installation of the Ink Supply Tubes and Trailing Cable	271
ISS to Cartridge Cables	272
Removal	272
Cutter Assembly	273
Removal	273
Ink Supply Station (ISS)	274
Removal	274
APS Assembly	276
Removal	276
Most Left Spittoons	277
Removal	277
Middle Left Spittoons	278
Removal	278
Encoder Strip and Encoder Sensor	279
Removal	279
Carriage PCA	282
Removal	282
Carriage Flex Cables	285
Removal	285
Carriage Assembly	287
Removal	287
Belt Assembly	292
Removal	292
Scan-Axis Motor	293
Removal	293
Media-Axis Motor	296
Removal	296
Interconnect PCA	298
Removal	298
EIO to PCA Interface Card	301
Removal	301
Gamut PCI PCA	303
Removal	303
Memory Module	306
Removal	306
Main PCA Formatter	308
Removal	308
Hard Disk Drive (HDD)	310
Removal	310
Power Supply Unit (PSU)	312
Removal	312
PrintMech PCA	318
Removal	318
Formatter Battery	321
Removal	321
Line Sensor Assembly	323
Removal	323
Media Deflector	325
Removal	325
Front Platen	326
Removal	326
Center Platen	328
Removal	328
Installation of the Foams	331
Cartridge Trays	332
Removal	332
Input Roller	333
Removal	333
Push-Push Mechanism	334
Removal	334
Media Sensor	335
Removal	335
Encoder Disc and Sensor	337
Removal	337
Media Lever Assembly	340
Removal	340
Media Lever Sensor	342
Removal	342
Pinchwheel Assembly	345
Removal	345
Removing individual Pinchwheels	347
Important Information on Installation of Pinchwheels	348
Center Guide	349
Removal	349
Drive Roller	352
Removal	352
Installation of the Drive Roller	356
Right Rollfeed Module Assembly	359
Removal	359
Installation	360
Right Spindle Lever	362
Removal	362
Installation	363
Preventive Maintenance	365
Moisture on the Printer	366
Noisy Carriage Bushing	366
Belt Swelling	366
Cleaning the Printer	366
General Cleaning	366
Cleaning the Drive Roller and Overdrive	367
Cleaning the Center Platen	367
Applying Oil to the Overdrive	369
Lubricating the Carriage Assembly	369
Scheduled Maintenance	370