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HP Designjet 4500 Service Manual

HP Designjet 4500
604 pages
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HP Designjet 4500 Specifications

General IconGeneral
SafetyCompliant with IEC 60950, including EU LVD and EN60950, UL-certified for US and Canada, Mexico NYCE, Argentina IRAM, Singapore PSB, Russia VNIIS, DEMKO, China CCC, Taiwan BSMI
FunctionsCopy, scan
I/O ports1 Fast Ethernet, 1 FireWire
HDD capacity30 GB
Copier resize1 - 10000 %
Keyboard typeMini keyboard
Network readyYes
Pallet weight146000 g
Print technologyInkjet
Minimum scan area6 x 4.5 \
Minimum scan size152 x 114 mm
Weight (imperial)204 lb lbs
Dimensions (WxDxH)1800 x 850 x 1380 mm
Power requirements100 - 240 VAC (+/- 10%), 50/60 Hz, 5 amp
Storage drive typeStandard, 40 GB
Color space standardsRGB
Downloadable softwareWinXPe
Media types supportedNon-abrasive paper, vellum, Mylar, sepia, blueprints, plastic, film, plastic laminate, foam board, cardboard (no plywood, stone plates, metal plates or abrasive dirty, rough, sharp edged, metal-clamped, burned surfaces)
All-In-One-multitaskingNo
Maximum internal memory1 GB
Acoustic power emissions6.3 B(A)
Maximum number of copies1000 copies
Pallet weight (imperial)321.9 lbs
Drive device, buffer size1000 MB
Media thickness (imperial)0.6 \
Case or master carton weight1490 kg
Case or master carton quantity5 pc(s)
Maximum dimensions (W x D x H)1800 x 1020 x 1380 mm
Product dimensions when open (LxWxD)70.8 \
Print resolution (color, normal quality)600 x 600 DPI
Recommended operating temperature range (T-T)18 - 32 °C
Power consumption (typical)300 W
Internal memory1024 MB
Scan file formatsTIFF
Built-in processorIntel® Pentium® 4
Processor frequency2300 MHz
Grayscale levels256
Input color depth24 bit
Display15” Touch-Screen
Scanner typeSheet-fed scanner
Storage temperature (T-T)-20 - 55 °C
Operating temperature (T-T)5 - 40 °C
Operating relative humidity (H-H)20 - 80 %
Package weightWeight of the packaged product in gram.
Package weight (imperial)316 lbs
Package dimensions (W x D x H)75.2 x 27.2 x 28.7 \
Compatible operating systemsMicrosoft Windows 2000, XP Home, XP Professional; Mac OS 9.x, Mac OS X; UNIX; Linux
Supported network protocolsTCP/IP
Bundled softwareSystem recovery software for the scanning system, including HP Macroinstaller with Windows drivers for HP Designjet 500, 800, 1000, 4000, 4500, 5000, 5500, T610, T1100, Z2100, Z3100, and Z6100 series printers
Quantity per pallet960 pc(s)
Number of cartons per pallet20 pc(s)
Electromagnetic compatibilityCompliant with the requirements for Class A ITE products: EU (EMC Directive), US (FCC, DoC), Canada (DoC), Australia (ACA), New Zealand (MoC), Japan (VCCI), Taiwan (BSMI), China (CCC)
Weight and Dimensions IconWeight and Dimensions
Weight95000 g

Summary

Using this Manual

Purpose

Details the purpose of the service manual, covering testing, calibration, and servicing procedures.

Readership

Specifies that manual procedures are for HP Certified service personnel only.

Part Numbers

Indicates that part numbers for options, accessories, and service parts are in Chapter 7.

Troubleshooting

Troubleshooting System Error Codes

Explains how to troubleshoot system error codes.

Performing a Service Test on a Failed Assembly

Details on performing service tests before replacing parts.

Solving Print Quality Problems

Provides solutions for print quality issues.

The Printer does not Power ON

Troubleshooting steps for power-on issues.

Solving Media-Handling Problems

Solutions for media handling issues.

Using the Power-up Sequence to Troubleshoot

Troubleshooting using the printer's power-up sequence.

Using the Power Switch LEDs to Troubleshoot

Troubleshooting using power switch LEDs.

Using the PCA LEDs to Troubleshoot

Troubleshooting using PCA LEDs.

How to Interpret the Service Information Pages

Guidance on interpreting service information pages.

System Error Codes

Introduction

Introduction to system error codes.

Continuable and Non-Continuable Error Codes

Explanation of continuable vs. non-continuable error codes.

Printer System Error Codes

List of printer system error codes and their descriptions.

Stacker System Error Codes

List of stacker system error codes.

System Error Codes and Warnings - Explanation

Explanation of system error code and warning formats.

