HP DesignJet 5000 and 5500 Series Large-Format Printers Service Manual
For HP Internal Use Only Warranty ©Copyright Hewlett-Packard Company 2002 The information contained in this The procedures described in this document is subject to change manual are to be performed by without notice. HP-qualified service personnel only. Hewlett-Packard makes no This document contains proprietary information that is protected by copyright. All rights are reserved.
1 HP DesignJet 5000 and 5500 Series Large-Format Printers Service Manual
Using this Manual Purpose This Service Manual contains information necessary to test, calibrate and service: HP DesignJet 5000 Printer - 42” Model (P/N C6090A/V) HP DesignJet 5000 Printer - 60” Model (P/N C6095A/V) HP DesignJet 5000PS Printer - 42” Model (P/N C6091A/V) HP DesignJet 5000PS Printer - 60” Model (P/N C6096A/V) HP DesignJet 5500 Printer - 42” Model (P/N Q1251A/V) HP DesignJet 5500 Printer - 60” Model (P/N Q1253A/V) HP DesignJet 5500PS Printer - 42” Model (P/N Q1252A/V) HP DesignJ
Table of Contents Table of Contents 1 Troubleshooting 1-1 System Error Codes 2-1 HP Ink Supplies Troubleshooting 3-1 Service Tests and Utilities 4-1 Service Calibrations 5-1 Print Quality 6-1 Parts and Diagrams 7-1 Removal and Installation 8-1 Preventive Maintenance 9-1 Functional Overview 10-1 HP DesignJet 5000 and 5500 Series Printers Service Manual 3
Table of Contents 4 HP DesignJet 5000 and 5500 Series Printers Service Manual
Troubleshooting 1 Introduction 1-2 Phone Support 1-2 Which Firmware Version Relates to Which Ink System 1-2 Troubleshooting System Error Codes 1-2 Performing a Service Test on a Failed Assembly 1-3 Performing the Necessary Service Calibrations 1-3 Troubleshooting Calibration Error Codes 1-3 Troubleshooting Ink Supplies Error Codes 1-4 Troubleshooting Initialization - Self Diagnostic Errors 1-4 Solving Image Quality Problems 1-4 The Printer does not Power ON 1-5 ALL the Front-Panel LEDs are Lit but Nothing
Troubleshooting Guide to Troubleshooting the Printer Introduction This chapter will guide you through the relevant steps to take when troubleshooting the Printer. Phone Support In certain circumstances, a Call Agent can try and troubleshoot the Printer by requesting the Customer to perform a Service Calibration, Test or Utility via the phone. Using this process, it can be determined whether the Printer requires any on-site maintenance. Which Firmware Version Relates to Which Ink System A.01.
Troubleshooting Performing a Service Test on a Failed Assembly If possible, always perform a Service Test on the component/ assembly that you are about to replace, just to make sure that is the component/assembly that has failed. NOTE If the test on that component/assembly passes, you should NOT replace it. For information on the Service Tests and how to use them see Chapter 4, Service Tests and Utilities.
Troubleshooting Troubleshooting Ink Supplies Error Codes Chapter 3, HP Ink Supplies Troubleshooting, contains a list of Error Codes that are reported for Ink Supplies i.e. Ink Cartridges, Printheads and Printhead Cleaners. The error codes are described and recommended corrective actions are provided. Only try one recommended action at a time and check if the error code has disappeared. Ink Supplies error codes consist of a four digit number [XXXX].
Troubleshooting The Printer does not Power ON 1. Check that the Power Cord is connected correctly to the Printer and to the Power Socket. 2. Check that the Power Switch on the BACK of the Printer is in the ON position. 3. Remove the DIMM’s Cover (See Page 8-77) and check the green and red Status LED’s on the Main PCA. If they are both NOT lit, replace the Power Supply Unit Page 8-88. Status LED’s 4. Check that the Front-Panel Cable is correctly connected to the Electronics Module.
Troubleshooting ALL the Front-Panel LEDs are Lit but Nothing Else Happens The BootROM DIMM is NOT correctly installed or is the wrong type. 1. Power OFF the Printer from the back and disconnect the Power Cord. Reseat the BootROM DIMM (looking from the rear of the Printer, the first slot from the left - See Page 8-77) making sure that it is installed correctly. 2. If the problem persists replace the BootROM DIMM Page 8-77. NOTE For more information, refer to “Electronics Problems” on page 1-21.
Troubleshooting Troubleshooting Shutdowns - User Message "Warning: Switch Power Off" If a shutdown occurs, you will get the message “Warning: Switch Power Off” followed by: Check Printhead Cleaner Path. Check Paper Path. Check Printhead Path (followed by (1), (2) or (3)). A shutdown in each path will require different steps to resolve the problem as explained as follows. WARNING In each case, make sure that you power OFF the Printer before attempting any procedures to resolve the problem.
Troubleshooting Check Paper Path This warning appears whenever the friction on the Paper-Axis is too high: the electrical current needed by the Paper-Axis Motor to move the paper is too high, so before burning the motor or the Main PCA, this warning appears. The common reason for this error is an internal paper jam or at the end of a roll of media the paper is glued to the media core. It can also be due to a defective motor or Main PCA.
Troubleshooting NOTE Also, after replacing the Scan-Axis Motor, perform the Scan-Axis Test ( Page 4-10 and check that the values are within the given limits. If the Printer still fails, replace the Main PCA Page 8-81. Check Printhead Path (2) This is a safety shutdown and occurs whenever there is a discontinuity in the Printhead path, because of an obstacle, oil drops on the Encoder Strip, the Carriage cover touching the tube guides, etc.
Troubleshooting Problems with Vacuum If you have problems loading either Roll or Sheet Media, then there could be a problem with the Vacuum Fan or Booster Fan. To verify if there really is a problem with Vacuum, try the following: 1. With the Printer ON, open the Window of the Printer and place a sheet of HP High Gloss Photo Paper (must be D-Size), aligned with the blue lines on the Center Platen. If the Vacuum holds the sheet in place, and then loads it correctly, then the Fans function correctly.
Troubleshooting Printhead Crashes/Smears on High Density Prints Using Coated Media High density prints can cause cockle mainly on HP Coated Media. This causes two main problems: 1. Cockling in the borders - Because the Printer places too much ink on the Coated Media, the borders of the print become raised, causing the Printhead to crash against the media. To solve the problem, try the following: Try using Heavy Weight Coated Media instead of Coated Media.
Troubleshooting Banding at variable extreme environmental conditions The Accuracy Calibration has been done at normal environmental conditions, therefore printing in extreme environmental conditions will cause banding because the advance of the Drive Roller does not correspond to the same conditions that the calibration was done in. To solve the problem, try the following: Perform the Accuracy Calibration in the new environmental conditions (Refer to the User’s Guide - Media Solutions).
Troubleshooting Hue shift on HP Colorfast Adhesive Vinyl media Under high humidity conditions (approx. >65%) the colors tend to fade over time, particularly colors that require Magenta. To solve the problem, try the following: Reduce the level of humidity (<65%) that the Printer is working in. To find the humidity level, print the Service Configuration Print (Printer Setup Menu / Utilities / Test prints / Service config). Laminate the prints.
Troubleshooting Loss of Gloss on HP Photo Imaging Gloss when using the Take-Up Reel Under high humidity conditions (approx. >70%) the polymer chain in the coating of this media relaxes and the drying rate decreases. If the printed media is rolled onto a Take-Up Reel or is covered by another print, the contact between the two surfaces could cause blotches in the gloss. Try the following: Reduce the level of humidity (<70%) that the Printer is working in.
Troubleshooting Wrinkles and scratches (cockle) on HP Coated and Heavyweight Coated Media. Images may be damaged if prints are not handled with care, particularly when handling wide plots. This can happen when images are placed on top of one another and there is movement between them, causing friction and loss of ink from the surface if it is not completely attached. Also, if plots are rolled up, wrinkles can occur. To avoid this problem try the following: Always handle plots with care.
Troubleshooting Drying Time Too Long for HP Studio Canvas Under conditions of high humidity (> 70%) HP Studio Canvas retains a high amount of water and takes too long to dry, also creating problems in using the Take-Up Reel and Bin. To solve the problem try the following: Reduce the level of humidity (<70%) that the Printer is working in. To find the humidity level, print the Service Configuration Print (Printer Setup Menu / Utilities / Test prints / Service config).
Troubleshooting 2. The media sensor is defective. To verify this, remove the media and re-boot the Printer. If the message comes up during initialization, the media sensor is defective. To solve this, try the following: Check that the media sensor cable is connected correctly Check that the media sensor cable is not damaged and that the media sensor is clipped correctly. Replace the Media Sensor Page 8-109. 3. The Line Sensor does not detect the leading edge of the media.
Troubleshooting Trailing Cable connection, so just reconnect the Trailing Cable again to double-check that the Printer now works. If, after reconnecting the cable, the error appears again, either the Carriage PCA or the Trailing Cable is defective. In this case, first try replacing the Trailing Cable and then the Carriage Assembly. If the Printer did not initialize correctly, even after removing the Trailing Cable, the problem is either in the Main PCA or the ISS PCA.
Troubleshooting Cutter Assembly Problems 1. The Printer does not cut (even when using the Form Feed & Cut option in the Front Panel). In this case it is very likely that the cutter is disabled in the EEROM. This can happen whenever the Diagnostic Print is cancelled in the middle of the print, or if the Printer was turned OFF in the middle of the Diagnostic Print. To re-activate the Cutter, print the Diagnostic Print again and this time letting it finish to the end without any interruptions.
Troubleshooting Carriage and Scan-Axis Problems 1. Printhead continuity problems. When installing the Ink Tubes System, it is possible that the crane (the part of the Tubes System that is connected to the front of the Carriage) is not clipped properly. This can cause Printhead continuity problems afterwards, especially in the light cyan and light magenta Printheads (XX16 REPLACE message appears for these Printheads).
Troubleshooting Electronics Problems 1. The Printer hangs with the front panel completely blank and the three Image Quality LED’s lit. The firmware has a bug that creates this situation whenever the Printer is receiving data from an external RIP. The customer should print using the HP Driver to check that the Printer is printing without any problems. The only solution to this problem will be to upgrade to the firmware for the UV inks (A.02.XX) when it is available.
Troubleshooting 3. The Printer is printing slower compared to another HP DesignJet 5000. It is important first to determine whether the differences are during receiving/processing, during printing or once the print is finished. 1. The time the printer takes to start printing is longer. Check that the "Start printing option" is set the same for all Printers. NOTE For troubleshooting purposes, set this option to "After Processing".
Troubleshooting 3. The dry time at the end of the print is longer. Normally the Printer uses the temperature and the humidity reading from the ISS PCA to calculate the dry time, which is required for the print to dry before being cut. The specification of these readings is +/- 15%, so a variation in the calculated dry time of up to 30% is within specification.
Troubleshooting Typical Failures After Exchanging the Ink Tubes The following table contains typical failures that could appear after changing the Ink Tubes: Failure Description Solution After completing the initialization process, the Front Panel displays: WARNING Incorrect type of Tubes System Switch power off The electrical connector has not been correctly connected to the Ink Cartridge connector. 1 Switch OFF the Printer. 2 Connect the electrical connector into the Ink Cartridge tube connector.
Troubleshooting Solving Media-Handling Problems NOTE HP Designjet Printers minimum media size is A3 in portrait mode. The Front Panel Keeps Indicating that Media Is Misaligned or Incorrectly Positioned Roll media The roll may be loaded the wrong way. The paper should load over the roll toward you. The media may be crumpled or warped or have irregular edges. The paper may be loaded at an angle. The right-hand edge must be parallel to the blue line on the paper entry roller.
Troubleshooting How to Navigate through the Front Panel Menus Shaded boxes always appear in the front panel. White boxes appear only in Full menu mode. I/O Setup Menu I/O setup No I/O card found Card ID Card ID Card Setup Card Setup Configuration Advanced Reset Card 0.5 min ..
1-27 Always Appear Only Appear in Full Menu Mode Device Setup On, Off HP-GL/2 Reduced Margins Lang Drying Time On, Off Cutter @ PostScript Only 255 ..
Utilities 1-28 Print usage, View usage Short, Full Printhead alignment, Usage Menu Mode Calibrations Automatic, Manual PS Code Rev, PS Font code Up, Down Automatic clean Clean now … Default Menu Display Contrast Clean Platen Lens Maintenance On, Off Ram present, Service ID Hard Disk, Code Rev. Statistics Recalibrate HP-GL/2 config Service config.
1-29 100% ..
Nesting 1-30 Only Appear in Full Menu Mode Nest Queue mgmt Always Appear In order ... Off # .... @ width, Length Statistics PostScript Only 99 .. 2, 1 min Move to top, Delete Page 99 ..
HPGL/2 settings HP DesignJet 5000 and 5500 Series Printers Service Manual Only Appear in Full Menu Mode Always Appear Width Width PostScript Only @ Factory On/Off Pen no. 0 … 15 Palette A, Palette B Define Palette Merge Pen no. 0 … 15 Software, Factory, Palette A, B Palette 255 .. 1, 0 0.13 ... 12.
1-32 Always Appear On, Off @ 30 .. 5, 0 mm PostScript Only Automatic Nest Spacing Mirroring Normal, Extended Margins Manual 0 .. 270 Best ISO A, ISO A4 .. A0 Best JIS B, JIS B4..B1 JIS ISO Best ARCH, ARCH A.. E1 Arch Best ANSI, ANSI A ..E Over A2, Over A1 Oversize ANSI 1.0X1.4m 42inX59in 44X62in 1.2X1.
Troubleshooting HP DesignJet 5000 and 5500 Series Printers Service Manual PostScript Only Always Appear Only Appear in Full Menu Mode Menu Palette Demos Samples @ Demos Menu 1-33
1-34 HW Coated (Economy) HW Coated Coated Paper Photo Imaging Gloss Colorfast Vinyl Paper Semi-Gloss Poster Paper Studio Canvas and more....... *HW Coated (Economy) *HW Coated *Coated Paper *Photo Imaging Gloss *Colorfast Vinyl *Paper Semi-Gloss *Poster Paper *Studio Canvas and more....... Media Selection Delete Media Yes, No Yes, No TUR Loaded= Form Feed & Cut Move Media Vendor Name Type of Media Width Printable Area Profile Revision Roll/Sheet Info.
HP DesignJet 5000 and 5500 Series Printers Service Manual Replace Ink Cartridge Light Cyan cart Info Light Magenta cart Info Yellow cart. Info Cyan cart Info Magenta cart Info Black cart Info Yes, No Ink Level Capacity Part Number Manufacture Date HP No.
Troubleshooting Printhead Menu Printhead Info 1-36 Light Cyan Info Light Magenta Info Yellow Info Cyan Info Magenta Info Black Info Recover Printheads All Printheads Cyan Magenta Yellow Black Light C Light M Replace Printheads Yes, No HP DesignJet 5000 and 5500 Series Printers Service Manual
Troubleshooting Service Configuration Print The Service Configuration Print is a useful tool for troubleshooting the Printer. The Service Configuration Print contains the following information about the Printer: General Configuration Printhead Info. Ink Cartridge Info. Operating Conditions. Calibrations. Maintenance. I/O Configuration. How to Print the Service Configuration Print 1. Load media (Roll media or at least an A0 Sheet) into the Printer. 2.
Troubleshooting 4. Once inside the “Utilities” menu, use the Arrow keys to scroll to the “Test prints” menu display and press the Enter key. Utilities Utilities Display Contrast ... Calibrations ... Reset WebAccess paswd Contrast ... Test Prints Statistics ... ... Default menu... Test Prints Display contrast ... Top Back n p Press Up and Enter Enter 5. Use the Arrow keys to scroll to “Service Config.” and press the Enter key to print the Service Configuration Print.
Troubleshooting General Printer Information 1. Interaction between start printing and nesting. Of the four possible combinations between "Start Printing = Optimized or After processing" and "Nesting = In order or OFF" only two are possible. For example, if you have nesting set to "In order" and you change start printing to "Optimized" the Printer will automatically change nesting to "Off".
Troubleshooting of the print. Perform a manual recovery if the Printhead status is (XX20) RECOVER/ (XX21) REPLACE. With longer plots, average productivity will increase (i.e. same area is printed in less prints > reduction of servicing at the beginning/end of the print).
System Error Codes 2 System Error Codes 2-3 Introduction 2-3 Continuable and Non-Continuable Error Codes 2-4 System Error Groups 2-4 ffff ffff xxxxxxxx (General Firmware Error) 2-5 ffff ffff 02b301b0 2-5 ffff ffff 01dcxxxx 2-6 ffff ffff 030d0170 or ffff ffff 030d0171 2-6 ffff ffff 031609xx 2-6 ffff ffff 03450097 2-7 ffff ffff 036000bd 2-7 ffff ffff 036e0136 2-7 01002D (Non-Continuable) 2-7 010023 (Non-Continuable) 2-8 010030 034c095e 2-8 010040 2-8 010041 2-9 010042 2-9 010090 (Continuable) 2-10 010091 (C
System Error Codes 0B0001 2-16 0B0002 2-16 0B0003 2-16 0B0004 2-17 0B0005 2-17 0B0006 2-17 0B000X 2-18 0B0010 xxxxxxxx (Non-Continuable) 2-18 0B000A 2-18 0B000B 2-19 0B000C 2-19 0B000D 2-19 0B000E 2-19 0B000F (Continuable) (Only applicable to DesignJet 5500 Series) 2-20 0C0030 2-20 0C0032 (Continuable) 2-21 0C0040 2-21 0C00FF 2-22 0C1000 2-22 0C1001 2-22 0D0000 (Continuable) 2-23 0D0000 033f019C 2-23 0D0002 (Continuable) 2-23 0D0003 xxxxxxxx (Non-Continuable) 2-23 0D0004 xxxxxxxx (Non-Continuable) 2-23 0D00
System Error Codes System Error Codes Introduction NOTE Before troubleshooting System Errors, if possible, repeat the procedure performed when the error was reported. NOTE When reporting the System Error Code, make sure that you supply the full Error Code and the firmware version (displayed during the initialization process when powering ON the Printer or available in the User’s Printer Setup Utilities Statistics menu).
System Error Codes If you have an error code which is not documented in this Service Manual or you have an error which you cannot resolve, then report the error to the HP Response Center or the nearest HP Support Office. When reporting the error, have the following information ready: Which firmware revision the Printer is using. The complete error number. Which software application the customer is using (name, version, etc.).
System Error Codes System Error: ffff ffff xxxxxxxx (General Firmware Error) Problem Description: All ffff ffff errors are general firmware errors. This does not mean that the firmware has failed, but that the firmware (as a piece of software) has experienced an internal crash and before doing anything incorrectly it displays this error. We can compare this to the "blue-screen" that appears in the Windows operating system when there is a software problem. These errors also mean a system crash.
