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HP DESIGNJET 5000 User's Manual

1. ACCURACY Load media for calibration 4 The Printer will start to print the Accuracy Calibration Pattern and the following message will be displayed on the front panel ACCURACY Calibrating Below is a sample of the pattern printed A b b bo ho hb hb 4 5 Once the Accuracy Calibration Pattern is completed the following message will be displayed Select Measure Pattern and press Enter to automatically start the Load Unload Media procedure E o Recalibrat Back gag Meke Selection HP DesignJet 5000 and 5500 Series Printers Service Manual 5 15 Service Calibrations 6 The Printer will unload the media and request you to remove it from the Printer Press Enter to continue E o Roll Unloaded Back Remove Media i it Press Enter to continue Sj 4 Enter 7 The following message is displayed Press Load Unload Media to start the load procedure for the printed sheet Load Unload Top an ACCURACY E Press Load Unload EE t key to load printed sheet feel 4 Press Load Unload Media Snir Press Enter 8 When loading rotate the pattern so that the edge with the arrows points to the leading edge and then reload the pattern with the arrow edge print facing down The Printer will load the pattern and then measure the alignment marks using the Line Sensor on the Carriage Assembly The following message will be displayed while the Printer measures the pattern A
2. In this situation please take note of the Firmware version the situation where the problem can be reproduced and the COMPLETE system error code and report it to the division Try the following m Power cycle the Printer and to check whether it still fails m If it still fails upgrade to the latest Firmware revision as the newer revisions are more stable and solve many of the problems and check whether it still fails E If it still fails report the error to the division In this case it is important to report the firmware revision the printer is using the complete error number which software application the customer is using name version etc and as much information as possible about when it occurred ffff ffff 02b301b0 This error usually appears at the beginning of Printhead Alignment due to a firmware bug If the error appears frequently upgrade to firmware release A 02 xx This problem is solved in any A 02 xx firmware release HP DesignJet 5000 and 5500 Series Printers Service Manual 2 5 System Error Codes System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action ffff ffff Oldexxxx There is a problem with the I O Card happens during power up Try the following m Disconnect the Network Cable and check if the error still appears during power up m If the error does
3. This error usually appears at the beginning of Printhead Alignment due to a firmware bug If the error appears frequently upgrade to firmware release A 02 xx 0D0004 xxxxxxxx Non Continuable This is an internal general error code which can appear during the Printhead Alignment process The chance of this error appearing is less than 0 5 and there is nothing wrong with the Printer Re boot the Printer and the error code should not appear again HP DesignJet 5000 and 5500 Series Printers Service Manual 2 23 System Error Codes System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action NOTE System Error 0D0005 03180382 Non Continuable After cutting the media the Printer cannot deactivate the Cutter Try the following m Check the Cutter and the Carriage Assembly to make sure that they are installed correctly OFXXXX Non Continuable A Firmware Error has occurred Refer to System Error Code ffff ffff xxxxxxxx OF0200 00b007be This is an error related to an internal crash involving media profiles and memory Try the following m This error is sporadic and very rare just switching the Printer OFF and ON again will cause it to disappear m If the customer has this problem frequently recommend upgrading the firmware revision to A 02 xx in order to lower the
4. Use the following table to configure your system correctly What to Configure Configuration Setting Optimal Setting Printer Front Media Set to match the media Panel Menu type loaded in the Printer Dry time Set to Automatic HP driver Print mode setting Set to Max Quality Windows AutoCAD or Mac Non HP drivers The settings available In the software Software RIPs depend on the driver The application most typical settings are E Print Quality Settings E Half Tone E Media selection See the user s guide for your application for more information about its print quality settings E Set Print Quality to Max Quality E Use no Half Tone or Printer default E Make sure that the media setting matches the media loaded in the Printer Print Quality Problems For Color Accuracy and Consistency problems do the following E Set the Color Calibration in Printer Setup Internal RIP Settings Color Calibration to ON or turn it ON E Perform a color calibration and print the plot again any plots that have already been processed by the Printer will not benefit from the Calibration unless they are sent to the Printer again 6 16 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 E Perform the Printhead Alignment
5. 2 Service Calibrations 3 Service Tests 4 Use the Arrow keys to scroll through the Service Utilities selections Press Enter 1 2 Prime TUBES 1 3 Altitude Setup 1 4 EEROM Setup 1 5 Reset Life Counters 1 6 Backup EEROM Press Enter 5 Press the Enter key to begin a specific operation when the required Service Utility is highlighted HP DesignJet 5000 and 5500 Series Printers Service Manual 4 15 Service Tests and Utilities 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 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 If the Printer hangs up during an operation switch the Printer OFF and restart from step 1 4 16 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Tests and Utilities 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 Lift the Window on the printer and deactivate the Win
6. 3 Replacing the Hard Disk Drive HDD NOTE 5000 SERIES ONLY 5500 SERIES ONLY NOTE Only replace the HDD when there is an actual hardware problem with the HDD The HDD should NOT be replaced solely for the purpose of upgrading the Firmware Downloading the Firmware from the DesignJet Online Website You can check for newer releases of the firmware at the Hewlett Packard DesignJet Online Web site at http www designjet hp com Select the Technical Support link and select the product When you download Firmware from this site it is supplied with a utility called DesignJet System Maintenance to simplify the process of upgrading Printer Firmware and media profiles For a detailed description of the Utility refer to the System Maintenance Utility documentation Use the download utility inside the internal webserver To troubleshoot Firmware Upgrade problems refer to the DesignJet System Maintenance Utility documentation or for I O Card configuration problems the LAN Card documentation Using the Firmware Upgrade CD Upgrading the Firmware using the Firmware Upgrade CD is the fastest and easiest method If possible always use this method since downloading the Firmware from the website could take a long time because of the size of the files HP DesignJet 5000 and 5500 Series Printers Service Manual 9 11 Preventive Maintenance Upgrade Instructions 5000 Series ONLY 5500 SERIES ONLY UPGRADE INSTRUCTIONS FO
7. 6 Push the retaining clips on the left side of the APS to release it from the ISS HP DesignJet 5000 and 5500 Series Printers Service Manual 8 67 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 NOTE Before installing the ISS on the Printer make sure the cable and tube are inserted in the ISS slot 8 68 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 69 Removal and Installation 5 Disconnect the Service Station Cable from the Main PCA P15 6 Unclip the Scan Axis Motor Cable from the Service Station NOTE Follow the instructions in step 7 carefully
8. HP Ink Supplies Troubleshooting 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 Messages 3 12 Printhead Errors 3 13 Ink Cartridge Errors 3 16 Printhead Cleaner Errors First Digit A B or 3 18 Replace Message xx15 Replace and xx16 Replace 3 18 Replace Message xx15 Replace and xx16 Replace 3 18 Replace Message xx16 Replace for ALL Printheads During Replacement 3 19 Refill Information DesignJet 5500 Series Only 3 19 Ink Level Sensing ILS Out of Control 3 19 Ink Cartridge Delivers Too Much Ink 3 19 Risks with the Ink Cartridge Delivering Too Much Ink 3 20 Non HP Hardware Detected in the Ink Delivery System 3 21 Risks with Using Non HP Hardware 3 22 ILS Out of Control Detection 3 22 ILS Out of Control Warranty Statement 3 23 HP DesignJet 5000 and 5500 Series Printers Service Manual 3 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
9. NOTE If the Printer hangs up during an operation switch the Printer OFF and restart from step 1 5 6 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Calibrations NOTE NOTE NOTE 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 E Line Sensor to calibrate the intensity of the Line Sensor in the Carriage PCA m Printhead to Media Spacing If you get an error code refer to Page 5 26 Calibration Error Codes for its description and resolution To perform this Service Calibration for a specific LED in the Line Sensor the Line Sensor identifier ID is required The Line Sensor identifier is indicated on the label on the side of the Line Sensor Assembly on the right side of the Carriage If you do not specify a correct value the Printer will use default values for the calibration For the 5000 Series use the ID 00 and for the 5500 Series use the ID 20 Perform Scan Axis Calibration whenever m Carriage is disassembled or replaced m Encoder strip is disassembled or replaced m Center platen is disassembled or replaced Perform the Scan Axis Calibration as follows To perform this Calibration make sure you load white medium that is the full width of t
10. RH Module LED is RED The Spindle LOCK Lever is not closed Check that the TUR Spindle is inserted on the TUR and the automatic lock is closed Check that the LED turns from RED to GREEN when manually closing the Spindle Lock Lever RH Module LED is blinking RED GREEN Problem with the RH Module Sensor connection Check that the sensor cable is well connected to the Sensor Assembly If the problem persists call an HP representative Media is not being rolled TUR is ON but is not set up correctly Check that the RH Module LED is ON and GREEN Check that the TUR Spindle is inserted and the Spindle Lock Lever is closed Media is not supported or it is not set up correctly in the TUR and the Media skew is causing problems Check that the media weights are being used set to the media size used and the blue flanges are inserted on the media weight Check that the media is stuck to the Spindle as parallel as possible to prevent skew Check that the Deflector Bar is correctly installed and that the Media routing is OK Check that the media is HP supported Transparent media are not supported for being used with the TUR Media is being cut after each print The TUR is not set up in the Front Panel Menu Check that the TUR ON option is activated on the Front Panel Devices Menu 1 40 HP DesignJet 5000 and 5500 Series Printers Service Manual System Error Co
11. m The use of non HP media can easily be the cause of media jams and head crashes especially head crashes because HP media is specially formulated to avoid cockle one of the primary causes of head crashes If the media is not HP approved advise the customer to use HP media and check to see if the problem is now solved The Carriage is at the incorrect height in relation to the Center Platen Adjust the carriage to the correct height Page 5 8 and try to load the media again Check that the Vacuum Fans work correctly Refer to Page 1 10 Problems with Vacuum 1 6 HP DesignJet 5000 and 5500 Series Printers Service Manual Troubleshooting Troubleshooting Shutdowns User Message Warning Switch Power Off If a shutdown occurs you will get the message Warning Switch Power Off followed by Em Check Printhead Cleaner Path m Check Paper Path m 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 Check Printhead Cleaner Path This message appears whenever the Service Station Carriage does not move either because of a bad cable connection a defective motor or because of some obstacle inside the Service Station m If the Printer is new check that the Service Station cable which i
12. 1 3 2 2000m or more Press ENTER to confirm Press Enter to confirm and exit this utility or press Back to return to the altitude settings menu 4 22 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 m The Main PCA and Hard Disk Drive are replaced at the same time EEROM empty m The Hard Disk Drive and Main PCA are replaced at the same time and the Main PCA has already been used valid EEROM content the Printer backs up the data to the Hard Disk Drive storing wrong values for the current Printer m The main PCA EEROM and the Hard Disk Drive EEROM backup are valid at initialization but data is conflicting because they do not come from the same Printer they have a different Model Number or Serial Number and the user has performed the Backup EEROM Utility incorrectly See Page 4 30 m Both the Main PCA EEROM and the Hard Disk Drive EEROM backup are corrupt or fail during Printer initialization 1 In the Service Utilities submenu scroll to 1 4 EEROM Setup and press Enter 1 Service Utilities 1 1 Turn DRIVE ROLLER 1 2 Prime TUBES 1 3 Altitude Setup 1 5
13. For HP Internal Use Only Copyright Hewlett Packard Company 2002 This document contains proprietary information that is protected by copyright All rights are reserved No part of this document may be photocopied reproduced or translated to another language without the prior written consent of Hewlett Packard Company First Edition August 2000 Second Edition January 2001 Third Edition September 2002 Technical Marketing Barcelona Division Warranty The information contained in this document is subject to change without notice Hewlett Packard makes no warranty of any kind with regard to this material including but not limited to the implied warranties of merchantability and fitness for a particular purpose Hewlett Packard shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing performance or use of this material Hewlett Packard Espanola S A Avda Graells 501 08190 Sant Cugat del Valles Spain WARNING The procedures described in this manual are to be performed by HP qualified service personnel only Electrical Shock Hazard Serious shock hazard leading to death or injury may result if you do not take the following precautions Ensure that the ac power outlet mains has a protective earth ground terminal Disconnect the Printer from the power source prior to performing any maintenance Prevent wat
14. remove from the Printer HP DesignJet 5000 and 5500 Series Printers Service Manual 8 85 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 Vox P36 Connector gt lt No P11 Connector DO NOT USE THIS CONNECTOR IF THE P36 CONNECTOR IS PRESENT ON THE PCI to IDE PCA 8 86 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Looped End connects to the Hard Disk Drive Short Connector connects to the PCI to IDE PCA IF THE HDD CABLE IS NOT CONNECTED CORRECTLY IT MAY CAUSE SOME INTERMITTENT PROBLEMS 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 Rea
15. Page 5 11 Replace the Drop Detector Assembly gt Page 8 72 Replace the Service Station Assembly gt Page 8 69 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 0C0040 Error in Printhead Drop Detection This error code appears when the Printer detects that the same area of nozzles do not work in different Printheads The possible causes are either fibres or a piece of paper in the Drop Detector or that the Scan Axis reference is incorrect Try the following m Manually recover the Printheads gt Page 6 15 and check whether the error still appears m If the error does appear again then check that there no fibres or pieces of paper in the Drop Detector E If the error does not appear again then check that the Scan Axis stop of the Carriage is not deformed too much some slight deformation of upto 0 5mm is normal but if it is bigger than that then replace the Carriage Assembly and recalibrate the Printer m If the Scan Axis is OK also then replace the Drop Detector gt Page 8 72 or the Service Station Assembly Page 8 69 and recalibrate the Printer HP DesignJet 5000 and 5500 Series Printers Service Manual 2 21 System Error Codes System Error Problem Description Corrective Action System Error Problem Description Corrective Action System
16. Page 8 46 4 10 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Tests and Utilities i Media Axis Test The purpose of this test is to verify m Overdrive Roller movement E 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 Inthe 3 Service Tests menu scroll to 3 2 Media Axis and press Enter E Tor 3 Service Tests at ee Press Enter 2 The test will start and the following message will appear on the front panel as the test is performed E Top DY Back XX XX u t Analyzing Data Ey 4 P Enter 3 When the test has completed the Maximum and the Average Pulse Modulation Values are displayed for each direction down and up Press Enter to return to the Service Tests menu E o Back i t 3 2 Paper Axis Max PWM Avg PWM 3 2 Paper Axis Max PWM Avg PWM XX XX XX XX hea J Press ENTER to continue Enter Press Enter HP DesignJet 5000 and 5500 Series Printers Service Manual 4 11 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 m The Service Configur
17. 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 amp 3500 2 Use of Coated Media when trying to get precise output If the customer is using any type of Coated Media Bond etc advise them to use glossy or polyester based films when the print accuracy is important Colors are not as Expected If the Application or Driver settings are not correct this could result in colors which are different than the one that were expected m To have full control of the colors that are printed use the CMYK option and no emulation in Driver Sending a file in RGB even with no color emulation could end up in undesirable results If a Postscript file is not sent from a DesignJet 5X00 PS driver make sure you have the following settings in the Front Panel Printer Setup Menu gt Internal RIP settings gt Ink Emulation gt CMYK Native E As a special case Adobe PhotoShop sends Pantone Colors as CMYK no Pantone name Therefore Pantone Calibration does not make any difference The file should be created as CMYK to prevent unexpected color changes Banding at the Top of the Page So
18. 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 ISS 8 64 Air Pressurization System APS 8 67 Service Station Assembly 8 69 Drop Detector Assembly 8 72 Hard Disk Drive HDD 8 74 LAN Card 8 76 Memory and BootROM DIMM s 8 77 Electronics Module Cover 8 79 Main PCA 8 81 PCI to IDE PCA 8 85 Power Supply Unit PSU 8 88 Ink Supply Station ISS PCA 8 91 Ink Leak Detector If Present Only Applicable to the 5000 Series 8 93 Cooling Fans 8 95 Electronics Module as one complete Assembly 8 97 Pinch Wheels 8 98 Pinch Wheel Cam 8 100 Vacuum Fan 8 103 Paper Axis Motor Assembly 8 105 Booster Fan 8 108 Media Sensor 8 109 Entry Roller 8 111 Center Guide Assembly 8 112 Drive Roller Gear 8 114 Front Platen Assembly Only Applicable to the 5000 Series 8 115 Center Platen Assembly 8 117 Deflectors Only Applicable to the 5000 Series 8 119 Heater Assembly Only Applicable to the 5500 Series 8 120 Tube Guide Door 8 124 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 1 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 wh
19. 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 Press Enter to continue INK STARTUP Back Printer startup has finished T Press ENTER to mL Continue ze Enter Press Enter HP DesignJet 5000 and 5500 Series Printers Service Manual 4 2 Service Tests and Utilities lt C ne a NOTE 1 2 3 4 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 In the Service Utilities submenu scroll to 1 3 Altitude Setup and press Enter 1 Service Utilities 1 1 Turn DRIVE ROLLER 1 2 Prime TUBES 1 4 EEROM Setup Za Make Selection 1 5 Reset Life Counters 1 6 Backup EEROM Press Enter The following options are displayed Use the Arrow keys to make the selection and then press Enter To 1 3 Altitude Setup Ea Back Select an altitude Make Selection 1 3 1 0 2000 5 Press Enter Once the option has been selected the following confirmation screen is displayed 1 3 Altitude Setup You have selected the following altitude
20. replace either the ISS cable or the ISS PCA E f the Printer still does not initialize even after removing the Trailing Cable and the ISS cable replace the Main PCA HP DesignJet 5000 and 5500 Series Printers Service Manual Troubleshooting NOTE NOTE Cutter Assembly Problems The Printer does not cut even when using the Form Feed amp 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 m To re activate the Cutter print the Diagnostic Print again and this time letting it finish to the end without any interruptions m If the Cutter still doesn t cut after re printing the Diagnostic Print replace the Cutter Assembly gt Page 8 60 This problem is solved in any A 02 xx firmware release The Cutter does not cut thick paper Canvas amp Non HP Media As in all DesignJets the Cutter can only cut media up to a certain thickness such as Heavy Coated or Photo paper Thicker media or special media such as Canvas cannot be cut E Taking this into consideration when Canvas is selected on the front panel the cutter is automatically disabled but there is nothing wrong with the cutter The Printer hangs while cutting The Printer hangs and the Carriage stops if the window is opened dur
21. 03180382 Non Continuable 2 24 OFXXXX Non Continuable 2 24 0F0200 00b007bc 2 24 0F0200 00b007E5 2 24 0F0200 01E603d2 2 25 0F0100 03180382 Non Continuable 2 25 1f500XX Boot Failed 2 25 e50000 2 26 2 2 HP DesignJet 5000 and 5500 Series Printers Service Manual System Error Codes System Error Codes NOTE NOTE NOTE Introduction Before troubleshooting System Errors if possible repeat the procedure performed when the error was reported 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 gt Utilities Statistics menu The following pages contain a list of System Error Codes and their respective descriptions and recommended corrective actions Only try one recommended action at a time and check if the Error Code has disappeared System Error Codes consist of two groups of alpha numerics XXXXXX YYYYZZZZ The first set of 6 alphanumeric characters consists of the System Error and the second set of 8 digits when present refer to the internal error data If the YYYY digits in the second set of 8 characters are zero 0000ZZZZ this indicates a LAN Card System Error The last four digits ZZZZ of the Error Code must be reported to the vendor support organization For HP JetDirect Cards this error code must be reported to
22. 20 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Marks and or scratches on double sided media If you are using double sided media and there are marks and scratches evident on the media the platen may need cleaning See gt Page 9 9 There are Smears or Scratching on the Printed Media This problem can appear on paper based coated media if a lot of ink printed quickly The media cannot absorb the ink quickly enough and becomes distorted As the Printheads move over the media the Printheads and the media come into contact with each other and the printed image is smeared 1 Press the Cancel key on the front panel if you continue to print the paper may damage the Printheads 2 Cancel the print job from your computer application In order to obtain better results perform the following m Use HP recommended media If the image you are printing has intense color use HP Heavy Weight Coated Economy Paper m Use extended margins or try to increase the print margins by relocating the image on the page from the software application m Ensure the Deflecto
23. 5 million cycles then this message will appear on the Front Panel In this case you must replace BOTH the Service Preventive Maintenance Kit and the Ink Tubes System either Dye or UV depending on which ink system the User has installed 3 Printer Maintenance Advised If ONLY the Scan Axis System has done more than 6 5 million cycles then this message will appear on the Front Panel In this case you must replace Only the Service Preventive Maintenance Kit Ink Tube Maintenance Advised If ONLY the Ink Tubes have done more than 6 5 million cycles then this message will appear on the Front Panel In this case you must replace ONLY the Ink Tubes System either Dye or UV depending on which ink system the User has installed HP DesignJet 5000 and 5500 Series Printers Service Manual 9 3 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 To continue printing without replacing the Ink Tubes press Enter Have Ink Tube Replaced or Risk Printer Damage Contact HP Press ENTER to continue WARNING If Printing is continued the Tubes can break causing a significant ink spillage It is advisable to replace the Ink Tubes as soon as possible For the necessary part numbers refer
24. 60192 1 Left Arc Assembly 7 50 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Quantity Description Comments on Drawing DJ 5000 DJ 5500 Series Series 1 C6095 60190 1 EMC Covers 60 Model only C6090 60180 1 EMC Covers 42 Model only 2 0515 0382 9 Screw center to bottom and top C6071 20026 8 60 6 42 Screw top to chassis 3 0515 2248 4 Screw bottom to chassis C6090 60107 1 Mount Bracket includes right left and center 0515 2248 6 Screw for each bracket 7 52 HP DesignJet 5000 and 5500 Series Printers Service Manual Parts and Diagrams Figure 28 EMC Covers HP DesignJet 5000 and 5500 Series Printers Service Manual 7 53 Parts and Diagrams Spindle and Hub 1 C6095 60182 Spindle 60 Model Spindle 42 Model Blue Hub 3 Spindle Adaptors C6090 60074 C6090 60105 3 C6090 60112 Nl 7 54 HP DesignJet 5000 and 5500 Series Printers Service Manual Parts and Diagrams Figure 29 Spindle and Hub HP DesignJet 5000 and 5500 Series Printers Service Manual 7 55 Parts and Diagrams Rollfeed Brakes C6072 60158 1 1 Left Rollf
25. 9 5 E Replace the Carriage Assembly gt Page 8 46 1060 User Scan Axis Alignment Error in fast speed section in Black and Magenta Pattern Refer to Calibration Error Code 1040 1061 User Scan Axis Alignment Error in fast speed section in Cyan and Yellow Pattern Refer to Calibration Error Code 1041 1062 User Scan Axis Alignment Error in fast speed section in Light Cyan and Light Magenta Pattern Refer to Calibration Error Code 1042 2001 User and 2002 User Closed Loop Color plot file is not available or is in the wrong format m Download a Firmware Upgrade gt Page 9 13 2003 User The Printer has used all its SWAP memory and does not have sufficient memory to read the plot E Power the Printer OFF and ON from the back of the Printer HP DesignJet 5000 and 5500 Series Printers Service Manual 5 31 Service Calibrations Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action 2004 User Media Profile Error Try the following m Download a Media Profile for the current medium E Power the Printer OFF and ON from the rear of the Printer m Download a Firmware Upgrade gt Page 9 13 2005 User Closed Loop Color Pattern Error Try the fol
26. Accuracy Calibration has not been done for the Media now loaded Banding may occur 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 E Select the Media loaded in the Media Options menu and perform the Accuracy Calibration Refer to the User s Guide Media Solutions Banding due to Ink Cartridge replacement while printing A user has removed the Ink Cartridge while the Printer was printing which has caused the Printer to stop If the user does not replace the Ink Cartridge immediately when the Printer starts to print again a band will appear in the position where the printing restarted This is because the wet ink interacts with the dried ink on the media causing the band to appear To solve the problem try the following Do NOT remove the Ink Cartridge while the Printer is Printing Only replace remove Ink Cartridges in between Prints m If the Ink Cartridge was replaced due to the Empty status on the Front Panel then advise the customer to replace the Ink Cartridge when the Very Low status is showing on the Front Panel HP DesignJet 5000 and 5500 Series Printers Service Manual Troubleshooting Hue shift on HP Colorfast Adhesive Vinyl media Under high humidity conditions approx gt 65 the colors tend to fade over time particularly colors that require Magenta To solve the problem try t
27. Calibrations Printhead Alignment using the same media with which you were experiencing problems Media m Make sure that you use HP media E Store media according to its Environmental Specifications E Select the correct media type through the Front Panel when loading it 6 2 HP DesignJet 5000 and 5500 Series Printers Service Manual Print Quality WARNING 6 10 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 m Print the same sample using the Non HP driver and their normal media E Print one of the internal demos or Diagnostic Print using HP Media and configuring the Printer as indicated previously If the output obtained using the HP Solution is good and the one obtained through the 3rd party solution is bad HP support organization should communicate to the customer that the problem is not in the Printer and that they should address it through the 3rd party vendor support structure Service Accuracy Calibration E Perform the Service Accuracy calibration using HP High Gloss Photo Paper gt Page 5 14 Do NOT use any other type of media apart from HP High Gloss Photo Paper when performing the Service Accuracy Calibration If the problem is in Production Mode perform the Banding Calibration on the media and Printmode in which the problem appears gt Page 5 44 If the customer is using HP
28. Color Print 6 22 Enrichment Issue 6 24 Ink Marks on Printouts 6 27 HP DesignJet 5000 and 5500 Series Printers Service Manual 6 1 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 Problem reproduction m Reproduce the problem that the customer is seeing using their original settings You can use the Demo Print in order to do it Printer configuration m Print Mode Set to Max Quality in the Printer and in the driver m Dry time Set to Automatic Select the correct media setting when loading the media Hardware check list Firmware Revision m Check if the latest version of the Firmware is installed If not Install the latest Firmware revision gt Page 9 11 Printheads Printhead Troubleshooting Process m Check the Printhead status in the front panel E If xxxx REPLACE is displayed the faulty Printhead may be replaced gt Page 3 13 E If the xxxx RECOVER is displayed recover the Printhead gt Page 6 15 m If you don t have any samples yet reproduce the original problem with the correct Printer settings m Print the Diagnostic Print See Page 6 5 using the exact settings and Media that the Customer used when faced with the Print Quality problem Printhead Alignment and Check E Perform the Printhead Alignment from the Printer Setup menu Utilities
29. Cover 1 Do steps 1 2 and 6 of the EMC Covers as one assembly procedure 2 Remove the following screws Type B and N screws from the Top EMC Cover m 13 T 15 screws for 60 Model m 11 T 15 screws for 42 Model 3 Lift the Top EMC Cover off Printer HP DesignJet 5000 and 5500 Series Printers Service Manual 8 33 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 The next step is performed by putting pressure on the Spring Clip as shown 7 Release the Encoder strip from the 1 Apply Pressure 2 Release Encoder Strip Spring Clip 8 34 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 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 Insert Encoder Strip Encoder Sensor HP Des
30. DesignJet 5000 and 5500 Series Printers Service Manual Service Tests and Utilities 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 TUBES 4 18 Altitude Setup 4 22 EEROM Setup 4 23 Reset Life Counters 4 28 Backup EEROM 4 30 Image Quality Warning 4 32 Diagnostic Print 4 33 Sleep Mode DesignJet 5500 Series Only 4 34 HP DesignJet 5000 and 5500 Series Printers Service Manual 4 1 Service Tests and Utilities Introduction NOTE NOTE 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 Phone Support In certain circumstances a Call Agent can try and troubleshoot the Printer by requesting the Customer to perform a Service Test or Utility via the phone Using this process it can