Ink Supplies Troubleshooting

What are Ink Supplies?

Defines the components of ink supplies in the printer.

Ink Cartridges

Information about the printer's ink cartridges.

Printheads

Information about the printer's printheads.

General Precautions When Handling Ink Supplies

Important precautions for handling ink supplies.

Priming the Ink System

Procedure for priming the printer's ink system.

Ink Cartridge Status Messages

Explanation of ink cartridge status messages.

Summary of Solving Ink Supplies Problems

Summary of solutions for ink supply problems.

Troubleshooting Printhead Error Codes

How to troubleshoot printhead error codes.

Service Tests and Utilities

Service Tests (Diagnostics)

A list of all internal service tests available in the printer.

Service Utilities

A list of all internal service utilities available in the printers.

Entering the Service Tests Menu

Instructions for entering the service tests menu.

Entering the Service Utilities Menu

Instructions for entering the service utilities menu.

1. Scan Axis Test

Verifies components related to the scan axis operation.

2. Media Drive Test

Verifies components related to the media axis operation.

5. Sensors Test

Verifies the operation of various sensors.

11. EEROM Reset

Resets the EEROM values.

5. Diagnostic Print

Prints diagnostic information to identify image quality problems.

Service Calibrations

Entering the Service Calibrations Menu

Instructions for entering the service calibrations menu.

1. Scan Axis Calibration

Checks PWM and calibrates line sensor intensity and position.

3. Paper Advance Calibration

Calibrates media advance to control movement and prevent banding.

5. Line Sensor Calibration

Calibrates the line sensor intensity for edge detection.

6. Vacuum Calibration

Sets default nominal and real values for the vacuum fan assembly.

7. Carriage Setup

Resets ink short thresholds after carriage PCA replacement.

Print Quality

Print Quality Troubleshooting Actions

Actions to take when facing print quality problems.

Choosing the Correct Print Quality Settings

Guidance on selecting appropriate print quality settings and paper types.

How to Use the Service Image Quality Diagnostic Print

Instructions for using the service image quality diagnostic print.

Diagnostic Part 1: Alignment Test

Checks color-to-color and bi-directional misalignment.

Diagnostic Part 3: Printhead Problems

Identifies which printhead is faulty.

Nozzle Print Test

Tests individual printhead nozzles for correct printing.

Horizontal Lines Across the Image (Banding)

Troubleshooting horizontal lines (banding) in prints.

Advanced Banding Troubleshooting for Experts

Advanced troubleshooting flowchart for banding issues.

Lines are Missing or Thinner than Expected

Troubleshooting thin or missing lines in prints.

Paper is not Flat

Troubleshooting issues with paper not lying flat.

Problems with Stepped Lines

Troubleshooting stepped lines in borders and diagonal lines.

Problems with Color Accuracy

Requirements for achieving color accuracy.

Problems with Image Clipping

Troubleshooting image clipping due to printable area discrepancies.

Image is Completely Blank

Troubleshooting when the image is completely blank.

Parts and Diagrams

Printer

Lists printer components and their corresponding page numbers.

Stacker

Lists stacker components and their corresponding page numbers.

Center Covers

Lists and illustrates center cover components.

Electronics Module

Lists and illustrates components of the electronics module.

Right Hand Cover

Lists and illustrates parts of the right hand cover.

Left Hand Cover

Lists and illustrates parts of the left hand cover.

Carriage Assembly

Lists and illustrates parts of the carriage assembly.

Scan-Axis Assemblies

Lists and illustrates scan-axis assemblies.

Drive Roller and Media-Axis Motor

Lists and illustrates drive roller and media-axis motor parts.

Paper Path Assemblies

Lists and illustrates paper path assemblies.

Pinchwheel Assembly

Lists and illustrates pinchwheel assembly parts.

Rear Path Assembly

Lists and illustrates rear path assembly components.

Roll 1 Module (Front Path)

Lists and illustrates roll 1 module (front path) components.

Roll 1 Drawer Assembly

Lists and illustrates roll 1 drawer assembly parts.

Roll 2 Module

Lists and illustrates roll 2 module components.

Roll 2 Drawer Assembly

Lists and illustrates roll 2 drawer assembly parts.

Miscellaneous Parts

Lists miscellaneous parts like arcs, cutter blades, and power cords.

Stacker Stand

Lists and illustrates stacker stand components.

Covers and Sensors

Lists and illustrates printer covers and sensors.

Rollers and Transport Belt

Lists and illustrates rollers and transport belt parts.

Drive Motor

Lists and illustrates drive motor assembly parts.

Electronics Module

Lists and illustrates electronics module components.

Input Trays

Lists and illustrates input tray components.