System Error Codes System Error: ffff ffff 01dcxxxx Problem Description: There is a problem with the I/O Card (happens during power-up). Corrective Action: Try the following: Disconnect the Network Cable and check if the error still appears during power-up. If the error does not appear again, then the problem may have been that the Printer was receiving some information through the port while powering-up.
System Error Codes System Error: ffff ffff 03450097 Problem Description: If the Window is opened during the cutting operation, the Printer hangs and the Carriage suddenly stops. Also, if you press any key on the front panel this error code (ffff ffff 03450097) may be displayed. Corrective Action: Re-boot the Printer and make sure that the Window is never opened during the cutting operation. NOTE This problem is solved in any A.02.xx firmware release.
System Error Codes System Error: 010023 (Non-Continuable) Problem Description: EEROM Test failure. Corrective Action: Replace the Main PCA Page 8-81. NOTE After replacing the Main PCA, make sure you perform the Backup EEROM Page 4-30, making sure that you select "Main PCA" when prompted. System Error: 010030 034c095e Problem Description: This error code appears when the power supply detects a low spike (e.g. due to a temporary loss of tension). There is nothing wrong with the Printer.
System Error Codes System Error: 010041 Problem Description: Error in Scan-axis Encoder quadrature. Corrective Action: Try the following: Check that the Encoder Strip is NOT broken or damaged. Replace the Encoder Strip Page 8-34. Replace the Carriage Assembly Page 8-46. If the Error Code continues, replace the Main PCA Page 8-81. WARNING Only replace one component at a time and check if the error has gone before replacing another component.
System Error Codes System Error: 010090 (Continuable) Problem Description: Error in Paper-axis Motor Encoder Corrective Action: Try the following: Check that the Paper-Axis Motor cable is NOT broken or damaged. Check that the Paper-Axis Motor cable is correctly connected. Replace the Paper-Axis Motor Page 8-105. If the Error Code continues, replace the Main PCA Page 8-81. WARNING Only replace one component at a time and check if the error has gone before replacing another component.
System Error Codes System Error: 040000 01E603D9 Problem Description: This is an error that is related to the Parallel Port. It happens normally in New Printers and only once (it is unlikely to appear again). Even if the error appears again, there is nothing wrong with the Printer. Corrective Action: Try the following: Recommend to the customer to print via the Network Card because the transmission time via the Parallel Port is very slow.
System Error Codes System Error: 06030C Problem Description: Bad Line Sensor. Corrective Action: Try the following: Replace the Line Sensor Page 8-53. Replace the Carriage Assembly Page 8-46. Replace the Trailing Cable Page 8-36. Replace the Main PCA Page 8-81. WARNING Only replace one component at a time and check if the error has gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.
System Error Codes System Error: 0A0000 Problem Description: APS Failure. Corrective Action: Try the following: Check all the cables of the APS and make sure they are correctly connected and are NOT damaged. Check all the tubes of the APS and Tubes System and make sure they are correctly connected and are NOT pinched or damaged. Check that the Air Tube from the APS is correctly connected to the Tubes System. Replace ONE Ink Cartridge at a time, checking if the System Error Code disappears.
System Error Codes System Error: 0A0030 Problem Description: Problem in Depressurizing Air System. Corrective Action: Try the following: Check the APS for any signs of Ink. Also inspect ALL Ink Cartridges for any signs of leaking (the bottom valve of the Ink Cartridge will contain ink). If there is ink leakage, replace ALL Ink Cartridges, the APS ( Page 8-67) and the Tubes System ( Page 8-25).
System Error Codes System Error: 0A0050 (Non-Continuable) Problem Description: The Printer has detected a leak in the Tubes System - Should ONLY appear in printers with the Ink Leak Detector installed. Corrective Action: Try the following: Check for ink in the Ink Leak Detector and, if present, replace the complete Tubes System Page 8-25. The Ink Leak Detector could have been triggered due to condensation in the Printer. Power OFF the Printer and allow the Printer to dry for 15 minutes.
System Error Codes System Error: 0B0001 Problem Description: Bad Humidity Read Corrective Action: Try the following: Replace the ISS PCA Page 8-91 Replace the Main PCA Page 8-81. WARNING Only replace one component at a time and check if the error has gone before replacing another component. Using this procedure you will be able to determine exactly which component failed. System Error: 0B0002 Problem Description: Bad IDS pressure read.
System Error Codes System Error: 0B0004 Problem Description: APS Failure. Corrective Action: Try the following: Check that the cable from the Ink Supply Station (ISS) PCA to the Ink Supply Station is correctly connected. Faulty APS. Replace the APS Page 8-67. If the error code continues, replace the Main PCA Page 8-81. WARNING Only replace one component at a time and check if the error has gone before replacing another component.
System Error Codes System Error: 0B000X Problem Description: Unable to detect Fan (X = 7 - Vacuum, 8 - Cooling, 9 - Aerosol). Corrective Action: Try the following: Make sure that the Fan is connected correctly to the Main PCA. Turn the Printer OFF and disconnect the Fan from the Main PCA. Connect a New Fan to the Main PCA and power ON the Printer. If the New Fan functions correctly without any Error Codes then remove the Old Fan from the Printer and install the New one.
System Error Codes System Error: 0B000B Problem Description: APS Failure. Corrective Action: Try the following: Check that the cable from the Ink Supply Station (ISS) PCA to the Ink Supply Station is correctly connected. Check that the Air Pressurization System Sensor Cable is correctly connected and is NOT damaged. Check all the tubes of the APS and make sure they are NOT pinched or damaged. Faulty APS. Replace the APS Page 8-67.
System Error Codes System Error: 0B000F (Continuable) (Only applicable to DesignJet 5500 Series) Problem Description: Unable to detect the Heater - If this error appears, all settings related to the heater will disappear from the front Panel. Corrective Action: Try the following: Check that the cable from the Heater to the Main PCA is correctly connected and is NOT damaged. Replace the Heater Page 8-120. System Error: 0C0030 Problem Description: Drop Detector Failure.
System Error Codes System Error: 0C0032 (Continuable) Problem Description: Drop Detector not calibrated or the calibration settings have been lost. Corrective Action: Try the following: Perform the EEROM Backup from the HDD to the Main PCA (select Main PCA replaced). Switch the printer Off and ON again. If the System Error Code continues: – Perform the Service Station Calibration Page 5-11. – Replace the Drop Detector Assembly Page 8-72. – Replace the Service Station Assembly Page 8-69.
System Error Codes System Error: 0C00FF Problem Description: Print Mask could not be generated. The mask generation algorithm could not generate the print mask. Possible causes are memory corruption, print mode definition incompatible with mask restrictions (if using an external RIP). The cause is not likely to be the Printhead because if it was, the Printhead would be marked as XX21 REPLACE. Corrective Action: Try the following: Re-boot the Printer and the error code should not appear again.
System Error Codes System Error: 0D0000 (Continuable) Problem Description: No Media Profiles Available. Corrective Action: Download a media profile for the ink type being used. System Error: 0D0000 033f019C Problem Description: No Media Profiles Available. Corrective Action: If you upgrade the firmware while media is loaded, you will get the system error "0d0000 033f019C". In this case, press Enter and you will get the message "no media profiles available".
System Error Codes System Error: 0D0005 03180382 (Non-Continuable) Problem Description: After cutting the media, the Printer cannot deactivate the Cutter. Corrective Action: Try the following: Check the Cutter and the Carriage Assembly to make sure that they are installed correctly. System Error: 0FXXXX (Non-Continuable) Problem Description: A Firmware Error has occurred. Corrective Action: Refer to System Error Code ffff ffff xxxxxxxx.
System Error Codes System Error: 0F0200 01E603d2 Problem Description: This is an error that is related to the Parallel Port. It happens normally in New Printers and only once (it is unlikely to appear again). Even if the error appears again, there is nothing wrong with the Printer. Corrective Action: Try the following: Recommend to the customer to print via the Network Card because the transmission time via the Parallel Port is very slow.
System Error Codes System Error: e50000 Problem Description: This is an error that is related to the Hard Disk Drive, either the connections are bad or that the Hard Disk Drive or the Main PCA are defective. Corrective Action: Try the following: Unplug the Printer, remove the HDD cover and check that the two cables (a flat one and the power cable) are connected. Also check that the flat cable connector is clipped in correctly. If the problem persists, replace the Hard Disk Drive Page 8-74.
HP Ink Supplies Troubleshooting 3 What are HP Ink Supplies? 3-2 Ink Cartridges 3-2 Printheads and Printhead Cleaners 3-2 Identifying the Components 3-3 General Information About HP Ink Supplies 3-3 Some General Precautions When Handling HP Ink Supplies 3-4 Priming a Brand New Ink System 3-5 When Should You Replace the HP Ink Supplies? 3-5 The Front Panel Display 3-6 Obtaining Ink Cartridge Information 3-7 Obtaining Printhead Information 3-8 Status Codes and Messages 3-10 Status Messages 3-11 Error Status
HP Ink Supplies Troubleshooting What are HP Ink Supplies? For each of the six colors used in the Printer, there are three separate components. The Printhead and the Printhead Cleaner are supplied together, the Ink Cartridge is supplied separately. All of these components are called the HP Ink Supplies. They are coded with an HP selection number to help you re-order the correct replacement supplies.The Printhead and the Printhead Cleaner are supplied together, and the Ink Cartridge is supplied separately.
HP Ink Supplies Troubleshooting Identifying the Components The following illustration will help you identify the components of the HP Ink Supplies.
HP Ink Supplies Troubleshooting Avoid unnecessary removal of the Ink Cartridges and Printheads. When turning off the Printer always use the soft-power Off button on the Front Panel. The Printheads are then stored correctly which prevents them from drying out. The Ink Cartridges should never be removed while the Printer is printing. They should only be removed when the Printer is ready for you to replace them. The Front Panel will guide you through the removal and installation procedure.
HP Ink Supplies Troubleshooting Priming a Brand New Ink System When the customer first receives the Printer, it is supplied with a set of six Setup Printheads pre-installed in the Carriage Assembly. These Setup Printheads are used for the priming of the tubes in the modular ink delivery system. The customer must not remove the setup Printheads from the Carriage Assembly without following the procedures in the Setup Guide.
HP Ink Supplies Troubleshooting The Front Panel Display The front panel display has a dedicated area to report the status of your HP Ink supplies. Status messages consist of a code and an action message Ready Roll Hewlett Packard Photo Imaging Gloss Ink Printheads OK (1421) REPLACE Action Message Printhead Status Ink Cartridge Status Status Code Ink displays information on the Ink Cartridges.
HP Ink Supplies Troubleshooting Obtaining Ink Cartridge Information 1. To get information on the Ink Cartridges press the Top key on the front panel to go to the main menu. Ink info. Light Cyan cart. info... RollLight Magenta cart. info... Ready Hewlett Packard Photo Imaging Gloss Ink Magenta Printheads OK cart info... OK Black cart info... 2. Press the n or p key to select the cartridges icon and view status bars indicating ink levels in the Ink Cartridges.
HP Ink Supplies Troubleshooting 4. The front panel displays information on the selected Ink Cartridge. Yellow cart. info HP No.81 ink cartridge Ink level=87% Capacity=680ml Part Part number=C4934A number=C4934A Mfg.month=12/1999 Mfg. month=5/1999 The information supplied is: The make of the Ink Cartridge (No.81 for Dye and No.83 for UV Ink). Unknown Ink Cartridge may mean the use of refilled Ink Cartridges. The percentage of how much ink is remaining.
HP Ink Supplies Troubleshooting 3. Press n or p key until the front panel highlights “Printhead info”. Press Enter to view the Printheads information. Printhead info Printhead info... Recover printheads Replace printheads 4. Press the n or p key until the front panel highlights the color that you want to see information on. Press the Enter key. Printhead info. Light Cyan cart. info... Light Magenta cart. info... Yellow cart. info... Cyan cart info... Magenta cart info... Black cart info... 5.
HP Ink Supplies Troubleshooting Status Codes and Messages Most problems with Ink Supplies will be solved by the user simply following the instructions in the action message. NOTE E ON PH RT PO P SU If a problem persists, a Call Agent can try and troubleshoot Consumables problems by requesting the HP Status code from the Customer via the phone. Using this process, it can be determined whether the Printer requires any on-site maintenance.
HP Ink Supplies Troubleshooting Status Messages These messages provide only an action message for the user to perform. For information on accessing detailed information on consumables refer to 3-7, Obtaining Ink Cartridge Information and 3-8, Obtaining Printhead Information . Status Description Procedure OK The ink consumable is working correctly None Insert There is no consumable installed Insert the correct consumable.
HP Ink Supplies Troubleshooting Error Status Messages Error status messages consist of the HP Status Code and the action message. The following tables group error messages according to the consumable, the action message (i.e. all Replace errors are grouped together), and then the status number i.e. last two digits. The first digit in the HP ID code (see table below), identifies the consumable and/or provides specific consumables information. Status Code First Digit Part / Information 0 HP No.
HP Ink Supplies Troubleshooting Printhead Errors NOTE If you think your Printer is requesting you to replace your Printheads too frequently you can check Printhead nozzle status by printing the Diagnostic Print Refer to 6, Print Quality. NOTE Do not touch, wipe or attempt to clean the Printhead nozzles. This can damage the Printhead and reduce print quality (See Page 9-6 for Maintenance Procedures). NOTE When replacing Printheads: Ensure that you have the correct Printhead.
HP Ink Supplies Troubleshooting Printhead Information Status Numbers Error Description Procedure XX02 Reseat XX06 Reseat XX08 Reseat Continuity problem between the Printhead and the Carriage Assembly. XX10 Reseat Electrical failure. Try the following (verify if the message returns to OK after each one). 1. Reseat the Printhead. 2. Remove the Printhead and clean the interconnect, refer to 9-6, Carriage Interconnect Wiper . 3. Replace the failing Printhead. 4.
HP Ink Supplies Troubleshooting Printhead Recovery Procedure The Printer regularly performs a series of controls on the health of the Printheads and when they start to degrade the Printer will prompt the user to recover the Printhead [(XX20)Recover]. Ready Printheads LIGHT CYAN LIGHT MAGENTA YELLOW CYAN MAGENTA BLACK (1520) RECOVER OK OK OK OK OK At this stage, the customer should obtain new Printheads. Depending on the print mode being used (Max. Quality, Productivity or Max.
HP Ink Supplies Troubleshooting Ink Cartridge Errors NOTE When replacing Ink Cartridges: Use the Replace item in the Ink Cartridges menu. This will release all air from the Ink Cartridge and avoid problems in its removal. Ensure that you have the correct Ink Cartridge. Ensure that the Ink Cartridge is the correct color for that slot. Ensure that the Ink Cartridge is the correct orientation, with the color coded label at the top.
HP Ink Supplies Troubleshooting Status Numbers Error Description Procedure XX03 Replace 1. Remove the Ink Cartridge immediately. 2. Open the Door at the rear of the Left Cover and check the Air Tubes for Ink and do the following: 3. If there is no ink in the Air Tubes: a) Replace the Ink Cartridge and, if the XX03Replace error reappears for any Ink Cartridge, go to step 5. 4. If there is ink in the Air Tubes: a) Remove all the Ink Cartridges to allow the ink to drain from the Tubes.
HP Ink Supplies Troubleshooting Printhead Cleaner Errors (First Digit = A, B or *) NOTE When replacing Printhead Cleaners: Ensure that you have the correct Printhead Cleaner. Ensure that the Printhead Cleaner is the correct color for that slot. Ensure that the Printhead Cleaner is the correct orientation. NOTE If all 6 Printhead Cleaners present the same error message, check the following: All Printhead Cleaners installed are NOT wrong type i.e. wrong model, unapproved etc.
HP Ink Supplies Troubleshooting Replace Message "xx16 Replace" for ALL Printheads During Replacement During Printhead replacement, the message "xx16 Replace" can appear for ALL the Printheads due to a firmware bug. Clean the Printheads and the Carriage interconnects (refer to page 9-6, Carriage Interconnect Wiper ) and reseat the failing Printheads.
HP Ink Supplies Troubleshooting Error Message Warning!... supply ink level? (Error code 8x09) See user manual Description If you choose to continue printing with this ink supply you will not have an ink level indicator. You may not know when the ink supply is running low or empty. Printing with an empty ink supply may seriously damage your printhead, ink tubes, and printer. See below for a complete listing of features that will not be available with continued use of this ink supply.
HP Ink Supplies Troubleshooting Non-HP Hardware Detected in the Ink Delivery System The following information explains the front panel message flow: (QDEOH µ2XW RI &RQWUROµ ELW LQ WKH 3+ DQG LQN WXEHV VPDUW FKLSV 8SGDWH 6HUYLFH &RQILJ SULQW QRQ KS LQN ILHOG RQ WXEHV 3+ DQG ,& ,QN FDUWULGJH EDUV IRU DOO FRORUV ZLOO FRQWLQXH ZRUNLQJ EXW WKH\ ZLOO EH VHPL WUDQVSDUHQW QRW VROLG 1RQ +3 KDUGZDUH LV GHWHFWHG HP is not r es ponsi bl e f or damage fr om use of non-HP ink.
HP Ink Supplies Troubleshooting Risks with Using Non-HP Hardware The risks in using non-hp hardware refill systems are: Printhead dry fire. Probable empty ink tubes. These issues can be caused by: Cartridge not refilled to 100%. A customer could perform a counter reset when the cartridge was not refilled to 100%. If so, the printer thinks the IC is 100% full when, in fact, it could be 80% full. When the ink is depleted, the printer may continue printing without ink. Uninstalling non-hp hardware.
HP Ink Supplies Troubleshooting ILS Out of Control Warranty Statement Printhead and cleaner warranty: Until the “end of warranty” date printed on the product is reached, or 700 cc of HP ink is delivered through the printhead, whichever occurs first. Ink Cartridge warranty: Until the genuine HP ink is depleted as indicated by the printer, or the “end of warranty” date printed on the product is reached, whichever occurs first.
HP Ink Supplies Troubleshooting 3-24 HP DesignJet 5000 and 5500 Series Printers Service Manual
Service Tests and Utilities 4 Introduction 4-2 Diagnostics - Self Test 4-2 The Printer hangs and nothing else happens 4-3 Error Memory Config:X 4-3 Error Memory Test 4-3 Power Supply Error #1 4-3 BootROM checksum failed 4-3 Boot Failed:1f500XX 4-4 Boot FAILED 4-4 BOOTROM ERROR: 4-4 COMPONENT MISMATCH: 4-4 Service Tests (Diagnostics) 4-5 Entering the Service Tests Menu 4-6 Scan Axis Test 4-9 Media Axis Test 4-11 Service Utilities 4-13 Entering the Service Utilities Menu 4-14 Turn DRIVE ROLLER 4-17 Prime TU
Service Tests and Utilities Introduction This chapter explains how to use the built-in Service Tests and Service Utilities and what to do if any of the Service Tests fail. If possible, always perform a Service Test on the component that you are about to replace, just to make sure that is the component that has failed. If the test on that component passes, there is no need to replace it.
