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HP Designjet CP Series Printers - System Error 020004

	Parts required (part numbers are subject to change)
	Troubleshooting steps
	Perform the D05 Service Station diagnostic test
	Performing service calibrations

Document number: BPP90053

Last updated: 13-Jan-2003

Minimum skill level: 2

System Error 020004 is caused when the Service Station cannot find the home position. The most common cause is a defective or malfunctioning Service Station Assembly. Follow the steps listed in this document to accurately determine and replace the appropriate parts.

NOTE: Service Notes Referencing this issue, and the affected serial number range: 2000cp C4703A-05A (ESA0000000 - ESC8A07320), 2500cp C4704A-05A (ESA0000000 - ESC8A18978), 3000cp C4723A-03 (ESA0000000 - ESA8C03538), 3500cp C4724A-03 (ESA0000000 - ESA8C04905). The services notes listed above do not cover printers outside the specified serial number ranges, or printers that fall within the range but have had the Service Station previously replaced. The expiration date for all of these service notes is 08-Jul-2001.

Parts required (part numbers are subject to change)

Part description	2X00CP - C4703A, C4704A, C6085A	3X00CP - C4723A, C4724A, C6084A
Service Station Assembly (Required)	C4723-60276	C4723-60276

NOTE: If Removal and Installation instructions are needed for reference during any repairs performed, refer to the CP Series Service Manual available on the Computer Care Web site for review or download.

Troubleshooting steps

If parts are replaced or fixed in any of the steps listed below, attempt to verify printer functionality by turning the printer on and printing internal test prints. If functionality is verified, no additional parts should be replaced.

1. Turn the printer off using the power switch on the back of the printer.
2. Open the right door and the top cover.
3. Ensure all Print head cleaners are correctly seated.
4. Check for any media or other obstructions under the right-hand cover.
5. If problems were detected and rectified in the steps above test printer functionality. If no problems were found or the problem persists continue with the remaining steps.
6. Remove the right-end cover from the printer, and turn the printer on. (Place the end cover on a chair or other elevated object to prevent the right-end cover from falling.)

NOTE: The cable routing from the front panel to the Electronics module may be catching the flag assembly. Verify that the cable is not impeding the functionality of the flag. If the cable is routed incorrectly or is impeding the flag, reroute the cable as needed.

7. Locate the Service Station flag, attached to the side of the Service Station (refer to figure 1).

Figure 1: Service Station flag

8. Check that the flag is not sticking. If the flag is sticking, clean it with a Q-tip or lint-free cloth dampened with water.
9. Check that the flag is installed correctly.

NOTE: Two different flag assemblies are available, one has two slots for attachment and the other has one slot. If the flag with two slots is used, the bottom slot must be used when being attached.

10. Check the pivot of the service station flag, the flag should pivot freely.
11. If problems were noticed and corrected in any of the above steps, turn on the printer and verify functionality. If functionality is proven, no parts need to be replaced.
12. If no problems are found, or the error re-appears, continue with performing the "D05 Service Station diagnostic test" as listed below.

NOTE: If the printer has been serviced recently, make sure the Service Station nut is installed correctly (new Service Stations C4723-60276 have the nut). Check that the Service Station inter-connect cable is correctly connected to the Electronics module, and that all cables for the Service Station assembly are correctly connected to the Service Station interconnect PCA. Verify printer functionality if any problems are noticed and fixed. Continue with the remaining steps if the error reappears.

Perform the D05 Service Station diagnostic test

1. Turn the printer on, and wait for the printer to initialize.

NOTE: Certain printer failures can occur that will prevent the printer from completing the initialization. If this problem occurs, turn the printer off. Press and hold down the Enter key and the Up Arrow key while turning on the printer, this will allow access to the Service tests submenu.

2. Press Enter at the Status display.
3. Using the Arrow keys, scroll to the Utilities and press Enter.
4. Simultaneously press the Enter key and the Up Arrow key to access the Service test submenu.
5. Scroll to Diagnostics and press Enter.
6. Scroll to D05 Service Station and press Enter.
7. The printer will begin to test the operation of the Service Station and Primer assemblies.
8. If the message "D0500 OK" is displayed the test has passed.
9. If the test fails, replace the Service Station assembly (refer to pages 8-26, 8-87 of the service manual).
10. Verify printer functionality by printing several internal prints.

Performing service calibrations

Following each calibration, turn the printer off to store the new calibration values in the EEROM. Turn the printer on (entering Service mode) and perform the next required calibration. Repeat this cycle until all necessary calibrations have been performed.

1. Make sure the printer is turned off from the power switch on the back of the printer.
2. Hold the Up Arrow key and the Enter key down while turning the printer on.

NOTE: Continue to press both the Up Arrow key and the Enter keys until letters begin to scroll on the lower right corner of the front-panel display.

3. Once the message Status/Ready is displayed on the front panel, press Enter.
4. Use the Arrow keys to scroll to the Utilities menu display and press Enter.
5. Scroll to Service Tests and press Enter.
6. Scroll to Service Calibrations and press Enter.
7. Use the Arrow keys to scroll through the specific calibrations and press Enter when the required calibration is displayed.

NOTE: For the best results when performing the Accuracy calibration, use a Polyester Matte film. If Polyester Matte film is not available, use HP High Gloss or Heavy Coated media.

Copyright Hewlett-Packard Co. 2001
This information is subject to change without notice and
is provided "as is" with no warranty.
Hewlett-Packard shall not be liable for any direct,
indirect, special, incidental or consequential damages
in connection with the use of this material.

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