31. Error Problem Description Corrective Action WARNING OCOOFF 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 Try the following E Re boot the Printer and the error code should not appear again If the problem continues to appear and the customer is using an external RIP ask them to try one of the internal print modes by printing from the HP Driver If the problem disappears then the RIP print mode was causing the problem and the customer should contact the RIP vendor m Check whether there is a printhead in the XX21 REPLACE status If there is replace that Printhead m If there is no Printhead in the XX21 REPLACE status print the Diagnostic Print to find the Printhead with the failing nozzles 0C1000 Primer not calibrated or the calibration settings have been lost Try the following E Perform the Service Station Calibration gt Page 5 Em Replace the Service Station Assembly gt Page 8 69 0C1001 Primer Shutdown Error Try the following m Check that the Primer Stepper Motor Cable is NOT broken or damaged and that the Primer Arm moves freely from side to side E Replace the Service Station gt Page 8 69 m
32. If the Error Code continues replace the Main PCA gt Page 8 61 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 2 22 HP DesignJet 5000 and 5500 Series Printers Service Manual System Error Problem Description Corrective Action System Error Problem Description Corrective Action NOTE System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Codes 0D0000 Continuable No Media Profiles Available Download a media profile for the ink type being used 0D0000 033f019C No Media Profiles Available If you upgrade the firmware while media is loaded you will get the system error Od0000 033f019C In this case press Enter and you will get the message no media profiles available The solution is to unload the media and switch the Printer ON and OFF again This problem only appears when you try to upgrade from Non UV ink firmware to UV ink firmware while the media is loaded 0D0002 Continuable Insufficient Memory to Initialize HPGL2 RTL The minimum memory required is 96 Mbytes so verify memory installed on the printer using the Statistics menu refer to the User s Guide 0D0003 xxxxxxxx Non Continuable
33. LOOSEN the screw and DO NOT remove 7 Loosen the T 20 screw Type A securing the Service Station to the side plate 8 70 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 E Service Station gt Page 5 11 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 71 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 5 Release the cable from the Service Station 8 72 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Move the Drop Detector towards the front of the Service Station until the locating pin reaches
34. Miscellaneous Items 7 58 Media Types 7 59 HP DesignJet 5000 and 5500 Series Printers Service Manual 7 1 Parts and Diagrams Printer Support Printer Support Reference HP Part Number Quantity Description Comments on Drawing DJ 5000 DJ 5500 Series Series C6090 60049 2 Foot Assembly C6090 60047 2 Legs Assembly C6095 60167 1 Top X Brace Assembly 60 Model C6090 60055 1 Top X Brace Assembly 42 Model 4 C6095 60166 1 Bottom X Brace Assembly 60 Model C6090 60056 1 Bottom X Brace Assembly 42 Model C6090 60046 1 Hardware Kit Includes Screws and Screw Drivers 7 2 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP Part Number Quantity Description Comments TEM DJ 5000 DJ 5500 Series Series 1 C7770 60148 1 42 Bin includes the Bin Support 2 C6095 60282 1 Take Up Reel Spindle 60 Model C6090 603 10 1 Take Up Reel Spindle 42 Model 3 C6090 60183 1 Left Take Up Reel Holder 4 C6090 60182 1 Right Take Up Reel Holder C6095 60189 1 Take Up Reel Tubes 60 Model C6090 60177 1 Take Up Reel Tubes 42 Model 6 Q1253 60017 1 Take up Reel Deflector 60 Model Q1251 60076 1 Take up Reel Defl
35. Page 8 111 8 100 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation 16 Remove the Center Guide Refer to Page 8 1 2 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 101 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 o ENNA m ta INSERT INTO a CAM SLOT IN BEAM SIDEPLATE 2 Hold the Cam Lever Linkage over its slot in the Sideplate and insert the Cam into it 2 INSERT 3 Push the Cam with the Cam Lever Linkage into the Sideplate 8 102 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 5 Remove the 4 T 20 screws Type L tha
36. RTL Boot ROM DIMM 05 00 01 OEM Boot ROM DIMM Reference HP Part Number Quantity Description Comments on Drawing DJ 5000 DJ 5500 Series Series 6 Q1252 60006 1 OEM PS Boot ROM DIMM 06 00 01 Q1251 60089 1 OEM RTL Boot ROM DIMM 06 00 01 C6090 60299 1 OEM RTL Boot ROM DIMM 02 01 02 7 26 HP DesignJet 5000 and 5500 Series Printers Service Manual Parts and Diagrams N ham ye r e f 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 HP Part Number Quantity Description Comments TEM DJ 5000 DJ 5500 Series Series 1 Q1251 60085 1 Right Rear Cover 2 0515 0382 1 Screw 3 Q1251 60086 1 Left Rear Cover 4 0515 0382 1 Screw 5 C6095 60140 1 Extension Cover 60 Model only 6 0515 0382 4 Screw 7 C6090 60032 1 Electronics Module Cover Includes EIO Cover and Hard Disk Cover 8 0515 0382 15 Electronics Module Cover Screw C6090 60109 1 Electronics Cable Retainer 7 28 HP DesignJet 5000 and 5500 Series Printers Service Manual 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
37. Service Configuration Print indicates that the Calibration has not been performed E Just ignore this information about the Line Sensor calibration m If there are any errors related to the Line Sensor perform the Scan Axis calibration to make sure that the Line Sensor calibration is completed Media Axis Problems Printer unloads media it suddenly starts to rewind and unloads the media If the window was raised at exactly the same moment when the Printer moved the media e g during media loading from that moment onwards the Printer will always reject the media unless the Printer is turned OFF and then back ON again Em Problem disappears after re booting the Printer This problem is solved in any A 02 xx firmware release 1 20 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 m The customer should print using the HP Driver to check that the Printer is printing without any problems m The only solution to this problem will be to upgrade to the firmware for the UV inks A 02 XX when it is available NOTE This problem is solved in any A 02 xx firmware release 2 The Printer hangs at Initializing Please Wait The Printer hangs showing the fol
38. 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 m Always handle plots with care m Use of the Take Up Reel eliminates handling and avoids wrinkles m Use heavier media m For Heavyweight Coated media select faster print modes such as Heavyweight Coated Economy for Media selection and or Productivity Print mode m If damage is slight Lamination will help towhead defects m Use of Fixative Sprays immediately after printing may protect the image Worm marks cockle on part of plots on paper based media At high temperatures and under dry conditions worm marks may occur on initial parts of plots when printing solid fill areas in medium tone colors Try the following m Advance the media manually by 15 mm m Select Heavy Coated for Media setting E Select Productivity mode to reduce ink density HP DesignJet 5000 and 5500 Series Printers Service Manual 1 15 Troubleshooting Drying Time Too Long for HP Studio Canvas Under conditions of high humidity gt 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 m Reduce the level of humidity lt 70 that the Printer is wo
39. 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 8 16 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 17 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 T 15 screw Type D from the support that attaches the Media Lever to the Sideplate 8 18 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation 5 Remove 1 T 15 screw Type H t
40. be determined whether the Printer requires any on site maintenance In Phone Support the user will have access to a limited number of Service Tests or Utilities Diagnostics Self Test Initialization Sequences Whenever the Printer is switched ON it automatically performs a series of internal self tests and mechanical initialization sequences If any of the parts fail an error code will appear Below is a description of the initialization sequence describing front panel messages and the sequence of the Print Quality LEDs the error messages and error codes that may appear and the corrective action Because of the speed at which the initialization sequence is performed some of the steps described in the intialization process may not be visible unless they are interrupted by an error code Before troubleshooting error codes try the following Check that the BootROM DIMM the DRAM DIMM s and the Hard Disk Drive are correctly installed Try powering the Printer Off and On to see if the error code disappears 4 2 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Self Diagnostics Initializati
41. component Refer to the table on Page 5 2 to determine when a calibration is required NOTE Remember that certain Calibrations are required even if an Assembly has been disassembled to gain access to another Assembly or Component For information on the Service Calibrations and how to use them see 5 Service Calibrations Troubleshooting Calibration Error Codes Chapter 5 Service Calibrations contains a list of Error Codes that are reported when a Calibration fails Calibration error codes consist of a four digit number XXXX 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 1 3 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 Initialization Self Diagnostic Errors Chapter 4 Service Tests and Utilities describes the Printer initialization sequence and reports errors that may be repo
42. frequency of the error This problem is solved in any A 02 xx firmware release OF0200 00b007ES Problem Refer to System Error Code 0F0200 00b007bce Description 2 24 HP DesignJet 5000 and 5500 Series Printers Service Manual System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Codes OF0200 01E603d2 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 Try the following E Recommend to the customer to print via the Network Card because the transmission time via the Parallel Port is very slow m If the customer insists on printing via the Parallel Port ask them to check the Parallel Port settings on the PC that was used when the error occurred The Parallel Port setting in the PC BIOS should be in the ECP mode This configuration should decrease the frequency of the error OF0100 03180382 Non Continuable After cutting the media the Printer cannot deactivate the Cutter Try the following m Check the Cutter and the Carriage Assembly to make sure that they are installed correctly 1f500XX Boot Failed This is an error related to the Hard Disk Drive either the connections are bad or the Hard Disk
43. in the Carriage If there are Printhead insertion problems or Ink Supplies Error Codes occur frequently see Page 3 1 2 the Service Configuration Print available in Printer Setup Utilities Test Prints indicates usage limits to see whether excessive wear is the likely cause of the problem Printhead insertion limits are m 600 Carriage flex circuit insertions m 350 Tubes septum insertions There are no warning triggers when the Printhead insertion limits are reached 9 2 HP DesignJet 5000 and 5500 Series Printers Service Manual Preventive Maintenance NOTE NOTE Warning Stop Triggers 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 m 6 5 million for the Carriage m 6 5 million for the Tubes The number of cycles can be checked at anytime by printing the Service Configuration Print Remember to perform the Reset Life Counters Service Utility Refer to gt Page 4 28 to set the usage cycles to zero for the worn parts replaced with parts from the Service Preventive Maintenance Kit Service preventive maintenance messages will not disappear until the counter is reset for the part replaced Printer Maintenance Advised If BOTH the Scan Axis System and the Ink Tubes have done more than 6
44. in the Ink Supply Station m Color lockouts allowing insertion of only one color in a given slot Ink Type Lockout Smart Chip Ink Connector p d Ai c t Color Type V r Connector Lockout HP DesignJet 5000 and 5500 Series Printers Service Manual 10 5 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 These are the key functions of the ISS E Ink Cartridges support and location E Limit creep of cartridge side walls m Avoid incorrect insertion of colors and inks m Contain ink from leaks E Support the Air Pressurization System APS Air Connector Connector to to APS ISS PCA Ink Type Tubes Lockout Latch to ISS Floaters Tubes System The Tubes System is the assembly that performs these functions Conduct the ink pumped from the Ink Cartridge to the Printhead Conduct the air from the pump into the Ink Cartridge E Keep the ink in good condition until it is delivered to the Printhead E Avoid leaks and minimize ink on customer 10 6 HP DesignJet 5000 Series Printers Service Manual Functional Over
45. it moves smoothly m If the Printer still fails check that the Scan Axis motor is connected correctly to the Main PCA and that the cable is not damaged m If the error remains replace the Belt gt Page 8 46 or the Scan Axis Motor gt Page 8 57 1 8 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 m If the Printer still fails replace the Main PCA Page 8 681 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 m Switch OFF the Printer and move the Carriage from side to side to verify that it moves smoothly m If it still fails check the Encoder Strip and if necessary clean it Check Printhead Path 3 This is always caused by high friction in the Printhead path Only in very special cases when it happens inside the Left Hand Cover incorrect assembly of the tube system causes it m Apply Oil along the complete axis of the Slider Rods with the User s Slider Rods Lubrification Kit gt Page 9 8 Replace Message xx15 Replace and xx16 Replace In certain circumstances e g Printhead crash without Printer shutdown the message xx15 Replace or xx16 Replace
46. juO papeo7 0N S AUOVRUOSISOS D atdesddy AUO ogewony O IdUoS sod i c 19 dH _ Bue q 4O UO suie paonpay HO UO Joung Device Setup Menu Jeaddy skemv poN Nueyy In ul Je ddy j uO wele HP DesignJet 5000 and 5500 Series Printers Service Manual 1 27 Troubleshooting Utilities Menu ul ed AINSE N UB d 942919 ayeiquyeoey Asoyjoey 0 Say __ soueusluley SUS P09 1U04 Sd Ad POD Sd nueyy yneyoq A34 BPOD ASIC PIEH ad ed1as juasaid wey Soses Ayen ud yoda abesn ByUOd BdIAIES B1jU09 Z 19 dH SJUWd SOL Aoeinooy UONBIGIED 10109 uawuBbIye peeujud SUOIesgIeD gt HP DesignJet 5000 and 5500 Series Printers Service Manual 1 28 Troubleshooting Internal RIP Settings Menu PostScript Only Always Appear Only Appear in Full Menu Mode 1 29 HP DesignJet 5000 and 5500 Series Printers Service Manual Troubleshooting Queuing and Nesting Menu PostScript Only Only Appear in Full Menu Mode Always Appear Boo 1 30 HP DesignJet 5000 and 5500 Series Printers Service Manual Troubleshooti
47. make sure that the Front Panel Cable is not damaged HP DesignJet 5000 and 5500 Series Printers Service Manual 1 5 Troubleshooting NOTE NOTE NOTE ALL the Front Panel LEDs are Lit but Nothing Else Happens The BootROM DIMM is NOT correctly installed or is the wrong type 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 Ifthe problem persists replace the BootROM DIMM Page 8 77 For more information refer to Electronics Problems on page 1 21 Troubleshooting Media Jams Printhead Crashes If using HP Coated Media when problem occurred please also refer to Page 1 11 The failure modes media jam and head crash are grouped together because in many cases a media jam causes the media to lift up into the carriage path and cause a head crash thus causing many media jam failures to be reported as head crashes Did the media jam occur when loading media m If the client has had media jams it is common for pieces of media to get stuck in the media path Clear the media path When clearing a media jam sometimes media is stuck in the paper path To clear this you must lift the media lever and insert thicker media into the paper path to push out the media that is still stuck there Is the customer using non HP media
48. may appear on the front panel This is due to a temporal disconnection between the Printhead and the flex circuit in the Carriage Assembly m Clean the Printheads and the Carriage interconnects refer to page 9 6 Carriage Interconnect Wiper and reseat the failing Printheads HP DesignJet 5000 and 5500 Series Printers Service Manual 1 9 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 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 If the Vacuum does not hold the sheet in place no suction then try the following m Check that the holes in the Center Platen are NOT blocked Em Clean the Overdrive using the Platen Cleaning Utility gt Page 9 9 m Check that the Vacuum and Booster Fans are installed correctly Em Replace the Vacuum Fan gt Page 8 103 m Replace the Booster Fan gt Page 8 108 Ifthe Vacuum held the sheet in place but couldn t correctly load it then there could be a problem with the Overdrive In this case replace the Center Platen Assembly gt Page 8 717 Vacuum suction much lower at high
49. media and repeat the Diagnostic Print 5 Study each of the test patterns in the order that they are shown i e 1 through 5 6 If you do not see any problems with the Diagnostic Print then the problem may not be with the Printer itself The problem may be with the RIP or the driver for example Refer to Page 6 3 Step 6 However if you do see problems with the Diagnostic Print then continue with the following procedures which will help you to diagnose the problem 6 4 HP DesignJet 5000 and 5500 Series Printers Service Manual Print Quality Printing the Diagnostic Print Once the message Ready is displayed on the Front Panel scroll to the Printer Setup Options icon and press the Enter key Press Enter 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 Top Back Internal RIP settings E Make Selection Queuein ng amp Nesting sl HP GL 2 settings a I Enter Press Enter For On Site Engineers accessing the complete list of Service Utilities a Once inside the Utilities Menu press the following key combination to access the complete list of Service Utilities Utilities DY wp Usage Es Back Menu Mode Full Ea 7 Reset WebAccess paswd Press Up Image quality print OOo 4 and Enter Statistics Enter Together The option selected in the menu does no
50. model Printers HP DesignJet 5000 and 5500 Series Printers Service Manual 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 m Check that the media sensor cable is connected correctly m Check that the media sensor cable is not damaged and that the media sensor is clipped correctly m Replace the Media Sensor gt Page 8 109 3 The Line Sensor does not detect the leading edge of the media To verify this load media ideally white media such as Coated or Photo Gloss into the Printer If the message comes up during the loading process the Lens Cover Assembly is either not installed correctly or it is dirty In this case replace the Lens Cover Assembly gt Page 9 5 If this fails replace the Carriage Assembly gt Page 8 46 User message Warning Incorrect type of tubes system This error message appears if the electrical connector of the Ink Tubes System is not connected correctly especially after the Tubes have been replaced Other causes are defective EEROM in the Ink Tubes System or ISS PCA m Switch OFF the printer open the rear left cover and connect or re connect the Electrical Cable the colored flat cable that is connected to the rear of the Ink cartridge Tube Connector E If the problem persists check that the Electrical Cable i
51. not appear again then the problem may have been that the Printer was receiving some information through the port while powering up E If the error does appear again then power OFF the Printer remove the I O Card from the back of the Printer and power ON the Printer again Check if the error still appears during power up If the error does appear again replace the Main PCA gt Page 8 81 or the Hard Disk Drive gt Page 8 74 If the error does not appear again powers up correctly without the I O Card then try inserting the I O card in the second slot to check if it works If it doesn t work in the second slot then replace the I O Card If the new I O card also fails replace the Main PCA gt Page 8 8 or the Hard Disk Drive Page 8 74 ffff ffff 030d0170 or ffff ffff 030d0171 At power up the Printer thinks it is smaller than 42 inches Try the following m Check that there are no obstacles in the Scan Axis which stops the Carriage from reaching the end stops on both sides m Check that the Carriage moves freely from side to side m Check that the IDS Crane is installed correctly on top of the Carriage and that the Carriage Cover is clipped on correctly ffff ffff 031609xx This error code only appears if the Main PCA was replaced without removing the media from the Printer because the firmware tries to find the last media information in the EEROM Since the information cannot be found this err
52. not available and the message below will be displayed Press Back to return to the EEROM menu EE To 1 4 2 Set Japanese Fonts B Press Back Font type not available a ao for this model of printer T Press BACK oa to return e iL ae Enter NOTE If the printer is an HP DesignJet 5000PS or 5500PS but the Hard Disk Drive does not contain any Japanese Fonts then the message below will be displayed Press Back to return to the EEROM menu EE o 1 4 2 Set Japanese Fonts Only Roman fonts peg pack Press Back ilable F NOT bechanged mt Press BACK to return E 4 to menu Oo Enter a Select 1 4 3 Set Japanese Font and press the Enter key The message below will be displayed Select Yes to load the Japanese fonts to the hard disk Select No Cancel to return to the EEROM Setup utility E To 1 4 2 Set Japanese Fonts Back Set default font type to Japanese T may 4 26 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 E Tor 1 4 2 Set Japanese Fonts Back You have set the E default font type to Japanese E T Press ENTER to confirm or J BACK to correct e Enter Make Selection HP DesignJet 5000 and 5500 Series Printers Service Manual 4 27 Service Tests and Utilities Reset Life Counters The purpos
53. print quality problems like banding Carriage Height Calibration gt Page 5 8 The purpose of this Service Calibration is to adjust the distance between the Carriage and the Center Platen This calibration is necessary in order to prevent problems like Printhead crashes HP DesignJet 5000 and 5500 Series Printers Service Manual 5 3 Service Calibrations Entering the Service Calibrations Menu Once the message Ready is displayed on the front panel scroll to Printer Setup Options icon and press the Enter key Roll Hewlett Packard Photo Imaging Gloss For On Site Engineers accessing the complete list of Service Calibrations 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 DY ve Device setup T O setup Internal RIP Sung Queuein ng amp Nesting HP GL 2 settings Press Enter Once inside the Utilities Menu press the following key combination to access the complete list of Service Calibrations Utilities I Top Usage Ooo Back Menu Mode Full E 1 Reset WebAccess paswd E J Press Up Image quality print and Enter Statistics a Enter Together 5 4 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Calibrations For Call Agents requesting the User to access a limited number of Service Calibrations Once inside the Printer Setup Options menu and the Device
54. ranges 1 10 A F hexadecimal format ES or SG site of manufacture Backspace The current parameter is displayed in the New field To select the current parameter press the Enter key To delete a character previously confirmed using the Enter key select the Backspace character from the list E To 1 4 2 Set Serial Number Current ESA80035674 Back New ES_ Ooo t Use Up Down buttons Z Make Selection to scroll Ea i b When the last digit has been entered the message below is displayed Press Enter to confirm the number and return to the EEROM Setup utility or Back to modify the number E vor E eac Serial number selected ESB7531008 Es t Press ENTER to confirm or BACK to correct 4 Ey Enter c If you decided to press Back the utility will return to the Serial Number selection menu and the last digit of the Serial Number will be automatically deleted MM tp 1 4 2 Set Serial Number Serial number selected Back ESB7531008 eal T Press ENTER to confirm 4 or BACK to correct z Enter 1 4 2 Set Serial Number Make Selection Make Selection HP DesignJet 5000 and 5500 Series Printers Service Manual 4 25 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
55. setup menu is highlighted press the following key combination Printer setup options DY ve BE Back T O setup Utilities et Internal RIP settings Press Down Queueing amp Nesting faa IL HP GL 2 settings and Enter HY Enter Together 2 The message below is displayed Select Yes to continue Warning Top This mode should NOT be used without having the B Back guidance of a HP EI representative person i Enter 3 You are now in the Service Menu Use the Arrow keys to scroll to the Service Calibrations menu and press the Enter key E o Press Enter Service Tools a 1 Service Utilities Make Selection E Press Enter 4 Use the Arrow keys to scroll through the Service Calibrations selections Press the Enter key to begin a specific operation when the Service Calibration required is highlighted 2 Service Calibrations 2 2 Service Station 2 3 ACCURACY This appears in the On Site Repair Menu only HP DesignJet 5000 and 5500 Series Printers Service Manual 5 5 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
56. sheet media m If the media you are trying to load is very slippery hold the media with both hands and gently push the media into the Printer until it buckles upwards in the middle this will help the Printer to load it m If the Overdrive is covered in dust it will have problems picking up the sheet media during the load process Clean the Overdrive using the Platen Cleaning Utility gt Page 9 7 m The Printer may be too close to the end of the roll The natural curl near the end of the roll can cause stacking problems Load a new roll or remove prints manually as they are completed E If you are mixing prints or nesting sets of several different sizes you may have stacking problems because of the different sizes of media in the bin HP DesignJet 5000 and 5500 Series Printers Service Manual 1 25 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 T O Setup Menu I O setup No I O card found Card ID Card ID Card Setup VEG t Card Setup a Configuration Advanced Reset Card I O timeout 0 5 min 30 min Only Appear in Always Appear PostScript Only Full Menu Mode 1 26 HP DesignJet 5000 and 5500 Series Printers Service Manual Troubleshooting p peo7 pue payje sul s HNL 1e ddy
57. sound if you hear a sound already you may proceed directly with step 9 if not you must lower the Carriage Assembly step 8 and try again until a scraping sound is heard HP DesignJet 5000 and 5500 Series Printers Service Manual 5 21 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 N A aN Xs ON J COB ae 5 22 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Calibrations 11 Raise the Carriage Assembly slightly by turning the T9 screw shown below clockwise 12 HP DesignJet 5000 and 5500 Series Printers Service Manual 5 23 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 Conti
58. sure they are correctly connected and are NOT damaged m Check all the tubes of the APS and Tubes System and make sure they are correctly connected and are NOT pinched or damaged m Check that the Air Tube from the APS is correctly connected to the Tubes System Em Replace ONE Ink Cartridge at a time checking if the System Error Code disappears m Faulty APS Replace the APS gt Page 8 67 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 0A0010 APS Failure Refer to System Error Code 0A0000 0A0020 Error in Calibrating the APS Sensor Try the following m Check the APS Sensor and the valve cables making sure that they are NOT damaged and connected correctly m Replace the APS Page 8 67 or the ISS PCA gt Page 8 9 HP DesignJet 5000 and 5500 Series Printers Service Manual 2 13 System Error Codes System Error Problem Description Corrective Action WARNING System Error Problem Description Corrective Action WARNING 0A0030 Problem in Depressurizing Air System Try the following m 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 m If there is ink leakage replace ALL Ink Cartridges the APS gt Page 8 67 and the Tubes Sys
59. 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 These consumables are designed with a lock out feature that will allow only one color to be inserted into a given slot m No 81 HP Selection Number for Dye Ink Supplies m No 83 HP Selection Number for UV Ink Supplies Ink Cartridges The HP Ink Cartridges for the HP DesignJet 5000 and 5500 Series Printers require no maintenance or cleaning As long as each Ink Cartridge is inserted correctly into its slot the ink will flow to the Printheads The front panel displays the status of the Ink Cartridges With the front panel detailed information can be checked on the Ink Cartridges Printheads and Printhead Cleaners The HP Printheads for the HP DesignJet 5000 and 5500 series are extremely durable and do not need to be replaced every time an Ink Cartridge is replaced They are independent of the Ink Cartridges and will continue giving excellent image quality results even if the Ink Cartridges are low on ink See page 3 5 When Should You Replace the HP Ink Supplies If you notice a decline in print quality such as lines or dots missing from text graphics go to page 6 1 Print Quality The HP Printhead Cleaners keep the Printheads
60. 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 m If the New Fan does not function correctly either then replace the Main PCA gt Page 8 81 0B0010 xxxxxxxx Non Continuable This firmware error code is related to the detection of the Printhead cleaners by the line sensor It always happens during initialization while checking the Printhead Cleaners In most case it is a problem of incorrectly inserted Printhead Cleaners but it can also be caused by an incorrectly assembled Service Station Try the following m Remove the Printhead Cleaners and reinsert them again E If the error still persists perform the Service Station Calibration gt Page 5 11 m If the error still persists an onsite visit is necessary to repeat the calibration or to change the Service Station assembly or the Carriage Assembly OBOO0A Primer Shutdown Error Try the following Check that the Service Station Cable the grey flat cable with the grey connector is plugged into the Main PCA and that the clips of the connector are closed Also check that the cable is not damaged E Replace the Service Station gt Page 8 69 2 18 HP DesignJet 5000 and 5500 Series Printers Service Manual System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Descripti
61. the Turn DRIVE ROLLER Utility gt Page 4 17 011000 NIB Crash Power the Printer OFF and ON again using the Power Switch at the back of the Printer 2 10 HP DesignJet 5000 and 5500 Series Printers Service Manual System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Codes 040000 01E603D9 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 Try the following E Recommend to the customer to print via the Network Card because the transmission time via the Parallel Port is very slow m If the customer insists on printing via the Parallel Port ask them to check the Parallel Port settings on the PC that was used when the error occurred The Parallel Port setting in the PC BIOS should be in the ECP mode This configuration should decrease the frequency of the error 050000 Continuable Lens has problems reading the Mark Encoder on the Drive Roller Try the following m Clean the Mark Encoder on the Drive Roller using the Turn DRIVE ROLLER Utility gt Page 4 17 E Replace the Lens Cover Assembly gt Page 9 5 050001 Continuable Lens has problems reading the Mark Encoder on the Drive Roller