Service Tests and Utilities WARNING Only replace one component at a time and check if the error has gone before replacing another component. If the error is still present after replacing a component, remember to REINSTALL the component that was first removed before replacing another component.
Service Tests and Utilities Self Diagnostics - Initialization Sequence LED’s Max. Quality Front Panel Message Printer Error - Error Message/Code Spinning up disk Productivity Max. Speed Corrective Action Boot Failed:1f500XX Unplug the Printer, remove the HDD cover and check that the two cables (a flat one and the power cable) are This is an error related connected. Also check that the flat to the Hard Disk cable connector is clipped in correctly.
Service Tests and Utilities Service Tests (Diagnostics) The following is a list of all internal Service Tests available in the Printer. Instructions for entering the Service Tests menu are given on Page 4-6. 1. Scan Axis Test Page 4-9 The purpose of this Service Test is to verify the correct functioning of parts relating to Carriage movement along the Printer axis. 2.
Service Tests and Utilities Entering the Service Tests Menu 1. Once the message "Ready" is displayed on the front-panel, scroll to the "Printer Setup Options" icon and press the Enter key.
Service Tests and Utilities ON PH RT PO P U ES For Call Agents requesting the User to access a limited number of Service Tests a Once inside the "Printer Setup Options" menu and the "Device setup" menu is highlighted, press the following key combination: Printer setup options Device setup... I/O setup... Utilities... Internal RIP settings... Queueing & Nesting... HP-GL/2 settings... Top Back n p Enter Press Down and Enter Together 2 The message below is displayed. Select Yes to continue.
Service Tests and Utilities If your Firmware does not support Service Tests, the following message is displayed. You should press Enter to exit. If you need the Service Tests, download the latest Firmware and repeat the whole procedure to enter the Service Tests menu. Top 3. Service Tests Error!! Svs Test not available. Upgrade Firmware rev.
Service Tests and Utilities E ON H P RT PO P SU Scan Axis Test The purpose of this test is to verify: Carriage movement along the Printer axis. Scan-Axis motor. This test measures the maximum and the average current required to move the Scan Axis parts in order to verify if parts are moving freely or not. Perform the Scan Axis Test as follows: 1. In the "3 Service Tests" menu, scroll to "3.1 Scan Axis" and press Enter. Top 3 Service Tests Back n 3.1 Scan Axis 3.
Service Tests and Utilities NOTE Report the values to the nearest HP Response Center or HP Support Office to determine whether values are within the accepted range. When reporting the values, have the following information ready: Model and Serial Number of the Printer. All values reported in the test. The Service Configuration Print Page 1-37.
Service Tests and Utilities E ON H P RT PO P SU Media Axis Test The purpose of this test is to verify: Overdrive Roller movement. Paper-Axis motor. This test measures the current required to move the Media Axis parts in order to verify if parts are moving freely or not. Perform the Media Axis Test as follows: 1. In the "3 Service Tests" menu, scroll to "3.2 Media Axis" and press Enter. Top 3 Service Tests Back n 3.1 Scan Axis 3.2 Media Axis p Enter Make Selection Press Enter 2.
Service Tests and Utilities NOTE Report the values to the nearest HP Response Center or HP Support Office to determine whether values are within the accepted range. When reporting the values, have the following information ready: Model and Serial Number of the Printer. All values reported in the test. The Service Configuration Print Page 1-37.
Service Tests and Utilities Service Utilities The following is a list of all internal Service Utilities available in the Printers. Instructions for entering the Service Utilities menu are given on Page 4-14. 1. Turn DRIVE ROLLER Page 4-17 The purpose of this Service Utility is to facilitate the cleaning of the Drive Roller and the Overdrive. 2.
Service Tests and Utilities Entering the Service Utilities Menu 1. Once the message "Ready" is displayed on the front-panel, scroll to the "Printer Setup Options" icon and press the Enter key.
Service Tests and Utilities ON PH RT PO U U ES For Call Agents requesting the User to access a limited number of Service Utilities a Once inside the "Printer Setup Options" menu and the "Device setup" menu is highlighted, press the following key combination. Top Printer setup options Back Device setup... I/O setup... Utilities... Internal RIP settings... Queueing & Nesting... HP-GL/2 settings... n p Press Down and Enter Enter 2 The message below is displayed. Select Yes to continue.
Service Tests and Utilities NOTE If the Printer is not used for 3 minutes, the Printer exits the Service Utilities Menu and you must repeat the above steps to enter Service Utilities again. NOTE In some cases a quick press of a button may not be recognized by the Printer. When pressing a button, be sure to press it deliberately and all the way to the bottom of its travel. NOTE If the Printer hangs up during an operation, switch the Printer OFF and restart from step 1.
Service Tests and Utilities E ON H P NOTE RT PO P SU Turn DRIVE ROLLER The purpose of this Service Utility is to rotate the Overdrive, Drive Roller and Roller Mark in order to clean them. Remove the media before performing this operation. If media is detected, the message below is displayed. 1.1 Turn DRIVE ROLLER Please remove media completely Press ENTER to continue Perform the Turn DRIVE ROLLER utility as follows: 1.
Service Tests and Utilities E ON H P RT PO P SU Prime TUBES The purpose of this Service Utility is to prime the Tubes when the tubes are NOT new and they need to be reprimed or automatic priming was not completed. NOTE Remember that the priming process is automatically performed when NEW tubes are installed. NOTE If you are using this Service Utility because automatic priming has failed, you will need to remove the Setup Printheads used and insert new Setup Printheads.
Service Tests and Utilities 4. The following message will be displayed on the front panel while the printer verifies the Ink Cartridges:. Ready Ink 5. When the following message is displayed, lift the Window and remove ALL the Printheads from the Carriage. Install the Setup Printheads into the Carriage. INK STARTUP Lift window to install SETUP printheads 6. Once all the Setup Printheads are installed, the following message will appear on the front panel. Close the Carriage Cover and close the Window.
Service Tests and Utilities 8. The Printer will then begin to prime the Tubes System. INK STARTUP Initializing printer Please wait. xx sec 9. Once the Tubes System is purged, the following message will be displayed. Lift the Window and remove ALL the Setup Printheads from the Carriage and install the previously removed printing Printheads into the Carriage. INK STARTUP Lift window to replace SETUP printheads 10. Once all the Printheads are installed, the following message will appear on the front panel.
Service Tests and Utilities 12. If media is not loaded, the following message appears on the front panel and you must load media into the Printer. INK STARTUP Load paper for calibration 13. The Printer will start to print the Printhead Alignment Pattern and the following message will be displayed on the front panel: INK STARTUP Aligning printheads Approximate time remaining x min xx sec 14. Once the Printhead Alignment is completed, the following message will be displayed on the front panel.
Service Tests and Utilities E ON H P NOTE RT PO P SU Altitude Setup This Service Utility allows the operating altitude to be set for the Printer for particular operating conditions when media load problems occur. This utility is required exclusively for Printer operating altitudes over 2000 m. 1. In the Service Utilities submenu, scroll to "1.3 Altitude Setup " and press Enter. Top 1. Service Utilities 1.1 Turn DRIVE ROLLER 1.2 Prime TUBES 1.3 Altitude Setup 1.4 EEROM Setup 1.5 Reset Life Counters 1.
Service Tests and Utilities EEROM Setup NOTE This test is only necessary in a situation where you have NOT been able to perform the EEROM backup test and you have lost all the EEROM parameters. The purpose of this Service Utility is to set the Printer Model, the Serial Number and Japanese Fonts. This is required in the following situations: The Main PCA and Hard Disk Drive are replaced at the same time (EEROM empty).
Service Tests and Utilities If you want to set the Model Number a If you want to set the Model Number select "1.4.1 Set Model Number" and press the Enter key to access the list of possible Model Numbers for the Printer. Select the Model Number using the Up and Down keys and then press Enter. Top 1.4.1 Set Model Number 1.4.1.1 C6095A 1.4.1.2 C6096A 1.4.1.3 Q1251A 1.4.1.4 Q1253A Back n p Enter Make Selection Press Enter b The following message is displayed.
Service Tests and Utilities If you want to set the Serial Number NOTE The Serial Number in the Current field is only displayed if it is encoded in the EEROM. a Select "1.4.2 Set Serial Number" and press the Enter key to view the message below. To define a new serial number use the Up and Down keys to scroll through a list of characters in the following ranges: 1...10, A...F (hexadecimal format), ES or SG (site of manufacture), (Backspace).The current parameter is displayed in the New field.
Service Tests and Utilities If you want to set the Japanese Fonts NOTE If the customer is not using any internal Japanese PS Fonts, then this Service Utility is not necessary. NOTE If the Printer is NOT an HP DesignJet 5000PS or 5500PS, this utility is not available and the message below will be displayed. Press Back to return to the EEROM menu. Top 1.4.
Service Tests and Utilities b If you select Yes the message below will be displayed. Press Enter to complete loading and return to the EEROM Setup utility or press Back to return to the previous message. Top 1.4.
Service Tests and Utilities Reset Life Counters The purpose of this Service Utility is to reset the preventive maintenance counters when parts have been replaced. When you reset a preventive maintenance counter for a part, the Printer will stop displaying the maintenance warning or stop message for the part. NOTE You should only reset the life counter for a certain component when it has been replaced by a new one. Never reset the life counter for a component when it has not been replaced. 1.
Service Tests and Utilities The front panel message displays the following information: Color (Printhead Insertions only); the Printhead color for which the counter is being reset. Limit; the number of cycles when the part requires replacing. Current; the current number of usage cycles for the part. 4. When you reset the Life Counter, the following message is displayed: Top 1.5.
Service Tests and Utilities Backup EEROM This Service Utility is used to restore the contents of the EEROM when a service engineer has replaced the Main PCA or the Hard Disk Drive. If the Main PCA is replaced the EEROM content, backed up on the hard disk, is restored to the Main PCA and if the Hard Disk Drive is replaced the EEROM content is saved to the new Hard Disk Drive. WARNING Before using this utility, make sure that you are using Firmware 5000 Series Only version A.02.xx.
Service Tests and Utilities 3. If you select "Main PCA" a message confirming the selection is displayed. Press Enter to confirm and exit this utility or press Back to cancel. Top 1.6.1 Backup EEROM Back You have REPLACED the Main PCA Press ENTER to confirm or BACK to cancel n p Make Selection Enter 4. If you select "Hard Disk Drive (HDD)" a message confirming selection is displayed. Press Enter to confirm and exit this utility or press Back to cancel. Top 1.6.
Service Tests and Utilities E ON H P RT PO P SU Image Quality Warning This Service Utility is used to turn the Image Quality Warning On or Off.
Service Tests and Utilities Diagnostic Print This Service Utility allows you to print a Diagnostic print that will help you to troubleshoot image quality problems and verify printhead nozzle status. 1. In the Service Utilities submenu, scroll to "1.8 Diagnostic Print" and press Enter. 1. Service Utilities 1.3 Altitude Setup 1.4 EEROM Setup 1.5 Reset Life Counters 1.6 Backup EEROM 1.7 Img. Quality Warning 1.
Service Tests and Utilities Sleep Mode (DesignJet 5500 Series Only) The purpose of this Service Utility is to disable the Sleep Mode so that the Printer is never switched OFF automatically if not used after a certain period. 1. In the Service Utilities submenu, scroll to "1.9 Sleep Mode " and press Enter. 2. Select either yes or no in order to enable/disable the Sleep Mode and press Enter.
Service Calibrations 5 Service Calibrations 5-3 Entering the Service Calibrations Menu 5-4 1. Scan-Axis Calibration 5-7 2. Service Station Calibration 5-11 3.
Service Calibrations Introduction The Printer has several calibration procedures that must be performed under certain conditions. Refer to the table on the next page to determine when calibrations are required. S NE O PH RT PO UP Phone Support In certain circumstances, a Call Agent can try and troubleshoot the Printer by requesting the Customer to perform a Service Calibration via the phone.
Service Calibrations Service Calibrations The following is a list of all internal Service Calibrations available in the Printers. Instructions for entering the Service Calibrations menu are given on Page 5-4. 1. Scan Axis Calibration Page 5-7 The purpose of this Service Calibration is to calibrate the Printhead in relation to the media and the Platen Assembly. This Calibration also allows you to calibrate the Line Sensor and define the Line Sensor ID. 2.
Service Calibrations Entering the Service Calibrations Menu 1. Once the message "Ready" is displayed on the front-panel, scroll to "Printer Setup Options" icon and press the Enter key.
Service Calibrations ON PH RT PO U U ES For Call Agents requesting the User to access a limited number of Service Calibrations a Once inside the "Printer Setup Options" menu and the "Device setup" menu is highlighted, press the following key combination: Top Printer setup options Device setup... I/O setup... Utilities... Internal RIP settings... Queueing & Nesting... HP-GL/2 settings... Back n p Enter Press Down and Enter Together 2 The message below is displayed. Select Yes to continue.
Service Calibrations NOTE If the Printer is not used for 3 minutes, the Printer exits out of the Service Calibrations Menu and you must repeat the above steps to enter Service Calibrations again. NOTE In some cases a quick press of a button may not be recognized by the Printer. When pressing a button, be sure to press it deliberately and all the way to the bottom of its travel. NOTE If the Printer hangs up during an operation, switch the Printer OFF and restart from step 1.
Service Calibrations ON PH RT PO P U ES 1. Scan-Axis Calibration The purpose of this Service Calibration is to calibrate the Printhead in relation to the media and the Platen Assembly. This Calibration also allows you to calibrate the Line Sensor and define the Line Sensor ID. The Scan-Axis Calibration performs the following: Line Sensor to calibrate the intensity of the Line Sensor in the Carriage PCA. Printhead to Media Spacing.
Service Calibrations If the Media loaded is not the right size, the following message is displayed. Press Enter to exit. Load the correct media and repeat the procedure. Top 2.1 Scan Axis Back Media too small. Remove Media. n Press ENTER to continue p Enter Press Enter 2. If the correct media is loaded, the following message is displayed. Press Enter to confirm or Back to return to the Service Calibrations menu. Top 2.
Service Calibrations 4. When you have inserted the Line Sensor Id. the message below is displayed. Press Enter to confirm the number and continue the calibration or Back to modify the number. Top Line Sensor Id: 20 Press ENTER to confirm or BACK to correct Back n p Make Selection Enter 5. If you do not insert correct values the message below is displayed. Press Enter to continue the calibration using default values.
Service Calibrations 7. The Printer then performs the Printhead to media spacing calibration and displays the following message: Printhead to media spacing Calibrating... During this stage the Printer will print the following pattern. 8. On successfully completing the Calibration, the following message is displayed: Top 2.1 Scan Axis Calib Back Calibration Calibratingperformed line sensor. correctly Please wait. Press BACK to return to previous menu Press Back n p Enter 9.
Service Calibrations ON PH RT PO P U ES 2. Service Station Calibration The purpose of this Service Calibration is to calibrate the Service Station in relation to the Carriage Assembly. The Service Station Calibration performs the following calibrations: Line Sensor to Black Pen. Drop Detector. Primer. Perform the Service Station Calibration whenever: Carriage Assembly is disassembled or replaced. Service Station is disassembled or replaced.
Service Calibrations 2. If the correct media is loaded, the following message is displayed. Press Enter to confirm or Back to return to the Service Calibrations menu. Top 2.2 Service Station Back n Press ENTER to confirm or BACK to correct p Make Selection Enter 3. Once the media is detected, the calibration starts and the following message is displayed: Line Sensor to Black Pen Calibrating During this stage the Printer will print the following pattern. 4.
Service Calibrations 5. On completing the Drop Detector calibration, the following message is displayed: Primer Calibrating... 6. On completing the calibration successfully, the following message is displayed. Top 2.2 Service Station Back Calibration Calibratingperformed line sensor. correctly Please wait. Press BACK to return to previous menu Press Back n p Enter 7. Press Back to return to the Service Calibrations menu. If the Calibration fails, the following message is displayed.
Service Calibrations 3. Accuracy Calibration The purpose of this Accuracy Calibration is to set the nominal advance of the media, changing the factory default values stored on the EEROM. This calibration is necessary to control the exact movement of the media in order to avoid print quality problems like banding. NOTE This changes the factory default value for the nominal advance of the media. Perform the Service Accuracy Calibration whenever: Paper-axis Assembly is disassembled or replaced.
Service Calibrations 3. If media is not loaded, the following message appears on the front panel and you must load media into the Printer. Press the Load/ Unload Media button (see the User’s Guide for detailed information on loading media). NOTE Do NOT use any other type of media apart from HP High Gloss Photo Paper. ACCURACY Load media for calibration 4.
Service Calibrations 6. The Printer will unload the media and request you to remove it from the Printer. Press Enter to continue. Top Roll Unloaded. Remove Media. Back n Press Enter to continue p Press Enter Enter 7. The following message is displayed. Press Load/Unload Media to start the load procedure for the printed sheet. Load/Unload Media Top ACCURACY Back n Press Load/Unload key to load printed sheet p Enter Press Load/Unload Media 8.
Service Calibrations If the Calibration fails the following message is displayed. Press Enter to continue. Top ACCURACY Calibration Error (xxxx) Press ENTER to continue Back n p Enter Press Enter NOTE Refer to 5-26, Calibration Error Codes to troubleshoot error codes. NOTE After the Calibration has been performed, print the Service Configuration print to be sure that it has correctly been stored in the EEROM. For information on the Service Config Print Page 1-37.
Service Calibrations Carriage Height Calibration The purpose of this Service Calibration is to adjust the distance between the Carriage Assembly and the Center Platen. This calibration is necessary in order to prevent problems like Printhead crashes. Perform the Carriage Height Calibration whenever: Carriage Assembly is replaced. Center Platen is disassembled or replaced. Continuous Printhead Crashes.
Service Calibrations NOTE During the Carriage Height Calibration procedure the Carriage Assembly has to be moved along the length of the Printer for correct calibration. Make sure that the Carriage Assembly is only ever moved by pulling the Belt and never by direct contact with the Carriage itself (See Figure 2 below). Incorrect: never move using Carriage Assembly. Correct: move using the Belt. Figure 2: 1. Remove the Top Cover - Refer to Page 8-5. 2. Remove the Back Cover - Refer to Page 8-23. 3.
Service Calibrations 5. Insert the Carriage Height Tool into the black Printhead slot. 6. Close the Carriage Cover .
Service Calibrations 7. Loosen the two T10 screws at the back of the Carriage Assembly. NOTE The screws should not be removed. 8. Using the Belt, and beginning on the left hand side of the starting position (where the left hand edge of the paper is positioned when printing), move the Carriage Assembly back and forth along the length of the Printer.