Removal and Installation

Introduction

Step-by-step guide for component removal and installation.

Safety Precautions

Important warnings and cautions for servicing the printer.

Electrostatic Discharge (ESD) Precautions

Precautions to prevent damage from electrostatic discharge.

Required Tools

Lists the tools needed for disassembly and repair.

Screw Types

Details screw types, torx sizes, and part numbers.

Window

Instructions for removing and installing the printer window.

Right Cover

Instructions for removing and installing the right cover.

Left Cover

Instructions for removing and installing the left cover.

Left Trim

Instructions for removing and installing the left trim.

Right Trim

Instructions for removing and installing the right trim.

Top Cover

Instructions for removing and installing the top cover.

Rear Door

Instructions for removing and installing the rear door.

Right Connector Cover

Instructions for removing and installing the right connector cover.

Left Connector Cover

Instructions for removing and installing the left connector cover.

Front Panel

Instructions for removing and installing the front panel.

Service Station

Instructions for removing and installing the service station.

Vacuum Fan

Instructions for removing and installing the vacuum fan.

Aerosol Fan

Instructions for removing and installing the aerosol fan.

Drop Detector

Instructions for removing and installing the drop detector.

Ink Supply Tubes and Trailing Cable

Instructions for removing and installing ink supply tubes and trailing cable.

ISS to Cartridge Cables

Instructions for removing and installing ISS to cartridge cables.

Cutter Assembly

Instructions for removing and installing the cutter assembly.

Ink Supply Station (ISS)

Instructions for removing and installing the ink supply station.

APS Assembly

Instructions for removing and installing the APS assembly.

Most Left Spittoons

Instructions for removing and installing the most left spittoons.

Middle Left Spittoons

Instructions for removing and installing the middle left spittoons.

Encoder Strip and Encoder Sensor

Instructions for removing and installing the encoder strip and sensor.

Carriage PCA

Instructions for removing and installing the carriage PCA.

Carriage Flex Cables

Instructions for removing and installing carriage flex cables.

Carriage Assembly

Instructions for removing and installing the carriage assembly.

Belt Assembly

Instructions for removing and installing the belt assembly.

Scan-Axis Motor

Instructions for removing and installing the scan-axis motor.

Media-Axis Motor

Instructions for removing and installing the media-axis motor.

Printer Interconnect PCA

Instructions for removing and installing the printer interconnect PCA.

EIO to PCA Interface Card

Instructions for removing and installing the EIO to PCA interface card.

Gamut PCI PCA

Instructions for removing and installing the gamut PCI PCA.

Memory Module

Instructions for removing and installing the memory module.

Main PCA Formatter

Instructions for removing and installing the main PCA formatter.

Hard Disk Drive (HDD)

Instructions for removing and installing the hard disk drive.

Power Supply Unit (PSU)

Instructions for removing and installing the power supply unit.

PrintMech PCA

Instructions for removing and installing the PrintMech PCA.

Formatter Battery

Instructions for removing and installing the formatter battery.

Electronics Module

Instructions for removing and installing the electronics module.

Back Channel Sensor

Instructions for removing and installing the back channel sensor.

Line Sensor Assembly

Instructions for removing and installing the line sensor assembly.

Deflectors

Instructions for removing and installing deflectors.

Output Platen

Instructions for removing and installing the output platen.

Center Platen

Instructions for removing and installing the center platen.

Rear Path Mylar Strip

Instructions for removing and installing the rear path mylar strip.

Cartridge Trays

Instructions for removing and installing cartridge trays.

Push-Push Mechanism

Instructions for removing and installing the push-push mechanism.

Main Media Sensor

Instructions for removing and installing the main media sensor.

Single Sheet Load Sensor

Instructions for removing and installing the single sheet load sensor.

Encoder Disc and Sensor

Instructions for removing and installing the encoder disc and sensor.

Drive Pinch Lever Assembly

Instructions for removing and installing the drive pinch lever assembly.

Drive Pinch Lever Sensor

Instructions for removing and installing the drive pinch lever sensor.

Pinchwheel Assembly

Instructions for removing and installing the pinchwheel assembly.

Drive Roller

Instructions for removing and installing the drive roller.

Roll 1 Right Drawer Cover

Instructions for removing and installing the roll 1 right drawer cover.

Roll 1 Left Drawer Cover

Instructions for removing and installing the roll 1 left drawer cover.

Roll 1 Drawer

Instructions for removing and installing the roll 1 drawer.

Roll 1 Drawer Bar

Instructions for removing and installing the roll 1 drawer bar.

Roll 1 Right Spindle Support

Instructions for removing and installing the roll 1 right spindle support.

Roll 1 Left Spindle Support

Instructions for removing and installing the roll 1 left spindle support.