62. the end 8 Lift the Foam from the Service Station NOTE The Foam may be full of ink so be careful when handling it NOTE If you replace the Drop Detector you must perform the following Service Calibration E Service Station gt Page 5 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 73 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 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 8 74 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 gt Page 5 3 and the EEROM Setup Service Utility gt 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 E Backup EEROM select HDD replaced gt Page 4 30 NOTE If you have to replace the HDD Cable refer to the following drawing looped End connects to the Hard Disk Drive Short Connector connects to the PCl to IDE PCA IF THE HD
63. the front panel m Media advance problems Banding Caused by Printhead Problems Banding caused by problems with the Printhead s will be highlighted in the Diagnostic Print because the banding is not in all of the colors the colored strip that has banding was caused by the same colored Printhead 6 8 HP DesignJet 5000 and 5500 Series Printers Service Manual Print Quality NOTE In the following example there is a problem in the Magenta Printhead There will be clear repetitive bands perhaps white in the magenta column 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 Perform Printhead Recovery gt Page 6 5 If there is no improvement after Printhead Recovery replace the failing Printhead Banding Caused by Media Advance Problems Another type of banding is caused by an inaccurate media advance In this case there will be banding horizontal repetitive bands along the test pattern in all the color columns The bands can appear as dark bands due to a shorter advance of the roller which causes an overlap or lighter bands due to a longer advance causing spaces HP DesignJet 5000 and 5500 Series Printers Service Manual 6 9 Print Quality NOTE NOTE 55
64. the iIPS Division Support E For 3rd party LAN Cards the HP support organization should communicate to the customer that they should address it through the 3rd party vendor support structure HP DesignJet 5000 and 5500 Series Printers Service Manual 2 3 System Error Codes NOTE 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 m Which firmware revision the Printer is using m The complete error number m Which software application the customer is using name version etc Continuable and Non Continuable Error Codes Some of the Error Codes are continuable which means you can press Enter on the front panel and continue working with the Printer Non Continuable Error Codes do not allow you to continue working with the Printer in this case power the Printer OFF and ON again and see if the System Error disappears If the Error Code reappears then the Printer requires an on site visit in order to resolve the problem Even though the customer can continue working with a Continuable Error Code an on site visit should still be planned to troubleshoot the problem System Error Groups The System Errors are organized in groups as follows Group 01 Hardware Test Group Group 04 Intelligent I O Jetdirec
65. the latest Firmware and repeat the whole procedure to enter the Service Tests menu MN 3 Service Tests Error BACK Svs Test not available Es T Upgrade Firmware rev E a Enter Press Enter Press Enter to continue NOTE If the Printer is not used for 3 minutes the Printer exits the Service Tests Menu and you must repeat the above steps to enter Service Tests 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 4 8 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Tests and Utilities a 1 2 3 Scan Axis Test The purpose of this test is to verify m Carriage movement along the Printer axis E 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 In the 3 Service Tests menu scroll to 3 1 Scan Axis and press Enter EE Es Back E Make Selection oO _ H Press Enter 3 Service Tests 3 2 Media Axis The test will start and the following message will appear on the front panel as the test is performed E Top P Back it HP Enter When the test has completed the Maximum and
66. the soft power Off button on the Front Panel The Printheads are then stored correctly which prevents them from drying out m 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 See page 3 5 When Should You Replace the HP Ink Supplies Some General Precautions When Handling HP Ink Supplies Do not touch wipe or attempt to clean the Printhead nozzles This can damage the Printhead Do not touch wipe or attempt to clean the Printhead nozzles This can damage the Printhead Handle the HP Ink supplies with care In particular the Printhead which is a high precision device and must be handled carefully m Do not touch the Printhead nozzles Do not put the Printhead down on the nozzles Do not be rough when handling the Printheads Always set them down gently Do not drop the Printheads E Proper handling will assure optimum performance throughout the Printhead life m The Printhead Cleaner should always be handled and stored upright to avoid a potential spillage of ink m Do not touch the end of the Ink Cartridge which is inserted into the Printer as there may be a small amount of ink on the connection Avoid storing partially used Ink Cartridges on their ends 3 4 HP DesignJet 5000 and 5500 Series Printers Service Manual HP Ink
67. workarounds Clean the sides of the printheads the bottom of the carriage and the electrical contacts regularly E Increase the relative humidity to 30 or more for films with anti static coating or 60 70 for films without anti static coating but there might be some films where this is still not sufficient Change to UV inks which are not as susceptible to static DO NOT REPLACE ANY PRINTER HARDWARE PART OR PRINTHEADS THEY PROVIDE NO RESOLUTION FOR THIS ISSUE 6 34 HP DesignJet 5000 and 5500 Series Printers Service Manual Parts and Diagrams 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 and Encoder Strip 7 38 Platen Assemblies DesignJet 5000 Series 7 40 Platen Assemblies DesignJet 5500 Series 7 42 Pinch Wheels Assembly and Lever 7 44 Center Guide Deflectors and Entry Roller DesignJet 5000 Series 7 46 Center Guide and Entry Roller DesignJet 5500 Series 7 48 Tubes Guide Assemblies 7 50 EMC Covers 7 52 Spindle and Hub 7 54 Rollfeed Brakes 7 56
68. 00 Series Only Banding in all of the colors 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 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 Make sure that the media selection made in the front panel is the same as the media that you have loaded It is possible that the banding was caused because the customer was using non HP media If the customer still wants to use non HP media recalibrate the paper accuracy by performing the User s Accuracy calibration and NOT the Service Accuracy Calibration Refer to the User s Guide Performing this will overwrite the default setting for only the paper that you have selected Perform the Printheads alignment procedure Refer to the User s Guide For high production modes use the Banding Calibration gt Page 5 44 6 10 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 ano
69. 0181 1 Pinch Assembly 60 Model C6090 60073 1 Pinch Assembly 42 Model 2 C6095 60179 1 Cam Lever Shaft 60 Model Includes Cam Linkage Linkage Screw Cam Lever Arm and Cam Lever Arm Screw C6090 60076 1 Cam Lever Shaft 42 Model Includes Cam Linkage Linkage Screw Cam Lever Arm and Cam Lev Arm Screw 3 C6090 60102 1 Lever 4 0515 2981 1 Screw Lever Arm to Cam Linkage 5 0515 2981 1 Screw Lever to Lever Arm 6 C6090 60097 1 Lever Support 7 0515 2981 3 Screw 7 44 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP Part Number Quantity Description Comments on Drawing 1 C6095 60180 1 Center Guide 60 Model C6090 60075 1 Center Guide 42 Model 2 0515 2986 4 Screw 3 C3180 20001 2 Screw 4 C6090 60104 1 Media Deflectors 5 0515 2250 1 Screw 6 C6095 60178 1 Entry Roller 60 Model C6090 60077 1 Entry Roller 42 Model 7 0515 2986 2 Screw 7 46 HP DesignJet 5000 and 5500 Series Printers Service Manual Parts and Diagrams Figure 25 Center Guide Deflectors and Entry Roller DesignJet 5000 Series HP DesignJet 5000 and 5500 Series Printers Service
70. 1 17 Cutter Assembly Problems 1 19 Carriage and Scan Axis Problems 1 20 Media Axis Problems 1 20 Electronics Problems 1 21 Language Selection is blocked in a brand new printer 1 23 Firmware Upgrade Does Not Work Through the Parallel Port 1 23 Typical Failures After Exchanging the Ink Tubes 1 24 Solving Media Handling Problems 1 25 How to Navigate through the Front Panel Menus 1 26 Service Configuration Print 1 37 General Printer Information 1 39 Troubleshooting Take Up Reel Problems 1 40 HP DesignJet 5000 and 5500 Series Printers Service Manual 1 1 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 XX This firmware revision allows the Printers to only use Imaging Inks A 02 XX This firmware revision allows the Printers to use both the Imaging Inks and the UV Inks Troubleshooting System Error Codes Chapter 2 System Error Codes contains a list of system error codes and their respective descriptions and recommended corrective actions Only try one recomme
71. 2 Model 3 Remove the Deflectors from the Printer HP DesignJet 5000 and 5500 Series Printers Service Manual 8 119 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 8 120 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation NOTE NOTE NOTE 5 Remove 15 screws that secure the Heater from the top of the Printer The 42 Printer only has 11 screws securing the Heater from the top 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 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 Then gently tap the other side of the Heater from underneath until it can be removed HP DesignJet 5000 and 5500 Series Printers Service Manual 8 121 Removal and Installation 8 Before removing the Heather completely pull out the Heater Cable from the access hole in the sideplate 9 Remove
72. 6 Service and 4007 Service Firmware error Try the following m Power the Printer OFF and ON again using the Power Switch at the back of the Printer and retry the calibration Download the latest Firmware gt Page 9 13 5000 Service This code is not an error See the other codes reported 5001 Service Out of memory Try the following E Reset the memory by Powering the Printer OFF and ON again using the Power Switch at the back of the Printer HP DesignJet 5000 and 5500 Series Printers Service Manual 5 35 Service Calibrations Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action 5002 Service Black Printhead failure Try the following E Perform Recovery for Black Printhead gt Page 6 15 E Replace the Black Printhead 5003 Service Wrong media type or no media Try the following m Make sure you load white medium that is the full width of the Printer 5004 Service Mechanical error Try the following m Check the path and remove any obstructions e g media m Check all the cables of the Scan Axis Motor and make sure they are correctly connected and are NOT damaged Em Replace the Scan Axis Motor gt Page 8 57 E Replace the Carriage Assembly
73. 6 Replace may appear on the front panel This is due to a temporal disconnection between the Printhead and the flex circuit in the Carriage Assembly m Clean the Printheads and the Carriage interconnects refer to page 9 6 Carriage Interconnect Wiper and reseat the failing Printheads m Check that the crane the part of the Tubes System that is connected to the front of the Carriage is completely clipped to the front of the Carriage 3 18 HP DesignJet 5000 and 5500 Series Printers Service Manual HP Ink Supplies Troubleshooting Ink Cartridge marked empty before removal 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 m Clean the Printheads and the Carriage interconnects refer to page 9 6 Carriage Interconnect Wiper and reseat the failing Printheads Refill Information DesignJet 5500 Series Only Ink Level Sensing ILS Out of Control Two situations exist that could trigger an ILS Out of Control m HP Ink Cartridges deliver more ink than the expected 680cc Ink Cartridges refilled with non hp ink ILS coils become stuck rare Non hp hardware detected in the Ink Delivery System Each one of these situations could potentially damage the printer s Ink Tube System and Printheads However since we cannot tell for sure if damage to the printer will
74. 7 rae ioe the Printer a e Coupling Plate corresponding to COUPLING PLATES T T the position of the Mount Bracket 3 Mount Brackets in the 60 Model Mount Bracket in the 42 Model 8 From the rear of the Printer rotate the group 90 degrees and pull it through the gap left by the Coupling Plate Installation of Pinch Wheels NOTE During installation make sure you install the White Pinch Wheels at each end of the Printer axis HP DesignJet 5000 and 5500 Series Printers Service Manual 8 99 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 Remove the Right Hand Trim Refer to Page 8 20 8 Remove the Media Lever Assembly Refer to Page 8 18 9 Remove the ISS Refer to Page 8 64 10 Remove the Service Station Refer to Page 8 69 11 Remove the Vacuum Fan Refer to Page 8 103 12 Remove the Electronics Module Refer to Page 8 97 13 Remove the Booster Fan Refer to Page 8 108 14 Remove the Media Sensor Refer to Page 8 109 15 Remove the Entry Roller Refer to
75. 9 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 3 On the Main PCA disconnect the Aerosol Fan cable from position P30 and the service station door from position P29 8 10 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 11 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 8 12 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation TIP To check correct functioning of serviced p
76. Average Pulse Modulation Values are displayed for each direction left and right Press Enter to return to the Service Tests menu Ss Top I Back it mL PP Enter Max PWM Avg PWM Analyzing Data XXX XXX 3 1 Scan Axis Max PWM Avg PWM Press Enter Press ENTER to continue HP DesignJet 5000 and 5500 Series Printers Service Manual 4 9 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 m The Service Configuration Print gt Page 1 37 To check if the values displayed after the test are within the limits refer to the following table Forwards lt Backwards gt Maximum PWM 220 230 Average PWM 205 200 If values are not within the accepted ranges turn the Printer OFF and perform the following steps and repeat the test after each one 1 Clean the Slider Rods and Apply Oil along the complete axis of the Slider Rods using the content of the Users Maintenance Kit 2 Check the Encoder Strip and clean it if it is dirty 3 Replace the Scan Axis Motor gt Page 8 57 4 Replace the Tensioner Assembly gt Page 8 42 5 Check the Carriage Belt for excessive wear If necessary replace the Carriage Belt gt
77. CCURACY Measuring 9 Once the calibration is completed the following message will be displayed Press Enter to return to the Accuracy Calibration menu Ooo Top P Back i Press Enter to continue HY Enter Calibration done Press Enter 5 16 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Calibrations If the Calibration fails the following message is displayed Press Enter to continue EE E Back Calibration Error B T E Ooo Enter ACCURACY XXXX Press ENTER to continue 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 gt Page 1 37 HP DesignJet 5000 and 5500 Series Printers Service Manual 5 17 Service Calibrations NOTE 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 E Carriage Assembly is replaced m Center Platen is disassembled or replaced m Continuous Printhead Crashes Perform the Carriage Height Calibration as follows The procedure should be carried out using the Carriage Height Tool See
78. Calibrations Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error NOTE Calibration Error Problem Description Corrective Action 6018 Service Calibration position out of range for Light Cyan Printhead Replace the Drop Detector Assembly gt Page 8 72 6019 Service Calibration position out of range for Light Magenta Printhead Replace the Drop Detector Assembly gt Page 8 72 7000 Service This code is not an error See the other codes reported 7006 Service Firmware error Try the following m Power the Printer OFF and ON again using the Power Switch at the back of the Printer to reset the memory HP DesignJet 5000 and 5500 Series Printers Service Manual 5 41 Service Calibrations User Calibrations The following is a list of internal User Calibrations available in the Printers Printhead Alignment gt Page 5 43 Close Loop Color Calibration gt Page 5 43 Banding Calibration gt Page 5 44 e p P ia Accuracy Calibration gt Page 5 45 5 42 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 gt Alig
79. D CABLE IS NOT CONNECTED CORRECTLY IT MAY CAUSE SOME INTERMITTENT PROBLEMS HP DesignJet 5000 and 5500 Series Printers Service Manual 8 75 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 8 76 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 To remove a DIMM first push down the lower locking tab and then push up the upper locking tab to release the DIMM HP DesignJet 5000 and 5500 Series Printers Service Manual 8 77 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 J6 BootROM amp A J7 SDRAM J8 SDRAM 8 78 HP DesignJet 5000 and 5500 Series Printers Service Man
80. Drive and Cover Reference HP Part Number Quantity Description Comments on Drawing DJ 5000 DJ 5500 Series Series 1 C609 1 60255 1 Hard Disk Drive PS A 02 12 includes data cable and power cable C6090 60303 1 Hard Disk Drive RTL A 02 12 includes data cable and power cable Q1252 60004 1 Hard Disk Drive PS S 03 11 includes data cable and power cable Q1251 60067 1 Hard Disk Drive RTL S 03 11 includes data cable and power cable 2 C6095 0003 1 1 HDD Cover 3 0515 0382 6 Screw OEM Hard Disk Drive Reference HP Part Number Quantity Description Comments on Drawing DJ 5000 DJ 5500 Series Series 1 Q1252 60007 1 OEM Hard Disk Drive PS 0 03 10 includes data cable and power cable Used on EagleJet Systems Q1251 60090 1 OEM Hard Disk Drive RTL K 03 10 includes data cable and power cable Used on KPG Matchprint Inkjet Proofing Systems C6090 60300 1 OEM Hard Disk Drive RTL O 02 11 includes data cable and power cable 7 30 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 C6090 60012 Q1251 60030 1 Main PCA 0515 2200 11 Screw C6090 60041 1 ISS PCA Includes ISS PCA cable 0515 2200 5 Screw C6090 60318 1 PCI to IDE PCA 7 32 HP DesignJet 5000 and 5500 Series Printers Service Manual Parts and D
81. Drive or the Main PCA are defective Try the following m 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 gt Page 8 74 m If the problem continues check that the Green and Orange LED s on the Main PCA are ON If they are not ON probably the PWS or its connections are defective If the two LED s are ON and the error continues replace the Main PCA gt Page 8 681 HP DesignJet 5000 and 5500 Series Printers Service Manual 2 25 System Error Codes System Error e50000 Problem This is an error that is related to the Hard Disk Drive either the connections Description are bad or that the Hard Disk Drive or the Main PCA are defective Corrective Action Try the following m 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 gt Page 8 74 If the problem continues check that the Green and Orange LED s on the Main PCA are ON If they are not ON probably the PWS or its connections are defective If the two LED s are ON and the error continues replace the Main PCA gt Page 8 8 2 26 HP DesignJet 5000 and 5500 Series Printers Service Manual
82. Figure 1 below that came with the new Carriage Assembly or Center Platen Assembly Carriage Height Tool Figure 1 5 18 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Correct Incorrect move using the Belt never move using Carriage Assembly Figure 2 Remove the Top Cover Refer to Page 8 5 Remove the Back Cover Refer to Page 8 23 Remove the Top EMC Cover Refer to Page 8 32 Open the Carriage Cover on the left hand side of the printing area gt gt p a HP DesignJet 5000 and 5500 Series Printers Service Manual 5 19 Service Calibrations 5 Insert the Carriage Height Tool into the black Printhead slot 6 Close the Carriage Cover 5 E A CS 5 20 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Listen for a scraping
83. ING 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 8 6 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation 4 Disconnect the Electrical Cable from the rear of the Ink Cartridge Tube Connector 5 Disconnect the Air Tube 6 Twist the 3 latches at the rear of the Ink Cartridge Tube Connector and release the complete Assembly HP DesignJet 5000 and 5500 Series Printers Service Manual 8 7 Removal and Installation 7 Remove the Ink Cartridge Tube Connector and place safely on the window 8 Remove 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 8 8 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation Tue 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8
84. Manual 7 47 Parts and Diagrams Center Guide and Entry Roller DesignJet 5500 Series Center Guide and Entry Roller DesignJet 5500 Series Reference HP Part Number Quantity Description Comments on Drawing 1 C6095 60180 1 Center Guide 60 Model C6090 60075 1 Center Guide 42 Model 0515 2986 4 Screw C3180 20001 2 Screw C6095 60178 1 Entry Roller 60 Model C6090 60077 1 Entry Roller 42 Model 5 0515 2986 2 Screw 7 48 HP DesignJet 5000 and 5500 Series Printers Service Manual Parts and Diagrams gt S co NH Q om p o 7 2 S N 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 HP Part Number Quantity Description Comments on Drawing DJ 5000 DJ 5500 Series Series 1 C6095 60176 1 Back Tube Guide Assembly 60 Model Includes Safety Arm for Top Cover C6095 60078 1 Back Tube Guide Assembly 42 Model Includes Safety Arm for Top Cover 2 C6095 60269 1 Front Tube Guide Assembly 60 Model Includes Tube Guide Door and spring C6090 60271 1 Front Tube Guide Assembly 42 Model Includes Tube Guide Door and spring 3 0624 0771 8 Screw C6090 60272 1 Tube Guide Door includes spring 5 C6072 60193 1 Right Arc Assembly 0624 0771 8 Screw C6072
85. O and press the Enter key If you select YES the print job will be cancelled and Printhead replacement will be started If you select NO the Printer will finish the current print job This message will be displayed each time you send a print job to the Printer until you replace the failing Printhead s If you select NO the Printer finishes the current print job WITHOUT using the failed Printhead i e without using that color HP DesignJet 5000 and 5500 Series Printers Service Manual 3 15 HP Ink Supplies Troubleshooting NOTE NOTE Ink Cartridge Errors 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 If all 6 Ink Cartridges present the same error message check the following All Ink Cartridges installed are NOT of the wrong type i e wrong model If you replace or reseat Ink Cartridges one at a time and the error persists for all cartridges this indicates a hardware problem Do the following 1 Check ISS cable connections on the rear of the Ink Supply Station and the ISS PCA 2 Remove the Backplate and check that the connections on the floaters are clean and check that the fl
86. P DesignJet 5000 and 5500 Series Printers Service Manual 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 107 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 To remove the Booster Fan first slide it out then lift and pull out 8 108 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 08 8 Reach u
87. Printers m Check that the memory size shown on the front panel is the same for the Printers that are being compared Standard configuration 192Mbyte for C6096A and 128Mbytes for C6090A C6091A C6095A 1 22 HP DesignJet 5000 and 5500 Series Printers Service Manual Troubleshooting NOTE NOTE 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 m To check the correct functioning of the sensor print the Service Configuration Print and check that both the temperature and humidity readings are correct i e within the specification If not replace the ISS PCA gt Page 8 91 E Asan alternative solution turn OFF the dry time and then all the Printers should finish the print at the same time m Another alternative is to set the dry time manually on all the Printers This dry time will be applied to all the prints Language Selection is blocked in a brand new printer Normally the user has about 2 minutes initialization time to select the language in the Front Panel If the language is not selected within this time period the Front Panel is locked To recover from this problem just re boot the Printer and select the
88. R THE 5500 SERIES CAN BE WARNING NOTE NOTE WARNING NOTE NOTE FOUND IN THE USER S GUIDE The Firmware Upgrade process will delete all pending print jobs Ensure that the Printer is powered ON and that the Media has been removed from the Printer 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 The solution is to unload the media and switch the Printer ON and OFF again This problem only appears when you try to upgrade from Non UV ink firmware to UV ink firmware while the media is loaded If you are running the utility from Windows or Mac OS do the following If the previous Firmware version is A 01 xx then you MUST also upgrade the internal demo prints Download and save the installation application to the Computer hard disk After downloading all the files double click on the only executable file you will have The application will automatically expand the files and install the application in your computer The application will automatically start and will install all the necessary files first The application will then analyze each of the Printers configured for the computer and report on their current state upgrade or emergency If the application doesn t start automatically go to the Start button and look for Programs gt HP DesienJet folder and run it from ther
89. Refer to System Error Code 050001 HP DesignJet 5000 and 5500 Series Printers Service Manual 2 11 System Error Codes System Error Problem Description Corrective Action WARNING System Error Problem Description Corrective Action WARNING 06030C Bad Line Sensor Try the following Em Replace the Line Sensor gt Page 8 53 E Replace the Carriage Assembly gt Page 8 46 m Replace the Trailing Cable gt Page 8 36 m Replace the Main PCA gt Page 8 8 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 06040C Line Sensor not connected correctly Try the following m Check reconnect the Line Sensor E Replace the Line Sensor gt Page 8 53 m Replace the Carriage Assembly gt Page 8 46 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 2 12 HP DesignJet 5000 and 5500 Series Printers Service Manual System Error Problem Description Corrective Action WARNING System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Codes 0A0000 APS Failure Try the following m Check all the cables of the APS and make
90. 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 8 46 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 47 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 8 48 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 49 Removal and Installation 16 Carefully disconnect the Trailing Cables 3 from the connectors in the Ca
91. Reset Life Counters 1 6 Backup EEROM 2 The following options are displayed for EEROM setup Press Enter once you have made your selection E tp 1 4 EEROM Setup 4 2 Set Serial Number Oo 1 4 3 Set Japanese Font HP DesignJet 5000 and 5500 Series Printers Service Manual 4 23 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 Me 1 4 1 Set Model Number J Back 1 4 1 1 C6095A 1 4 1 2 C6096A t a Make Selection 1 4 1 4 Q1253A O ab Press Enter b The following message is displayed Press Enter to confirm and return to the EEROM Setup menu or Back to select another Model Number EE Tor 1 4 1 Set Model Number Model number selected Back 1 Q1251A EE Press ENTER to confirm Ooo J or BACK to correct Ooo Enter Make Selection 4 24 HP DesignJet 5000 and 5500 Series Printers Service Manual 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
92. SSEMBLED TO GAIN ACCESS TO ANOTHER ASSEMBLY OR COMPONENT Which Calibrations Need To Be Done When Required Scan Axis Service Station Accuracy Carriage Height Carriage is disassembled Yes Yes No Yes or replaced Paper Axis Motor is No No Yes No disassembled or replaced Platen Assembly is Yes No No Yes disassembled or replaced Service Station is No Yes No No disassembled or replaced NOTE Refer to the following page for the relevant Calibration 5 2 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Scan Axis Calibration gt 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 Service Station gt Page 5 The purpose of this Service Calibration is to calibrate the Service Station in relation to the Carriage Assembly Accuracy Calibration gt Page 5 14 The purpose of this Service Calibration is to calibrate the nominal advance of the Paper Axis Motor 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
93. Service Configuration Print The Service Configuration Print is divided into 7 different areas where you can find information to troubleshoot the Printer General Configuration In this area you can find information regarding the general configuration of the Printer for example the firmware version amount of memory installed or the capacity of the Hard Disk Drive Printhead Info In this area you can find all the information regarding the Printheads for example the part number the manufacturing date or the number of times a certain Printhead has been inserted in the carriage This information is useful for troubleshooting Printhead problems and even knowing if the Printheads have been used with Non HP Ink Cartridges Cartridge Info In this area you can find all the information regarding the Ink Cartridges for example the part number the manufacturing date or the ink level This area also shows you if the customer is using Non HP Ink Cartridges Operating Conditions In this area you can find the level of humidity and the temperature that the Printer is working in Calibrations In this area you can find information on certain calibrations that have been performed on the Printer It will also tell you if a required calibration was performed or not Maintenance In this area you can find information relating to maintenance for example the number times the Printer has been powered ON the number of Carriage cycle
94. Status Code The HP Status Code is made up of 4 digits the first two digits are the HP ID Code that identify the consumable and its color The last two digits are the status number indicating the nature of the problem The tables in the next few pages describe the messages and status codes for HP Ink Supplies 3 10 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 None correctly Insert There is no consumable installed Insert the correct consumable In the case of the Printhead if the correct consumable is inserted check the Carriage Tube Connector is correctly connected to the Carriage Setup The setup message is displayed When the setting up of the tube when new tubes have been installed system is complete the front panel into the Printer and you have will display a message installed the correct setup XX04 Replace asking you to Printheads remove them and replace them with normal Printheads Low Ink Cartridge Level has reached it s New supplies should be obtained low limit 100 ml This is an early ready to replace the partic
95. Supplies Troubleshooting CAUTION 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 When the Printer is powered ON for the first time the Printer will automatically perform the priming process Without the priming process the customer will NOT be able to use the Printer Why does the Printer require priming m The Tubes System is empty when the customer receives the Printer m The Tubes System has to be pressurized and filled with ink ejecting any air bubbles If the Printing Printheads are installed in the Carriage during the priming process they will be rejected and the front panel will show the XX11 Replace message Refer to 3 12 Error Status Messages When Should You Replace the HP Ink Supplies When to change the HP Ink supplies is mostly determined by you with guidance from the front panel In conjunction with the messages displayed in the front panel and the message explanations in this chapter you will be able to choose for yourself when is the right time to change the HP Ink supplies The Printer will also display the ink level and will tell you when the ink supply