Service Calibrations 9. Lower the Carriage Assembly slightly, by turning the T9 screw shown below anti-clockwise and then check for a scraping sound again as shown previously in step 7. 10. On moving the Carriage Assembly along the length of the Printer you should now hear a scraping sound: this sound indicates that you need to raise the Carriage Assembly (if there is no sound repeat step 8).
Service Calibrations 11. Raise the Carriage Assembly slightly, by turning the T9 screw (shown below) clockwise . 12. Check that there is no longer a scraping sound.
Service Calibrations 13. When the scraping has been eliminated it is important to leave the Carriage Assembly as close as possible to the Center Platen: move the Carriage Assembly back and forth across the area where the scraping sound was, gently lowering and raising the Carriage Assembly until you are sure that it is as close as it possibly can be to the Center Platen without touching. 14.
Service Calibrations 15. When the complete length of the Printer is calibrated (clear of any scraping sound), tighten the two T10 screws at the back of the Carriage Assembly to secure the current position. 16. Remove the Carriage Height Tool.
Service Calibrations Calibration Error Codes Introduction NOTE Calibration Error Codes are continuable, which means you can press Enter on the Front Panel to continue working with the Printer. If you have a Print Quality problem you must troubleshoot the error to restore quality. NOTE The Printer will use the previous successful calibrations if a calibration is cancelled (User Calibrations only), or if it is not successful.
Service Calibrations Calibration Error: 0000 NOTE This code is not an error. See the other codes reported. Calibration Error: 0001 Problem Description: Pen voltage error. Corrective Action: Try the following: Power the Printer OFF and ON again using the Power Switch at the back of the Printer and if a (XXXX)Replace message for a particular Printhead is displayed, replace that Printhead. If the (XXXX)Replace message is for all Printheads, replace the Carriage Assembly Page 8-46.
Service Calibrations Calibration Error: 0020 Problem Description: Line Sensor error. Corrective Action: Check the media used for the Calibration is WHITE. Replace the Lens Cover Assembly Page 9-5. Calibration Error: 0021 Problem Description: Line Sensor error. Corrective Action: Check the colors in the calibration pattern. If a color is absent the Printhead has failed for that color: Replace the Printhead for that color. Calibration Error: 0022 Problem Description: Line Sensor error.
Service Calibrations Calibration Error: 1002 (User) Problem Description: The Line Sensor pattern is not printed. Firmware error. Corrective Action: Try the following: Power the Printer OFF and ON (using the power switch at the back of the printer) to reset the memory. Upgrade the Firmware Page 9-13. Calibration Error: 1003 (User) Problem Description: Firmware Error.
Service Calibrations Calibration Error: 1005 (User) Problem Description: Paper Axis Error. Corrective Action: Try the following: Perform Printhead Recovery ( Page 6-15). Reseat ALL the Printheads and repeat the Printhead Alignment ( See the User’s Guide). Replace the Carriage Assembly Page 8-46. Calibration Error: 1040 (User) Problem Description: Scan-Axis Alignment Error in "slow" speed section in Black and Magenta Pattern.
Service Calibrations Calibration Error: 1042 (User) Problem Description: Scan-Axis Alignment Error in "slow" speed section in Light Cyan and Light Magenta Pattern. Corrective Action: Try the following: Perform Printhead Recovery ( Page 6-15). Perform the Service Scan-Axis Calibration ( Page 5-7). Replace both Printheads and repeat Printhead Alignment. If the media used is a color media try the calibration with white media. If the error persists replace the Lens Cover Page 9-5.
Service Calibrations Calibration Error: 2004 (User) Problem Description: Media Profile Error. Corrective Action: Try the following: Download a Media Profile for the current medium. Power the Printer OFF and ON from the rear of the Printer. Download a Firmware Upgrade Page 9-13. Calibration Error: 2005 (User) Problem Description: Closed Loop Color Pattern Error. Corrective Action: Try the following: Turn the Printer OFF and ON from the rear of the Printer to reset the memory.
Service Calibrations Calibration Error: 2101 (through to 2607) (User) Problem Description: Firmware Error. Corrective Action: Try the following: Repeat the Closed Loop Color calibration ( See the User’s Guide). Download the latest Firmware Page 9-13. NOTE System Errors from 2101 to 2607 indicate the same type of error and the Corrective Action is identical. It is important to report the exact error code as this will help in identifying and resolving any errors that occur.
Service Calibrations Calibration Error: 3130 Problem Description: Firmware Error. Corrective Action: Try the following: Power the Printer OFF and ON again using the Power Switch at the back of the Printer to reset the memory. Upgrade the Firmware Page 9-13. Calibration Error: 3200 Problem Description: Error while scanning calibration pattern.
Service Calibrations Calibration Error: 4003 (Service) Problem Description: Line Detection Error. Corrective Action: Try the following: Check that the Lens Cover is clean. Replace the Lens Cover Assembly Page 9-5. Download the Firmware Page 9-13. Calibration Error: 4004 (Service) Problem Description: Firmware Error. Corrective Action: Use full Printer width media. Try the following: Verify the Black Printhead status and perform Recovery Page 6-15. Replace Black Printhead.
Service Calibrations Calibration Error: 5002 (Service) Problem Description: Black Printhead failure. Corrective Action: Try the following: Perform Recovery for Black Printhead Page 6-15. Replace the Black Printhead. Calibration Error: 5003 (Service) Problem Description: Wrong media type or no media. Corrective Action: Try the following: Make sure you load white medium that is the full width of the Printer. Calibration Error: 5004 (Service) Problem Description: Mechanical error.
Service Calibrations Calibration Error: 5010 (Service) Problem Description: Too many Black Printhead nozzles not working. Corrective Action: Try the following: Recover the Black Printhead ( Page 6-15) and if the problem persists replace the Black Printhead. Calibration Error: 5011 (Service) and 5012 (Service) Problem Description: Printhead Cleaner detection error. Corrective Action: Try the following: Verify Printhead Cleaners are correct type. Replace the Lens Cover Assembly Page 9-5.
Service Calibrations Calibration Error: 6000 (Service) NOTE This code is not an error. See the other codes reported. Calibration Error: 6001 (Service) Problem Description: Drop Detector not working. Corrective Action: Try the following: Turn the Printer OFF and ON and repeat the Service Station Calibration Page 5-11. Replace the Drop Detector Assembly Page 8-72. If the Error Code continues, replace the Main PCA Page 8-81.
Service Calibrations Calibration Error: 6006 (Service) Problem Description: Drop Detector failed to reach position for calibration. Corrective Action: Refer to Error Code 6005. Calibration Error: 6007 (Service) Problem Description: Drop Detector failed to uncap pens. Corrective Action: Refer to Error Code 6005. Calibration Error: 6008 (Service) Problem Description: Calibration failed for Cyan Printhead. Corrective Action: Try the following: Recover the Cyan Printhead Page 6-15.
Service Calibrations Calibration Error: 6012 (Service) Problem Description: Calibration failed for Light Cyan Printhead. Corrective Action: Recover the Light Cyan Printhead Page 6-15. Replace the Light Cyan Printhead. Calibration Error: 6013 (Service) Problem Description: Calibration failed for Light Magenta Printhead. Corrective Action: Recover the Light Magenta Printhead Page 6-15. Replace the Light Magenta Printhead.
Service Calibrations Calibration Error: 6018 (Service) Problem Description: Calibration position out of range for Light Cyan Printhead. Corrective Action: Replace the Drop Detector Assembly Page 8-72. Calibration Error: 6019 (Service) Problem Description: Calibration position out of range for Light Magenta Printhead. Corrective Action: Replace the Drop Detector Assembly Page 8-72. Calibration Error: 7000 (Service) NOTE This code is not an error. See the other codes reported.
Service Calibrations User Calibrations The following is a list of internal User Calibrations available in the Printers. 1. Printhead Alignment Page 5-43 2. Close-Loop-Color Calibration Page 5-43 3. Banding Calibration Page 5-44 4.
Service Calibrations Printhead Alignment The printer will normally perform an alignment automatically whenever any printhead is replaced. However, you can turn Off this automatic alignment by choosing the printer icon, then Internal RIP Setting > Align Calibration > Off. You can also request a Printhead Alignment from the front panel at any time by choosing the printer icon, then Utilities > Calibrations > Printhead Alignment.
Service Calibrations Banding Calibration The banding calibration is intended to eliminate the problem of banding, by optimizing the media advance settings to suit the printing material, and the environmental conditions such as humidity and temperature. It is available only for paper types with short drying times; all HP coated papers, plus HP Bright White InkJet paper, HP Productivity Photo Gloss, and HP Productivity Photo Semi-Gloss.
Service Calibrations Accuracy Calibration The printer is calibrated at the factory to ensure that it operates with the greatest accuracy in normal environmental conditions. If the printer is operated under significantly different conditions, it should be recalibrated as explained here. The printer should also be recalibrated if non-HP printing material is being used or if Image Quality problems are being experienced for some other reason.
Service Calibrations 5-46 HP DesignJet 5000 and 5500 Series Printers Service Manual
Print Quality 6 Print Quality 6-2 Print Quality Troubleshooting Checklist 6-2 How to Use the Diagnostic Print 6-4 What is the Diagnostic Print? 6-4 Considerations for Printing the Diagnostic Print.
Print Quality Print Quality Print Quality Troubleshooting Checklist When faced with a Print Quality problem, use the following checklist as a guide in troubleshooting the problem: 1 Problem reproduction Reproduce the problem that the customer is seeing using their original settings. You can use the Demo Print in order to do it. 2 Printer configuration: Print Mode: Set to "Max. Quality" (in the Printer and in the driver). Dry time: Set to “Automatic”.
Print Quality 6 Driver print quality configuration: To clarify if the reason of the problem is related with the print mode defined with the Non-HP Driver try the following: Print the same sample using the Non-HP driver and their normal media. Print one of the internal demos or Diagnostic Print using HP Media and configuring the Printer as indicated previously.
Print Quality How to Use the Diagnostic Print What is the Diagnostic Print? The Printer contains internal Diagnostic Prints to help you diagnose the possible source of some print quality defects. The Diagnostic Print is divided into five numbered parts: 1 Primary colors specifically designed to diagnose banding problems. 2 Color to color alignment. 3 Bidirectional alignment to check alignment when printing bidirectionally. 4 Vertical line straightness.
Print Quality Printing the Diagnostic Print 1 Once the message “Ready” is displayed on the Front Panel, scroll to the “Printer Setup Options” icon and press the Enter key. Top Ready Back Roll Hewlett Packard Photo Imaging Gloss Ink Printheads n OK OK p Enter Press Enter 2 Once inside the “Printer Setup Options” menu, use the Arrow keys to scroll to the “Utilities” menu and press the Enter key. Printer setup options Device setup... I/O setup... Utilities... Internal RIP settings... Queueing & Nesting.
Print Quality ON PH RT PO P U ES For Call Agents requesting the User to print the Service Diagnostic print a Once inside the “Printer Setup Options” menu and the “Device setup” menu is highlighted, press the following key combination. Top Printer setup options Device setup... I/O setup... Utilities... Internal RIP settings... Queueing & Nesting... HP-GL/2 settings... Back n p Press Down and Enter Enter 2 The message below is displayed. Select Yes to continue.
Print Quality NOTE For Firmware Version A.02.xx in the 5000 Series and on the 5500 Series, the Printer DOES NOT print the complete Diagnostic Print. Instead you must select which part of the Diagnostic Print that you need. 5 Use the Arrow keys to select the page that you need and press Enter to print it. 1.8 Diagnostic Print Top Back Page 1 Page 2 Page 3 Page 4 Page 5 n p Enter Make Selection Press Enter Page 1 - Checks for banding in the Primary Colors Page 6-8.
Print Quality Overall Print Quality Test - Page 1 This test pattern checks for banding in the print mode and media that is being used. 1 What is Banding? Banding is when you see repetitive horizontal bands within the printed image (these may appear as light or dark bands). This array of colored stripes is designed to check for certain defects with the Printer. It should not be used to check for color consistency or accuracy.
Print Quality In the following example, there is a problem in the Magenta Printhead. There will be clear repetitive bands (perhaps white) in the magenta column. 1 NOTE The Printer has automatic procedures to hide many Printhead defects. This type of problem affects print quality mostly in Productivity and Max. Speed modes. If you use Max. Quality print mode, banding caused by a malfunctioning Printhead may be “hidden” and image quality may not be affected. 1 Perform Printhead Recovery Page 6-15.
Print Quality Banding in all of the colors NOTE In high quality modes media advance problems may not appear as lines of banding, they may appear grainy instead. The banding or graininess will appear in all the colors. 1 If the image is grainy, this could also be a symptom of problems with the bidirectional alignment (See Solving Bidirectional Alignment Problems 6-12). If the Bidirectional Alignment pattern has no problems go to step two.
Print Quality Color Alignment Print Test - Page 2 This part of the Diagnostic Print Test is designed to check the color alignment. It produces five crosses: one for each color compared to magenta. All lines are printed in one direction. If there is misalignment between Magenta and another color, the lines in the cross will not be aligned. There are two types of misalignment: Horizontal - when the misalignment is in the horizontal axis. Vertical - when the misalignment is in the vertical axis.
Print Quality Bidirectional Alignment - Page 3 If a Printer has Bidirectional alignment problems, lines are not straight. The pattern shown below is designed to highlight this kind of problem. A pair of vertical lines is printed with each Printhead color except yellow. Each section of the vertical line is printed by a different group of Printhead nozzles (one quarter), in one pass. Check the lines on this test pattern, if they have any defects like the ones described above, perform the corrective action.
Print Quality Vertical Line Straightness - Page 4 If a Printer has Vertical Line Straightness problems, lines are not straight. The pattern seen below is designed to highlight this kind of problem. A pair of vertical lines is printed in each direction, comparing line straightness for each Printhead color compared to Magenta. Check the lines on this test pattern, if they have any defects like the ones described above perform the corrective action.
Print Quality Nozzle Print Test - Page 5 NOTE If your Printer has nozzle defects, it does not mean that you will not get perfect print quality results. The Printer has automatic procedures to hide many nozzle defects. This type of problem affects print quality mostly in Productivity and Max. Speed modes. The nozzle print test is number 5 in the Diagnostic Print. In this test the 512 nozzles that each Printhead uses to print with are tested.
Print Quality How to fix the Nozzle Defects NOTE The Printer will automatically request you to recover Printheads with a number of defective nozzles that may affect print quality, or replace them if the Printhead defect cannot be recovered. NOTE If your Printer has nozzle defects, it does not mean that you will not get perfect print quality results. 1 Go to the Printheads submenu and press Enter.
Print Quality No Printing Defects Found in the Diagnostic Print If all the test patterns from the Diagnostic Print are correct and you still experience print quality problems, here are some of the more likely causes to check: The print mode used in the Printer is not right for the image that is being printed (this is defined by the Printer’s Front Panel menu selections). Non-HP driver. The RIP. The software applications you are using. Use the following table to configure your system correctly.
Print Quality If the problem persists check the lens and if it is dirty replace the Lens Cover Assembly ( Page 9-5 and repeat the calibrations. Perform the Printhead Alignment Page 5-43. Perform the Banding Calibration Page 5-44. Solving Color Accuracy problems These are two areas you should review when troubleshooting a color accuracy problem: Configuration (PostScript option only) Check that you are using the correct driver setting for the software.
Print Quality Color Accuracy Configuration The configurations of the Printer, the driver, and the software RIPs define how ink is applied to each type of media. Use the information in the following table to configure the Printer and software for best color accuracy. Location of Setting Setting Description Selection Printer FrontPanel Menu Media Set to match the media type loaded in the Printer.
Print Quality length by several centimeters. Depending on the type of problem, the troubleshooting sequence is different. 1 Improper use of crop marks. If the customer is using crop marks, this can be the cause of the length difference because the way the margins and the crop marks are implemented in the DJ5000 is very different from the way it is done in other Designjet products, e.g. DJ2000, 2500, 3000 & 3500. 2 Use of Coated Media when trying to get precise output.
Print Quality 3 If Heavy Coated media is being used, use the Front Panel to select Heavy Coated Economy with Normal paper margins. Other alternatives are either to add a 2.5 cm margin at the beginning of the print or switch to any other type of media. Vertical Banding Some prints with uniform area fills (ink density between 30 and 70%) show vertical banding when printed on High-Gloss Photo Paper.
Print Quality Warped Lines on Media The media itself may be warped. This can happen if it has been used or stored in an extreme environment. 1 Make sure the Environmental Conditions your Printer is operating in are within specifications (Refer to the User’s Guide) 2 Store all Media according to Environmental Specifications (Refer to the User’s Guide).
Print Quality Using the Color Print Objective and Description The objective of the Color Print is to determine whether the printer hardware has any color reproduction problems. Before starting, load a roll of HP High-Gloss Photo Paper or HP Heavyweight Coated Paper. To start the Color Print, choose the printer icon on the printer’s front panel, then Utilities > Test prints > Color print. The printer will then print a page consisting of three color scales as follows. 1 Yellow shading into blue.
Print Quality Bear in mind that the transition could happen anywhere along the line. Trust your perception! How to Interpret the Result If you get a number in the range 4.5 to 9.5, your printer is within the expected color reproduction accuracy. If you get a number lower than 4.5 or higher than 9.5, try the following: 1 Make sure that the Color Calibration is ON. 2 Perform Color Calibration on that paper. 3 Replace the lens on the Line Sensor and repeat the color calibration.
Print Quality Enrichment Issue Issues Description There can be some light color area fills that have two different (but related) image quality issues at the border: 1 The initial part of the area fill has a grading from white to the regular color of the area fill (~ 2-4mm high x 0-10mm long) 2 After this first grading, it may show a border darker than the rest of the area fill, creating another type of grading, which is shorter, but can appear along the entire border.
Print Quality See the following image: Cause: Before going to the root cause, we have to understand two main concepts of the inkjet technology: 1 The dye ink is made by a liquid and pigments (which, in fact, delivers the color to the ink). 2 This ink is contained on the printhead nozzles. 3 An internal heating process eject the drops of ink that are delivered though these nozzles.
Print Quality evaporates partially, which leaves the ink on the nozzle with more pigments. Therefore, the initial drops ejected from those nozzles will be darker (they have more pigment) than the following ones. This leads to the second issue (darker border). If we take the previous example, we will observe that the parts of the border which are darker corresponds to the parts which have not printed for some time.
Print Quality Workarounds This image quality problem is a product limitation. So, it has NO solution. Anyway, due to the limited cases where the problem could appear, large amounts of complaints are not expected. If any customer complains about this problem, provide the following workarounds: Rotate the image. Remember that this problem only appears on the scan-axis direction when there are light colors are fills in the borders.