Roll 1 Module (Front path assembly)

Instructions for removing and installing the roll 1 module.

Roll 1 BT Arm

Instructions for removing and installing the roll 1 BT arm.

Roll 1 Media Feed Motor

Instructions for removing and installing the roll 1 media feed motor.

Roll 1 Feed Roller Assembly

Instructions for removing and installing the roll 1 feed roller assembly.

Roll 1 BT Arm Encoder Disc

Instructions for removing and installing the roll 1 BT arm encoder disc.

Roll 1 BT Arm Encoder PCA

Instructions for removing and installing the roll 1 BT arm encoder PCA.

Roll 1 Paper Load Lever Sensor

Instructions for removing and installing the roll 1 paper load lever sensor.

Roll 1 Media Sensor

Instructions for removing and installing the roll 1 media sensor.

Roll 1 Drawer Sensor

Instructions for removing and installing the roll 1 drawer sensor.

Roll 2 Right Drawer Cover

Instructions for removing and installing the roll 2 right drawer cover.

Roll 2 Left Drawer Cover

Instructions for removing and installing the roll 2 left drawer cover.

Roll 2 Drawer Bar

Instructions for removing and installing the roll 2 drawer bar.

Roll 2 Drawer

Instructions for removing and installing the roll 2 drawer.

Roll 2 Module

Instructions for removing and installing the roll 2 module.

Roll 2 BT Arm Assembly

Instructions for removing and installing the roll 2 BT arm assembly.

Roll 2 Pinch Rollers

Instructions for removing and installing the roll 2 pinch rollers.

Roll 2 Feed Roller Assembly

Instructions for removing and installing the roll 2 feed roller assembly.

Roll 2 Paper Load Lever Sensor

Instructions for removing and installing the roll 2 paper load lever sensor.

Roll 2 Media Feed Motor

Instructions for removing and installing the roll 2 media feed motor.

Roll 2 Left Drawer Sensor

Instructions for removing and installing the roll 2 left drawer sensor.

Roll 2 Right Drawer Sensor

Instructions for removing and installing the roll 2 right drawer sensor.

Roll 2 Drawer Sliders

Instructions for removing and installing the roll 2 drawer sliders.

Roll 2 Right Spindle Support

Instructions for removing and installing the roll 2 right spindle support.

Roll 2 Left Spindle Support

Instructions for removing and installing the roll 2 left spindle support.

Roll 2 BT Arm Encoder Disc Assembly

Instructions for removing and installing the roll 2 BT arm encoder disc assembly.

Roll 2 Paper Load Lever Sensor

Instructions for removing and installing the roll 2 paper load lever sensor.

Rear Path

Instructions for removing and installing the rear path components.

Stacker

Lists stacker components and their removal/installation.

Right Cover

Instructions for removing and installing the stacker right cover.

Left Cover

Instructions for removing and installing the stacker left cover.

Top Cover

Instructions for removing and installing the stacker top cover.

Lower Front Cover

Instructions for removing and installing the lower front cover.

Pinch Wheels

Instructions for removing and installing pinch wheels.

Drive Motor

Instructions for removing and installing the drive motor.

Front Cover Sensor

Instructions for removing and installing the front cover sensor.

Safety Temperature Sensor

Instructions for removing and installing the safety temperature sensor.

Temperature Sensor PCA

Instructions for removing and installing the temperature sensor PCA.

Media Sensor

Instructions for removing and installing the media sensor.

Extension Tray

Instructions for removing and installing the extension tray.

Receiving Tray

Instructions for removing and installing the receiving tray.

Printer Interlocks

Instructions for removing and installing printer interlocks.

Paper Infeed Platen

Instructions for removing and installing the paper infeed platen.

Electronics PCA

Instructions for removing and installing the electronics PCA.

Power Supply Unit (PSU)

Instructions for removing and installing the power supply unit.

Heating Lamp

Instructions for removing and installing the heating lamp.

Heat Roller

Instructions for removing and installing the heat roller.

Stacker Transport Belt

Instructions for removing and installing the stacker transport belt.

Preventive Maintenance

Cleaning the Printer

General guidelines for cleaning the printer.

General Cleaning

Steps for proper general cleaning of the printer.

Cleaning the Drive Roller and Overdrive

Procedure for cleaning the drive roller and overdrive.

Cleaning the Center Platen

Procedure for cleaning the center platen.

Applying Oil to the Overdrive

Procedure for oiling the overdrive to stop roller squeaking.

Lubricating the Carriage Assembly

Steps for lubricating the carriage assembly.

Scheduled Maintenance

Information on scheduled preventive maintenance.

Level of Printer Usage

Information on normal printer usage and maintenance cycles.

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