96. V HP DesignJet 5500 Printer 60 Model P N Q1253A V HP DesignJet 5500PS Printer 42 Model P N Q1252A V HP DesignJet 5500PS Printer 60 Model P N Q1254A V For information about using these printers refer to the corresponding User and Quick Reference Guides Readership The procedures described in this Service Manual are to be performed by HP qualified Service Personnel only Part Numbers Part Numbers for Printer options accessories and service parts are located in Chapter 7 Conventions A small arrow gt is used to indicate other parts of the Service Manual where you can find information related to the topic you are consulting 2 HP DesignJet 5000 and 5500 Series Printers Service Manual Table of Contents Table of Contents 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 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 Troubles
97. V and the new Main PCA has the following connectors you do NOT need to use them they can be ignored NOT needed P11 aa Srami ldddddddskiikibikkihbhkibi l ONLY on hp designjet 5000 P28 Heater NOT needed HP DesignJet 5000 and 5500 Series Printers Service Manual 8 81 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 Remove ALL Firmware Memory DIMMs Refer to Page 8 77 NOTE Make sure you reinstall the Firmware Memory DIMMs on the new Main PCA Disconnect ALL Cables from the Electronics Module Remove 2 T 10 screws Type K to remove the PCI to IDE PCA 8 82 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation a Se 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 HP DesignJet 5000 and 5500 Series Printers Service Manu
98. Window INK STARTUP All SETUP printheads are OK Close cover and window to continue 7 The following messages will be displayed on the front panel while the Printer accesses and then stores the Printheads INK STARTUP INK STARTUP Accessing Printheads Storing Printheads HP DesignJet 5000 and 5500 Series Printers Service Manual 4 19 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 Close the carriage cover and close the window INK STARTUP All printheads are OK Close cover and window to continue 11 Open the Right Door and make sure the Printhead Cleaners are installed in the Service Station INK STARTUP Open right cover and install printhead cleaners 4 20 HP DesignJet 5000 and 5500 Series Printers Service Manual 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
99. acilitate the cleaning of the Drive Roller and the Overdrive 2 Prime TUBES gt Page 4 8 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 3 Altitude Setup gt Page 4 22 This Service Utility allows the operating altitude to be set for the Printer 4 EEROM Setup gt Page 4 23 The purpose of this Service Utility is to set the Printer Model the Serial Number and Japanese Fonts 5 Reset Life Counters gt Page 4 28 The purpose of this Service Utility is to reset the preventive maintenance counters when parts have been replaced 6 Backup EEROM gt Page 4 30 The purpose of this Service Utility is to restore the EEROM content when the Main PCA or Hard Disk Drive are replaced 7 Image Quality Warning gt Page 4 32 This Service Utility allows you to turn the Image Quality Warning message On or Off 8 Diagnostic Print gt Page 4 33 This Service Utility allows you to print a Diagnostic print that will help you to troubleshoot image quality problems and verify printhead nozzle status HP DesignJet 5000 and 5500 Series Printers Service Manual 4 13 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 Hewlett Packard Photo Imaging Gloss For On Site Engineers accessing th
100. ad gt Page 6 15 m Replace the Black Printhead HP DesignJet 5000 and 5500 Series Printers Service Manual 5 39 Service Calibrations Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action 6012 Service Calibration failed for Light Cyan Printhead m Recover the Light Cyan Printhead Page 6 15 m Replace the Light Cyan Printhead 6013 Service Calibration failed for Light Magenta Printhead m Recover the Light Magenta Printhead Page 6 15 Em Replace the Light Magenta Printhead 6014 Service Calibration position out of range for Cyan Printhead Replace the Drop Detector Assembly gt Page 8 72 6015 Service Calibration position out of range for Magenta Printhead Replace the Drop Detector Assembly gt Page 8 72 6016 Service Calibration position out of range for Yellow Printhead Replace the Drop Detector Assembly gt Page 8 72 6017 Service Calibration position out of range for Black Printhead Replace the Drop Detector Assembly gt Page 8 72 5 40 HP DesignJet 5000 and 5500 Series Printers Service Manual Service
101. 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 m Paper axis Assembly is disassembled or replaced NOTE If you get an error code refer to Page 5 26 Calibration Error Codes for its description and resolution Perform the Accuracy Calibration as follows WARNING Make sure you load HP High Gloss Photo Paper into the Printer before performing this calibration Do NOT use any other type of media apart from HP High Gloss Photo Paper 1 In the Service Calibrations submenu select 2 3 Accuracy and press Enter E vo 2 Service Calibrations si 1 Scan axis eg i 2 Service Station i Za Make Selection Press Enter 2 When the following message appears on the front panel select Create Pattern and press Enter 2 3 ACCURACY Measure Pattern 5 14 HP DesignJet 5000 and 5500 Series Printers Service Manual 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
102. age 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 T 25 screw Type S from the Drive Roller Gear 5 Remove the Drive Roller Gear Installation of Gear WARNING When installing the Drive Roller Gear make sure the screw is fully tightened 8 114 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Em 15 T 10 screws in the 60 Model Em 11 T 10 screws in the 42 Model NOTE Be very careful with these screws If they break you will not be able to remove them HP DesignJet 5000 and 5500 Series Printers Service Manual 8 115 Removal and Installation 4 Remove the Platen starting from the left side 8 116 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation Center Platen Assembly Removal WARNING Switch off the Printer and remove the Power Cord NOTE Refer to the table o
103. age 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 Use the User s Slider Rods Lubrification Kit to do this see the User s Guide Belt Swelling To prevent new Belts from swelling incorrectly keep them in their bags with desiccant until you need to install them General Cleaning To maintain the Printer in good operating condition keep it free of dust accumulation ink and other contamination Cleaning intervals are determined by the Printer environment and by the types of Printer supplies used Proper general cleaning should include the following Blow away dust accumulation with compressed air if available 2 Clean the outer surface of the Printer with a damp sponge or cloth Use a mild soap and water solution if necessary Do not use abrasive cleaners 3 Wipe the Printer dry with a soft lint free cloth 9 10 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Downloading the Firmware from the DesignJet Online Website http www designjet hp com Using the Firmware Upgrade CD See part number on Page 7 58
104. al 8 83 Removal and Installation 12 Remove by sliding the Main PCA to the left and lifting out see detail below Detail of Main PCA removal Installation of Main PCA NOTE NOTE NOTE NOTE When the Main PCA has been replaced perform the Backup EEROM Page 4 30 If you replace the Main PCA and the HDD at the same time you must perform ALL Service Calibrations gt Page 5 3 and the EEROM Setup Service Utility gt Page 4 23 If you are not sure how the cables are connected on the Main PCA each connector is labelled with the name of the assembly to which it is connected When installing the Hard Disk Drive please refer to the instructions for the installation of the PCI to IDE PCA Refer to Page 8 86 and the installation of the HDD Cable Refer to Page 8 87 8 84 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Remove 2 T 10 screws that secure the PCI to IDE PCA a 7 Disconnect the PCI to IDE PCA and
105. altitudes At altitudes above 2 000 meters the vacuum force holding down the media will be lower therefore the media will not be held in place properly causing E Ink Smearing on the Media m Printhead crashes against the Media m Cut Sheet loading problems high probability m Roll Media loading problems low probability To solve the problem try the following m Using the 1 3 Altitude Setup in the Service Utilities set the altitude to 1 3 2 2000 m or more see Altitude Setup 4 23 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 m Try using Heavy Weight Coated Media instead of Coated Media m Change the paper margins to Extended in the Printer Setup menu Page Format Margins or in the Driver If the customer is printing PostScript images send them a PPD file containing the extended margins m Use the Deflectors m Upgrade the Firmware gt Page 9 11 2 Cockling within the print If the Printer places too much ink within the print the media starts to ripple causing the Printhead to smea
106. and Restart Max Speed Drive either the cable connector is clipped in correctly connections are bad or If the problem persists replace the Hard the Hard Disk Drive or Disk Drive gt Page 8 74 the Main PCA are E If the problem continues check that the defective Green and Orange LED s on the Main PCA are ON If they are not ON probably the PWS or its connections are defective If the two LED s are ON and the error continues replace the Main PCA gt Page 8 81 Spinning up disk OK O Max Quality Loading Boot FAILED Download the Firmware file to the Printer firmware fmw Page 9 13 Productivity Initializing Max Speed Max Quality Initializing L2C O Productivity Initializing CLK Max Speed Initializing IO BOOTROM ERROR The BootROM version does not support the Current Version XXX firmware installed on the HDD Replace Necessary the BootROM Version XXX COMPONENT The firmware installed on the HDD and the MISMATCH BootROM personality does not match You are running a Make sure both parts are either RTL or PS XXX printer witha and make sure you do NOT mix them See XXX disk Parts List for Part Numbers Insert XXX disk and restart Max Quality Initializing Please Wait Productivity Code rev XXXXXX BootROM XXXxXxX Max Speed RAM present XXX MB Hard Disk XXXX MB PS Code rev XXXXX Only in PS Unit Ready or Ready for Media 4 4 HP DesignJet 5000 and 5500 Series Printers Servic
107. and press in the retaining J aa clip on the ISS 8 64 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation 6 While pressing in the retaining clip step 5 rotate the right side of the ISS up and left 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 65 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 8 66 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 E For the 42 Model open the Cable Clip under the ISS holding the APS Cables to the ISS NOTE When removing the APS from the ISS take care with the tube and cables attached to the ISS
108. arts 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 WARNING Make sure cables pass through slot at rear of chassis on the right hand side otherwise the Cover cannot be properly installed and cables may be damaged HP DesignJet 5000 and 5500 Series Printers Service Manual 8 13 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 8 14 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 15 Removal
109. ation Screw Types WARNING Chassis screws have a copper washer and should never be removed Type Torx Length Head Type Thread Type Part Number mm 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 25 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 5 Flat Taptite 0515 2984 J T 15 27 4 Pan Machined 0515 2986 K T 10 8 Pan Taptite 0515 2200 L T 20 14 Pan Taptite 0515 2248 M T 15 Flat Taptite 0515 2250 N T 15 24 Flat Machined C6071 20026 O T 15 10 Pan Washer Machined 0515 0380 P T 10 8 Pan Machined 0515 2246 Q T 20 10 Pan Washer Taptite 0515 2278 R T 10 8 Flat Countersunk 2200 1294 S T 25 54 Pan Machined C6071 20005 T T 20 20 Pan Machined C3180 20001 U T 25 10 Pan Taptite 0515 4268 V T 8 14 Pan Machined 0624 0737 8 4 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Detail of hinge mechanism HP DesignJet 5000 and 5500 Series Printers Service Manual 8 5 Removal and Installation Left Hand Cover Removal WARN
110. ation Print gt Page 1 37 To check if the values displayed after the test are within the limits refer to the following table Without Media With Media Maximum PWM Between 66 and 93 Between 65 and 100 Average PWM Between 67 and 85 Between 70 and 90 If values are not within the accepted ranges power the Printer OFF and perform the following steps and repeat the test after each one Lift the Media Lever and insert thick media into the paper path to push out any media that may be stuck there Open the Window and check for any visible obstacles restricting the movement of the Drive Roller If there is a wrinkled mass of media inside the paper path lift the Pinch Wheels using the Media Lever and clear the obstruction If you cannot reach the media remove the Entry Roller gt Page 8 111 to gain better access Remove the Paper Axis Motor Page 8 105 and check the Drive Roller movement is smooth and if it is not remove the Center Platen gt Page 8 1 7 to check for any obstructions Replace the Paper Axis Motor gt Page 8 105 4 12 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 4 1 Turn DRIVE ROLLER gt Page 4 17 The purpose of this Service Utility is to f
111. ays information on the selected Ink Cartridge Yellow cart info HP No 81 ink cartridge Ink level 87 Capacity 680ml Part number C4934A Mfg month 12 1999 The information supplied is m 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 m The percentage of how much ink is remaining m Original capacity of the Ink Cartridge in milliliters m Re order part number of the Ink Cartridge m The month and year that the Ink Cartridge was manufactured Obtaining Printhead Information 1 To get information on your Printheads press the Top key on the front panel to go to the main menu Roll Hewlett Packard Photo Imaging Gloss Ink OK Printheads OK 2 Press the or 4 key to select the Printheads icon and view information on the Printheads Press ENTER for printheads menu LIGHT CYAN OK LIGHT MAGENTA OK YELLOW OK CYAN 1421 REPLACE MAGENTA OK Printhead Menu BLACK OK 3 8 HP DesignJet 5000 and 5500 Series Printers Service Manual HP Ink Supplies Troubleshooting 3 Press or 4 key until the front panel highlights Printhead info Press Enter to view the Printheads information Printhead info Recover printheads Replace printheads 4 Press the or 4 key until the front panel highlights the color that you want to see information on Press the Enter key Printhead info Light Cyan cart inf
112. ce Guides The procedures described in this manual are to be performed by HP qualified Service Personnel only HP WEST ETIO RAUN G Large Format Printers
113. ce Station assembly or the Carriage Assembly ffff ffff 036e0136 This is an internal general error code which can appear during the Printhead Alignment process The chance of this error appearing is less than 0 5 and there is nothing wrong with the Printer Re boot the Printer and the error code should not appear again 01002D Non Continuable The Main PCA cannot communicate with the Carriage Try the following m Check the Trailing Cable is connected correctly m Replace the Trailing Cable gt Page 8 36 m Replace the Carriage Assembly gt Page 8 46 HP DesignJet 5000 and 5500 Series Printers Service Manual 2 7 System Error Codes System Error Problem Description Corrective Action NOTE System Error Problem Description Corrective Action NOTE System Error Problem Description Corrective Action WARNING 010023 Non Continuable EEROM Test failure m Replace the Main PCA gt Page 8 8 After replacing the Main PCA make sure you perform the Backup EEROM gt Page 4 30 making sure that you select Main PCA when prompted 010030 034c09S5e 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 Re boot the Printer and the error code should not appear again If the error code appears again try connecting the Printer to a different power socket 010040 Er
114. coder strip from the Spring Clip HP DesignJet 5000 and 5500 Series Printers Service Manual 8 57 Removal and Installation E 6 Using a screwdriver fully tighten the _S Spring Release Screw to release the A tension on the Belt a Tighten screw 7 Disconnect the Scan Axis Motor Cable from position P23 on the Main PCA 8 Unclip the Scan Axis Motor Cable from underneath the Service Station 8 58 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 WARNING When installing the Encoder Strip make sure it is inserted in the Encoder Sensor on the rear of the Carriage Assembly Note When installing the Belt make sure that it is not twisted Insert Encoder Strip Encoder Sensor HP DesignJet 5000 and 5500 Series Printers Service Manual 8 59 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 Carr
115. 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 Press Enter m Page 1 Checks for banding in the Primary Colors gt Page 6 8 m Page 2 Checks the Color to Color Alignment gt Page 6 11 Em Page 3 Check the Bidirectional Alignment gt Page 6 12 m Page 4 Check for Vertical Line Straightness gt Page 6 13 m Page 5 Performs the Nozzle Test gt Page 6 14 HP DesignJet 5000 and 5500 Series Printers Service Manual 6 7 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 Banding is when you see repetitive horizontal bands within the printed image these may appear as light or dark bands What is Banding 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 The test pattern is printed with the six Printhead colors Light Cyan Light Magenta Yellow Cyan Magenta and Black Each pair of colors is printed by only one Printhead one is the full color and the other is a lighter shade to help you detect any banding Solving the Banding Problem The main causes of banding are m Printhead problems m Use of Non HP media Incorrect media type selected in
116. crew Type L from the Left Hand Trim 2 Carefully remove the Left Hand Trim T Remove carefully U 8 22 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 E 8 Screws T 15 for the 60 Model E 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 23 Removal and Installation 4 Remove the Back Cover Installation of the Back Cover NOTE 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 8 24 HP DesignJet 5000 and 5500 Series Printers Service Manual 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
117. ction of the line Solving Bidirectional Alignment Problems Using the same media with which you were experiencing problems perform Printhead Alignment from the Printer Setup menu by selecting Utilities Calibration Printhead Alignment Please wait as the process of aligning the Printheads takes a few minutes 6 12 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Direction of printing a foreach pair of lines Solving Vertical Line Straightness 1 Using the same media with which you were experiencing problems perform Printhead Alignment from the Printer Setup menu by selecting Utilities Calibration Printhead Alignment Please wait as the process of aligning the Printheads takes a few minutes HP DesignJet 5000 and 5500 Series Printers Service Manual 6 13 Print Quality NOTE Nozzle Print Test Page 5 If your Printer has nozzle defects it does not mean that you will not get perfect print quality results The Printer has automatic procedu
118. d Try the following E Replace the ISS PCA Page 8 91 m Replace the Main PCA gt Page 8 61 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 0B0002 Bad IDS pressure read Try the following m Check that the cable from the Ink Supply Station ISS PCA to the Ink Supply Station is correctly connected m Check that the Air Pressurization System Sensor Cable is correctly connected and is NOT damaged m Check all the tubes of the APS and make sure they are NOT pinched or damaged m Faulty APS Replace the APS gt Page 8 67 m If the error code continues replace the Main PCA gt Page 8 681 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 0B0003 ADCO Internal channels check Failure Replace the Main PCA gt Page 8 681 2 16 HP DesignJet 5000 and 5500 Series Printers Service Manual System Error Problem Description Corrective Action WARNING System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Codes 0B0004 APS Failure Try the following m Check that the cable from the Ink Supply Station ISS PCA to the Ink Supply Station
119. d 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 Remove the Back Cover Refer to Page 8 23 Remove Right Rear Cover Refer to Page 8 16 Remove Left Rear Cover Refer to Page 8 15 Remove Electronics Module Refer to Page 8 97 Disconnect connector from Ink Leak Detector and remove 1 T 15 screw Type B to remove Ink Leak Detector cable clamp NOTE The Ink Leak Detector is NOT present in the DesignJet 5500 Series and in some DesignJet 5000 Series printers 8 32 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation 7 Remove the following screws Type N from the Top EMC Cover E 8 T 15 screws for the 60 Model E 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
120. d laminated 3 Throughput Maximum Throughput given in the Technical Data Sheet for HP Coated Paper is Em Print Mode Max Speed 60 inch model 569 sqft hour E Print Mode Max Speed 42 inch model 499 sqft hour NOTE These are maximum mechanical printing speeds and do not include for example printhead servicing at the beginning end of the print dry time at the end of the print etc So the average throughput when you are printing a run of several plots will be lower If you only want to maximize throughput the following settings are recommended Dry time NONE Internal RIP settings gt Start printing gt Immediately Print orientation if possible use Landscape instead of Portrait to reduce Carriage stops Printhead status OK to reduce servicing at the beginning end HP DesignJet 5000 and 5500 Series Printers Service Manual 1 39 Troubleshooting of the print Perform a manual recovery if the Printhead status is XX20 RECOVER XX21 REPLACE m With longer plots average productivity will increase i e same area is printed in less prints gt reduction of servicing at the beginning end of the print Troubleshooting Take Up Reel Problems Issue Main Reason Action Check Right Hand RH Module LED is OFF The Printer is not connected or switched ON Check that the TUR power cord is connected Check that the switch located at the rear side of the RH Module is ON
121. der As it will be explained both issues are related and have similarities m The appearance of the issue depends highly on the selected printmode MaxQuality Productivity or MaxSpeed and the medium and ink type loaded into the printer m The darker border issue may show along the entire border or appear in some determined locations and disappear in others m The direction of this grading is always in the printing direction This problem shows up much more in composite light colors and unidirectional printmodes when the printer lays ink only when the carriage moves in one direction 6 24 HP DesignJet 5000 and 5500 Series Printers Service Manual Print Quality See the following image irtner if 155 60 72 printing direction paper direction 10mm 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 An internal heating process eject the drops of ink that are delivered though these nozzles Therefore during the normal printing process the printer is firing the drops of ink over the media by heating the ink that is contained on the nozzles Heating chip at Heating chip at Resting status Firing status The cause of the issues is that when the nozzles are on the resting state f
122. des 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 Oldcxxxx 2 6 ffff ffff 030d0170 or ffff ffff O30d0171 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 Continuable 2 10 010092 Continuable 2 10 011000 2 10 040000 01E603D9 2 11 050000 Continuable 2 11 050001 Continuable 2 11 06030C 2 12 06040C 2 12 0A0000 2 13 0A0010 2 13 0A0020 2 13 0A0030 2 14 0A0040 2 14 0A0050 Non Continuable 2 15 0A0060 Non Continuable 2 15 0A0070 Continuable 2 15 0B0000 2 15 HP DesignJet 5000 and 5500 Series Printers Service Manual 2 1 System Error Codes 0B0001 2 16 0B0002 2 16 OB0003 2 16 OB0004 2 17 0B0005 2 17 0B0006 2 17 OBOOOX 2 18 0B0010 xxxxxxxx Non Continuable 2 18 OBOOOA 2 18 OBOOOB 2 19 OBOOOC 2 19 OBOOOD 2 19 OBOOOE 2 19 OBOOOF Continuable Only applicable to DesignJet 5500 Series 2 20 0C0030 2 20 0C0032 Continuable 2 21 0C0040 2 21 OCOOFF 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 0D0005
123. dow Sensor by inserting a pencil in the Sensor slot on the top of the Right Trim In the Service Utilities submenu scroll to Turn DRIVE ROLLER and press Enter E To E Back Make Selection m Enter Once the utility starts the Drive Roller will begin to turn slowly and the following message will be displayed Everytime the Drive Roller completes a turn the counter will increase by one Cancel 1 Service Utilities 1 2 Prime TUBES 1 3 Altitude Setup 1 4 EEROM Setup 1 5 Reset Life Counters 1 6 Backup EEROM Press Enter 1 1 Turn DRIVE ROLLER 1 turn s Press Cancel Press CANCEL to stop If you want to stop the Drive Roller from turning press Cancel and the following message will appear on the front panel Press Enter if you want to return to the Service Utility menu or press Back if you want to continue turning the Drive Roller i Top I Back it aL HP Enter 1 1 Turn DRIVE ROLLER Stopped Press ENTER to exit Make Selection or BACK to resume HP DesignJet 5000 and 5500 Series Printers Service Manual 4 17 Service Tests and Utilities Prime TUBES xn Ka one The purpose of this Service Utility is to prime the Tubes when the ee 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 u
124. e If the Firmware for the Printer is out of date the application will prompt you to update it The update process sends a special file to the Printer Once the update is complete the Printer may restart The upgrade process may take several minutes Do not Power OFF the Printer during this process 9 12 HP DesignJet 5000 and 5500 Series Printers Service Manual Functional Overview 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 m 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 It has a soft power switching feature allowing the firmware to control when power is removed from the system and eliminates the need for high tension cables to the front panel Main Electronics This block contains the I O cen
125. e Assembly gt Page 8 46 1041 User Scan Axis Alignment Error in slow speed section in Cyan and Yellow Pattern Try the following E Perform Printhead Recovery Page 6 15 m Perform the Service Scan Axis Calibration gt Page 5 7 m Replace the Cyan and Yellow Printheads and repeat the Printhead Alignment See the User s Guide If the media used is a color media try the calibration with white media and if the error persists replace the Lens Cover gt Page 9 5 m Replace the Carriage Assembly Page 8 46 5 30 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Calibrations Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action 1042 User Scan Axis Alignment Error in slow speed section in Light Cyan and Light Magenta Pattern Try the following E Perform Printhead Recovery Page 6 15 E Perform the Service Scan Axis Calibration gt Page 5 7 E Replace both Printheads and repeat Printhead Alignment E If the media used is a color media try the calibration with white media If the error persists replace the Lens Cover Page
126. e Manual 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 gt 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 Media Axis Test gt Page 4 11 The purpose of this Service Test is to verify the correct functioning of parts relating to Media movement through the Printer HP DesignJet 5000 and 5500 Series Printers Service Manual 4 5 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 Roll Hewlett Packard Photo Imaging Gloss For On Site Engineers accessing the complete list of Service Tests a 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 Top Device setup T O setup Internal RIP settings H Make Selection Queueing amp Nesting HP GL 2 settings Press Enter b Once inside the Utilities Menu press the following key combination to access the complete list of Service Test menus Utilities I Top Usage Back Menu Mode Full al 1 Reset WebAccess paswd Press Up Tes
127. e Printhead Cleaner is the correct color for that slot E Ensure that the Printhead Cleaner is the correct orientation 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 Replace Printhead Cleaners when Printheads are replaced The message status for Printhead Cleaners will not change until the door is closed there is no sensor detecting removal and insertion Status Numbers Printhead Cleaner Error Procedure Description X03 Replace There is a Printhead Cleaner detection Try the following failure you may continue to use the 1 Ensure that genuine HP Printhead Printhead Cleaner Cleaners are installed 2 Reseat the Printhead Cleaner 3 Check the lens is clean and perform Lens Maintenance if required Page 9 5 4 Replace the Printhead Cleaner XX05 Replace The Printhead detects that the Ensure that you have replaced the Printhead Cleaner does not match the Printhead Cleaner together with the rest of the ink system already installed Printhead XX06 Replace Printhead Cleaner Information Ensure that genuine HP Printhead Cleaners are installed The Printer detects an incorrect Printhead Cleaner Replace Message xx15 Replace and xx16 Replace In certain circumstances e g Printhead crash without Printer shutdown the message xx15 Replace or xx1
128. e Station Calibration whenever m Carriage Assembly is disassembled or replaced E Service Station is disassembled or replaced If you get an error code refer to Page 5 26 Calibration Error Codes for its description and resolution Perform the Service Station Calibration as follows To perform this Calibration make sure you load white medium that is minimum A3 B size In the Service Calibrations submenu scroll to 2 2 Service Station and press Enter E o 2 Service Calibrations t o H Make Selection 2 3 ACCURACY m 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 E Back Media too small Remove Media T m Enter 2 2 Service Station Press ENTER to continue Press Enter HP DesignJet 5000 and 5500 Series Printers Service Manual 5 11 Service Calibrations 2 Ifthe correct media is loaded the following message is displayed Press Enter to confirm or Back to return to the Service Calibrations menu ME i Back E Press ENTER to confirm or E it BACK to correct SS Enter 3 Once the media is detected the calibration starts and the following message is displayed 2 2 Service Station Make Selection Line Sensor to Black Pen Calibrating During this stage the Printer will print the following pattern 4 On completing the Line Sensor to Black Print
129. e as a result of using this supply E In the Ink Cartridge menu Ink level indicator Percentage of ink remaining m In WebAccess Ink Cartridges status Ink Level Recovery Action Select Yes to replace the Ink Cartridge with a genuine HP No 81 83 Ink Cartridge or No to continue Risks with the Ink Cartridge Delivering Too Much Ink Meeting Point Refills If the customer refills within the ink meeting point zone then the ink cartridge will operate normally If the customer refills after the meeting point then an ink cartridge error will appear Therefore no major issues in regards to printer damage are anticipated m Frozen Coils Refills The major risk of hardware failure in these kind of systems is printhead dry fire and probable empty ink tubes Since the coil signal is blocked the ILS will never detect an out of ink situation which could allow the printer to print without ink E In either case customers loose the unattendedness of the printer since they have to perform frequent ink cartridges refills to avoid the previously mentioned issues m Image quality printhead performance ink media compatibility cannot be guaranteed with the use of non hp ink Customer acceptance depends on their preferences 3 20 HP DesignJet 5000 and 5500 Series Printers Service Manual HP Ink Supplies Troubleshooting Non HP Hardware Detected in the Ink Delivery System The following informa
130. e complete list of Service Utilities a 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 Top Device setup T O setup Internal RIP settings H Make Selection Queueing amp Nesting HP GL 2 settings Press Enter b Once inside the Utilities Menu press the following key combination to access the complete list of Service Utilities Utilities I Top Menu Mode Full al 1 Reset WebAccess paswd Gel J Image quality print Enter Press Up and Enter Statistics 4 14 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Tests and Utilities For Call Agents requesting the User to access a limited sgo ore number of Service Utilities ne ae eve a Once inside the Printer Setup Options menu and the Device setup menu is highlighted press the following key combination Printer setup options Ea Top ial Back Utilities it Internal RIP settings Press Down Queueing amp Nesting nF HP GL 2 settings n and Enter T O setup The message below is es to continue Warning This mode should NOT be used without having the guidance of a HP representative person Press Enter Enter 3 You are now in the Service Menu Use the Arrow keys to scroll to the Service Utilities menu and press the Enter key Service Menu