Print Quality You will see that replacing any printer’s hardware part can not solve these problems. Let’s go problem by problem… Problem description: As we have already explained before, ink marks on printouts is caused by two different issues each with a different resolution: Cause 1: Aerosol and Cause 2: Static. Let’s describe both problems: Cause 1: Aerosol Aerosol: Background Through its normal operation the DesignJet 5000 printer fires drops of liquid ink from a printhead on to a media surface.
Print Quality Given that the DesignJet 5X00 series printer is a production speed printer and customer usage was expected to be at high volume; aerosol affects were an expected occurrence that customers would see. Because of this occurrence HP included cleaning and maintenance instructions with the printer. HP provided a clear message that the DesignJet 5X00 series printer is a production printer that would have to be cleaned from time to time. Aerosol ink accumulation will grow with time and usage.
Print Quality 2 Presence of marks on the front side of the media. The following figure shows the typical marks on the front side of the printout due to aerosol: 0DUNV FDXVHG E\ D GLUW\ &XWWHU :KHHO 0DUNV FDXVHG E\ WKH 3LQFK ZKHHOV /HDGLQJ (GJH PDUNV GXH WR LQN DFFXPXODWLRQ RQ WKH SODWHQ )5217 6,'( RI WKH 3ULQWRXW 3ULQWLQJ 'LUHFWLRQ So, as you have seen, we can have marks caused by the ink accumulation on: The center platen (and overdrive). The pinch-wheels. The cutter wheel.
Print Quality The HP DesignJet 5X00 series is already optimized to minimize the static build up within the printer, i.e. the spindle is connected to ground, the print zone is made out of carbon filled plastic to make it conductive, there is an antistatic brush in front of the printer, etc. Another of the measures we took to reduce the static charges was to place an anti-static back coating to the HP plastic media type. Without this backcoating, the media charges itself.
Print Quality 2 Presence of ink smears or even drops on the printout. See the following image to see an example. These marks are caused due by the fact that the static charge of the media forces the aerosol to accumulate at the edges of the printheads and at the bottom of the carriage. When there is too much ink accumulated, it may: Fall onto the media Smear the media Causing the problem. See the following images: Ink accumulation at the bottom edges of the Printheads.
Print Quality Ink accumulation at the bottom of the Carriage Assembly. 3 Ink stains on the media after changing/reseating the printheads NOTE This is a secondary effect of the ink accumulation. See the following image to for an example.
Print Quality Static: Solutions and Workarounds The following options resolve the issue: Use HP DesignJet 5X00 Series approved media Use 3rd party media types with ANTI-STATIC BACK COATING If these options are not possible, and they still want to continue printing with the current non-supported media, you can use the following workarounds: Clean the sides of the printheads, the bottom of the carriage and the electrical contacts regularly.
Parts and Diagrams 7 Printer Support 7-2 Bin and Take-Up Reel 7-4 Right Hand Cover 7-6 Left Hand Cover and Rear Door 7-8 Top and Back Covers 7-10 Service Station 7-12 Vacuum Fan 7-14 Booster Fan and Media Sensor 7-16 Paper-Axis Motor 7-18 Scan-Axis Motor 7-20 ISS and APS Assembly 7-22 Ink Tubes System 7-24 Boot ROM DIMM, DRAM Memory and Covers 7-26 Rear Electronics Access Covers 7-28 Hard Disk Drive and Cover 7-30 ISS PCA and Main PCA 7-32 Power Supply Unit 7-34 Carriage Assembly 7-36 Tensioner Assembly a
Parts and Diagrams Printer Support Printer Support Reference HP Part Number Quantity on Drawing DJ 5000 DJ 5500 Series Series 1 2 3 4 - 7-2 C6090-60049 C6090-60047 C6095-60167 C6090-60055 C6095-60166 C6090-60056 C6090-60046 2 2 1 1 1 1 1 Description/Comments Foot Assembly Legs Assembly Top X-Brace Assembly (60" Model) Top X-Brace Assembly (42" Model) Bottom X-Brace Assembly (60" Model) Bottom X-Brace Assembly (42" Model) Hardware Kit (Includes Screws and Screw Drivers) HP DesignJet 5000 and 5500 Seri
2 3 1 4 1 2 Parts and Diagrams Figure 3: Printer Support HP DesignJet 5000 and 5500 Series Printers Service Manual 7-3
Parts and Diagrams Bin and Take-Up Reel Bin and Take-Up Reel Reference on Drawing 1 2 3 4 5 6 7 8 9 7-4 HP Part Number DJ 5000 Series Quantity Description/Comments 1 1 1 1 1 1 1 1 1 1 1 2 42" Bin (includes the Bin Support) Take-Up Reel Spindle (60" Model) Take-Up Reel Spindle (42" Model) Left Take-Up Reel Holder Right Take-Up Reel Holder Take-Up Reel Tubes (60" Model) Take-Up Reel Tubes (42" Model) Take-up Reel Deflector (60" Model) Take-up Reel Deflector (42" Model) Take-Up Reel Sensor Left Hand Tak
Parts and Diagrams Bin Support 1 6 4 3 7 2 8 9 5 Figure 4: Bin and Take-Up Reel HP DesignJet 5000 and 5500 Series Printers Service Manual 7-5
Parts and Diagrams Right Hand Cover Right Hand Cover Reference on Drawing DJ 5000 Series Quantity Description/Comments Right Hand Cover (Includes Front Panel Cable) Screw Screw Right Hand Trim (Includes Window and Lever Sensors) Screw Screw Front Panel Assembly (Includes Front Panel Cable) Overlay (English) Overlay (Korean) Overlay (Taiwanese) Overlay (German) Overlay (French) Overlay (Spanish) Overlay (Italian) Overlay (Japanese) Overlay (Portuguese) Overlay (Chinese) Quick Reference Guide Holder DJ
Parts and Diagrams 5 4 7 8 1 2 6 2 9 3 Figure 5: Right Hand Cover HP DesignJet 5000 and 5500 Series Printers Service Manual 7-7
Parts and Diagrams Left Hand Cover and Rear Door Left Hand Cover and Rear Door Reference on Drawing 1 2 3 4 5 6 7 8 9 10 11 HP Part Number DJ 5000 Series Quantity Description/Comments 1 4 1 1 1 1 1 1 1 1 1 1 Left Hand Cover (includes door) Screw Screw Left Hand Trim Screw Screw Rear Door Nameplate PS Nameplate RTL Left Hand Back Door Adobe PS3 Logo Pantone Certified Logo DJ 5500 Series C6090-60039 0624-0771 0515-4268 C6090-60042 0624-0771 0515-2248 C6090-60040 C6091-00139 Q1252-00003 C6095-00116 Q12
6 11 10 1 8 12 2 4 5 2 7 9 2 3 Parts and Diagrams Figure 6: Left Hand Cover and Rear Door HP DesignJet 5000 and 5500 Series Printers Service Manual 7-9
Parts and Diagrams Top and Back Covers Top and Back Covers Reference on Drawing 1 2 3 4 7-10 HP Part Number DJ 5000 Series Quantity Description/Comments DJ 5500 Series C6095-60278 1 C6090-60291 1 Q1253-60012 1 Q1251-60032 1 C6095-60141 1 C6090-60037 1 0515-0382 8 (60")/6 (42") C6071-20026 3 Top Cover (60" Model) Top Cover (42" Model) Black Top Cover (60" Model) Black Top Cover (42" Model) Back Cover (60" Model) Back Cover (42" Model) Screw Screw HP DesignJet 5000 and 5500 Series Printers Service M
3 1 4 2 Parts and Diagrams Figure 7: Top and Back Covers HP DesignJet 5000 and 5500 Series Printers Service Manual 7-11
Parts and Diagrams Service Station Service Station Reference on Drawing 7-12 HP Part Number DJ 5000 Series Quantity Description/Comments DJ 5500 Series 1 C6090-60083 1 Service Station Assembly (Includes Drop Detector and Primer Assembly) 2 3 4 0624-0771 0515-1743 C6072-60179 2 1 1 5 0624-0771 1 Screw Screw Drop Detector Assembly (Includes Spittoon Foam and screw) Drop Detector Screw HP DesignJet 5000 and 5500 Series Printers Service Manual
2 5 4 2 1 3 Parts and Diagrams Figure 8: Service Station HP DesignJet 5000 and 5500 Series Printers Service Manual 7-13
Parts and Diagrams Vacuum Fan Vacuum Fan Reference on Drawing 1 2 7-14 HP Part Number DJ 5000 Series Quantity Description/Comments DJ 5500 Series C6090-60095 0515-2248 1 4 Vacuum Fan Screw HP DesignJet 5000 and 5500 Series Printers Service Manual
2 1 Parts and Diagrams Figure 9: Vacuum Fan HP DesignJet 5000 and 5500 Series Printers Service Manual 7-15
Parts and Diagrams Booster Fan and Media Sensor Booster Fan and Media Sensor Reference on Drawing 1 2 3 7-16 HP Part Number DJ 5000 Series Quantity Description/Comments DJ 5500 Series C6090-60093 0515-2248 C6090-60103 1 2 1 Booster Fan Screw Media Sensor HP DesignJet 5000 and 5500 Series Printers Service Manual
3 1 2 Parts and Diagrams Figure 10: Booster Fan and Media Sensor HP DesignJet 5000 and 5500 Series Printers Service Manual 7-17
Parts and Diagrams Paper-Axis Motor Paper-Axis Motor Reference on Drawing 7-18 HP Part Number DJ 5000 Series Quantity Description/Comments Paper-Axis Motor Assembly (includes Helical Gear and Grease) Screw Screw (Helical gear) DJ 5500 Series 1 C6072-60160 1 2 3 0515-2248 0515-1743 3 2 HP DesignJet 5000 and 5500 Series Printers Service Manual
1 2 3 Parts and Diagrams Figure 11: Paper-Axis Motor HP DesignJet 5000 and 5500 Series Printers Service Manual 7-19
Parts and Diagrams Scan-Axis Motor Scan-Axis Motor Reference on Drawing 1 2 7-20 HP Part Number DJ 5000 Series Quantity Description/Comments DJ 5500 Series C6090-60092 0515-0382 1 2 Scan-Axis Motor Assembly Screw HP DesignJet 5000 and 5500 Series Printers Service Manual
1 2 Parts and Diagrams Figure 12: Scan-Axis Motor HP DesignJet 5000 and 5500 Series Printers Service Manual 7-21
Parts and Diagrams ISS and APS Assembly ISS and APS Assembly Reference on Drawing 7-22 HP Part Number DJ 5000 Series Quantity Description/Comments Ink Supply Station (ISS) (Includes Grounding Strip) Air Pressurization System (APS) DJ 5500 Series 1 C6090-60085 1 2 C6090-60084 1 HP DesignJet 5000 and 5500 Series Printers Service Manual
1 2 Parts and Diagrams Figure 13: ISS and APS Assembly HP DesignJet 5000 and 5500 Series Printers Service Manual 7-23
Parts and Diagrams Ink Tubes System Ink Tubes System Reference on Drawing Quantity Description/Comments C6095-60186 1 C6090-60058 1 C6090-60231 1 C6090-60232 1 - C6090-60106 6 2 C6090-60235 1 Dye Ink Tubes System (60" Model) (Includes Setup Printheads and Carrier Clip) Dye Ink Tubes System (42" Model) (Includes Setup Printheads and Carrier Clip) UV Ink Tubes System (60" Model) (Includes Setup Printheads and Carrier Clip) UV Ink Tubes System (42" Model) (Includes Setup Printheads and Carrie
2 1 Parts and Diagrams Figure 14: Ink Tubes System HP DesignJet 5000 and 5500 Series Printers Service Manual 7-25
Parts and Diagrams Boot ROM DIMM, DRAM Memory and Covers Boot ROM DIMM, DRAM Memory and Covers Reference on Drawing 1 2 3 4 5 6 HP Part Number DJ 5000 Series Description/Comments 1 1 1 4 1 1 1 1 EIO Card (615N) EIO Card Cover DIMM Cover Screw SDRAM DIMM 64MB SDRAM DIMM 128MB PS Boot ROM DIMM A.01.01 RTL Boot ROM DIMM A.01.01 PS Boot ROM DIMM 05.00.01 RTL Boot ROM DIMM 05.00.
4 3 6 5 2 1 Parts and Diagrams Figure 15: BootROM, Memory and Covers HP DesignJet 5000 and 5500 Series Printers Service Manual 7-27
Parts and Diagrams Rear Electronics Access Covers Rear Electronics Access Covers Reference on Drawing 7-28 HP Part Number DJ 5000 Series Quantity Description/Comments Right Rear Cover Screw Left Rear Cover Screw Extension Cover (60" Model only) Screw Electronics Module Cover (Includes EIO Cover and Hard Disk Cover) Electronics Module Cover Screw Electronics Cable Retainer DJ 5500 Series 1 2 3 4 5 6 7 Q1251-60085 0515-0382 Q1251-60086 0515-0382 C6095-60140 0515-0382 C6090-60032 1 1 1 1 1 4 1 8 -
2 1 8 7 4 3 6 5 Parts and Diagrams Figure 16: Rear Electronics Access Covers HP DesignJet 5000 and 5500 Series Printers Service Manual 7-29
Parts and Diagrams Hard Disk Drive and Cover Hard Disk Drive and Cover Reference on Drawing 1 HP Part Number Quantity DJ 5000 Series DJ 5500 Series C6091-60255 - 1 C6090-60303 - 1 - Q1252-60004 1 - Q1251-60067 1 2 3 C6095-00031 0515-0382 1 6 Description/Comments Hard Disk Drive PS A.02.12 (includes data cable and power cable) Hard Disk Drive RTL A.02.12 (includes data cable and power cable) Hard Disk Drive PS S.03.11 (includes data cable and power cable) Hard Disk Drive RTL S.03.
1 2 3 Parts and Diagrams Figure 17: Hard Disk Drive and Cover HP DesignJet 5000 and 5500 Series Printers Service Manual 7-31
Parts and Diagrams ISS PCA and Main PCA ISS PCA and Main PCA Reference on Drawing 7-32 HP Part Number DJ 5000 Series Quantity Description/Comments DJ 5500 Series 1 2 3 C6090-60012 Q1251-60030 0515-2200 C6090-60041 1 11 1 4 5 0515-2200 C6090-60318 5 1 Main PCA Screw ISS PCA (Includes ISS PCA cable) Screw PCI-to-IDE PCA HP DesignJet 5000 and 5500 Series Printers Service Manual
2 1 5 2 4 3 Parts and Diagrams Figure 18: ISS PCA and Main PCA HP DesignJet 5000 and 5500 Series Printers Service Manual 7-33
Parts and Diagrams Power Supply Unit Power Supply Unit Reference on Drawing 7-34 HP Part Number DJ 5000 Series Quantity Description/Comments DJ 5500 Series 1 2 3 4 5 C6090-60028 C6090-60315 0515-2200 C6090-60029 0515-2278 C6090-60033 C6090-60316 1 7 2 4 1 6 0515-0382 4 Power Supply Unit Screw Cooling Fans Screw Electronics Module Base (includes Power Supply Unit and cooling fans) Screw HP DesignJet 5000 and 5500 Series Printers Service Manual
6 5 4 3 1 2 Parts and Diagrams Figure 19: Power Supply Unit HP DesignJet 5000 and 5500 Series Printers Service Manual 7-35
Parts and Diagrams Carriage Assembly Carriage Assembly Reference on Drawing DJ 5000 Series Quantity Description/Comments Carriage Assembly (Includes Carriage Height Tool, Cutter Assembly and Line Sensor) Cutter Assembly (Includes Screw and Washer) Screw Washer for cutter screw Trailing Cable (60" Model) (Includes Trailing Cable Clip and screws, Cover Cap, Trailing Ferrite) Trailing Cable (42" Model) (Includes Trailing Cable Clip and screws, Cover Cap, Trailing Ferrite) Line Sensor Carriage Height Tool
3 1 2 4 5 Parts and Diagrams Figure 20: Carriage Assembly HP DesignJet 5000 and 5500 Series Printers Service Manual 7-37
Parts and Diagrams Tensioner Assembly and Encoder Strip Tensioner Assembly and Encoder Strip Reference on Drawing DJ 5000 Series Quantity C6090-60088 1 2 3 0515-2248 C6095-60183 C6090-60072 C6095-60265 C6090-60267 0535-0031 3050-0026 1 1 1 1 1 2 2 5 - Description/Comments DJ 5500 Series 1 4 7-38 HP Part Number Tensioner Assembly (Includes Pulley Assembly, Pulley Spring, Wedge and Actuator Arm) Screw Belt (60" Model) Belt (42" Model) Encoder Strip (60" Model) Encoder Strip (42" Model) Nut Was
3 4 5 2 1 Parts and Diagrams Figure 21: Tensioner Assembly and Encoder Strip HP DesignJet 5000 and 5500 Series Printers Service Manual 7-39
Parts and Diagrams Platen Assemblies - DesignJet 5000 Series Platen Assemblies - DesignJet 5000 Series Reference on Drawing HP Part Number Quantity Description/Comments 1 C6095-60174 1 C6090-60079 1 C6095-60284 1 C6090-60311 1 C6090-60096 C6071-20005 1 1 Front Platen Assembly (including screws) (60" Model) Front Platen Assembly (including screws) (42" Model) Center Platen Assembly (including screws and Carriage Height Tool) (60" Model) Center Platen Assembly (including screws and Carriage He
4 3 2 5000 Series Only 1 Parts and Diagrams Figure 22: Platen Assemblies - DesignJet 5000 Series HP DesignJet 5000 and 5500 Series Printers Service Manual 7-41
Parts and Diagrams Platen Assemblies - DesignJet 5500 Series Platen Assemblies - DesignJet 5500 Series Reference on Drawing HP Part Number Quantity Description/Comments 1 Q1253-60011 1 Q1251-60031 1 C6095-60284 1 C6090-60311 1 C6090-60096 C6071-20005 1 1 Heater Assembly (including screws) (60" Model) Heater Assembly (including screws) (42" Model) Center Platen Assembly (including screws and Carriage Height Tool) (60" Model) Center Platen Assembly (including screws and Carriage Height Tool) (
1 4 3 2 5500 Series Only Parts and Diagrams Figure 23: Platen Assemblies - DesignJet 5500 Series HP DesignJet 5000 and 5500 Series Printers Service Manual 7-43
Parts and Diagrams Pinch-Wheels Assembly and Lever Pinch-Wheels Assembly and Lever Reference on Drawing 1 2 3 4 5 6 7 7-44 HP Part Number Quantity Description/Comments C6095-60181 C6090-60073 C6095-60179 1 1 1 C6090-60076 1 C6090-60102 0515-2981 0515-2981 C6090-60097 0515-2981 1 1 1 1 3 Pinch Assembly (60" Model) Pinch Assembly (42" Model) Cam Lever Shaft (60" Model) (Includes Cam Linkage, Linkage Screw, Cam Lever Arm and Cam Lever Arm Screw) Cam Lever Shaft (42" Model) (Includes Cam Linkage, L
1 4 5 2 7 6 3 Parts and Diagrams Figure 24: Pinch-Wheels Assembly and Lever HP DesignJet 5000 and 5500 Series Printers Service Manual 7-45
Parts and Diagrams Center Guide, Deflectors and Entry Roller - DesignJet 5000 Series Center Guide, Deflectors and Entry Roller - DesignJet 5000 Series Reference on Drawing HP Part Number Quantity 1 C6095-60180 C6090-60075 0515-2986 C3180-20001 C6090-60104 0515-2250 C6095-60178 C6090-60077 0515-2986 1 1 4 2 1 1 1 1 2 2 3 4 5 6 7 7-46 Description/Comments Center Guide (60" Model) Center Guide (42" Model) Screw Screw Media Deflectors Screw Entry Roller (60" Model) Entry Roller (42" Model) Screw HP D
6 2 1 7 5000 Series Only 3 2 5 4 Parts and Diagrams Figure 25: Center Guide, Deflectors and Entry Roller - DesignJet 5000 Series HP DesignJet 5000 and 5500 Series Printers Service Manual 7-47
Parts and Diagrams Center Guide and Entry Roller - DesignJet 5500 Series Center Guide and Entry Roller - DesignJet 5500 Series Reference on Drawing HP Part Number Quantity 1 C6095-60180 C6090-60075 0515-2986 C3180-20001 C6095-60178 C6090-60077 0515-2986 1 1 4 2 1 1 2 2 3 4 5 7-48 Description/Comments Center Guide (60" Model) Center Guide (42" Model) Screw Screw Entry Roller (60" Model) Entry Roller (42" Model) Screw HP DesignJet 5000 and 5500 Series Printers Service Manual
4 2 1 5000 Series Only 5 3 2 Parts and Diagrams Figure 26: Center Guide and Entry Roller - DesignJet 5500 Series HP DesignJet 5000 and 5500 Series Printers Service Manual 7-49
Parts and Diagrams Tubes Guide Assemblies Tubes Guide Assemblies Reference on Drawing Quantity Description/Comments C6095-60176 1 C6095-60078 1 C6095-60269 1 C6090-60271 1 3 4 0624-0771 C6090-60272 8 1 5 6 7 C6072-60193 0624-0771 C6072-60192 1 8 1 Back Tube Guide Assembly (60" Model) (Includes Safety Arm for Top Cover) Back Tube Guide Assembly (42" Model) (Includes Safety Arm for Top Cover) Front Tube Guide Assembly (60" Model) (Includes Tube Guide Door and spring) Front Tube Guide Assembl
7 2 6 4 1 3 5 Parts and Diagrams Figure 27: Tubes Guide Assemblies HP DesignJet 5000 and 5500 Series Printers Service Manual 7-51
Parts and Diagrams EMC Covers EMC Covers Reference HP Part Number on Drawing DJ 5000 DJ 5500 Series Series Quantity Description/Comments 2 3 - C6095-60190 C6090-60180 0515-0382 C6071-20026 0515-2248 C6090-60107 1 1 9 8 (60")/6 (42") 4 1 - 0515-2248 6 EMC Covers (60" Model only) EMC Covers (42" Model only) Screw (center to bottom and top) Screw (top to chassis) Screw (bottom to chassis) Mount Bracket (includes right, left and center) Screw (for each bracket) 1 7-52 HP DesignJet 5000 and 5500 Ser
3 1 1 1 2 Parts and Diagrams Figure 28: EMC Covers HP DesignJet 5000 and 5500 Series Printers Service Manual 7-53
Parts and Diagrams Spindle and Hub Spindle and Hub Reference on Drawing 1 2 3 7-54 HP Part Number DJ 5000 Series Quantity Description/Comments DJ 5500 Series C6095-60182 C6090-60074 C6090-60105 C6090-60112 1 1 1 2 Spindle (60" Model) Spindle (42" Model) Blue Hub 3" Spindle Adaptors HP DesignJet 5000 and 5500 Series Printers Service Manual
2 3 1 Parts and Diagrams Figure 29: Spindle and Hub HP DesignJet 5000 and 5500 Series Printers Service Manual 7-55
Parts and Diagrams Rollfeed Brakes Rollfeed Brakes Reference on Drawing 1 2 3 4 5 6 7-56 HP Part Number DJ 5000 Series Quantity Description/Comments DJ 5500 Series C6072-60158 C6072-60155 C6072-60156 0624-0704 C6072-60157 0624-0704 1 1 1 1 1 1 Left Rollfeed Module Right Rollfeed Module Right Rollfeed Brake Screw Left Rollfeed Brake Screw HP DesignJet 5000 and 5500 Series Printers Service Manual
Parts and Diagrams 2 3 and 4 Right Hand Side 1 5 and 6 Left Hand Side Figure 30: Rollfeed Brakes HP DesignJet 5000 and 5500 Series Printers Service Manual 7-57
Parts and Diagrams Miscellaneous Items Miscellaneous Items Reference HP Part Number Quantity on Drawing DJ 5000 Series DJ 5500 Series - C6090-60081 - C6090-60314 C6090-60304 - - 7-58 - Q1251-60073 Q1251-60068 1 1 1 1 Description/Comments Service Preventive Maintenance Kit (for both 42" and 60" Models) User Maintenance Kit 5000 FW Upgrade CD (A.02.12) 5500 FW Upgrade CD (S.03.
Parts and Diagrams Media Types +3 'XUDEOH ,PDJH *ORVV 89 +3 &RDWHG 3DSHU OE J P IW P OE J P IW P +3 +HDY\ZHLJKW &RDWHG 3DSHU IRU 6HULHV SULQWHUV OE J P IW P '\H 89 LQ LQ LQ LQ LQ PP PP PP PP PP z z z z & $ & % &
Parts and Diagrams 7-60 HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation 8 Screw Types 8-4 Top Cover Assembly 8-5 Left Hand Cover 8-6 Right Hand Cover 8-10 Front Panel Assembly 8-14 Left Rear Cover 8-15 Right Rear Cover 8-16 Extension Cover (60" Model only) 8-17 Media Lever Assembly 8-18 Right Hand Trim 8-20 Left Hand Trim 8-22 Back Cover 8-23 Ink Tubes System 8-25 EMC Covers 8-32 Encoder Strip 8-34 Trailing Cable 8-36 Tensioner Assembly 8-42 Carriage Assembly and Belt 8-46 Line Sensor 8-53 Scan-Axis Motor 8-57 Cutter Assembly 8-60 Ink Supply Station (
Removal and Installation Introduction This chapter is a step by step guide to the removal and installation of the key components in the Printer. You may find it useful to tick off the steps as they are performed. Use the illustration at each procedure to identify the parts referred to in the text. The procedures appear in order of removal. So the whole machine can be stripped down by starting at the beginning of this chapter and working through the subsequent procedures.
Removal and Installation Electrostatic Discharge (ESD) Precautions To prevent damage to the Printer circuits from high-voltage electrostatic discharge (ESD): 1. Do not wear clothing that is subject to static build-up. 2. Do not handle integrated circuits (ICs) in carpeted areas. 3. Do not remove an IC or a printed circuit assembly (PCA) from its conductive foam pad or conductive packaging until you are ready to install it. 4. Ground (earth) your body while disassembling and working on the Printer.
Removal and Installation Screw Types WARNING Chassis screws have a copper washer and should never be removed. Type Torx Length (mm) Head Type Thread Type Part Number A T-20 17 Pan Taptite 0515-1743 B T-15 12 Pan Machined 0515-0382 C T-20 10 Pan Taptite 0515-2282 D T-15 12.5 Pan Washer Plastite 0515-3040 E T-15 12.7 Pan Plastite 0624-0769 F T-15 20 Pan Plastite 0624-0771 G T-8 12.7 Pan Plastite 0624-0768 H T-15 9.5 Pan Plastite 0515-2981 I T-10 7.
Removal and Installation Top Cover Assembly Removal WARNING Switch off the Printer and remove the power cable. 1. Open the Top Cover and lift UP and remove from Printer (see detail of hinge mechanism below). NOTE HP DesignJet 5000 and 5500 Series Printers Service Manual Detail of hinge mechanism.
Removal and Installation Left Hand Cover Removal WARNING Switch off the Printer and remove the power cable. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove ALL the Ink Cartridges from the Printer. 2. Open the Top Cover. 3. Open the door at the back of the Left Hand Cover.
Removal and Installation 4. Disconnect the Electrical Cable from the rear of the Ink Cartridge Tube Connector. 5. Disconnect the Air Tube. 1 2 6. Twist the 3 latches at the rear of the Ink Cartridge Tube Connector and release the complete Assembly.
Removal and Installation 7. Remove the Ink Cartridge Tube Connector and place safely on the window. 8. Remove 1 T-15 screw (Type F) from the Left Hand Cover (rear). 9. Close the Left Back door and remove 1 T- 25 screw (Type U) from bottom side (rear) of Left Hand Cover.
Removal and Installation 10. Remove 3 T-15 screws (Type F) from the Left Hand Cover (front). 11. Remove the Left Hand Cover from the Printer. Installation of Left Hand Cover WARNING When handling the Tubes make sure you do not damage them by twisting. WARNING When inserting the Left Hand Cover, be careful not to pinch/ twist the air tube or the electrical cable.
Removal and Installation Right Hand Cover Removal WARNING Switch off the Printer and remove the Power Cord. WARNING To remove the Right Hand Cover you must open the Right Cover door and push in the Printhead Cleaner Carriage. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Right Rear Cover - Refer to Page 8-16. 2. Remove the Ferrite (if present) and disconnect the Front Panel cable from the Main PCA (P24) from the left side of the Electronics Module. P24 3.
Removal and Installation 4. Remove 1 T-15 screw (Type F) and 1 T-25 screw (Type U) (bottom) from the rear of the Right Hand Cover. 5. Open the Top Cover. 6. Raise the Media Lever.
Removal and Installation NOTE Take care not to drop the Cover when removing the screws. Support the Cover throughout the next step. 7. Remove 3 T-15 (Type F) screws from the front of the Right Hand Cover. 8. To release the cables, carefully pull out the Right Hand Cover until the cables can be accessed. 9. Remove the Right Hand Cover.
Removal and Installation TIP To check correct functioning of serviced parts on the Printer axis you can do the following: a Reinsert the top T-15 screw (Type F) at the rear of the Printer. b Hang the Cover on the screw. c Connect all cables at the Rear of the Right Cover and turn on the Printer. Installation of Right Hand Cover NOTE Make sure the Front Panel cable and the Aerosol Fan cables are secured inside the Right Hand Cover with cable clamps and retaining pins.
Removal and Installation Front Panel Assembly Removal WARNING Switch off the Printer and remove the Power Cord. 1. Remove Right Rear Cover - Refer to Page 8-15. 2. Remove Right Hand Cover - Refer to Page 8-10. 3. Disconnect the cable from Front Panel. 4. Unclip Front Panel supports inside the Right Hand Cover and remove.
Removal and Installation Left Rear Cover Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove one T-15 screw (Type B) from the Left Rear Cover. NOTE Support the Cover as it is released. 2. Remove the Left Rear Cover.
Removal and Installation Right Rear Cover Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove one T-15 screw (Type B) from the Right Rear Cover. NOTE Support the Cover as it is released. 2. Remove the Right Rear Cover.
Removal and Installation Extension Cover (60" Model only) Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Left Rear Cover - Refer to Page 8-15. 2. Remove 4 T-15 screws (Type B) from the Extension Cover. 3. Lift the Cover and remove from the Printer.
Removal and Installation Media Lever Assembly Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Only applicable to the DesignJet 5000 Series - Remove the Deflector closest to the Right Cover - Refer to Page 8-119. 2. Remove the Right Hand Cover - Refer to Page 8-10. 3. Raise the Media Lever. 4. Remove 1 T-15 screw (Type D) from the support that attaches the Media Lever to the Sideplate.
Removal and Installation 5. Remove 1 T-15 screw (Type H) that attaches the Lever Arm to the Lever. 6. Remove the Media Lever. Installation of the Media Lever Assembly WARNING When installing the Media Lever, you must insert it in the Trim and Sideplate in the UP position to avoid damaging the Lever Spring in the Trim.
Removal and Installation Right Hand Trim Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove Right Rear Cover - Refer to Page 8-16. 2. Remove Right Hand Cover - Refer to Page 8-10. 3. Remove Media Lever Assembly Refer to Page 8-18. 4. Disconnect the Sensors cable from position P27 on the Main PCA. P27 5. Remove 1 T-15 screws (Type F) and 1 T-20 (Type L) from the Right Hand Trim.
Removal and Installation 6. Carefully remove the Right Hand Trim. Remove carefully Installation of Right Hand Trim WARNING When installing the Media Lever in the Trim, install with the Lever in the UP position to avoid damaging the Lever spring in the Trim.
Removal and Installation Left Hand Trim Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove 4 T-15 screws (Type F) and 1 T-20 screw (Type L) from the Left Hand Trim. 2. Carefully remove the Left Hand Trim.
Removal and Installation Back Cover Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Top Cover - Refer to Page 8-5. 2. Remove the following (Type B) screws from the upper part of the Back Cover: 8 Screws (T-15) for the 60" Model. 6 Screws (T-15) for the 42" Model. NOTE Support the Back Cover as it is released. 3. Remove 3 T-15 screws (Type N) from the lower part of the Back Cover.
Removal and Installation 4. Remove the Back Cover. Installation of the Back Cover NOTE 8-24 If the Back Cover is replaced, remember to apply a new Printer Label to the new Back Cover before it is installed. Once the new label has been applied, copy the product number and serial number onto it.
Removal and Installation Ink Tubes System Removal WARNING Switch off the Printer and remove the Power Cord. 1. Open the Right Cover door and pull out the Printhead Cleaner Carriage. 2. Open the Top Cover and pull the Carriage out along the Printer to the position shown. 3. Lift up the Carriage Cover and remove ALL the Printheads and close the Carriage Cover.
Removal and Installation 4. Slide the Carriage to the position shown. 5. Push in the 2 retaining clips either side of the Printhead Tube Connector. 6. Pull the Printhead Tube Connector towards you.
Removal and Installation 7. Push the button to release the Printhead Tubes in the Carriage. 8. Release the Retaining Clip by pulling it away from the holding brackets. 9. Pull the Printhead Tube Connector up between the two Tube Guides.
Removal and Installation 10. Lift out the blue Retaining Clip. 11. Remove ALL the Ink Cartridges from the Printer. 12. Open the door at the back of the Left Cover.
Removal and Installation 13. Disconnect the Electrical Cable from the rear of the Ink Cartridge Tube Connector. 14. Disconnect the Air Tube. 1 2 15. Twist the 3 latches at the rear of the Ink Cartridge Tube Connector and release the complete Assembly.
Removal and Installation 16. The complete assembly can now be removed by sliding the Ink Cartridge Connector out from the rear of the Left Hand Cover. Installation of Ink Tubes System WARNING When installing the Ink Tubes System it is very important that the Tubes are NOT TWISTED. Make sure that the Tubes are correctly routed at the rear of the Left Cover and before powering On the printer, check again that they are NOT TWISTED.
Removal and Installation NOTE When the Ink Tubes System is replaced, to restart the Printer perform the following procedures. 1. Install the Setup Printheads (refer to the User’s Guide). 2. Connect the Power Cable and turn on the main Power Switch at the rear of the Printer. 3. The Front Panel warns that there are no Ink Cartridges installed. 4. Install the Ink Cartridges (refer to the User’s Guide for details). INK STARTUP Initializing Printer Please wait 60 sec 5.
Removal and Installation EMC Covers Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. NOTE The EMC Cover is composed of three parts; Top, Lower Left and Lower Right. Procedures below describe removal of the EMC Covers as; one assembly, the Top only, the Lower Right only. The procedure you select depends on the part you want to access. EMC Covers as one assembly 1. Remove the Top Cover - Refer to Page 8-5. 2.
Removal and Installation 7. Remove the following screws (Type N) from the Top EMC Cover. 8 T-15 screws for the 60" Model. 6 T-15 screws for the 42" Model. 8. Loosen 4 T-15 screws (Type L) on Lower Covers and remove all Covers as one assembly. Lower Right Cover 1. Do steps 1 to 5 of the EMC Covers as one assembly procedure. 2. Remove 2 T-15 screws (Type B) and loosen 2 T-15 bottom screws (Type L) to remove cover. Top EMC Cover 1. Do steps 1, 2 and 6 of the EMC Covers as one assembly procedure. 2.
Removal and Installation Encoder Strip Removal WARNING Switch off the Printer and remove the Power Cord. 1. Remove the Left Hand Cover - Refer to Page 8-6. 2. Remove the Right Hand Cover - Refer to Page 8-10. 3. Remove the Top Cover - Refer to Page 8-5. 4. Remove the Back Cover - Refer to Page 8-23. 5. Remove the Top EMC Cover - Refer to Page 8-32. 6. Remove the 5.5 mm nut from the left hand side of the Printer that attaches the Encoder Strip to the Spring Clip. TIP 1.
Removal and Installation 8. Remove the 5.5 mm nut from the right hand side of the Printer. 9. Remove the Encoder Strip from the Printer. 2 Pull strip out 1 Lift off pins Installation of Encoder Strip WARNING When Installing the Encoder Strip, make sure it is placed in the Encoder Sensor on the rear of the Carriage Assembly as shown below.
Removal and Installation Trailing Cable Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Top Cover - Refer to Page 8-5. 2. Remove the Right Rear Cover - Refer to Page 8-16. 3. Remove the Right Hand Cover - Refer to Page 8-10. 4. Remove the Left Hand Cover - Refer to Page 8-6. 5. Slide the Carriage to the left side of the Printer. 6.
Removal and Installation 7. Carefully disconnect the Trailing Cables (3) from the connectors in the Carriage PCA. NOTE Remove Trailing Cable Ferrites if they fall into the Carriage 3 for 60" Model 1 for 42" Model Press down in center to release 8. Remove the Trailing Cables from the Trailing Cable Holder. Press the Trailing Cables firmly in the center to release. TIP 9. Slide the Trailing Cable Guide out of the Carriage.
Removal and Installation 10. Carefully disconnect the Trailing Cable from the Main PCA. NOTE Unclip the Trailing Cable when disconnecting from the Main PCA. 11. Remove the T-20 screw (Type C) from the Trailing Cable Clip on the left. NOTE There is a hole in the Tube Guide to access the screw. 12. Remove 2 T-10 screws (Type I) from the Trailing Cable Clip on the right. NOTE 8-38 Take care when removing and inserting these screws as they are easily damaged and not easy to access.
Removal and Installation 13. Carefully lift the Clips and the Trailing Cable from the Printer. Installation of Trailing Cable WARNING Do not install damaged Trailing Cables. If the Trailing Cable is incorrectly installed or it is damaged, a "Power Supply Error #1" message will appear on the Front Panel during initialization. Check edge for damage WARNING When Installing the Trailing Cable, make sure you install it as follows: 1.