131. e 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 Take care when removing and inserting these screws as they are easily damaged and not easy to access 8 38 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation 13 Carefully lift the Clips and the Trailing Cable from the Printer Installation of Trailing Cable Do not install damaged Trailing Cables If the Trailing Cable is incorrectly installed or it is damaged a Power Supply Error WARNING 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 Install the Trailing Cable starting from the Clip on the left as this will provide a reference point for adjusting the p gt length of the Trailing Cable eg Left Clip locating pin HP DesignJet 5000 and 5500 Series Printers Service Manual 8 39 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 E 3 for 60 Model E 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 o
132. e 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 Inthe Service Utilities submenu scroll to 1 5 Reset Life Counters and press Enter To 1 Service Utilities Ss P 1 1 Turn DRIVE ROLLER Back 1 2 Prime TUBES 13 Altitude Setup at l 1 4 EEROM Setup a Za Make Selection 1 6 Backup EEROM Press Enter 2 The following options are displayed for Reset Life Counters Press Enter once you have made your selection E Tor 1 5 Reset Life Counters I Back Make Selection Enter 2 Cuts 3 Printh Insertions Press Enter 3 A message confirming the selection is displayed Press Enter to confirm the reset of the life counter or Back to cancel 1 5 1 Scan Axis Limit 11000000 Current 11005000 Reset this life counter Make Selection Press ENTER to accept or BACK to exit 4 28 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Tests and Utilities The front panel message displays the following information Color Printhead Insertions only the Printhead color for which the counter is bein
133. e power source prior to performing any maintenance Prevent water or other liquids from running onto electrical components or circuits or through openings in the module 8 2 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 After removing a cover from the Printer attach an earthing ground lead between the PCA common and earth ground Touch all tools to earth ground to remove static charges before using them on the Printer 6 After removing any PCA from the Printer place it on a conductive foam pad or into its conductive packaging to prevent ESD damage to any ICs on the PCA Required Tools The following tools are required to disassemble and repair the Printer EE Long Torx Screwdriver with i i i i i the indicated attachments T8 T10 T15 T20 T25 OO O O Nut driver with the indicated attachments m 5 5 mm HP DesignJet 5000 and 5500 Series Printers Service Manual 8 3 Removal and Install
134. e they are correctly connected and are NOT damaged m Replace the Scan Axis Motor Page 8 57 E Replace the Carriage Assembly gt Page 8 46 m If the Error Code continues replace the Main PCA gt Page 8 8 5 38 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Calibrations Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action 6006 Service Drop Detector failed to reach position for calibration Refer to Error Code 6005 6007 Service Drop Detector failed to uncap pens Refer to Error Code 6005 6008 Service Calibration failed for Cyan Printhead Try the following m Recover the Cyan Printhead Page 6 15 m Replace the Cyan Printhead 6009 Service Calibration failed for Magenta Printhead Try the following m Recover the Magenta Printhead Page 6 15 m Replace the Magenta Printhead 6010 Service Calibration failed for Yellow Printhead Try the following m Recover the Yellow Printhead Page 6 5 E Replace the Yellow Printhead 6011 Service Calibration failed for Black Printhead m Recover the Black Printhe
135. ecause 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 This accumulation is not a big problem if the usage of the customer allows the ink to dry The issue is more severe under HEAVY USAGE more than 30 high density prints a day This usage profile does not allow the ink on the platen or other places to dry and thus causes marks on the printouts Aerosol ink accumulation is a result of the printhead architecture and the way the printer manages it the writing systems DO NOT REPLACE any internal hardware component because of this issue Aerosol What customers see Presence of marks on the backside of the media This is the first manifestation of aerosol Remember that the media drags along the platen while printing If there is aerosol ink accumulation on the platen the backside of the media will collect some of that ink The following figure shows the typical marks you can get Marks caused LEADING EDGE marks due to by the overdrive ink accumulation on the platen i BACK SIDE of N the printout i Later Edges marks due to ai y s ink accumulation 3 on the platen Printing directio HP DesignJet 5000 and 5500 Series Printers Service Manual 6 29 Print Q
136. eces of paper left inside the Printer especially if it happens after a paper jam One way to verify this easily is to take a rigid sheet of paper and move it along the paper path with the media load lever lifted m Also check that the customer has inserted the spindle hubs completely otherwise they may rub against the side plate and increase the friction m If the error still persists check that the Paper Axis Motor cables are connected correctly and that they are not damaged m If the Printer still fails replace the Paper Axis Motor gt Page 8 105 Turn the Drive Roller by hand once the motor is removed to verify that it turns smoothly Also after replacing the Paper Axis Motor perform the Media Axis Test Page 4 12 and check that the values are within the given limits m If the Printer still fails replace the Main PCA Page 8 8 Check Printhead Path 1 This warning appears whenever friction on the Scan Axis is too high the electrical current needed by the Scan Axis Motor to move the Carriage is too high so before burning the motor or the Main PCA this warning appears The usual reason for this error is an internal paper jam an obstacle in the Printhead path a broken belt badly installed Ink Supply Tubes etc E Apply Oil along the complete axis of the Slider Rods with the User s Slider Rods Lubrification Kit gt Page 9 8 E Also switch OFF the Printer and move the Carriage from side to side to verify that
137. ector 42 Model 7 C6090 60184 1 Take Up Reel Sensor 8 C6090 60309 1 Left Hand Take Up Reel Spindle Guide C6090 60112 2 3 Adaptors 7 4 HP DesignJet 5000 and 5500 Series Printers Service Manual Parts and Diagrams a 1 Bin Support 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 HP Part Number Quantity Description Comments Drie DJ5000 DJ 5500 Series Series 1 C6090 60038 1 Right Hand Cover Includes Front Panel Cable 2 0624 0771 4 Screw 3 0515 4268 1 Screw 4 C6090 60043 1 Right Hand Trim Includes Win dow and Lever Sensors 5 0624 0771 1 Screw 6 0515 2248 1 Screw C6090 60111 1 Front Panel Assembly Includes Front Panel Cable 8 C6095 90021 Q1251 90011 1 Overlay English C6095 90022 01251 90012 1 Overlay Korean C6095 90023 Q1251 90013 1 Overlay Taiwanese C6095 90024 Q1251 90014 1 Overlay German C6095 90025 01251 90015 1 Overlay French C6095 90026 Q1251 90016 1 Overlay Spanish C6095 90027 Q1251 90017 1 Overlay Italian C6095 90028 Q1251 90018 1 Overlay Japanese C6095 90029 Q1251 90019 1 Overlay Portuguese C6095 90030 Q1251 90020 1 Overlay Chinese 9 C6095 40065 1 Quick Reference Guide Holder 7 6 HP DesignJet 5000 and 5500 Series Printers Service Manual Parts and Dia
138. eed Module 2 C6072 60155 1 Right Rollfeed Module 3 C6072 60156 1 Right Rollfeed Brake 4 0624 0704 1 Screw 5 C6072 60157 1 Left Rollfeed Brake 6 0624 0704 1 Screw 7 56 HP DesignJet 5000 and 5500 Series Printers Service Manual Parts and Diagrams 3 and 4 o gt Right Hand Side 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 Description Comments on x A Drawing DJ 5000 Series DJ 5500 Series C6090 60081 Q1251 60073 1 Service Preventive Maintenance Kit for both 42 and 60 Models C6090 603 14 1 User Maintenance Kit C6090 60304 1 5000 FW Upgrade CD A 02 12 Q1251 60068 1 5500 FW Upgrade CD S 03 11 7 58 HP DesignJet 5000 and 5500 Series Printers Service Manual Parts and Diagrams Media Types P Durable Image 24 in 610mm 36 in 914mm C6794A 42 in 54 in 60 in 1067mm 1372mm 1524mm C6795A C6796A HP Coated Paper 26 Ib 98g m2 150 ft 45m 26 Ib 98g m2 300 ft 91m C6019B C6020B C6980A C6559B C6560B C6567B C6568B HP Heavyweight Coated Paper for 5000 800 amp 500 Series printers 35 Ib 130g m2 100 ft 30m C6029C C6030C C6569C C6570C C977CC HP Photo Imagi
139. ent User Guide Color Calibration gt User Guide 8 52 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Make sure both sides of the cover are unclipped before removing Also make sure the cover is removed vertically if not the Cover Retaining Pins can be broken HP DesignJet 5000 and 5500 Series Printers Service Manual 8 53 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 8 54 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation Installation 3 When installing the new Line Sensor make sure you insert the Line Sensor Cable through the correct hole as highlighted 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
140. er O bn ug The printhead loaded in the The ink cartridge loaded in the printer is or was using non hp ink printer is using non hp ink Not on the Printer History case of Cyan non hp hw DYE PH IC consumed O PH C installed PH IC consumed O PH E ink consumed Changes Non HP ink tubes IC to YES The inktube system loaded in the printer is or was using non hp ink 3 22 HP DesignJet 5000 and 5500 Series Printers Service Manual HP Ink Supplies Troubleshooting ILS Out of Control Warranty Statement m 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 m 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 E For HP printer products the use of a refilled or non original HP consumable product ink printhead or ink cartridge does not affect either the warranty to the customer or any HP support contract with the customer However if printer failure or damage is attributable to the use of a non HP or refilled ink cartridge HP will charge its standard time and materials charges to service the printer for the particular failure or damage HP DesignJet 5000 and 5500 Series Printers Service Manual 3 23 HP Ink Supplies Troubleshooting 3 24 HP
141. er 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 Press ENTER for printheads menu Printheads LIGHT CYAN LIGHT MAGENTA YELLOW OK CYAN 1420 RECOVER MAGENTA OK BLACK OK Printhead Menu 2 Go to Recover Printheads Select the Printhead color that is responsible for the problem The Printer will try to Recover the defective Printhead Please wait as the process of recovery takes a few minutes 4 Reprint the Diagnostic Print to check that the defective nozzles have been corrected If the error is still present replace the worst Printheads If your Printer displays a xxxx REPLACE or XXXX RECOVER message for a Printhead that has recently been changed or recovered successfully 1 Perform Service Station Calibration to verify the correct functioning of the Drop Detector gt Page 5 11 HP DesignJet 5000 and 5500 Series Printers Service Manual 6 15 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 m 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 E Non HP driver m The RIP m The software applications you are using
142. er or any other liquids from running onto electrical components or circuits or through openings in the enclosure Electrostatic Discharge Refer to the beginning of Chapter 8 of this manual for precautions you should take to prevent damage to the Printer circuits from electrostatic discharge Safety Symbols General definitions of safety symbols are given immediately after the table of contents WARNING The Warning symbol calls attention to a procedure practice or the like which if not correctly performed or adhered to could result in personal injury Do not proceed beyond a Warning symbol until the indicated conditions are fully understood and met CAUTION The Caution symbol calls attention to an operating procedure practice or the like which if not correctly performed or adhered to could result in damage to or destruction of part or all of the product Do not proceed beyond a Caution symbol until the indicated conditions are fully understood and met HP DSA ETORRA Large Format Printers Service Manual Using this Manual Purpose This Service Manual contains information necessary to test calibrate and service m HP DesignJet 5000 Printer 42 Model P N C6090A V HP DesignJet 5000 Printer 60 Model P N C6095A V HP DesignJet SOOOPS Printer 42 Model P N C6091 A V HP DesignJet SOOOPS Printer 60 Model P N C6096A V HP DesignJet 5500 Printer 42 Model P N Q1251A
143. erence HP Part Number Quantity Description Comments on Drawing DJ 5000 DJ 5500 Series Series 1 C6095 60278 1 Top Cover 60 Model C6090 60291 1 Top Cover 42 Model Q1253 60012 1 Black Top Cover 60 Model Q1251 60032 1 Black Top Cover 42 Model 2 C6095 60141 1 Back Cover 60 Model C6090 60037 1 Back Cover 42 Model 3 0515 0382 8 60 6 42 Screw 4 C6071 20026 3 Screw 7 10 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 1 C6090 60083 1 Service Station Assembly Includes Drop Detector and Primer Assembly 0624 0771 2 Screw 3 0515 1743 1 Screw C6072 60179 1 Drop Detector Assembly Includes Spittoon Foam and screw 5 0624 0771 1 Drop Detector Screw 7 12 HP DesignJet 5000 and 5500 Series Printers Service Manual Parts and Diagrams Figure 8 Service Station HP DesignJet 5000 and 5500 Series Printers Service Manual 7 13 Parts and Diagrams Vacuum Fan 1 C6090 60095 1 Vacuum Fan 2 0515 2248 4 Screw 7 14 HP DesignJet 5000 and 5500 Series Printers Service Manual Parts and Diagrams 5 rw Prea Figure 9 Vacuum Fan J HP DesignJet 5000 and 5500 Series Printers Service Manual 7 15 Parts and Diagrams Booster Fan and Media Senso
144. ern recover the failing Printhead s gt Page 6 15 m If Printhead recovery does not solve the problem replace the failing Printhead s and repeat the Printhead Alignment gt See the User s Guide m If the media used is a color media try the Printhead Alignment with opaque media with no patterns and if the error persists replace the Lens Cover gt Page 9 5 Em Replace the Carriage Assembly gt Page 8 46 HP DesignJet 5000 and 5500 Series Printers Service Manual 5 29 Service Calibrations Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action 1005 User Paper Axis Error Try the following E Perform Printhead Recovery Page 6 15 E Reseat ALL the Printheads and repeat the Printhead Alignment See the User s Guide Em Replace the Carriage Assembly gt Page 8 46 1040 User Scan Axis Alignment Error in slow speed section in Black and Magenta Pattern Try the following E Perform Printhead Recovery Page 6 15 E Perform the Service Scan Axis Calibration gt Page 5 7 E Replace the Black and Magenta Printheads and repeat Printhead Alignment See the User s Guide m If the media used is a color media try the Printhead Alignment with white media and if the error persists replace the Lens Cover gt Page 9 5 Em Replace the Carriag
145. eset Life Counters 1 Service Utilities Press Enter Select the part that has been replaced and press Enter E Tor 1 6 Backup EEROM MEDET Ml 4 4 30 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 E tp i eac You have REPLACED the Main PCA ES T Press ENTER to confirm or BACK to cancel J 4 eS Enter 1 6 1 Backup EEROM Make Selection 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 E or B Back You have REPLACED the Hard Disk Drive HDD t Press ENTER to confirm or BACK to cancel p 4 Pea Enter 1 6 1 Backup EEROM Make Selection 5 Press Back to return to the Service Utilities menu E Tor B 22c Backup performed correctly T Press BACK to return to previous menu 4 Oo Enter 1 6 1 Backup EEROM Press Back HP DesignJet 5000 and 5500 Series Printers Service Manual 4 31 Service Tests and Utilities lt Image Quality Warning a This Service Utility is used to turn the Image Quality Warning On or e Off If the printer is about to print a job and Printhead health status means that a Printhead is not usable the front panel will display a warning Wa
146. f the Trailing Cable NOTE This clip has a locating pin so make sure this is in position and the Trailing Cable is the right length before installing the screw locating pin 8 40 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation NO BUBBLES X Right Clip Left Clip locating pin x gt i Li gt P Strip will not be visible when g installed correctly Install with edges straight on TIP NOTE 5 NOTE Make sure the Trailing Cable is flat on the chassis without bubbles Check the cable and clips are correctly installed by sliding the carriage along the Printer to see if it moves freely Connect the Trailing Cables to the Main PCA Make sure the vertical strips on Trailing Cable ends are fully inserted inside the connectors The strip should not be visible when inserted correctly HP DesignJet 5000 and 5500 Series Printers Service Manual 8 41 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 The next step is performed by putting pressure
147. fy ISS cable connections b Remove the Backplate and check that the slots and connections on the floaters are clean c Replace the Ink Tubes System gt Page 8 64 d Replace the ISS PCA Page 8 91 XX04 Replace Smart chip error You can not continue to use this Ink Cartridge 1 Remove the Ink Cartridge and reinstall 2 Replace the Ink Cartridge XX05 Replace Incorrect Ink Cartridge Check correct Ink Cartridge is installed Replace with approved Ink Cartridge XX06 Replace The Printer detects that the Ink Cartridge does not match the rest of the Ink System already installed Ensure that the Printheads and the Ink Cartridges are genuine HP XX08 Unknown The Ink Cartridge smart chip indicates that the Ink Cartridge installed is not supported by HP 1 Press Enter to continue or 2 Replace with a genuine HP Ink Cartridge This error only appears in Refill situations XX02 Reseat Continuity problem between Ink Cartridge and Ink Supply Station 1 Remove the Ink Cartridge and reinsert 2 Replace the Ink Cartridge 3 Remove the Ink Supply Station and check contacts on floaters HP DesignJet 5000 and 5500 Series Printers Service Manual 3 17 HP Ink Supplies Troubleshooting NOTE NOTE NOTE Printhead Cleaner Errors First Digit A B or When replacing Printhead Cleaners Ensure that you have the correct Printhead Cleaner E Ensure that th
148. g reset E 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 E T 1 5 1 Scan Axis Press Back Life Counter has been reset correctly T Press BACK to return 4 to previous menu a E nter HP DesignJet 5000 and 5500 Series Printers Service Manual 4 29 Service Tests and Utilities WARNING 5000 Series Only NOTE 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 Before using this utility make sure that you are using Firmware version A 02 xx If NOT make sure that you upgrade the Firmware version to A 02 xx BEFORE using this utility If both the Hard Disk Drive and the Main PCA are replaced on Printer start up a continuable system error is displayed and you must perform all ALL the Calibrations as well as the EEROM Setup Service Utility See Page 4 23 In the Service Utilities submenu scroll to 1 6 Backup EEROM and press Enter E Ter 1 1 Turn DRIVE ROLLER Back 1 2 Prime TUBES 1 3 Altitude Setup SJ t 1 4 EEROM Setup Zi Make Selection 1 5 R
149. g the media a few millimeters to the right or left of the blue line on the Platen this should be enough to prevent the error Alternatively paint the black arrows with white correction fluid or stick a white label on top of the arrows Em Replace the Carriage Assembly gt Page 8 46 4000 Service This code is not an error See the other codes reported 4001 Service and 4002 Service Firmware error Try the following m Power the Printer OFF and ON again using the Power Switch at the back of the Printer and retry the calibration Download the latest Firmware gt Page 9 13 5 34 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Calibrations Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error NOTE Calibration Error Problem Description Corrective Action 4003 Service Line Detection Error Try the following m Check that the Lens Cover is clean Em Replace the Lens Cover Assembly gt Page 9 5 m Download the Firmware gt Page 9 13 4004 Service Firmware Error Use full Printer width media Try the following Em Verify the Black Printhead status and perform Recovery gt Page 6 15 m Replace Black Printhead m Download the Firmware gt Page 9 13 4005 Service 400
150. grams 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 HP Part Number Quantity Description Comments Drawing DJ 5000 DJ 5500 Series Series 1 C6090 60039 1 Left Hand Cover includes door 2 0624 0771 4 Screw 3 0515 4268 1 Screw 4 C6090 60042 1 Left Hand Trim 5 0624 0771 1 Screw 6 0515 2248 1 Screw 7 C6090 60040 1 Rear Door 8 C6091 00139 Q1252 00003 1 Nameplate PS C6095 00116 Q1251 00017 1 Nameplate RTL 9 C6090 60040 1 Left Hand Back Door 10 1 Adobe PS3 Logo 11 1 Pantone Certified Logo OEM Logos Reference HP Part Number Quantity Description Comments ie ie DJ 5000 DJ 5500 Series Series 8 C6090 00235 1 Matchprint InkJet Proofer 5042 Nameplate C6090 00220 1 Matchprint InkJet Proofer 5060 Nameplate 1 Matchprint InkJet Proofer 5542 Nameplate 1 Matchprint InkJet Proofer 5560 Nameplate 1 EagleJet 12 C6090 00244 1 HP Technology Logo 7 8 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Ref
151. gt Color Calibration HP DesignJet 5000 and 5500 Series Printers Service Manual 5 43 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 The Banding Calibration is most likely to be useful in the fastest print modes Max Speed and Production To perform the Banding Calibration At the printer s front panel choose the printer icon then Utilities gt Calibrations gt Banding gt Recalibrate The printer will print the calibration print nice times using nine different media advance settings in the print mode currently selected in the front panel This takes about seven minutes depending on the print mode and the printing material When prompted to select a print in the front panel choose the print that shows the best image quality in your opinion or select Cancel to cancel the calibration The Banding Calibration has now been completed for the selected printing material Whenever the same printing material is used in the future the media advance settings chosen will be used If required the process can be repeated for another print
152. gt Page 5 43 E Perform the Banding Calibration gt 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 Check which ink emulation mode has been selected in the front panel Media Make sure that the media loaded is genuine HP media and that the correct media type has been selected on the front panel Solving Color Consistency problems If color consistency is important for the customer it is recommended that they do not use HP GL 2 to print with m Some media may discolor or change with age Check that the media is fresh and has been stored correctly Em If the environmental conditions that the customer is printing in change rapidly you may see changes in the color consistency By reducing the time the print stays in extreme environmental conditions after being printed especially very high humidity you can reduce the color consistency problems m There will be color differences between HP DesignJet Printers because the other Printers use a different type of ink HP DesignJet 5000 and 5500 Series Printers Service Manual 6 17 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 tab
153. gt Page 8 46 m If the Error Code continues replace the Main PCA gt Page 8 8 5005 Service 5006 Service and 5007 Service Could not detect pattern Try the following E Make sure you load white medium that is the full width of the Printer the Printer may have problems calibrating with non white media Em Replace the Lens Cover Assembly gt Page 9 5 Em Replace the Carriage Assembly gt Page 8 46 5 36 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Calibrations Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action 5010 Service Too many Black Printhead nozzles not working Try the following m Recover the Black Printhead gt Page 6 15 and if the problem persists replace the Black Printhead 5011 Service and 5012 Service Printhead Cleaner detection error Try the following m Verify Printhead Cleaners are correct type E Replace the Lens Cover Assembly gt Page 9 5 E Replace the Carriage Assembly gt Page 8 46 5013 Service Two scans of the pattern do not match each other Try the following E Replace the Lens Cover Assembly gt Page 9 5 m Replace the Carriage A
154. handle top surface to recognize if the PHC is present or not In addition there is a built in mark on the handle a vertical hole to calibrate the Service Station Scan axis if there is a problem and the EEROM is erased Printable Label Alignment ki f Bin P datums Calibration Mark HP DesignJet 5000 and 5500 Series Printers Service Manual 10 9 Functional Overview 10 10 HP DesignJet 5000 Series Printers Service Manual About this Edition This is the 2nd edition of this Service Manual lst 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 La invent 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 SOOOPS Printer 42 Model P N C6091A V HP DesignJet 5O00PS 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 5500PS Printer 60 Model P N Q1254A V For information about using these printers refer to the corresponding User and Quick Referen
155. hat 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 19 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 5 Remove T 15 screws Type F and 1 T 20 Type L from the Right Hand Trim 8 20 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation 6 Carefully remove the Right Hand Trim 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 21 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 s
156. hat this problem only appears on the scan axis direction when there are light colors are fills in the borders By rotating the image you may avoid this type of colors in the scan axis direction m If using a RIP print in bi directional print mode m Circle the print with a black frame that will stabilize the printheads before doing the print Ink Marks on Printouts Problem statement Customers usually describe the issue as Ink marks on printouts or Ink smearing These marks are not located everywhere but at very distinct places on the printout Depending on their location we have identified two different problems that can create these marks As a summary Position of Marks Root Cause Problem Marks on the back side of the media A 1 Probl Marks on the lateral sides of the media erosol Problem Marks on the leading edge of the media Shadows in the print Non repetitive marks in the print area of the ae f Static Problem media while printing or inserting printheads It is very important to identify the problem very clear because their work arounds are different It is important that you thoroughly follow the qualification steps explained in this document in order to solve correctly the customer s problem HP DesignJet 5000 and 5500 Series Printers Service Manual 6 27 Print Quality You will see that replacing any printer s hardware part can not solve these pr
157. he same type as the rest of the consumables No 81 or No 83 Replace the incorrect ones 1 24 HP DesignJet 5000 and 5500 Series Printers Service Manual Troubleshooting NOTE Roll media WARNING Sheet media Prints Do Not Stack Properly in the Media Bin Solving Media Handling Problems HP Designjet Printers minimum media size is A3 in portrait mode The Front Panel Keeps Indicating that Media Is Misaligned or Incorrectly Positioned m The roll may be loaded the wrong way The paper should load over the roll toward you m The media may be crumpled or warped or have irregular edges m The paper may be loaded at an angle The right hand edge must be parallel to the blue line on the paper entry roller Ensure that the paper is wrapped tightly on the roll This is a very important step to remember because if this is not done the media may be loaded at an angle causing the media to be rejected E Perform the manual alignment procedure Refer to the User s Guide m Check that the paper is correctly loaded onto the spindle E It must be loaded with the right hand edge against the blue perforated line on the Printer m Align the media against the trailing edge coming out of the Printer m The media may be crumpled or warped or may have irregular edges E If you are using hand cut media the edges may not form a right angle or they may be rough Do not use hand cut media Use only purchased
158. he Carriage Assembly gt Page 8 46 0004 The Line Sensor pattern is not printed Firmware error Try the following m Power the Printer OFF and ON again using the Power Switch at the back of the Printer to reset the memory m Upgrade the Firmware gt Page 9 13 0005 Line Sensor error Try the following Em Replace the Carriage Assembly gt Page 8 46 HP DesignJet 5000 and 5500 Series Printers Service Manual 5 27 Service Calibrations Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action 0020 Line Sensor error Check the media used for the Calibration is WHITE Em Replace the Lens Cover Assembly gt Page 9 5 0021 Line Sensor error Check the colors in the calibration pattern If a color is absent the Printhead has failed for that color m Replace the Printhead for that color 0022 Line Sensor error Try the following Em Replace the Lens Cover Assembly gt Page 9 5 m Clean the Mark Encoder on the Overdrive gt Page 9 9 m Replace the Carriage Assembly gt Page 8 46 0100 Printhead error Try the following Check the colors in the calibration pattern If the quality of a colo
159. he Ink Cartridge and Printhead menu information Press ENTER for cartridges menu Licht cyan K LIGHT MAGENTA YELLOW CYAN MAGENTA BLACK overlay colors The Ink Cartridges Menu 3 6 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Roll Hewlett Packard Photo Imaging Gloss Ink OK Printheads OK 2 Press the or 4 key to select the cartridges icon and view status bars indicating ink levels in the Ink Cartridges Press ENTER for cartridges menu LIGHT CYAN LIGHT MAGENTA Ink Cartridges Menu YELLOW CYAN MAGENTA BLACK The front panel displays six horizontal bars These bars represent how much ink is remaining in the Ink Cartridges as ink is used up the bars get shorter in length The Ink Cartridge color on the overlay indicates the Ink Cartridge color related to each bar Press the Enter key to view the Ink Cartridges menu 3 Press the or 4 key until the front panel highlights the color that you want to see information on Press the Enter key Ink cartridge info Light Magenta cart info Cyan cart info Magenta cart info Black cart info Replace HP DesignJet 5000 and 5500 Series Printers Service Manual 3 7 HP Ink Supplies Troubleshooting 4 The front panel displ
160. he Printer In the Service Calibrations submenu scroll to 2 1 Scan axis and press Enter E o sh m a Make Selection i Press Enter 2 Service Calibrations 2 2 Service Station 2 3 ACCURACY HP DesignJet 5000 and 5500 Series Printers Service Manual 5 7 Service Calibrations NOTE 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 ml 2 1 Scan Axis HI Back Remove Media T Sj Enter Media too small Press ENTER to continue Press Enter 2 Ifthe correct media is loaded the following message is displayed Press Enter to confirm or Back to return to the Service Calibrations menu l E o 2 1 Scan Axis Back i t Press ENTER to confirm or J BACK to correct le Enter Make Selection When the following message is displayed you will need to enter the Line Sensor id The Line Sensor Id is a two digit figure in a 01 99 range which can be located on the label on the side of the Line Sensor Assembly on the right side of the Carriage For the 5000 Series use the ID 00 and for the 5500 Series use the ID 20 To insert a number use the UP and DOWN keys to scroll through a list of characters in the following ranges 1 9 and Backspace to delete a character previously confirmed using the Enter key After selecting the first digit press Enter to insert the second digit Pres
161. he 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 Remove 2 T 15 screws Type B from the both sides of the Electronics Module 5 Lift the Electronics Module up to clear it from the shoulder screws and remove from the Printer HP DesignJet 5000 and 5500 Series Printers Service Manual 8 97 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 Remove the following T 20 screws Type Q E For the 60 Model remove 4 screws from each group of 4 Pinch Wheels 5 groups in total E For the 42 Model remove 4 screws from each group of 4 Pinch Wheels 3 groups in total and 2 screws from the one group with 2 Pinch Wheels 8 98 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation 6 First remove lateral Pinch Wheels with their Coupling Plates NOTE For Pinch Wheel groups installed around the Mount Brackets do the following REMOVE
162. he 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 Using a vacuum cleaner with a brush attachment will make this process easier 3 Usea clean slightly damp cloth to wipe off the loosened ink deposits from the Platen Do not wipe the Rollers with this cloth Using a vacuum cleaner will make this part easier 4 Perform the Turn Drive Roller Utility see Page 4 17 to clean the exposed part of the Roller while it is rotating with another slightly damp cloth It is important that the cloth is not too damp otherwise you will leave too much moisture behind and the Roller will not work well when it is wet Also make sure that you clean the Mark Encoder on the left side of the Driver Roller 5 Press Cancel when you have completed the cleaning procedure HP DesignJet 5000 and 5500 Series Printers Service Manual 9 9 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 Carri
163. he following m Reduce the level of humidity lt 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 m Laminate the prints Black Smearing on HP Photo Imaging Gloss Narrow black lines can smear on this type of media particularly if the lines are narrow and have white gaps in between them Try the following Em Increase the Dry Time using the Front Panel Refer to the User s Guide m Laminate the prints Magenta Bleeding on HP Photo Imaging Gloss when using the Take Up Reel Under high humidity conditions approx gt 70 this media reduces its capacity to absorb Magenta because of this color s particular characteristics When an area fill with magenta is printed and then rolled onto the Take Up Reel the ink that is not completely dry moves laterally on the media To solve the problem try the following m Reduce the level of humidity lt 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 E Increase the Dry Time using the Front Panel Refer to the User s Guide Do not use the Take Up Reel or Bin for this media when humidity levels are high HP DesignJet 5000 and 5500 Series Printers Service Manual 1 13 Troubleshooting Loss of Gloss on HP Photo Imaging Gloss when using
164. he required vacuum to maintain the media flat over the Center Platen Pinch Wheels Center Platen Includes overdrive amp linear blade 5000 Series Only Front Platen Media Lever Center Guide Includes media holder stip Entry Roller Lever Cam Linkage The diagram below illustrates the air flow created by the Vacuum Fans Foams to create different vacuum chambers depending on media length Vacuum Fan Booster Fan 10 4 HP DesignJet 5000 Series Printers Service Manual 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 m The Ink Cartridges m The Ink Supply Station ISS m The Tubes System m The Printheads m The Air Pressurization System APS m The Leak Detect System LDS Ink Cartridge The HP No 81 Ink Cartridges for the HP DesignJet 5000 Series deliver 680 cc of ink Residual ink in the Ink Cartridge is required to avoid starvation in the Ink System that could cause damage to components Ink Cartridges are designed with Smart chip storing Ink Cartridge information E Ink connector to deliver ink to the Ink Tubes m Air connector that forces ink out of the Ink Cartridge m Ink Type lockouts that avoid Ink Cartridges with the wrong type of ink being installed
165. head calibration the following message is displayed Drop Detector Calibrating 5 12 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Calibrations NOTE NOTE On completing the Drop Detector calibration the following message is displayed Primer Calibrating On completing the calibration successfully the following message is displayed ME E Back Calibration performed correctly B t Press BACK to return 4 to previous menu P Ooo Enter 2 2 Service Station Press Back Press Back to return to the Service Calibrations menu If the Calibration fails the following message is displayed Error codes are displayed for L2K Line Sensor to black Printhead DD Drop Detection and Prim Primer Press Enter to continue ME 2 2 Service Station Calib Calibration Error a Back Error 0000 L2K xxxx 7 means OK DD xxxx OO Prim xxxx E Press ENTER to continue Enter Refer to 5 26 Calibration Error Codes to troubleshoot error codes Press Enter 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 gt Page 1 37 HP DesignJet 5000 and 5500 Series Printers Service Manual 5 13 Service Calibrations 3 Accuracy Calibration The purpose of this Accuracy Calibration is to set the nominal
166. hooting 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 Else Happens 1 6 Troubleshooting Media Jams Printhead Crashes 1 6 Troubleshooting Shutdowns User Message Warning Switch Power Off 1 7 Problems with Vacuum 1 10 Vacuum suction much lower at high altitudes 1 10 Printhead Crashes Smears on High Density Prints Using Coated Media 1 11 Color differences in different HP DesignJet Printers 1 11 Banding at variable extreme environmental conditions 1 12 Banding with unsupported Media 1 12 Banding due to Ink Cartridge replacement while printing 1 12 Hue shift on HP Colorfast Adhesive Vinyl media 1 13 Black Smearing on HP Photo Imaging Gloss 1 13 Magenta Bleeding on HP Photo Imaging Gloss when using the Take Up Reel 1 13 Loss of Gloss on HP Photo Imaging Gloss when using the Take Up Reel 1 14 Wrinkles and scratches cockle on HP Coated and Heavyweight Coated Media 1 15 Dry Cockle on High Density Prints Using Paper Based Media 1 14 Worm marks cockle on part of plots on paper based media 1 15 Drying Time Too Long for HP Studio Canvas 1 16 Media Skew when Printing a Banner Plot 1 16 User message Media loaded incorrectly Remove media 1 16 User message Warning Incorrect type of tubes system 1 17 User message Power Supply Error 1
167. iage out along the Printer to the position shown 3 Lift up the Carriage Cover and remove ALL the Printheads and close the Carriage Cover 8 60 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 61 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 T 8 screw Type V and washer that attaches the Cutter to the Carriage 8 62 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation 10 Slide the Cutter towards you and remove from the Printer HP DesignJet 5000 and 5500 Series Printers Service Manual 8 63 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 sraza pae 5 To remove the ISS stand at the end of Press ner f the Printer
168. iagrams Figure 18 ISS PCA and Main PCA HP DesignJet 5000 and 5500 Series Printers Service Manual 7 33 Parts and Diagrams Power Supply Unit 1 C6090 60028 C6090 60315 1 Power Supply Unit 2 0515 2200 7 Screw 3 C6090 60029 2 Cooling Fans 4 0515 2278 4 Screw 5 C6090 60033 C6090 60316 1 Electronics Module Base includes Power Supply Unit and cooling fans 6 0515 0382 4 Screw 7 34 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP Part Number Quantity Description Comments on Drawins DJ 5000 DJ 5500 Series Series 1 C6090 60236 Q1251 60070 1 Carriage Assembly Includes Carriage Height Tool Cutter Assembly and Line Sensor 2 C6090 60094 1 Cutter Assembly Includes Screw and Washer 3 0624 0737 1 Screw 3050 1982 1 Washer for cutter screw 4 C6095 60184 1 Trailing Cable 60 Model Includes Trailing Cable Clip and screws Cover Cap Trailing Ferrite C6090 60060 1 Trailing Cable 42 Model Includes Trailing Cable Clip and screws Cover Cap Trailing Ferrite 5 C6090 60285 Q1251 60074 1 Line Sensor C6071 60166 1 Carriage Height Tool Also Included with the Carriage Assembly 7 36 HP DesignJe
169. ice Calibrations NOTE NOTE 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 E B Back Calibration performed correctly Si T Press BACK to return ea a to previous menu Enter 2 1 Scan Axis Calib Press Back 9 Press Back to return to the Service Calibrations menu If the Calibration fails the following message is displayed Press Enter to continue eS Ej Back Calibration Error T m Enter 2 1 Scan Axis Calib XXXX Press ENTER to continue Press Enter Refer to page 5 26 Calibration Error Codes to troubleshoot error codes 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 gt Page 1 37 5 10 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Calibrations NOTE NOTE 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 E Line Sensor to Black Pen E Drop Detector E Primer Perform the Servic
170. ignJet 5000 and 5500 Series Printers Service Manual 8 35 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 Unclip and remove the Carriage Cover to access the Trailing Cable in the Carriage 8 36 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 E 3 for 60 Model E for 42 Model 8 Remove the Trailing Cables from the Trailing Cable Holder Press down in center to release TIP Press the Trailing Cables firmly in the center to release 9 Slide the Trailing Cable Guide out of the Carriage HP DesignJet 5000 and 5500 Series Printers Service Manual 8 37 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 hol
171. in good condition and they prevent them from being damaged when the Printer is not active They service the Printheads making sure they are always ready to be used 3 2 HP DesignJet 5000 and 5500 Series Printers Service Manual HP Ink Supplies Troubleshooting Identifying the Components The following illustration will help you identify the components of the HP Ink Supplies Printhead EE 1 Ink Cartridge Printhead Cleaner Printhead and Printhead Cleaner are supplied together General Information About HP Ink Supplies For optimum results from the Printer and modular ink delivery system always follow these guidelines when handling the HP Ink Supplies m Always install the Ink Cartridges Printheads and Printhead Cleaners before the expiration date which is on the packaging E Install a new Printhead Cleaner every time you change a Printhead Allow the Printer and Printhead Cleaners to automatically clean the Printheads E Ink Cartridges Printheads and Printhead Cleaners are designed with lock outs that only allow their installation in their color coded slots they must not be forced m Follow the instructions on the Front Panel of the Printer during installation HP DesignJet 5000 and 5500 Series Printers Service Manual 3 3 HP Ink Supplies Troubleshooting CAUTION m Avoid unnecessary removal of the Ink Cartridges and Printheads m When turning off the Printer always use
172. ing material If the Image Quality is worse after the Banding Calibration the original settings can be returned choose Utilities gt Banding gt Restore Factory 5 44 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Calibrations NOTE 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 Before recalibrating the printer the Image Quality print should always be used to verify the appearance of any Image Quality problems caused by media advance problems The Accuracy Calibration applies only to the media type currently selected in the front panel Other media types will keep their original media advance settings To perform the Accuracy Calibration At the printer s front panel choose the printer icon then Utilities gt Calibrations gt Accuracy gt Recalibrate gt Create Pattern Once the Accuracy Calibration print is completed choose the printer icon then Utilities gt Calibrations gt Accuracy gt Recalibrate gt Measure Pattern Then reload the print back into the printer For more information and detail about the Acc
173. ing the cutting operation In addition when pressing any key the Error Code ffff ffff 03450097 may appear on the front panel m Re boot the Printer and make sure the customer does not open the window while the Printer is cutting This problem is solved in any A 02 xx firmware release HP DesignJet 5000 and 5500 Series Printers Service Manual 1 19 Troubleshooting NOTE Carriage and Scan Axis Problems 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 m Whenever there is a Printhead continuity problem always check that the crane is completely clipped to the front of the carriage Unknown Line Sensor ID When performing the Scan Axis Calibration the Printer asks for the Line Sensor ID But there is no label on the Line Sensor indicating it E Ifthe Line Sensor ID is not indicated on the Line Sensor use the default value which is 0 In the future if the LED s are modified a sticker will be included with the new Line Sensor ID Line Sensor is shown as Not calibrated in the Service Configuration Print This is a firmware bug It is possible that the Line Sensor is calibrated even though the
174. ip 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 8 94 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 ge Yu ra BMY Z s Remove the LAN Card Refer to Page 8 76 Remove the Left Rear Cover Refer to Page 8 15 Remove the Right Rear Cover Refer to Page 8 16 Remove the Electronics Module Cover Refer to Page 8 79 Disconnect and remove the Hard Disk Drive for safety reasons Refer to Page 8 74 Remove 2 screws for each Cooling Fan from underneath the Electronics Module HP DesignJet 5000 and 5500 Series Printers Service Manual 8 95 Removal and Installation Remove the plastic Protective Cover from the Power Supply Unit Disconnect the Cooling Fan Cables from the Power Supply Unit Remove the Cooling Fans from the Printer 8 96 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 t
175. is clipped correctly and securely if not the Line Sensor will malfunction Connect the Line Sensor Connector to the Carriage PCA HP DesignJet 5000 and 5500 Series Printers Service Manual 8 55 Removal and Installation 4 Install the Carriage Cover NOTE 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 NOTE You must perform the following Calibration when the Line Sensor is replaced E Scan Axis Calibration gt Page 5 7 8 56 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 1 Apply Pressure 2 Release Encoder Strip i TIP 5 Remove the Right Rear Cover Refer to Page 8 16 Remove the Left Hand Cover Refer to Page 8 6 Remove the Right Hand Cover Refer to Page 8 10 Remove the 5 5 mm nut from the left hand side of the Printer that attaches the Encoder Strip to the Spring Clip The next step is performed by putting pressure on the Spring Clip as shown Release the En
176. is correctly connected m Faulty APS Replace the APS gt Page 8 67 m If the error code continues replace the Main PCA gt Page 8 681 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 0B0005 APS Failure Refer to System Error Code 0B0004 0B0006 The Trailing Cable has been incorrectly connected Try the following m Power the Printer OFF disconnect the Trailing Cable Replace the Trailing Cable if the ends are not flat or are damaged Reconnect the Trailing Cable correctly making sure it is pushed in firmly refer to the instructions on page Page 8 36 Power ON the Printer and check if the Error Code has disappeared m If the Error Code continues replace the Main PCA gt Page 8 8 taking care when connecting the Trailing Cable HP DesignJet 5000 and 5500 Series Printers Service Manual 2 17 System Error Codes System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action OBOOOX Unable to detect Fan X 7 Vacuum 8 Cooling 9 Aerosol Try the following m Make sure that the Fan is connected correctly to the Main PCA m Turn the Printer OFF and disconnect the Fan from the Main PCA Connect a New Fan to the Main PCA and power ON
177. is low very low or empty This means you have constantly updated information about the HP Ink supplies Printhead life is anticipated to be 700m1 or twelve months in the Printer whichever occurs first provided that the Printhead is used under normal operating conditions using HP Ink Cartridges only and its install before date has not lapsed However results vary depending on the print quality setting being used HP DesignJet 5000 and 5500 Series Printers Service Manual 3 5 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 Roll Hewlett Packard Photo Imaging Gloss Printheads TaD REPLACE Action Printhead Status Message Ink Cartridge Status Status Code m Ink displays information on the Ink Cartridges Printheads displays information on the Printheads and the Printhead Cleaners m The Status code indicates the exact nature of the HP Supplies problem see 3 10 Status Codes and Messages m The Action Message provides instructions to return to normal status i e OK see 3 10 Status Codes and Messages To view information for a specific Ink Cartridge color or Printhead you must access the cartridge and Printhead menus See 3 7 Obtaining Ink Cartridge Information and 3 8 Obtaining Printhead Information The overlay indicates the color related to t
178. ize 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 So despite the printer antistatic features we have discovered that the anti static backcoating of the media is a MUST for the 5X00 Series in order to avoid the image quality and ink accumulation issues we will describe later on Which printers are affected by this m Customers who print on a 3rd party polyester based film without anti static back coating are more susceptible to static related issues If they do not see any of the below mentioned symptoms the media probably has an anti static back coating thus they are not affected E Printers are not affected if they print using HP media approved for HP DesignJet 5000 Series or Any paper based media Customers use only photo based media are probably not affected Most photo based media work fine However there are some photo based media with a plastic back coating that is conducive to static build up These media could be affected too What can you see 1 Presence of shadows on the printout See the following image to see an example These shadows are particu
179. k 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 Power ON and check if the System Error Code has disappeared E Replace the ISS PCA gt Page 8 91 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 0A0060 Non Continuable The Printer has detected a leak in the Tubes System Should ONLY appear in printers with the Ink Leak Detector installed Refer to System Error Code 0A0050 0A0070 Continuable The Backup EEROM contents stored in the Hard Disk Drive are not consistent with the ones required by the firmware Try the following E Perform Backup EEROM gt Page 4 30 and ALL calibrations Perform EEROM Setup gt Page 4 23 to reconfigure the Printer 0B0000 Bad Ambient Temperature measured Try the following m Make sure that the Ambient temperature is within the allowed range between 0 and 55 Degrees Centigrade m Replace the Main PCA gt Page 8 8 HP DesignJet 5000 and 5500 Series Printers Service Manual 2 15 System Error Codes System Error Problem Description Corrective Action WARNING System Error Problem Description Corrective Action WARNING System Error Problem Description Corrective Action 0B0001 Bad Humidity Rea
180. k that the Start printing option is set the same for all Printers For troubleshooting purposes set this option to After Processing In this way the time reported is the time needed to receive the data and to process it and the printing time is not taken into account E If there are differences still it is probably due to the customer s network configuration Make sure that the Printer is not processing or printing another job while doing this test because this might have affect the outcome m Once finished return the Printer to the recommended setting which is Optimized The actual printing time is slower This may be due to the Carriage stopping at the end of each swath one Printer making more passes or the Carriage moving slower Check that the dry time is turned off If the dry time is turned ON the Carriage might stop at the end of each swath because the Printer uses the dry time i e the humidity and temperature reading to adjust the printing speed This is necessary to ensure that the print is completely dry before it can either touch the Media Bin or is rolled up with the Take Up Reel Check that the Image Quality setting on the front panel while the Printer is printing is the same for all Printers The setting while the Printer is in the stand by mode might be different to the actual LED that lights up during printing m Check that the Image Quality setting in the Driver is the same for all the
181. l 42 Model 3 C6090 60096 1 Drive Roller Gear 4 C6071 20005 1 Screw 7 40 HP DesignJet 5000 and 5500 Series Printers Service Manual Parts and Diagrams gt Nn Q o p f o n 2 S S in 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 HP Part Number Quantity Description Comments on Drawing 1 Q1253 60011 1 Heater Assembly including screws 60 Model Q1251 60031 1 Heater Assembly including screws 42 Model 2 C6095 60284 1 Center Platen Assembly including screws and Carriage Height Tool 60 Model C6090 60311 1 Center Platen Assembly including screws and Carriage Height Tool 42 Model 3 C6090 60096 1 Drive Roller Gear 4 C607 1 20005 1 Screw 7 42 HP DesignJet 5000 and 5500 Series Printers Service Manual Parts and Diagrams gt co ND Q o p f o A 2 S in Te 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 HP Part Number Quantity Description Comments on Drawing DJ 5000 DJ 5500 Series Series 1 C6095 6
182. language within the specified time 2 minutes Firmware Upgrade Does Not Work Through the Parallel Port With firmware revisions A 01 10 11 amp 12 the Printer will remain at 90 when doing a Firmware upgrade via the parallel port m For the customer recommend using the network to print and to perform the Firmware upgrade m For Service Engineers Keep the Top Arrow key on the Front panel pressed down when turning the Printer ON and release it once the Boot Menu appears Select Upgrade Firmware in the Boot Menu Send the firmware through the parallel port This problem is solved in any A 02 xx firmware release HP DesignJet 5000 and 5500 Series Printers Service Manual 1 23 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 The electrical 1 Switch OFF the Printer initialization process the Front connector has not 2 Connect the electrical Panel displays been correctly connector into the Ink WARNING connected to the Ink paielube tbe comme cian Incorrect type of Tubes Cartridge connector 3 Switch ON the Printer System Switch power off When you try to print the The air tube has not Switch OFF the Printer Front Panel displays been correctly Connect the air tube into the System Error connected to the Ink Ink Cartridge tube c
183. larly visible next to black areas or at the border of the print This is because the media is statically charged and misdirects the smallest drop HP DesignJet 5000 and 5500 Series Printers Service Manual 6 31 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 m Fall onto the media m Smear the media Causing the problem See the following images Ink accumulation at the bottom edges of the Printheads 6 32 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 6 33 Print Quality Static Solutions and Workarounds The following options resolve the issue m Use HP DesignJet 5X00 Series approved media m 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
184. le to configure the Printer and software for best color accuracy Location of Setting Description Selection Setting Printer Front Media Set to match the media type Panel Menu loaded in the Printer Internal RIP Ink Emulation Set the type of inks that your settings RGB software generates CMYK PS 5XOOPS only Color Calibration Set to ON both PS and RTL Non HP drivers Media or Set to match the media type Software equivalent setting loaded in the Printer See the RIPS documentation that came with your software for information Color correction Do the color correction option or calibration if one is available equivalent Blurred Lines Ink Bleeds from Lines Perhaps you have adjusted the drying time in the Front Panel menu to speed up the Printer output Set Drying time to Automatic m For details of drying time adjustments see the User s Reference Guide m The printer is laying too much ink for the media type Check that HP media is being used The Prints are Too Short DesignJet 5000 Series Only There are several situations where the print length can be too short Improper use of crop marks m Use of Coated Media when trying to get precise output However in the last case the length difference is a maximum of 4 to 6mm per meter whereas the first two cases can affect the print 6 18 HP DesignJet 5000 and 5500 Series Printers Service Manual
185. llation of ISS PCA for connections 6 Remove 5 T 10 screws Type K from the ISS PCA 7 Remove the ISS PCA HP DesignJet 5000 and 5500 Series Printers Service Manual 8 91 Removal and Installation Installation of the ISS PCA NOTE The ISS PCA connections are illustrated below J Position Connection Connector P Position Connection Connector Color Color l J ISS Cable white p2 Ink Leak Detector white J3 Main PCA white P3 APS Temperature white P4 APS Valve red l p5 APS Pump white l P6 APS Pump Spare white The Ink LeakDetector has been discontinued so this connector is no longer used There are 2 connectors available for the APS Pump and any one of them can be used 8 92 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Remove the Top Cover Refer to Page 8 5 Remove the Back Cover Refer to Page 8 23 Disconnect the Ink Leak Detector cable at position P2 from the ISS PCA release the cable clip on the Top EMC cover HP DesignJet 5000 and 5500 Series Printers Service Manual 8 93 Removal and Installation 6 Press the retaining cl
186. lowing E Turn the Printer OFF and ON from the rear of the Printer to reset the memory Download a Firmware Upgrade gt Page 9 13 2006 User and 2007 User Media Profile Corrupted Try the following E Download Media Profile E Power the Printer OFF and ON from the back of the Printer m Download a Firmware Upgrade gt Page 9 13 2008 User Firmware Error Download the latest Firmware gt Page 9 13 5 32 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Calibrations Calibration Error Problem Description Corrective Action NOTE Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action 2101 through to 2607 User Firmware Error Try the following Em Repeat the Closed Loop Color calibration See the User s Guide m Download the latest Firmware Page 9 13 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 3100 Firmware Error Try the following m Power the Printer OFF and ON again using the Power Switch at the back of the Printer to reset the memory m Upgrade the Firmware gt Page 9 13 3110 Black Printhead does no
187. lowing front panel message for more than 5 minutes Initializing Please Wait Code Rev xxxx Boot ROM xxx etc The cause for this failure could be either a print sent through the Parallel or LAN port during initialization or a defective I O card E Power OFF the Printer disconnect the Parallel and or the Network cable and power ON the Printer again to see if the Printer hangs again If the Printer did not hang again then the problem was due to the Printer receiving data through the ports while the Printer was initializing Before connecting the cables again make sure that all the pending print jobs are purged m If the Printer did hang again then power OFF the Printer remove the I O card and power ON the Printer again to see if the Printer still hangs If the Printer did not hang again install the I O card in the second slot and check whether it works there If the I O card causes the Printer to hang again replace the I O card If the Printer continues to hang even with a new I O card then replace the Main PCA Page 8 81 HP DesignJet 5000 and 5500 Series Printers Service Manual 1 21 Troubleshooting NOTE NOTE NOTE NOTE 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 The time the printer takes to start printing is longer Chec
188. me prints may have banding in the first 2 3 centimeters or swaths This kind of problem normally happens at the top of the page the rest of the print is not affected because the error hiding algorithm cannot be applied at the beginning of the print in certain circumstances This depends on the Take Up Reel installation settings the media used and the plot margins selected To prevent banding at the top of the page the Printer should be configured as follows 1 Take Up reel installed and loaded only for customers that have a Take Up Reel if not got to the following step 2 Select the paper margins as normal only for customers which use the extended margin PPD in the driver if not go to the following step HP DesignJet 5000 and 5500 Series Printers Service Manual 6 19 Print Quality NOTE 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 m The problem can be minimized by printing with Composite Black when the problem appears in Black areas or by printing in RGB mode instead of CMYK when the effect appears in Color area fills Media Always make sure that the customer is using the app
189. media which is not present in the front panel menu advise him to download the appropriate media profile There are two production limitations which affects both the 5000 and 5500 Series printers m Enrichment Issue gt Page 6 24 E Ink Marks on Printouts Page 6 27 These problems cannot be solved but they can be reduced HP DesignJet 5000 and 5500 Series Printers Service Manual 6 3 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 5 Nozzle print test to check each Printhead nozzle in a Printhead Considerations for Printing the Diagnostic Print 1 The Diagnostic Print requires A2 or C size media so you must have media loaded roll or sheet that is this size or larger 2 Use the same type of media that the customer was using when they experienced the print quality problem 3 Use the same print mode the customer was using when they experienced the print quality problem 4 Ifthe customer is using non HP media and after the Diagnostic Print you still have the same print quality problems change to genuine HP
190. n Calibration gt Off You can also request a Printhead Alignment from the front panel at any time by choosing the printer icon then Utilities gt Calibrations gt Printhead Alignment In this case the printer will align the printheads immediately or if an image is being printed as soon as the current print job is finished The alignment procedure requires a minimum paper size of Al D size 24 inches You should also perform the Printhead Alignment if the Image Quality Print indicates an alignment error Close Loop Color CLC Calibration CLC Calibration improves color consistency between prints and from one printer to another The printer calibrates the color by printing a calibration strip and then scanning the strip with a built in optical sensor The printer will then calculate the color correction required which is then applied to all the subsequent prints CLC Calibration can be performed automatically or manually To turn the automatic calibration On or Off choose the printer icon then Internal RIP Settings gt Color Calibration ON An Automatic calibration is performed whenever the current set of printheads and the current printing material have not previously been calibrated together OFF The printer uses a default color correction different for each printing material and print quality setting A CLC calibration can be started manually at any time choose the printer icon then Utilities gt Calibrations
191. n Page 8 4 for information on screw types NOTE NOTE NOTE 1 Open the Top Cover Make sure the Carriage is not in the print Platen area 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 E 39 T 10 screws in the 60 Model Em 35 T 10 screws in the 42 Model Be very careful when removing the screws because they can easily get damaged HP DesignJet 5000 and 5500 Series Printers Service Manual 8 117 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 E Scan Axis Calibration gt Page 5 7 m Carriage Height Calibration gt Page 5 18 Installation of the Center Platen Assembly WARNING When installing the Center Platen Assembly make sure the foam guides under the Platen are placed in their slots as shown below 8 118 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 2 Remove 1 T 15 Type M screw from each Deflector E 4 Deflectors in the 60 Model E 3 Deflectors in the 4