Removal and Installation 2. Insert the Trailing Cable Guide into the Carriage and connect the Trailing Cables. NOTE Remember to pass the Trailing Cables through the Ferrite(s). 3 for 60" Model. 1 for 42" Model. 3. Insert the Trailing Cable through the Chassis slot next to the Trailing Cable Clip on the right (see diagram in step 4). 4. Place the Right Trailing Cable Clip in position and adjust the length of the Trailing Cable.
Removal and Installation TIP Make sure the Trailing Cable is flat on the chassis without bubbles. NOTE Check the cable and clips are correctly installed by sliding the carriage along the Printer to see if it moves freely. NO BUBBLES Right Clip Left Clip locating pin 5. Connect the Trailing Cables to the Main PCA.
Removal and Installation Tensioner Assembly Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Left Hand Cover - Refer to Page 8-6. 2. Remove the Right Hand Cover - Refer to Page 8-10. 3. Remove the 5.5 mm nut from the left hand side of the Printer that attaches the Encoder Strip to the Spring Clip. TIP 1. Apply Pressure The next step is performed by putting pressure on the Spring Clip as shown. 4.
Removal and Installation Tighten Tightenscrew screw 5. Using a screwdriver, fully tighten the Spring Release Screw to release the tension on the Belt. 6. From the right-hand side, lift the Tensioner Belt off the Scan-Axis Motor. 7. Remove 1 T-15 screw (Type L) from the Tensioner Assembly.
Removal and Installation 8. Remove the Belt Wheel on the left side. 9. Remove the Tensioner Assembly from the left-hand side.
Removal and Installation Installation of Tensioner Assembly NOTE Before installation, clean and oil the Slider Rods using the User’s Slider Rods Lubrification Kit (Refer to Page 9-8). WARNING Be careful not to twist the Belt when installing the Tensioner Assembly. WARNING When installing the Encoder Strip, make sure it is inserted in the Encoder Sensor on the rear of the Carriage Assembly as shown below.
Removal and Installation Carriage Assembly and Belt Removal WARNING Switch off the Printer and remove the power cord. 1. Remove the Left Hand Cover - Refer to Page 8-6. 2. Remove the Right Rear Cover - Refer to Page 8-16. 3. Remove the Right Hand Cover - Refer to Page 8-10. 4. Remove the Tensioner Assembly Refer to Page 8-42. 5. Pull out Printhead Cleaner Carriage. 6. Slide Carriage Assembly to position shown.
Removal and Installation 7. Lift up the Carriage Cover and remove ALL the Printheads and close the Carriage Cover. 8. Slide the Carriage along the Printer to the position shown. 9. Push in the 2 retaining clips either side of the Printhead Tube Connector.
Removal and Installation 10. Pull the Printhead Tube Connector towards you. 11. Push the button to release the Printhead Tubes in the Carriage. 12. Release the retaining clip by pulling it away from the holding brackets.
Removal and Installation 13. Pull the Printhead Tube Connector up between the two Tube Guides. 14. Slide the Carriage to the left side of the Printer. 15. Unclip and remove the Carriage Cover to access the Trailing Cable in the Carriage.
Removal and Installation 16. Carefully disconnect the Trailing Cables (3) from the connectors in the Carriage PCA. NOTE Remove Trailing Cable Ferrites if they fall into the Carriage 3 for 60" Model. 1 for 42" Model. Press down in center to release 17. Remove the Trailing Cables from the Trailing Cable Holder. TIP Press the Trailing Cables firmly in the center to release. 18. Slide the Trailing Cable Guide out of the Carriage.
Removal and Installation 19. Slide the Carriage (including the Belt) to the left and out of the Printer. 20. Remove the Belt from the Carriage by releasing it from the retaining clips underneath the Carriage.
Removal and Installation Installation of Carriage and Belt NOTE Before installation, clean and oil the Slider Rods using the User’s Slider Rods Lubrification Kit (Refer to the User’s Guide). WARNING Make sure you install the Carriage Assembly and Belt as follows: 1. Insert belt as indicated on the underside of Carriage. An arrow on the bottom of the Carriage indicates position and direction. TIP 2. Line up the Carriage Guide, on the underside of the carriage, with the Slider Rods on the Printer.
Removal and Installation Line Sensor Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Carriage Assembly Refer to Page 8-46. 2. Unclip the Carriage Cover from both sides of the Carriage Assembly. 3. Remove the Carriage Cover. NOTE HP DesignJet 5000 and 5500 Series Printers Service Manual Make sure both sides of the cover are unclipped before removing.
Removal and Installation 4. Disconnect the Line Sensor Connector from the Carriage PCA. 5. Insert a flat screwdriver inside the Line Sensor clip in order to release it. 6. Once the clip is released, rotate the Line Sensor downwards so that the locating pins on both sides are also released.
Removal and Installation Installation 1. When installing the new Line Sensor, make sure you insert the Line Sensor Cable through the correct hole (as highlighted). 2. Install the Line Sensor by first inserting the 2 locating pins and then rotating upwards so that the clip locks into place. NOTE Make sure the Line Sensor is clipped correctly and securely, if not the Line Sensor will malfunction. 3. Connect the Line Sensor Connector to the Carriage PCA.
Removal and Installation 4. Install the Carriage Cover. NOTE 3XVK KHUH Make sure the cover is installed vertically, if not the Cover Retaining Pins can be broken. 5. Clip the Carriage Cover on both sides of the Carriage Assembly by pushing the clip downwards (with force if necessary). NOTE Make sure the clips are locked correctly, if not the Carriage Cover could become loose and cause major damage to the printer.
Removal and Installation Scan-Axis Motor Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Right Rear Cover - Refer to Page 8-16. 2. Remove the Left Hand Cover - Refer to Page 8-6. 3. Remove the Right Hand Cover - Refer to Page 8-10. 4. Remove the 5.5 mm nut from the left hand side of the Printer that attaches the Encoder Strip to the Spring Clip. TIP 1.
Removal and Installation 6. Using a screwdriver, fully tighten the Spring Release Screw to release the tension on the Belt. Tighten screw 7. Disconnect the Scan-Axis Motor Cable from position P23 on the Main PCA. P23 8. Unclip the Scan-Axis Motor Cable from underneath the Service Station.
Removal and Installation 9. From the right-hand side, lift the Tensioner Belt off the Scan-Axis Motor. 10. While supporting the Scan-Axis Motor, remove 2 T-15 screws (Type B). 11. Lower the Scan-Axis Motor and remove from the Printer. Installation of the Scan-Axis Motor NOTE Before installation, clean and oil the Slider Rods using the User’s Slider Rods Lubrification Kit (Refer to Page 9-8).
Removal and Installation Cutter Assembly Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Open the Top Cover. 2. Pull the Carriage out along the Printer to the position shown. 3. Lift up the Carriage Cover and remove ALL the Printheads and close the Carriage Cover.
Removal and Installation 4. Slide the Carriage to the position shown. 5. Push in the 2 retaining clips either side of the Printhead Tube Connector. 6. Pull the Printhead Tube Connector towards you.
Removal and Installation 7. Push the button to release the Printhead Tubes from the Carriage. 8. Release the retaining clip by pulling it away from the holding brackets. 9. Remove 1 T-8 screw (Type V) and washer that attaches the Cutter to the Carriage.
Removal and Installation 10. Slide the Cutter towards you and remove from the Printer.
Removal and Installation Ink Supply Station (ISS) Removal WARNING Switch off the Printer and remove the Power Cord. 1. Remove the Left Hand Cover - Refer to Page 8-6. 2. Remove the Left Rear Cover - Refer to Page 8-15. 3. Remove the Back Extension Cover (Only for the 60" Model) - Refer to Page 8-17. 4. Disconnect APS Cables (P5, P4 and P3) from the ISS PCA. P5 P4 P3 Press here 8-64 5. To remove the ISS, stand at the end of the Printer and press in the retaining clip on the ISS.
Removal and Installation 6. While pressing in the retaining clip (step 5), rotate the right side of the ISS up and left. INSIDE VIEW FRONT 7. Pull out the right side of the ISS. 8. Slide the ISS to the left and pull out the left side to remove from the Printer.
Removal and Installation Installation of ISS NOTE If the ISS is to be replaced, make sure you remove the APS from the old ISS and, after installing the Grounding Plate, reinstall it on the new ISS. WARNING When replacing the ISS remember to insert the Grounding Plate into the slot as shown (before reinstalling the APS).
Removal and Installation Air Pressurization System (APS) Removal WARNING Switch off the Printer and remove the Power Cord. 1. Remove the Left Hand Cover - Refer to Page 8-6. 2. Remove the Left Rear Cover - Refer to Page 8-15. 3. Remove the Back Extension Cover (Only for the 60" Model) - Refer to Page 8-17. 4. Remove the ISS - Refer to Page 8-64. 5. Remove the cables and tube from the slot on the ISS. For the 42" Model, open the Cable Clip under the ISS holding the APS Cables to the ISS.
Removal and Installation Installation of APS WARNING When Installing the Air Pressurization System make sure the tube and wires are placed in the dedicated slots and perform the following steps: 1. Before installing the APS on the ISS, insert first the 3 cables and then the tube in the dedicated slot. 2. Install the APS on the ISS. 3. For the 42" Model, secure the APS Cables to the ISS using the Cable Clip under the ISS.
Removal and Installation Service Station Assembly Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Right Rear Cover - Refer to Page 8-16. 2. Remove the Right Hand Cover - Refer to Page 8-10. 3. Remove the Printhead Cleaners. 4. Manually slide the Carriage out of the Service Station.
Removal and Installation 5. Disconnect the Service Station Cable from the Main PCA (P15). P15 6. Unclip the Scan-Axis Motor Cable from the Service Station. NOTE Follow the instructions in step 7 carefully; LOOSEN the screw and DO NOT remove. 7. Loosen the T-20 screw (Type A) securing the Service Station to the side plate.
Removal and Installation 8. Remove 2 T-15 screws (Type F) between the two slider rods that attach the Service Station to the Chassis. 9. Standing in front of the Service Station, lift it off the loosened screw. 10. Pull the assembly out towards you and remove from the Printer. NOTE Perform the following Service Calibration if the Service Station Assembly is replaced: Service Station Page 5-11.
Removal and Installation Drop Detector Assembly Removal WARNING Switch off the Printer and remove the Power Cord. 1. Remove the Right Rear Cover - Refer to Page 8-16. 2. Remove the Right Hand Cover - Refer to Page 8-10. 3. Remove the Service Station Assembly - Refer to Page 8-69. 4. Disconnect the Drop Detector cable from the Service Station Cable. Press clip to disconnect 5. Release the cable from the Service Station.
Removal and Installation 6. Remove the T-15 screw (Type F) that attaches the Drop Detector Assembly to the Service Station. 7. Remove the Drop Detector from the Service Station. NOTE 1 2 Move the Drop Detector towards the front of the Service Station until the locating pin reaches the end. Pin 8. Lift the Foam from the Service Station. NOTE The Foam may be full of ink so be careful when handling it.
Removal and Installation Hard Disk Drive (HDD) Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove 6 T-15 screws (Type B) from the HDD Access Cover. Remove the HDD Access Cover. 2. Remove the HDD with its foam holder. 3. Disconnect the HDD Cable and Power Supply Cable from the HDD.
Removal and Installation Installation of Hard Disk Drive NOTE If you replace the Main PCA and the HDD at the same time you must perform ALL Service Calibrations ( Page 5-3) and the EEROM Setup Service Utility ( Page 4-23). WARNING When Installing the Hard Disk Drive make sure the holder is placed in the right position so that it cannot move. NOTE When the Hard Disk Drive is replaced perform the following Service Utility: Backup EEROM (select HDD replaced) Page 4-30.
Removal and Installation LAN Card Removal WARNING Switch off the Printer and remove the Power Cord. 1. Disconnect the LAN cable from the LAN Card at the rear of the Printer. 2. Using a flat end screwdriver, unscrew the two screws that attach the LAN Card to the Printer. 3. Remove the LAN Card and store in a safe place.
Removal and Installation Memory and BootROM DIMM’s Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove 4 T-10 screws (Type P) from the DIMM Access Cover. Remove the DIMM Access Cover. 2 2. To remove a DIMM, first push down the lower locking tab and then push up the upper locking tab to release the DIMM.
Removal and Installation 3. Pull out the DIMM. Take care that it does not fall out. Installation of DIMM’s WARNING When installing the DIMM’s make sure they are in the correct position as shown in the diagram. NOTE Note the position of the BootROM and the SDRAM (memory) modules.
Removal and Installation Electronics Module Cover Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the LAN Card - Refer to Page 8-76. 2. Remove Left Rear Cover - Refer to Page 8-15. 3. Remove Right Rear Cover - Refer to Page 8-16. 4. If present, remove the Ferrites from the Ferrite Holder on the right side. Push clip to release Ferrite (if present) 5.
Removal and Installation NOTE Lift the Parallel Port Clips before removing the Cover. Lift clips 6. Remove the Electronics Module Cover. Installation of the Electronics Module Cover NOTE When Installing the Electronics Module Cover make sure the parallel port connector clips are in closed position i.e. UP, so that they pass through the slot in the Cover.
Removal and Installation Main PCA WARNING This assembly does NOT include the PCI-to-IDE PCA (the small PCA that connects the Main PCA to the Hard Disk Drive) as it used to in the past. When installing the new Main PCA, make sure that you reuse the PCI-to-IDE PCA that was disassembled previously.
Removal and Installation Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the LAN Card - Refer to Page 8-76. 2. Remove the Left Rear Cover - Refer to Page 8-15. 3. Remove the Right Rear Cover - Refer to Page 8-16. 4. Remove the Electronics Module Cover - Refer to Page 8-79. 5. Disconnect and remove the Hard Disk Drive for safety reasons - Refer to Page 8-74. 6.
Removal and Installation 9. Disconnect the PCI-to-IDE PCA and remove from the Printer. NOTE Make sure you reuse the PCI-to-IDE PCA when reassembling. 10. Remove 6 T-10 screws (Type K) from the Main PCA. 11. Loosen 2 T-10 screws on the Main PCA.
Removal and Installation 12. Remove by sliding the Main PCA to the left and lifting out (see detail below). NOTE Detail of Main PCA removal. Installation of Main PCA NOTE When the Main PCA has been replaced, perform the Backup EEROM Page 4-30. NOTE If you replace the Main PCA and the HDD at the same time you must perform ALL Service Calibrations ( Page 5-3) and the EEROM Setup Service Utility ( Page 4-23 .
Removal and Installation PCI-to-IDE PCA Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the LAN Card - Refer to Page 8-76. 2. Remove the Left Rear Cover - Refer to Page 8-15. 3. Remove the Right Rear Cover - Refer to Page 8-16. 4. Remove the Electronics Module Cover - Refer to Page 8-79. 5. Disconnect and remove the HDD for safety reasons - Refer to Page 8-74. 6.
Removal and Installation Installation of the PCI-to-IDE PCA NOTE When installing the new PCI-to-IDE PCA, CONNECT THE HDD POWER CABLE TO THE P36 CONNECTOR (IF PRESENT) ON THE PCI-TO-IDE PCA AND NOT TO THE P11 CONNECTOR ON THE MAIN PCA (even if the P11 connector is present and the HDD Power Cable was connected there previously). 2.
Removal and Installation Installing the HDD Cable When installing the HDD Cable between the HDD and the PCI-to-IDE PCA, make sure you connect the correct ends as follows: 6KRUW &RQQHFWRU FRQQHFWV WR WKH 3&, WR ,'( 3&$ /RRSHG (QG FRQQHFWV WR WKH +DUG 'LVN 'ULYH ,) 7+( +'' &$%/( ,6 127 &211(&7(' &255(&7/< ,7 0$< &$86( 620( ,17(50,77(17 352%/(06 HP DesignJet 5000 and 5500 Series Printers Service Manual 8-87
Removal and Installation Power Supply Unit (PSU) Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the LAN Card - Refer to Page 8-76. 2. Remove the Left Rear Cover - Refer to Page 8-15. 3. Remove the Right Rear Cover - Refer to Page 8-16. 4. Remove the Electronics Module Cover - Refer to Page 8-79. 5. Disconnect and remove the Hard Disk Drive for safety reasons - Refer to Page 8-74. PCA PS Connector 8-88 6.
Removal and Installation 7. Remove the plastic protective cover from the Power Supply Unit. 8. Disconnect ALL Cables from the PSU (see Installation of PSU for connections). Press PS Fans PS Switch PS Socket 9. Remove 7 T-10 screws (Type K) and remove the PSU.
Removal and Installation Installation of the Power Supply Unit (PSU) WARNING After installing the Power Supply Unit, remember to place the plastic protective cover over the unit. NOTE The Power Supply Unit connections are illustrated below.
Removal and Installation Ink Supply Station (ISS) PCA Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the LAN Card - Refer to Page 8-76. 2. Remove the Left Rear Cover - Refer to Page 8-15 3. Remove the Right Rear Cover - Refer to Page 8-16. 4. Remove the Electronics Module Cover - Refer to Page 8-79. 5. Disconnect ALL Cables from the ISS PCA (see installation of ISS PCA for connections). 6.
Removal and Installation Installation of the ISS PCA The ISS PCA connections are illustrated below. NOTE P5 P6 P4 J3 P3 P2 J1 J Position Connection Connector Color P Position Connection Connector Color J1 ISS Cable white P2* Ink Leak Detector white J3 Main PCA white P3 APS Temperature white P4 APS Valve red P5** APS Pump white P6** APS Pump (Spare) white * The Ink LeakDetector has been discontinued so this connector is no longer used.
Removal and Installation Ink Leak Detector - If Present (Only Applicable to the 5000 Series) Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Left Rear Cover - Refer to Page 8-15. 2. Remove the Top Cover - Refer to Page 8-5. 3. Remove the Back Cover - Refer to Page 8-23. 4. Disconnect the Ink Leak Detector cable at position P2 from the ISS PCA. P2 5.
Removal and Installation 6. Press the retaining clip on the Ink Leak Detector and release it. TIP A screwdriver can be used to press the retaining clip down. 7. Remove the Ink Leak Detector from the Printer.
Removal and Installation Cooling Fans Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the LAN Card - Refer to Page 8-76. 2. Remove the Left Rear Cover - Refer to Page 8-15. 3. Remove the Right Rear Cover - Refer to Page 8-16. 4. Remove the Electronics Module Cover - Refer to Page 8-79. 5. Disconnect and remove the Hard Disk Drive for safety reasons - Refer to Page 8-74. 6.
Removal and Installation 7. Remove the plastic Protective Cover from the Power Supply Unit. 8. Disconnect the Cooling Fan Cables from the Power Supply Unit. 9. Remove the Cooling Fans from the Printer.