192. nded action at a time and check if the error code has disappeared 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 NOTE When reporting the System Error Code make sure that you supply the full Error Code including the last 8 numbers where applicable and the firmware version as well as the status of the Printer when the Error occurred was it printing calibrating processing etc Without this information HP Support Personnel cannot help you NOTE When reporting the 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 gt Utilities gt Statistics menu 1 2 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Performing the Necessary Service Calibrations Is the Printer calibrated correctly after replacing a
193. nder the Center Guide and carefully remove the Media Sensor mount by pulling it down gently as shown below TIP Pull down the Media Sensor 1 Insert Pal 2 Pull down by inserting a finger on each side of the sensor and pulling down HP DesignJet 5000 and 5500 Series Printers Service Manual 8 109 Removal and Installation Installation of Media Sensor WARNING When installing the Media Sensor insert the moving part as shown in the diagram 8 110 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Pull out the left side of the Entry Roller first and then remove completely HP DesignJet 5000 and 5500 Series Printers Service Manual 8 111 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 L
194. ng HP GL 2 Settings Menu AluO JduoSsisod Jeaddy s em y spo NU W IINA ul seaddy juO LoL 44 0 UO ehiey OL SSZ UIPIM GL Q OUUdd Ayoyoe 4 wore ero ME Sl 0 O0UU d g N Jed V ayaled y jed euyeq wele 1 31 HP DesignJet 5000 and 5500 Series Printers Service Manual Troubleshooting Page Format Menu m BATT Alu 3d149S s0d Jeaddy s emjy ee apoy nue IN4 ul seaddy AjuO HO UO Buoy ww 0 G 0 enuen OIeWOINY Buloeds s y H p pu x4 JewIoyN suben 0ZzZ 0 9ye 0Y HP DesignJet 5000 and 5500 Series Printers Service Manual 1 32 Troubleshooting Demos Menu PostScript Only Always Appear Only Appear in Full Menu Mode fi 2 3 HP DesignJet 5000 and 5500 Series Printers Service Manual 1 33 Troubleshooting Media Menu mi RET 1 34 HP DesignJet 5000 and 5500 Series Printers Service Manual Troubleshooting Ink Cartridge Menu OE ed C HP DesignJet 5000 and 5500 Series Printers Service Manual 1 35 Troubleshooting Printhead Menu 1 36 HP DesignJet 5000 and 5500 Series Printers Service Manual Troubleshooting Service Configura
195. ng 9 10 Firmware Upgrade 9 11 HP DesignJet 5000 and 5500 Series Printers Service Manual 9 1 Preventive Maintenance Introduction NOTE 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 Maintenance information can be obtained from Printer Setup Utilities Service Configuration Print As the frequency of service maintenance depends on how the Printer is used there are no specific preventive maintenance intervals For Service Maintenance purposes Printer usage is defined by the number of cycles performed by the following components E Scan Axis System movement of the carriage and flex circuit Printhead insertions m Tubes movement and Tubes septum Printhead insertions The number of cycles performed by a part depends on the print mode and the total length of prints performed by the Printer For example if Max Quality print mode is used on Glossy media the Printer performs 10 passes per inch whereas Max Speed on Coated media only requires 1 pass per inch There are two different EEROM counters for the number of Carriage cycles and Tubes cycles For information on Carriage and Tubes usage limits see Warning Stop Triggers on Page 9 3 There is also an EEROM counter for the number of Printhead insertions
196. ng Gloss 7 mil 178g m 100 ft 30m C6963A C6964A C6965A HP Photo Imaging Satin 7 mil 178g m2 100 ft 30m HP Paper Based Semi Gloss 6 mil 160g m2 100 ft 30m C6782A C6959A C6783A C6960A C6961A C6785A HP Colorlucent Backlit UV 6 mil 200g m2 100 ft 30m C6778A C6779A C6780A HP Studio Canvas 20 mil 368g m2 35 ft 10m HP Banners with Tyvek 10 mil 140g m2 50 ft 15m HP Colorfast Adhesive Vinyl 6 mil 328g m2 40 ft 12m C6771A C6775A C6773A HP Satin Poster Paper 43 Ib Text 162g m 100 ft 30m C7011A 3M Changeable Opaque Imaging Media 7 mil 178 microns 45 ft 13m C6760A C1882A 3M Lustre Overlaminate 2 mil 51 microns 75 ft 23m C6761A C1884A 3M Matte Overlaminate 2 mil 51 microns 75 ft 23m C6762A C1886A HP DesignJet 5000 and 5500 Series Printers Service Manual 7 59 Parts and Diagrams 7 60 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation 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
197. nter For Firmware Versions earlier than A 02 xx the Printer will start to print the Diagnostic Print immediately after selecting For Firmware Version A 02 xx and for the DesignJet 5500 Series the Printer DOES NOT print the complete Diagnostic Print Instead you must select which part of the Diagnostic Print that you need Use the Arrow keys to select the page that you need and press Enter to print it ME o 1 8 Diagnostic Print Press Enter m Page 1 Checks for banding in the Primary Colors E Page 2 Checks the Color to Color Alignment m Page 3 Check the Bidirectional Alignment Em Page 4 Check for Vertical Line Straightness m Page 5 Performs the Nozzle Test For information on how to use the Diagnostic Print refer to How to Use the Diagnostic Print on page 6 4 HP DesignJet 5000 and 5500 Series Printers Service Manual 4 33 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 4 34 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Calibrations Service Calibrations 5 3 Entering the Service Calibrations Menu 5 4 1 Scan A
198. nue checking the full length of the Printer until you arrive at the blue line used to load the cut sheet paper repeating steps 10 11 and 12 whenever a scraping sound is heard 5 24 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 5 25 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 Calibration Error Codes refer to both User and Service Calibrations and include their descriptions and recommended corrective actions If a code can only be obtained for either Service or User Calibrations the code will be followed by User or Service Calibration error codes consist of a four digit number XXXX You may get up to a maximum of three error codes for a single calibration Only try one recommended corrective action at a time and retry the Calibration to check if the e
199. o Light Magenta cart info Cyan cart info Magenta cart info Black cart info 5 The front panel displays information on the selected Printhead Cyan printhead info HP No 81 printhead IN Warranty Part Number C4821A Usage time 50h Ink consumed 3ml Mfg month 5 1998 The information supplied is m The make of the Printheads No 81 for Dye and No 83 for UV Ink m The current status of the Printhead m The Printhead warranty status m Re order part number of the Printhead m The time hours the Printhead has been operating in the Printer How much ink has been consumed by the Printhead Note It is possible for a Printhead to consume more than one Ink Cartridge m The year and the month that the Printhead was manufactured HP DesignJet 5000 and 5500 Series Printers Service Manual 3 9 HP Ink Supplies Troubleshooting Status Codes and Messages NOTE Most problems with Ink Supplies will be solved by the user simply following the instructions in the action message 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 Press ENTER for printheads menu Printheads LIGHT CYAN LIGHT MAGENTA YELLOW CYAN MAGENTA BLACK Printhead Menu 2l HP ID Code Status Number Action Message HP
200. oaters move freely 3 Replace the Ink Tubes System Page 8 64 Replace the ISS PCA gt Page 8 9 3 16 HP DesignJet 5000 and 5500 Series Printers Service Manual HP Ink Supplies Troubleshooting Status Numbers Error Description Procedure XX03 Replace Ink Cartridge Information The Ink Cartridge has a leak which prevents the ink pumping to the Printer WARNING If the Ink Bag in the Ink Cartridge is leaking the Tubes may be damaged 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 b Replace the faulty Ink Cartridge and reinsert the other Ink Cartridges If the XXO3Replace error reappears for any Ink Cartridge do the following 5 Remove the Ink Cartridge and check for ink on the Air Connector on the rear of the Ink Cartridge 6 If there is ink present do the following a Press the sides of the Ink Cartridge to see if ink is leaking from the Air Connector and replace the Ink Cartridge if it is faulty b If the Ink Cartridge is not faulty replace the Ink Tubes System Page 8 64 7 If there is no ink present do the following a Veri
201. oblems 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 As the ink is fired from the printhead minute droplets of the ink often break away from the main drop Because of their small size and weight these droplets can form a fine mist inside the printer The mist settles on the printer components and after a while visible ink deposits form inside the printer The term we use to describe the mist is aerosol Main drop EZ LELED y CLLLLLLLL LLL LL MLL LLL LEA CLLLLLLELLLLL s aerosol yeni mda We have seen in the DesignJet 5X00 printers that the majority of the aerosol is attracted to where the airflow is strongest this is at the lateral sides of the media at any given width and inside the linear blade We have also seen aerosol build up on the pinch wheels and cutter 6 28 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 B
202. occur we cannot prevent a customer from printing What we can do is warn the customer of possible damage but not stop the printing altogether Ink Cartridge Delivers Too Much Ink The following information explains the front panel message flow After printer detects ILS 1 Enable Out of Control bit in out of control situation is PH IC and inktube smart chips 2 Update Service Contig print Ink evel sense and non hp ink field on tubes printhead and ink cartridge 3 Ink cartridge bar for that specific color replaced by the error 2 8X09 8309 4 Ink cartridge info menu will show Unknown Ink Cartridge 5 Webaccess will show Ink supply info not available HP DesignJet 5000 and 5500 Series Printers Service Manual 3 19 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 Any damage resulting from use of this supply or non Hewlett Packard ink is not covered under your printer warranty The following features will not be availabl
203. ole machine can be stripped down by starting at the beginning of this chapter and working through the subsequent procedures NOTE NOTE NOTE NOTE THE INSTRUCTIONS IN THIS CHAPTER APPLY BOTH TO THE DESIGNJET 5000 AND 5500 SERIES UNLESS OTHERWISE NOTED EVEN THOUGH THE ILLUSTRATIONS ARE SHOWN USING THE DESIGNJET 5000 SERIES THESE ARE ALSO APPLICABLE TO THE DESIGNJET 5500 SERIES Before using this chapter to remove and or replace a component or assembly always make sure that you have performed the relevant service test for each component as described in 4 Service Tests and Utilities If the test passes you will not need to replace the component To install a component perform the removal procedures in reverse order unless a specific installation procedure is provided After removing and or replacing a component the relative procedure will state whether any calibrations and or tests are required Chapter 5 Service Calibrations Safety Precautions Safety symbols Immediately after the table of contents Review WARNING and CAUTION symbols and instructions before you service the Printer Follow these warnings and cautions for your protection and to avoid damaging the Printer WARNING Serious shock hazard leading to death or injury may result if you do not take the following precautions Ensure that the ac power outlet mains has a protective earth ground terminal Switch the printer off and disconnect it from th
204. on Corrective Action System Error Problem Description Corrective Action System Error Codes OBOOOB APS Failure Try the following m Check that the cable from the Ink Supply Station ISS PCA to the Ink Supply Station is correctly connected m Check that the Air Pressurization System Sensor Cable is correctly connected and is NOT damaged m Check all the tubes of the APS and make sure they are NOT pinched or damaged m Faulty APS Replace the APS gt Page 8 67 m If the error code continues replace the Main PCA gt Page 8 681 0B000C Serial Device ADC test failure Replace the Main PCA gt Page 8 681 0B000D 24 V source test failure Replace the Main PCA gt Page 8 681 OBOOOE At power up the Printer thinks it is smaller than 42 inches Try the following m Check that there are no obstacles in the Scan Axis which stops the Carriage from reaching the end stops on both sides m Check that the Carriage moves freely from side to side m Check that the IDS Crane is installed correctly on top of the Carriage and that the Carriage Cover is clipped on correctly HP DesignJet 5000 and 5500 Series Printers Service Manual 2 19 System Error Codes System Error Problem Description Corrective Action System Error Problem Description Corrective Action WARNING OBOOOF Continuable Only applicable to DesignJet 5500 Series Unable to detect the Hea
205. on Sequence LED s Front Panel Message Printer Error Error Corrective Action Message Code Max Quality The Printer hangs and Install the BootROM or replace it if already nothing else happens installed gt Page 8 77 Productivity Self Test Error Memory If X 7 reseat the DRAM DIMM s Max Speed Please Wait Config X otherwise sometimes only the replace the DRAM DIMM s gt Page 8 77 error code is displayed O Max Quality Error Memory Test Replace the DRAM DIMM s gt Page 8 77 O Productivity Max Speed Max Quality End Self Test Productivity Max Speed O Max Quality Initializing Power Supply Error The Trailing Cable is not connected 1 correctly Reconnect the Trailing Cable gt Productivity Contact HP Page 8 36 Representative Max Speed Initializing IO devs BootROM checksum Replace the BootROM Page 8 77 failed HP DesignJet 5000 and 5500 Series Printers Service Manual Service Tests and Utilities Self Diagnostics Initialization Sequence LED s Front Panel Message Printer Error Error Message Code Corrective Action O Max Quality Productivity Spinning up disk Boot Failed 1 500XX This is an error related to the Hard Disk E 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 Replace
206. on the Spring Clip as shown 4 Release the Encoder Strip from the retaining pin on the Spring Clip 1 Apply Pressure 8 42 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation gt 5 Using a screwdriver fully tighten the Spring Release Screw to release the A tension on the Belt Tighten screw gt gt gt 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 43 Removal and Installation 8 Remove the Belt Wheel on the left side 9 Remove the Tensioner Assembly from the left hand side 8 44 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Insert Encoder Strip Encoder Sensor HP DesignJet 5000 and 5500 Series Printers Service Manual 8 45 Removal and Installation Carriage Assembly and Belt Removal WARNING Switch off the Printer and remove the power cord 1
207. onnector 020000 00000002 Cartridge connector 3 Switch ON the Printer Contact HP Representative When you try to insert an Ink The three latches at 1 Remove the Ink Cartridges Cartridge you keep getting the the rear of the Ink 2 Open the door at the back of Printhead you keep getting the following message for one or more Printhead being inserted BUT the Printer requires Setup Printheads to following message for one or Cartridge tube the Left Hand Cover more Ink Cartridge connector have not 3 Correctly lock the 3 latches XX02 Reseat been locked correctly 4 Close the door and insert the Ink Cartridges When you try to insert a The Printhead tube 1 Remove any Printhead s Printhead you keep getting the connector has not been 2 Make sure the Printhead tube following message for one or correctly connected to connector is fully connected more Printhead the Carriage Assembly tothe Canines asta XX02 Reseat 3 Insert the Printheads When you try to insert a Normal Printheads are 1 Insert the Setup Printheads provided with the HP Upgrade Kit that allows automatic printing Panel displays the following message XX05 Replace have been inserted for the type of Ink System installed in the Printer XX11 Reseat prime the Ink Tubes After you have inserted the The wrong type of 1 Remove the Printhead Printhead Cleaners the Front Printhead Cleaners Cleaners 2 Make sure that they are of t
208. or code is displayed Remove the media and re boot the Printer This error code should not appear again 2 6 HP DesignJet 5000 and 5500 Series Printers Service Manual System Error Problem Description Corrective Action NOTE System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Codes ffff ffff 03450097 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 Re boot the Printer and make sure that the Window is never opened during the cutting operation This problem is solved in any A 02 xx firmware release ffff ffff 036000bd This firmware error code is related to the detection of the Printhead cleaners by the line sensor It always happens during initialization while checking the Printhead Cleaners In most case it is a problem of incorrectly inserted Printhead Cleaners but it can also be caused by an incorrectly assembled Service Station Try the following m Remove the Printhead Cleaners and reinsert them again E If the error still persists perform the Service Station Calibration gt Page 5 11 m If the error still persists an onsite visit is necessary to repeat the calibration or to change the Servi
209. or some time the liquid of the ink evaporates We have two different cases 1 If the resting state is not very long the water of the ink only HP DesignJet 5000 and 5500 Series Printers Service Manual 6 25 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 1rtner T 155 60 72 printing direction omm If we magnify the error you will see that the darker part which is not printing has darker drops because of the initial excess of pigments paper directior 2 If the resting state is maintained longer the water of the ink evaporates almost completely which blocks the nozzle from a small amount of time while it is refilled with fresh ink 6 26 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 E Rotate the image Remember t
210. oups key at the bottom left corner is used to select the Print Quality Max Quality Productivity or Max Speed The LEDs on top of the key show the selected option m 2 keys at the top left part are used to send commands directly to the printer Cancel and Load Unload Media E 5 keys to the right of the display are used to navigate through the menus Back Enter Up Down and Menu You can print a demo plot called Menu to get the complete menu tree m key on the upper right corner is used to set the Printer to Standby mode Scan Axis The Scan Axis determines the Carriage s motion and its position with respect to the media Its main parts are E Scan Axis Motor drives the Carriage using the Belt m Tensioner maintains the tension of the Belt m Encoder Strip determines the position of the Carriage using the LED Sensor on the Carriage PCA Tensioner Scan Axis Motor Encoder Strip HP DesignJet 5000 and 5500 Series Printers Service Manual 10 3 Functional Overview Paper Axis The Paper Axis determines the motion of the media through the printer Its main parts are m Paper Axis Motor provides traction to the Overdrive m Center Platen and Overdrive controls the printing path and expansion of the media m Pinch wheels and Lever captures the media and provides added friction m Center Guide and Entry Roller feeds media through the paper path m Vacuum Fans provides t
211. ower 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 Remove the Left Hand Cover Refer to Page 8 6 8 Remove the Right Hand Cover Refer to Page 8 10 9 Remove the Left Hand Trim Refer to Page 8 22 10 Remove the Right Hand Trim Refer to Page 8 20 11 Remove the Media Lever Assembly Refer to Page 8 18 12 Remove the ISS Refer to Page 8 64 13 Remove the Service Station Refer to Page 8 69 14 Remove the Vacuum Fan Refer to Page 8 103 15 Remove the Electronics Module Refer to Page 8 97 8 112 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 E Lift it from the front to release it E Pull it out in a rotating movement HP DesignJet 5000 and 5500 Series Printers Service Manual 8 113 Removal and Installation Drive Roller Gear Removal WARNING Switch off the Printer and remove the Power Cord NOTE Refer to the table on P
212. place the Service Station gt Page 8 69 m If the Error Code continues replace the Main PCA gt Page 8 61 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 2 9 System Error Codes System Error Problem Description Corrective Action WARNING System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action 010090 Continuable Error in Paper axis Motor Encoder Try the following m Check that the Paper Axis Motor cable is NOT broken or damaged m Check that the Paper Axis Motor cable is correctly connected m Replace the Paper Axis Motor gt Page 8 105 m If the Error Code continues replace the Main PCA gt Page 8 61 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 010091 Continuable Error in Paper axis Motor Encoder Refer to System Error Code 010090 010092 Continuable Mark Encoder position not detected on Drive Roller Try the following E Replace the Lens Cover gt Page 9 5 m Clean the Mark Encoder on the Drive Roller using
213. r C6090 60093 1 1 Booster Fan 2 0515 2248 2 Screw 3 C6090 60103 Media Sensor 7 16 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 1 C6072 60160 1 Paper Axis Motor Assembly includes Helical Gear and Grease 0515 2248 3 Screw 3 0515 1743 2 Screw Helical gear 7 18 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 1 C6090 60092 1 Scan Axis Motor Assembly 2 0515 0382 2 Screw 7 20 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 1 C6090 60085 1 Ink Supply Station ISS Includes Grounding Strip 2 C6090 60084 1 Air Pressurization System APS 7 22 HP DesignJet 5000 and 5500 Series Printers Service Manual Parts and Diagrams Figure 13 ISS and APS Assembly HP DesignJet 5000 and 5500 Series Printers Service Manual 7 23 Parts and Diagrams Ink Tube
214. r against the media To solve the problem try the following m Never use HP Coated Media for High Density prints As a substitute use HP Heavy Weight Coated or Heavy Weight Coated Economy Media Color differences in different HP DesignJet Printers Color differences between one image printed on the HP DesignJet 5000 Series and the rest of the DesignJet platforms are due to the different chemistry of the 5000 series inks compared with the rest of the inks for other printers This color variability among different HP DesignJet Series Printers has been always present You can try to achieve consistent colors with the following E Select the same color emulation settings in your Postscript Driver as the one used by the printer you want to emulate E Select the correct Ink Emulation from the Printer Setup Menu Internal RIP Settings HP DesignJet 5000 and 5500 Series Printers Service Manual 1 11 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 Em Perform the Accuracy Calibration in the new environmental conditions Refer to the User s Guide Media Solutions Banding with unsupported Media The
215. r 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 Disconnect the PCA Power Supply connector from the Main PCA PCA PS Connector 8 88 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 9 Remove 7 T 10 screws Type K and remove the PSU HP DesignJet 5000 and 5500 Series Printers Service Manual 8 89 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 8 90 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 insta
216. r is not acceptable the Printhead has failed for that color Perform Recovery Page 6 15 for the Printhead and repeat the calibration m If the error persists for that color replace the Printhead 1001 User Line Sensor Error Em Replace the Carriage Assembly gt Page 8 46 5 28 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Calibrations Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action 1002 User The Line Sensor pattern is not printed Firmware error Try the following m Power the Printer OFF and ON using the power switch at the back of the printer to reset the memory m Upgrade the Firmware gt Page 9 13 1003 User Firmware Error Try the following m Perform Printhead Recovery Page 6 5 and repeat the Printhead Alignment See the User s Guide m Power the Printer OFF and ON using the power switch at the back of the printer to reset the memory m Upgrade the Firmware gt Page 9 13 1004 User The Line Sensor cannot detect all the lines in the printed pattern Try the following m Perform Printhead Recovery Page 6 15 m Perform the Service Scan Axis Calibration gt Page 5 7 m Check the pattern to see if a Printhead is not printing correctly and if there are defects in the patt
217. remove ALL the Printheads and close the Carriage Cover HP DesignJet 5000 and 5500 Series Printers Service Manual 8 25 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 8 26 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 27 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 8 28 HP DesignJet 5000 and 5500 Series Printers Service Manual Removal and Installation 13 Disconnect the Electrical Cable from the rear of the Ink Cartridge Tube Connector 14 Disconnect the Air Tube 15 Twist the 3 latches at the rear of the Ink Cartridge Tube Connector and release the complete Assembly HP DesignJet 5000 and 5500 Series Printers Service Manual 8 29 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 Co
218. res 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 Nozzle Test for Cyan Printhead Missing Squares Each nozzle on each Printhead prints a series of very close lines that can be seen as small squares in the Diagnostic Print You can see whether a nozzle is not working if squares are missing or if a nozzle is malfunctioning the color fill is less dense If you have more than 30 defective nozzles the Printer will automatically request you to recover the Printhead s XX20 RECOVER or to replace the Printhead s XX21 REPLACE if the defect cannot be recovered This test also allows you to check the condition of the Printhead if your Printer displays a Xxxx REPLACE or XXXX RECOVER message for a Printhead that has recently been changed or recovered successfully If there are not a large number of squares missing and so the nozzles are firing correctly you may have a drop detector problem 6 14 HP DesignJet 5000 and 5500 Series Printers Service Manual Print Quality NOTE NOTE How to fix the Nozzle Defects 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 If your Print
219. rking in To find the humidity level print the Service Configuration Print Printer Setup Menu Utilities Test prints Service config E Increase the drying time using the Front Panel settings Refer to the User s Guide m Do not use the Take Up Reel or Bin under conditions of high humidity Media Skew when Printing a Banner Plot When printing banners media skew occurs This is particularly noticeable in the first plot when media is not perfectly aligned To solve this problem do the following m Use extended margins for banner plots Refer to the User s Guide User message Media loaded incorrectly Remove media This message appears when the media sensor has detected media but the line sensor has not detected the leading edge of the media at all or has found it in an incorrect position There are three possible situations when this message comes up The paper is in the incorrect position because the Printer was turned OFF in the middle of a print It should only happen in printers without the Take Up Reel 42 model because with the Take Up Reel installed the Printer will not search for the leading edge after the Printer has been powered up or after activating the media load lever The Printer simply continues to print wherever it stopped m To verify this setting check in Printer Setup Menu gt Device setup gt TUR installed It should be set as No for the 42 model Printers and Yes for the 60
220. rning Printhead quality degrading select YES to replace failing printhead s NO Continue You can still print without the failed Printhead but each time you send a print job to the Printer this warning is displayed If you set the Image Quality Warning to Off this message will not be displayed WARNING If you use degraded Printheads the print quality may be affected particularly in Max Quality print mode The image is printed WITHOUT using the failed Printhead i e without using that color To change the Image Quality Warning setting 1 In the Service Utilities submenu scroll to 1 7 Img Quality Warning and press Enter To 1 Service Utilities e P 1 2 Prime TUBES Back 1 3 Altitude Setup 1 4 EEROM Setup it 1 5 Reset Life Counters a Make Selection 1 6 Backup EEROM as el 4 Press Enter 2 The following message is displayed Select Yes or No and press Enter to confirm 4 32 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Tests and Utilities NOTE NOTE 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 Inthe 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 Z Make Selection 1 7 Img Quality Warning Press E
221. ropriate media for the required image and that it is consistent with the software application being used To ensure color accuracy and print quality performance of the Printer only media types that have been certified for the Printer should be used Use of non HP media or HP media not certified for the Printer may significantly reduce the color and print quality of the required images For details of HP media refer to the User s Guide or the Media Guide for the HP Designjet Printers To have accurate colors the media settings must match the type of media loaded in the Printer If the customer is using non HP media with HP drivers the colors in the required print may not be accurate Advise the customer to use HP media to improve the accuracy of the colors Printed surface smearing roll DesignJet 5000 Series Only As the media is printed and the image is coming out from the Printer the natural curl of the media causes it to rub against the roll of media installed in the Printer This causes image smearing In addition to this if the exiting media sticks against the roll because the ink is not dry or because of static some Polyester films get electrostatically charged it could cause the media to reenter into the Printer Make sure that the media deflectors are installed onto the Printer The increased distance between the roll and the exiting media reduces the probability of having both surfaces being attracted and smears 6
222. ror in Paper axis Encoder quadrature Try the following m Check that the Paper Axis Motor cable is NOT broken or damaged Check that the Paper Axis Motor cable is correctly connected m Replace the Paper Axis Motor gt Page 8 105 m If the Error Code continues replace the Main PCA gt Page 8 61 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 2 8 HP DesignJet 5000 and 5500 Series Printers Service Manual System Error Problem Description Corrective Action WARNING System Error Problem Description Corrective Action WARNING System Error Codes 010041 Error in Scan axis Encoder quadrature Try the following m Check that the Encoder Strip is NOT broken or damaged E Replace the Encoder Strip gt Page 8 34 Em Replace the Carriage Assembly gt Page 8 46 m If the Error Code continues replace the Main PCA gt Page 8 8 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 010042 Error in Service Station axis Encoder quadrature Try the following m Check that the Service Station Encoder Cable is NOT broken or damaged Em Check that the Service Station Encoder Cable is correctly connected Em Re