Removal and Installation Electronics Module (as one complete Assembly) Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Left Rear Cover - Refer to Page 8-15. 2. Remove the Right Rear Cover - Refer to Page 8-16. 3. Disconnect ALL Cables from the Main PCA (Right Rear Cover) and ISS PCA (Left Rear Cover) and remove the Ferrites from the left side. 4.
Removal and Installation Pinch-Wheels Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Top Cover - Refer to Page 8-5. 2. Remove the Back Cover - Refer to Page 8-23. 3. Remove the Electronics Module Refer to Page 8-97. 4. Remove EMC Covers as one assembly - Refer to Page 8-32. NOTE For the next steps place the Media Lever in the UP position. 5.
Removal and Installation 6. First remove lateral Pinch-Wheels with their Coupling Plates. NOTE REMOVE COUPLING PLATES 1 ROT ATE 90 0 For Pinch-Wheel groups installed around the Mount Brackets do the following: 7. From the front of the Printer, remove the Coupling Plate corresponding to the position of the Mount Bracket. 3 Mount Brackets in the 60" Model. 1 Mount Bracket in the 42" Model. 8.
Removal and Installation Pinch-Wheel Cam Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove Right Rear Cover - Refer to Page 8-16. 2. Remove Left Rear Cover - Refer to Page 8-15. 3. Remove the Deflectors - Refer to Page 8-119. 4. Remove the Left Hand Cover - Refer to Page 8-6. 5. Remove the Right Hand Cover - Refer to Page 8-10. 6. Remove the Left Hand Trim - Refer to Page 8-22. 7.
Removal and Installation 16. Remove the Center Guide - Refer to Page 8-112. 17. Remove the Pinch-Wheels - Refer to Page 8-97. 18. Through the slot in the right Sideplate, remove the T-15 screw (Type H) retaining the cam lever arm. 19. Remove the T-15 Cam screw (Type F). 20. Remove the Cam by sliding it through the slot in the left Sideplate.
Removal and Installation Installation of Cam 1. To install the Cam slide it through the left Sideplate and place it in the cam slot in the beam. 2. INSERT INTO CAM SLOT IN BEAM 1. INSERT THROUGH SIDEPLATE 2. Hold the Cam Lever Linkage over its slot in the Sideplate and insert the Cam into it. 2 2. INSERT 1. POSITION LINKAGE 3. Push the Cam with the Cam Lever Linkage into the Sideplate.
Removal and Installation Vacuum Fan Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Right Rear Cover - Refer to Page 8-16. 2. Remove the Right Hand Cover - Refer to Page 8-10. 3. Remove the Service Station Assembly - Refer to Page 8-69. 4. Disconnect the Vacuum Fan Cable at position P19 on the Main PCA. P19 5. Remove the 4 T-20 screws (Type L) that secure the Vacuum Fan to the Sideplate.
Removal and Installation 6. Remove the Vacuum Fan. Installation of Vacuum Fan WARNING 8-104 When installing the Vacuum Fan make sure that it fits tightly to the Guides in the Sideplate.
Removal and Installation Paper-Axis Motor Assembly Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Right Rear Cover - Refer to Page 8-16. 2. Remove the Right Hand Cover - Refer to Page 8-10. 3. Remove the Service Station Assembly - Refer to Page 8-69. P10 4. Disconnect the Paper-Axis Motor Cable at P10 and the Encoder Cable at P12 from the Main PCA (and NOT from Motor). P12 5.
Removal and Installation 6. Remove the Helical Gear. 7. Remove the 3 T-20 screws (Type L) that secure the Paper-Axis Motor Assembly to the Sideplate. 8. Remove the Paper-Axis Motor Assembly. NOTE When you replace the PaperAxis Motor Assembly you must perform the following Service Calibrations: Accuracy Page 5-14. Printhead Alignment User’s Guide.
Removal and Installation Installation of Paper-Axis Motor Assembly WARNING When reinstalling parts make sure that they fit tightly and that screws are tight. NOTE Apply grease to the Helical Gear.
Removal and Installation Booster Fan Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove Right Rear Cover - Refer to Page 8-16. 2. Remove Left Rear Cover - Refer to Page 8-15. 3. Remove the Electronics Module Refer to Page 8-97. 4. Remove the Lower Right EMC Cover - Refer to Page 8-32. 5. Remove the 2 T-20 screws (Type L) from the Booster Fan. 6.
Removal and Installation Media Sensor Removal WARNING Switch off the Printer and remove the Power Cord. 1. Remove the Top Cover - Refer to Page 8-5. 2. Remove the Right Rear Cover - Refer to Page 8-16. 3. Remove the Left Rear Cover - Refer to Page 8-15. 4. Remove the Back Cover - Refer to Page 8-23. 5. Remove the Electronics Module Refer to Page 8-97. 6. Remove the Lower Right EMC Cover - Refer to Page 8-32. 7. Remove the Booster Fan for better access - Refer to Page 8-108. 8.
Removal and Installation Installation of Media Sensor WARNING 8-110 When installing the Media Sensor, insert the moving part as shown in the diagram.
Removal and Installation Entry Roller Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove Left Hand Trim - Refer to Page 8-22. 2. Remove the Left Hand Cover - Refer to Page 8-6. 3. Remove Left Rear Cover - Refer to Page 8-15. 4. Remove the ISS - Refer to Page 8-64. 5. Remove one T-15 screw (Type J) that secures the Entry Roller to the left Sideplate. 6.
Removal and Installation Center Guide Assembly Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Top Cover - Refer to Page 8-5. 2. Remove the Back Cover - Refer to Page 8-23. 3. Remove the Lower Right EMC Cover - Refer to Page 8-32. 4. Remove Right Rear Cover - Refer to Page 8-16. 5. Remove Left Rear Cover - Refer to Page 8-15. 6. Remove the Deflectors - Refer to Page 8-119. 7.
Removal and Installation 16. Remove the Booster Fan - Refer to Page 8-108. 17. Remove the Media Sensor - Refer to Page 8-109. 18. Remove the Entry Roller - Refer to Page 8-111. 19. Remove 3 T-15 screws (Type J) that secure the Center Guide to the left Sideplate. 20. Remove 1 T-15 screw (Type J) and 2 T-20 screws (Type T) that secure the Center Guide to the right Sideplate. 21. Remove the Center Guide as follows: Lift it from the front to release it. Pull it out in a rotating movement.
Removal and Installation Drive Roller Gear Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Left Hand Cover - Refer to Page 8-6. 2. Remove the Left Rear Cover - Refer to Page 8-15. 3. Remove the ISS - Refer to Page 8-64. 4. Remove 1 T-25 screw (Type S) from the Drive Roller Gear 5. Remove the Drive Roller Gear.
Removal and Installation Front Platen Assembly (Only Applicable to the 5000 Series) Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Left Hand Trim - Refer to Page 8-22. 2. Open the Top Cover. NOTE Make sure the Carriage is not in the print Platen area. 3. Remove the following screws (Type R) from the Front Platen Assembly: 15 T-10 screws in the 60" Model. 11 T-10 screws in the 42" Model.
Removal and Installation 4. Remove the Platen starting from the left side.
Removal and Installation Center Platen Assembly Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Open the Top Cover. NOTE Make sure the Carriage is not in the print Platen area. NOTE Make sure the Media Lever is in the UP position (to raise the pinch-wheels) before removing the Platen Assembly. 2. Remove the following screws (Type R) from the Center Platen Assembly: 39 T-10 screws in the 60" Model.
Removal and Installation 3. Remove the complete Center Platen Assembly (includes the Overdrive Assembly and the Cutter guide). NOTE You must perform the following Calibrations when the Center Platen Assembly is replaced: Scan Axis Calibration Page 5-7. Carriage Height Calibration Page 5-18. Installation of the Center Platen Assembly WARNING 8-118 When installing the Center Platen Assembly, make sure the foam guides under the Platen are placed in their slots as shown below.
Removal and Installation Deflectors (Only Applicable to the 5000 Series) Removal NOTE Refer to the table on Page 8-4 for information on screw types. 1. Unclip the Deflector Extension. out Pull 2. Remove 1 T-15 (Type M) screw from each Deflector. 4 Deflectors in the 60" Model. 3 Deflectors in the 42" Model. 3. Remove the Deflectors from the Printer.
Removal and Installation Heater Assembly (Only Applicable to the 5500 Series) Removal WARNING Switch off the Printer and remove the Power Cord. NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Right Rear Cover - Refer to Page 8-16. 2. Remove the Right Cover - Refer to Page 8-10. 3. Disconnect the Heater Cable from the Main PCA. 4. Release the Heater Cable from the plastic clip.
Removal and Installation 5. Remove 15 screws that secure the Heater from the top of the Printer. NOTE The 42" Printer only has 11 screws securing the Heater from the top. NOTE Be very careful not to force the screws as they are screwed directly to the Printer Chassis. 6. Remove 4 screws that secure the heater from the bottom of the Printer. NOTE The 42" Printer only has 3 screws securing the Heater from the bottom. 7. Gently tap one side of the Heater from underneath to release it.
Removal and Installation 8. Before removing the Heather completely, pull out the Heater Cable from the access hole in the sideplate. 9. Remove the Heater from the Printer.
Removal and Installation Installing the Heater To install the Heater, follow the removal procedures in reverse order, taking care of the following information: 1. When installing the Heater, place the top lip of the Heater over the Center Platen Assembly and then push the Heater downwards. 2. Make sure that the inner lip of the Heater is linked with the lip on the Chassis frame.
Removal and Installation Tube Guide Door The Tube Guide Door kit contains 2 different types of springs which need to be installed depending on the design of the Tube Guide. Refer to the drawing below to determine which spring needs to be installed.
Preventive Maintenance 9 Introduction 9-2 Service Preventive Maintenance 9-2 Warning/Stop Triggers 9-3 User Maintenance 9-5 Lens Maintenance 9-5 Carriage Interconnect Wiper 9-6 Roller Lubrification Kit 9-7 Slider Rods Lubrification Kit 9-8 Cleaning the Platen 9-9 Noisy Carriage Bushing 9-10 Belt Swelling 9-10 General Cleaning 9-10 Firmware Upgrade 9-11 HP DesignJet 5000 and 5500 Series Printers Service Manual 9-1
Preventive Maintenance Introduction This chapter explains how to perform service preventive maintenance procedures when they are required, and routine maintenance procedures that are recommended when Service Engineers perform Removal and Installation procedures. Service Preventive Maintenance NOTE Maintenance information can be obtained from Printer Setup/ Utilities/Service Configuration Print.
Preventive Maintenance Warning/Stop Triggers NOTE If the Ink Tubes System needs to be replaced, this can be performed by the User. The Printer will advise the User when the Scan-Axis System and/or Tubes need to be replaced by displaying a Warning message. The Warning message is triggered by the following number of cycles: 6.5 million for the Carriage. 6.5 million for the Tubes. The number of cycles can be checked at anytime by printing the Service Configuration Print.
Preventive Maintenance If the Ink Tubes reach 7 million cycles, they risk breakage. The Printer is stopped and the following message is displayed: "Ink Tube Maintenance Required Now" If the Ink Tubes are not replaced, the following message is displayed each time a job is sent to the Printer.
Preventive Maintenance User Maintenance Warranty Statement HP’s limited warranty covers only those defects which arise as a result of appropriate use of the product, and does not apply to any: a. Improper or inadequate maintenance or modification; b. Software, interfacing, media, parts, or supplies not provided or supported by HP; or c. Operation outside the product’s specifications.
Preventive Maintenance Carriage Interconnect Wiper NOTE The Carriage Interconnect Wiper also comes with the Carriage. To clean the Printheads and Printhead connects select Replace Printheads in the Printhead menu to remove the Printheads from the Carriage Assembly: 1 Insert the Carriage Interconnect Wiper into the Printhead slot and move it up and down to clean the connections. 2 Change the angle of wipe as shown in 2 below, to properly clean all the connections.
Preventive Maintenance Roller Lubrification Kit WARNING This procedure is for Service Engineers only. Users should perform the procedure described in the User’s Guide. WARNING Prevent water or other liquids from running onto electrical components or circuits, or through openings in the module. 1 Open the window and apply 10 drops of oil to each hole in the Platen. NOTE Avoid oil spills and make sure you remove any excess oil.
Preventive Maintenance Slider Rods Lubrification Kit In addition to the wearing of the Scan-Axis Motor, the friction in this area can increase due to the accumulation of ink particles and dust from the media or the atmosphere in the vicinity of the Slider Rods. Scan-Axis maintenance requires the cleaning of the Slider Rods properly, and a lubricant to apply onto the Rods. Use the User’s Slider Rods Lubrification Kit to do this.
Preventive Maintenance Cleaning the Platen WARNING This procedure is for Service Engineers only. Users should perform the procedure described in the User’s Guide. WARNING Prevent water or other liquids from running onto electrical components or circuits, or through openings in the module. To clean the Platen, perform the following procedure: 1 Open the window and using a dry brush, remove the ink deposits from the cutter groove. 2 With the dry brush remove the ink deposits from the Platen surface.
Preventive Maintenance Moisture on the Printer Users should use the Printer in an environment between 20% and 80% relative humidity. To recover from moisture condensation, turn the Printer Off, and, using the main Roller as a reference, wait until the Printer is completely dry before using it again. Noisy Carriage Bushing To prevent noisy movement of the Carriage, remove aluminum or dust particles from the bushing at the back of the Carriage, and from the Slider Rods along which the bushing moves.
Preventive Maintenance Firmware Upgrade This section explains how to perform the System Software (Firmware) Upgrade and the Internal Demo Prints Upgrade (Only for the PostScript Printer) when they are required. There are 3 ways of upgrading the System Software: 1 Downloading the Firmware from the DesignJet Online Website http://www.designjet.hp.com. 2 Using the Firmware Upgrade CD (See part number on Page 7-58). 3 Replacing the Hard Disk Drive (HDD).
Preventive Maintenance Upgrade Instructions - 5000 Series ONLY 5500 SERIES ONLY UPGRADE INSTRUCTIONS FOR THE 5500 SERIES CAN BE FOUND IN THE USER’S GUIDE WARNING The Firmware Upgrade process will delete all pending print jobs. NOTE Ensure that the Printer is powered ON and that the Media has been removed from the Printer. NOTE If you upgrade the firmware while media is loaded, you will get the system error "0d0000 033f019C".
Functional Overview 10 Introduction, page 10-2 Electrical System, page 10-2 Front Panel, page 10-3 Scan Axis, page 10-3 Paper Axis, page 10-4 Ink Delivery System (IDS), page 10-5 Ink Supply Station (ISS), page 10-6 Tubes System, page 10-6 Printheads, page 10-7 Air Pressurization System (APS), page 10-8 Service Station, page 10-9 Print Head Cleaner (PHC), page 10-9 HP DesignJet 5000 and 5500 Series Printers Service Manual 10-1
Functional Overview Introduction This Chapter contains a simplified description of the HP DesignJet 5000 and 5500 Series Printers. Electrical System The electrical system of the Printer consists of six major blocks and their associated cabling: Power Supply Unit: Connected to the mains supply of whichever country this block provides 24V, 5V, 3.3V and -15V to the rest of the electrical system.
Functional Overview Front Panel The Front Panel is used to display messages, configure the Printer and send commands to the Printer via the keys. The display is a 128 x 64 pixel graphic LCD and can display both text and graphics at the same time. The display has an LED backlight to improve its viewing characteristics. The contrast of the LCD can also be adjusted. The navigation and command keys are distributed in three groups: 1 key at the bottom left corner is used to select the Print Quality (Max.
Functional Overview Paper Axis The Paper Axis determines the motion of the media through the printer. Its main parts are: Paper-Axis Motor - provides traction to the Overdrive. Center Platen and Overdrive - controls the printing path and expansion of the media. Pinch-wheels and Lever - “captures” the media and provides added friction. Center Guide and Entry Roller - feeds media through the paper path. Vacuum Fans - provides the required vacuum to maintain the media flat over the Center Platen.
Functional Overview Ink Delivery System (IDS) The Ink Delivery System (IDS) delivers ink under pressure from the large capacity off-axis Ink Cartridges via permanently connected tubes to the high throughput Printheads. The IDS consists of six major subsystems: The Ink Cartridges. The Ink Supply Station (ISS). The Tubes System. The Printheads. The Air Pressurization System (APS). The Leak Detect System (LDS). Ink Cartridge The HP No.
Functional Overview Ink Supply Station (ISS) In the Printer, the Ink Cartridges reside inside the Ink Supply Station (ISS). This module is situated on the left side of the machine. The ISS includes the plastic housing that surrounds the supplies, the latch mechanism, and the fluid and electrical connections to the Ink Cartridges. It also supports the Air Pressure System (APS) that forms a replaceable module clipped under the ISS.
Functional Overview Tubes to Printhead Connection Tubes Joint for Ink Leak Detection Ink Supply Station The Tubes move back and forth inside the volume defined by the Tube Guides. The Tube Guides are a pair of sheet metal parts with opposing U-shaped profiles. The Tubes are threaded inside a protective extrusion called the Tube Carrier which consists of a base material that provides the structure of the part, and a resistant outer part protecting the structure.
Functional Overview Air Pressurization System (APS) The APS is the system that provides and controls the pressurization of the ink in the Ink Cartridges and is located under the ISS. The key purpose of this system is to ensure the minimum required ink pressure at the inlet to each Printhead respectively at the required print rates. The APS is also used to provide pressure for tube purge and as part of the blow prime system operation.
Functional Overview Service Station The Service Station consists of a linear motion mechanism with a chassis containing one PrintHead Cleaner (PHC) for each printhead. Attached to the Service Station chassis, one optical drop detector provides nozzle check functionality. Print Head Cleaner (PHC) The PHC case is the main structural part of the replacement module.
Functional Overview 10-10 HP DesignJet 5000 Series Printers Service Manual
About this Edition This is the 2nd edition of this Service Manual 1st edition, titled HP DesignJet 5000 and 5000PS Service Manual - August 2000 2nd edition, titled HP DesignJet 5000 and 5000PS Service Manual - January 2001 3rd edition, titled HP DesignJet 5000 and 5500 Series Service Manual - September 2002
What’s in this Service Manual This manual contains information necessary to test, calibrate and service: - HP DesignJet 5000 Printer - 42” Model (P/N C6090A/V) - HP DesignJet 5000 Printer - 60” Model (P/N C6095A/V) - HP DesignJet 5000PS Printer - 42” Model (P/N C6091A/V) - HP DesignJet 5000PS Printer - 60” Model (P/N C6096A/V) - HP DesignJet 5500 Printer - 42” Model (P/N Q1251A/V) - HP DesignJet 5500 Printer - 60” Model (P/N Q1253A/V) - HP DesignJet 5500PS Printer - 42” Model (P/N Q1252A/V) - HP DesignJet 5