223. ror persists for all Printheads this indicates a hardware failure Do the following 1 Check that the Carriage Tube Connector is correctly connected to the Carriage 2 Check that the Trailing Cable connections between the Carriage Assembly and the Main PCA and if the cable is damaged replace it gt Page 8 36 3 Replace the Carriage Assembly gt Page 8 46 Replace the Main PCA gt Page 8 81 HP DesignJet 5000 and 5500 Series Printers Service Manual 3 13 HP Ink Supplies Troubleshooting Status Error Description Procedure Numbers XX02 Reseat Continuity problem between Try the following verify if the message returns to XX06 Reseat the Printhead and the OK after each one XX08 Reseat Carriage Assembly 1 Reseat the Printhead 2 Remove the Printhead and clean the XX10 Reseat Electrical failure interconnect refer to 9 6 Carriage Interconnect Wiper 3 Replace the failing Printhead 4 Check the Carriage Tube Connector is correctly connected to the Carriage 5 Check Trailing Cable connections between the Carriage Assembly and the Main PCA and replace the Trailing Cable if damaged gt Page 8 36 6 Replace the Carriage Assembly Page 8 46 XX03 Replace Printhead smartchip failure Replace Printheads XX04 Replace Setup Printhead installed Install normal Printheads XX05 Replace Used setup Printheads If priming Tubes install new Setup Printheads installed otherwise in
224. rriage PCA NOTE Remove Trailing Cable Ferrites if they fall into the Carriage E 3 for 60 Model E for 42 Model 17 Remove the Trailing Cables from the A Trailing Cable Holder Press down in center to release TIP Press the Trailing Cables firmly in the center to release 18 Slide the Trailing Cable Guide out of the Carriage 8 50 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 51 Removal and Installation NOTE WARNING Installation of Carriage and Belt Before installation clean and oil the Slider Rods using the User s Slider Rods Lubrification Kit Refer to the User s Guide Make sure you install the Carriage Assembly and Belt as follows 1 Insert belt as indicated on the underside of Carriage TIP An arrow on the bottom of the Carriage indicates position and direction 2 Line up the Carriage Guide on the underside of the carriage with the Slider Rods on the Printer NOTE Perform the following Service Calibrations after the installation of the Carriage Assembly E Carriage Height gt Page 5 18 E Service Station gt Page 5 E Scan Axis gt Page 5 7 E Printhead Alignm
225. rror code has disappeared If a problem persists a Call Agent can try and troubleshoot the problem by requesting the Calibration Error Code from the vow Customer via the phone Using this process it can be determined whether the Printer requires any on site maintenance 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 5 26 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Calibrations Calibration Error NOTE Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action 0000 This code is not an error See the other codes reported 0001 Pen voltage error Try the following m 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 m If the XXXX Replace message is for all Printheads replace the Carriage Assembly gt Page 8 46 0002 and 0003 Line sensor could not calibrate Check the media used for the Calibration is WHITE Try the following E Replace the Lens Cover Assembly gt Page 9 5 E Replace t
226. rs are installed on your Printer m If the customer is using Media Saving Options from the advanced section of the HP GL 2 Driver try disabling one or both of the options auto rotate and inked area m Use the Take Up Reel if you have one installed If the above fails to solve the problem of smears and scratching change the media that the customer is using to a non paper based media such as HP High Gloss Photo Paper HP DesignJet 5000 and 5500 Series Printers Service Manual 6 21 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 gt Test prints gt Color print The printer will then print a page consisting of three color scales as follows 1 Yellow shading into blue 2 Magenta shading into green 3 Cyan shading into red Color lightness and density have been tuned to maximize the effectiveness of the print 5 6 7 9 10 L 12 13 5 7 9 10 11 12 13 How to Evaluate the Print Place the print under a source of white light For each of the color scales in the print select the square or between two of them if in any doubt where the color transition happens The three following
227. rted when Printer initialization is performed Self Diagnostic error codes consist of seven alphanumeric characters XXXXXXX 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 m Which firmware revision the Printer is using m The complete error number Solving Image Quality Problems Whenever an Image Quality problem appears it is advisable to print the Diagnostic Print This will help you differentiate between possible Printhead errors and other problems such as incorrect front panel selection driver or RIP configuration or mechanical problems For information on solving Image Quality problems see Chapter 6 Print Quality 1 4 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 gt Page 8 88 Status LED s 4 Check that the Front Panel Cable is correctly connected to the Electronics Module Also
228. rules a b c show visually how to perform this evaluation Can t dedde Looks yellowish Looks bluish a nit _ 6 22 HP DesignJet 5000 and 5500 Series Printers Service Manual Print Quality Looks ydlowish Looks bluish oe Saa rN 4 5 Can t decide Can t decide TTT Eo a J 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 4 Replace the Line Sensor gt Page 8 53 HP DesignJet 5000 and 5500 Series Printers Service Manual 6 23 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 See the following image to better understand the explanation 1 Initial Grading 2 Darker Bor
229. s connected correctly to the ISS PCA m Replace the ISS PCA Page 8 97 or the Ink Tubes system gt Page 8 25 User message Power Supply Error 1 This error indicates a short in the 24V electronics circuits Do not replace the Power Supply This message only indicates the failure and is not the cause Usually this message appears after the insertion of a Trailing Cable into the connectors This message means that the Trailing cable is incorrectly connected and it is creating a short on the 24V circuit m To isolate the problem remove the Trailing Cable from the back of the Printer and check whether the Printers powers up correctly m Ifthe Printer powers up correctly the problem could have been a bad HP DesignJet 5000 and 5500 Series Printers Service Manual 1 17 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 So once again to isolate the failure disconnect first the ISS cable and check whether the Printer works If it does reconnect the cable again to verify the failure and then if necessary
230. s the grey flat cable with the grey connector is plugged into the Main PCA Make sure that the clips of the connector are closed completely Check also that the Service Station cable is not damaged E In already used Printers power OFF the Printer and try to move the Service Station backwards and forwards to see whether it is blocked Possible causes are Printhead Cleaners incorrectly positioned damaged or even pieces of paper within the Service Station Remove the Printhead Cleaners or the pieces of paper and check whether the problem persists E Ifthe problem disappears without the Printhead Cleaners reinsert them into the Service Station and see whether the problem reappears If the problem reappears replace the complete set of Printhead Cleaners m If the problem persists even without the Printhead Cleaners then replace the Service Station Page 8 69 and recalibrate the Printer HP DesignJet 5000 and 5500 Series Printers Service Manual 1 7 Troubleshooting NOTE NOTE 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 m Check that there are no pi
231. s Enter to continue when both digits have been entered mm Line Sensor Line Sensor Id _ _ T n H Make Selection Use Up Down buttons Oo to scroll E Enter E Ifthe Line Sensor ID is not indicated on the Line Sensor use the default value which is 0 5 8 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 3 Back Line Sensor Id E 20 EE Press ENTER to confirm 4 or BACK to correct ze S nter 5 If you do not insert correct values the message below is displayed Press Enter to continue the calibration using default values Make Selection NOTE If Scan Axis Calibration is performed without inserting the correct Line Sensor Id each time the user performs a Color Calibration a continuable System Error will be reported See Chapter 2 System Error Codes Top Line Sensor na Back This Firmware Revision m does not support at the selected Line Sensor Id Ey a Press ENTER to continue Enter Press Enter 6 Once the media is detected the Calibration starts and the following message is displayed Line Sensor Calibrating During this stage the Printer will print the following pattern HP DesignJet 5000 and 5500 Series Printers Service Manual 5 9 Serv
232. s System Ink Tubes System Reference HP Part Number Quantity Description Comments on Drawing DJ 5000 DJ 5500 Series Series 1 C6095 60186 1 Dye Ink Tubes System 60 Model Includes Setup Printheads and Carrier Clip C6090 60058 1 Dye Ink Tubes System 42 Model Includes Setup Printheads and Carrier Clip C6090 60231 1 UV Ink Tubes System 60 Model Includes Setup Printheads and Carrier Clip C6090 60232 1 UV Ink Tubes System 42 Model Includes Setup Printheads and Carrier Clip C6090 60106 6 Setup Printheads Also included in Ink Tubes System C6090 60235 1 Printhead Storage Container 7 24 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP Part Number Quantity Description Comments on Drawing DJ 5000 DJ 5500 Series Series 1 J6057 61001 1 EIO Card 615N 2 1 EIO Card Cover 3 C6072 60176 1 DIMM Cover 4 0515 2246 4 Screw 5 C6090 60187 1 SDRAM DIMM 64MB C6090 60185 1 SDRAM DIMM 128MB 6 C6091 60008 1 PS Boot ROM DIMM A 01 01 C6090 60027 1 RTL Boot ROM DIMM A 01 01 Q1252 60003 1 PS Boot ROM DIMM 05 00 01 Q1251 60066 1
233. s Troubleshooting Risks with Using Non HP Hardware The risks in using non hp hardware refill systems are m Printhead dry fire Probable empty ink tubes These issues can be caused by m 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 m Uninstalling non hp hardware While the non hp hardware is installed the ink cartridge smartchip is not updated Therefore an IC can be marked at 80 full when in fact it s only 70 full If the non hp hardware is uninstalled the printer thinks there is more ink available than there really is Thus the printer may continue to print without ink Not performing the reset process If customer is not performing the reset the initial status of the quantity of ink will not be 100 when it really is 100 ILS Out of Control Detection Current Printhead kit Current Ink cartridge H Cyan IN WTY i Cyan Y Printhead status OK ee info i si Gleaner status ey Product namber C4931A HP No BI pai avea COSA HP No 81 pors puna CSIRO 2 Q Expration date 1 2003 J tay i a Changes Manufacturer Genuine HP with non HP ink Number of insertions 20 Jnsertion to YES 2 Changes nk used wty spent 219 mi 3129 Used with non HP ink NO to YES Numb
234. s or the last System Error Code that was triggered I O Configuration In this area you can find information on the configuration of the JetDirect Card 1 38 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Likewise if you have start printing set to Optimized and you change nesting to In order the Printer will automatically set start printing to After Processing m There is no problem This is the way the Printer operates 2 Printhead crashes and ink smearing with Coated Paper HP Coated Paper is very prone to Printhead crashes especially in high humidity conditions and high density prints The HP recommendation is as follows HP Coated Paper For presentation quality images For a variety of everyday uses Produces excellent line and color quality for medium ink density illustrations and graphics working comps proofs and renderings HP Heavyweight Coated Paper For durable presentation quality images Designed for high ink density and rugged use and for final presentations and signs that are mounted an
235. sing this Service Utility because automatic priming has failed you will need to remove the Setup Printheads used and insert new Setup Printheads NOTE Check there is enough ink remaining in the Ink Cartridges before starting to prime the tubes if the ink level is LOW or VERY LOW replace the Ink Cartridges Prime the TUBES as follows Inthe Service Utilities submenu scroll to 1 2 Prime TUBES and press Enter 1 Service Utilities 3 Altitude Setup 1 4 EEROM Setup ZZ Make Selection re Reset Life Counters 1 6 Backup EEROM Press Enter The following message will be displayed Press Enter to confirm E Tor 1 2 Prime TUBES B Back at Press ENTER to confirm Ss sl OF BACK to correct HP Enter Press Enter The Printer will begin to startup and in order to continue press Enter E 7o INK STARTUP B Bac Printer startup at Press ENTER to oR Sonane B Ener Press Enter 4 18 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Tests and Utilities 4 The following message will be displayed on the front panel while the printer verifies the Ink Cartridges 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
236. ssembly gt Page 8 46 5014 Service Could not detect Printhead Cleaner Try the following E Insert a Printhead Cleaner 5015 Service Printhead Cleaner is not correct type Try the following m Check that the Printhead Cleaner type matches the ink set installed Dye or UV HP DesignJet 5000 and 5500 Series Printers Service Manual 5 37 Service Calibrations Calibration Error NOTE Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action 6000 Service This code is not an error See the other codes reported 6001 Service Drop Detector not working Try the following m Turn the Printer OFF and ON and repeat the Service Station Calibration gt Page 5 11 m Replace the Drop Detector Assembly gt Page 8 72 m If the Error Code continues replace the Main PCA gt Page 8 8 6003 Service Drop Detector did not calibrate for Black Printhead Refer to Error Code 6001 6004 Service More than one Printhead not calibrated Refer to Error Code 6001 6005 Service Drop Detector did not detect Printhead nozzles spitting Try the following m Check the path and remove any obstructions e g media m Check all the cables of the Scan Axis Motor and make sur
237. stall normal Printheads XX09 Replace Electrical failure 1 Replace the Printhead s 2 Check Trailing Cable connections between the Carriage Assembly and the Main PCA and replace S the Trailing Cable if damaged Page 8 36 3 Replace the Carriage Assembly gt Page 8 46 4 Replace the Main PCA gt Page 8 8 XX11 Replace Incorrect type of Printhead If Tubes system is priming install Setup i installed Printhead s E Ensure that you have genuine HP Printheads installed XX12 Replace Printhead does not match the Ensure that all the ink consumables are HP om rest of the ink consumables XX13 Replace Printhead smart chip failure Replace the Printhead s XX14 Replace The Printhead has an internal 1 Replace the Printhead s XX15 Replace electrical failure 2 Replace the Carriage Assembly Page 8 46 XX16 Replace The Printer was printing Select YES to replace Printheads or NO to finish XX17 Replace Printhead short print job without the failed Printhead print quality p is affected You must replace the Printhead after the print job XX18 Replace The Printhead smartchip Install genuine HP Printheads detects an unapproved manufacturer XX20 Recover The Printhead has detected 1 You can continue using the Printhead unless the nozzle failure XX21 Replace message is displayed the affect on print quality depends on the print mode 2 Perform the Reco
238. t Errors Group 06 Line Sensor Errors Group 08 Pen Energy and Thermal Management Errors Group 09 Hard Disk Drive Errors Group OA Ink Delivery System Errors Group OB Hardware Initialization Errors Group OC Drop Detection Nozzle Recovery Related Errors Group OD Miscellaneous Errors Group OF Firmware Software Errors 2 4 HP DesignJet 5000 and 5500 Series Printers Service Manual System Error Problem Description Corrective Action System Error Problem Description Corrective Action NOTE System Error Codes ffff ffff xxxxxxxx General Firmware Error 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 Usually the errors are sporadic and appear very randomly The best solution is just to switch the Printer OFF and ON and check if the problem has disappeared as in Windows Frequently the problem will disappear However sometimes the same system error appears quite often or it is permanent Its root cause as explained above may not necessarily be a firmware problem it could also be related to the Ink Supplies Electronics Module etc
239. t 5000 and 5500 Series Printers Service Manual 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 HP Part Number Quantity Description Comments Tem DJ 5000 DJ 5500 Series Series 1 C6090 60088 1 Tensioner Assembly Includes Pulley Assembly Pulley Spring Wedge and Actuator Arm 0515 2248 1 Screw C6095 60183 1 Belt 60 Model C6090 60072 1 Belt 42 Model 4 C6095 60265 1 Encoder Strip 60 Model C6090 60267 1 Encoder Strip 42 Model 5 0535 0031 2 Nut 3050 0026 2 Washer 7 38 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP Part Number Quantity Description Comments on Drawing 1 C6095 60174 1 Front Platen Assembly including screws 60 Model C6090 60079 1 Front Platen Assembly including screws 42 Model 2 C6095 60284 1 Center Platen Assembly including screws and Carriage Height Tool 60 Model C6090 60311 1 Center Platen Assembly including screws and Carriage Height Too
240. t Prints a 4 and Enter Statistics al Enter Tog ether 4 6 HP DesignJet 5000 and 5500 Series Printers Service Manual Service Tests and Utilities For Call Agents requesting the User to access a limited a re number of Service Tests we aly l l ge a Once inside the Printer Setup Options menu and the Device setup menu is highlighted press the following key combination Printer setup options Top Back Utilities at Internal RIP settings Press Down Queueing amp Nesting 4 and Enter HP GL 2 settings E Enter Together T O setup The message below is displayed Select Yes to continue Warning Ooo Top This mode should NOT be used without having the pack guidance of a HP t representative person No Ss Enter 3 You are now in the Service Menu Use the Arrow keys to scroll to the 3 Service Tests menu and press the Enter key Press Enter Service Menu Press Enter 4 Use the Arrow keys to scroll through the Service Tests selections 3 Service Tests 3 1 Scan Axis 5 Press the Enter key to begin a specific operation when the required Service Test is highlighted Press Enter HP DesignJet 5000 and 5500 Series Printers Service Manual 4 7 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
241. t allow paper advance calibration Try the following m Recover the Black Printhead Page 6 15 m Replace the Black Printhead 3120 Firmware Error Try the following m Power the Printer OFF and ON again using the Power Switch at the back of the Printer to reset the memory m Upgrade the Firmware gt Page 9 13 HP DesignJet 5000 and 5500 Series Printers Service Manual 5 33 Service Calibrations Calibration Error Problem Description Corrective Action Calibration Error Problem Description Corrective Action Calibration Error NOTE Calibration Error Problem Description Corrective Action 3130 Firmware Error Try the following m Power the Printer OFF and ON again using the Power Switch at the back of the Printer to reset the memory m Upgrade the Firmware gt Page 9 13 3200 Error while scanning calibration pattern It is also possible that when it calibrates the Line Sensor the Carriage positions itself directly over one of the black arrows of the calibration pattern If this happens the Printer thinks it has black or colored media loaded and the calibration fails Try the following E Check that the media used for the calibration is white m If the media used is too dark try the calibration with white media If the error persists replace Lens Cover Assembly gt Page 9 5 m If the Carriage positions itself directly over the black arrow try loadin
242. t matter HP DesignJet 5000 and 5500 Series Printers Service Manual 6 5 Print Quality For Call Agents requesting the User to print the Service Diagnostic print Once inside the Printer Setup Options menu and the Device setup menu is highlighted press the following key combination Printer setup options DY ve Te T O setup Utilities at Internal RIP settings Press Down Queueing amp Nesting HP GL 2 settings and Enter Ey Enter 2 The message below is displayed Select Yes to continue Warning ee Top This mode should NOT be used without having the py Back guidance of a HP Sy T representative person a Enter 3 You are now in the Service Menu Use the Arrow keys to scroll to the Service Utilities menu and press the Enter key Press Enter Service Menu Press Enter 4 Use the Arrow keys to select 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 a Make Selection 1 7 Img Quality Warning Press Enter NOTE For Firmware Versions earlier than A 02 xx the Printer will 5000 Series Only start to print the Diagnostic Print immediately after selecting 6 6 HP DesignJet 5000 and 5500 Series Printers Service Manual Print Quality NOTE For Firmware Version A 02 xx in the 5000 Series and on the 5500 Series the Printer DOES NOT print the
243. t secure the Vacuum Fan to the Sideplate HP DesignJet 5000 and 5500 Series Printers Service Manual 8 103 Removal and Installation 6 Remove the Vacuum Fan Installation of Vacuum Fan WARNING When installing the Vacuum Fan make sure that it fits tightly to the Guides in the Sideplate 8 104 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 4 Disconnect the Paper Axis Motor Cable at P10 and the Encoder Cable at P12 from the Main PCA and NOT from Motor SN 5 Remove the 2 T 20 screws Type A that secure the Helical Gear to the k right hand side of the Drive Roller HP DesignJet 5000 and 5500 Series Printers Service Manual 8 105 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 Paper Axis Motor Assembly you must perform the following Service Calibrations E Accuracy gt Page 5 14 E Printhead Alignment gt User s Guide 8 106 H
244. tem gt Page 8 25 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 0A0040 APS Failure Try the following m Check all the cables of the APS and make sure they are correctly connected and are NOT damaged m Check all the tubes of the APS and Tubes System and make sure they are correctly connected and are NOT pinched or damaged E Replace ONE Ink Cartridge at a time checking if the System Error Code disappears m Faulty APS Replace the complete APS gt Page 8 67 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 2 14 HP DesignJet 5000 and 5500 Series Printers Service Manual System Error Problem Description Corrective Action WARNING System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Problem Description Corrective Action System Error Codes 0A0050 Non Continuable The Printer has detected a leak in the Tubes System Should ONLY appear in printers with the Ink Leak Detector installed Try the following m Check for ink in the Ink Leak Detector and if present replace the complete Tubes System gt Page 8 25 m The In
245. tenance select Printer Setup Utilities Lens Maintenance Clean the Mark Encoder Remove the Lens Cover and clean it Reinsert the Lens Cover or replace it HP DesignJet 5000 and 5500 Series Printers Service Manual 9 5 Preventive Maintenance NOTE WARNING Carriage Interconnect Wiper 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 Insert the Carriage Interconnect Wiper into the Printhead slot and move it up and down to clean the connections Change the angle of wipe as shown in 2 below to properly clean all the connections Clean the Printhead connections on the Printhead Do not handle or attempt to clean the Nozzles on the bottom of the Printhead Carefully avoiding contact with the Nozzles remove any dirt or fibers close to the edges of the Nozzle Plate using a clean wipe Nozzle Plate 9 6 HP DesignJet 5000 and 5500 Series Printers Service Manual Preventive Maintenance WARNING WARNING NOTE WARNING Roller Lubrification Kit This procedure is for Service Engineers only Users should perform the procedure described in the User s Guide Prevent water or other liquids from running onto electrical components or circuits or through openings in the module Open the window and apply 10 drops of oil to each hole in
246. ter If this error appears all settings related to the heater will disappear from the front Panel Try the following Em Check that the cable from the Heater to the Main PCA is correctly connected and is NOT damaged m Replace the Heater gt Page 8 120 0C0030 Drop Detector Failure Try the following m Check that the Drop Detector Cable is NOT broken or damaged m Check that the Drop Detector cable is correctly connected to the Service Station Cable m Remove the Drop Detector and make sure that there are no obstacles inside which are blocking the sensor m Replace the Drop Detector Assembly gt Page 8 72 m If the System Error Code continues replace the Main PCA gt Page 8 81 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 2 20 HP DesignJet 5000 and 5500 Series Printers Service Manual System Error Problem Description Corrective Action WARNING System Error Problem Description Corrective Action System Error Codes 0C0032 Continuable Drop Detector not calibrated or the calibration settings have been lost Try the following E Perform the EEROM Backup from the HDD to the Main PCA select Main PCA replaced Switch the printer Off and ON again m If the System Error Code continues Perform the Service Station Calibration gt
247. tes The APS is also used to provide pressure for tube purge and as part of the blow prime system operation Cables to ISS PCA Air Tube to Air Connector and Ink Cartridges DC motor driven air pump D Analog pressure sensor Two way solenoid valve The APS pressurizes the ink in the Ink Cartridge bags by pressurizing the air around them The Printer controls the air pressure using the pump with feedback from the sensor when required the valve is opened to depressurize the air circuit This allows control of the ink pressure at the inlet to the Printheads 10 8 HP DesignJet 5000 Series Printers Service Manual 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 It is the part that the customer handles and contains the other sub components m Wiper to remove ink residue and external debris from the Printhead E Spittoon to receive ink from the firing Printheads when the nozzles are cleared of viscous plugs and any loose debris Cap to prevent the Printhead nozzles from drying out while the Printer is idle m Handle and Printable Label to remove and install the PHC Also the printer uses the
248. the Platen Avoid oil spills and make sure you remove any excess oil To clean the Roller Wheels close the window and perform the Turn Drive Roller Utility see Page 4 17 Use the cloth provided Do not touch the rotating Wheels with your hands Press Cancel when you have completed the cleaning procedure HP DesignJet 5000 and 5500 Series Printers Service Manual 9 7 Preventive Maintenance NOTE NOTE A U N 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 The most important parts to keep clean are the upper and internal sides of the Rods Power Off the Printer and remove the Power Cord Insert a new cleaning pad in the cleaning tool Apply 50 drops of the oil supplied to the pad Slide the cleaning tool along the Slider Rod until it is well oiled Replace the cleaning pad and repeat steps 2 and 3 for the second Slider Rod 9 8 HP DesignJet 5000 and 5500 Series Printers Service Manual Preventive Maintenance Cleaning the Platen WARNING This procedure is for Service Engineers only Users should perform the procedure described in t
249. the Heater from the Printer 8 122 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 HP DesignJet 5000 and 5500 Series Printers Service Manual 8 123 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 If the Tube Guide DOES NOT have If the Tube Guide DOES have a C shaped hook i e only has a a C shaped hook then install this small hole in the Tube Guide then type of spring install this type of spring CONN eal eS 8 124 HP DesignJet 5000 and 5500 Series Printers Service Manual Preventive Maintenance 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 Cleani
250. the Take Up Reel Under high humidity conditions approx gt 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 m Reduce the level of humidity lt 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 E Increase the Dry Time using the Front Panel Refer to the User s Guide m Do not use the Take Up Reel or Bin for this media when humidity levels are high Dry Cockle on High Density Prints Using Paper Based Media High density prints can cause dry cockle mainly on Paper Based Media To solve the problem do the following m Use the Take Up Reel and Take Up Reel deflectors m Set the Printer to Productivity mode to reduce the ink density E Select Coated media modes If the problem persists try the following m Laminate the prints m Use a heavier media that is more suitable to high ink density such as HP Paper based Semi Gloss or HP Poster Paper HP DesignJet 5000 and 5500 Series Printers Service Manual 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
251. thead Printhead Cleaner or cartridge Status Code Color Second Digit 5 Light Cyan 4 Light Magenta 3 Yellow 2 Cyan 1 Magenta 0 Black 3 12 HP DesignJet 5000 and 5500 Series Printers Service Manual HP Ink Supplies Troubleshooting NOTE NOTE NOTE NOTE Printhead Errors 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 gt Refer to 6 Print Quality 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 When replacing Printheads Ensure that you have the correct Printhead Ensure that the Printhead is the correct color for that slot Ensure that the protective cap is removed from the Printhead Check the empty slots to see if they need cleaning In extreme circumstances when a Printhead is inserted it is possible that the Printer will not recognize it due to the build up of ink on the electrical connection between the Printhead and the Printhead carriage To clean the build up of ink use the User Maintenance Kit If all 6 Printheads present the same error message check the following All Printheads installed are NOT wrong type i e wrong model Setup Printheads instead of normal etc If you replace or reseat Printheads one at a time and the er
252. ther color the lines in the cross will not be aligned There are two types of misalignment m Horizontal when the misalignment is in the horizontal axis E Vertical when the misalignment is in the vertical axis Below are shown an example of alignment and misalignment correct Incorrect Solving the Color Alignment Problem 1 Make sure you have A1 D size 24inches media loaded not clear film vellum or tracing paper 2 Go to the Printer submenu and press Enter Printer submenu Roll Hewlett Packard Photo Imaging Gloss 3 Go to Utilities Calibrations Printhead Alignment Please wait as the process of aligning the Printheads takes a few minutes 4 Reprint the image you were attempting to print before in the same mode to see if the problem still exists HP DesignJet 5000 and 5500 Series Printers Service Manual 6 11 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 3 lt Arrows indicate direction of gt printing for each se
253. tion Print The Service Configuration Print is a useful tool for troubleshooting the Printer The Service Configuration Print contains the following information about the Printer m General Configuration m Printhead Info m Ink Cartridge Info m Operating Conditions m Calibrations Maintenance m I O Configuration How to Print the Service Configuration Print 1 Load media Roll media or at least an AO Sheet into the Printer 2 Once the message Ready is displayed on the front panel scroll to the Printer Setup Options icon and press the Enter key Printer Setup Options 3 Once inside the Printer Setup Options menu use the Arrow keys to scroll to the Utilities menu display and press the Enter key Printer setup options i Top B Back men ee EET Make Select nterna settings ake selecnion Queueing amp Nesting en a HP GLIS settings Enter Press Enter HP DesignJet 5000 and 5500 Series Printers Service Manual 1 37 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 a Top Calibrations Back Reset WebAccess paswd at Statistics Press Up Default menu El 4 and Enter Display contrast l Enter 5 Use the Arrow keys to scroll to Service Config and press the Enter key to print the Service Configuration Print How to Use the
254. tion explains the front panel message flow Enable Out of Control bit in the PH and ink tubes smart chips Update Service Config print non hp ink field on tubes PH and IC Ink cartridge bars for all colors will continue working but they will be semi transparent not solid Non HP hardware is detected NO ee YES 4 When there is any action on the ink cartridges the FP will show Stays in the status it was prior to the non hp hardware 6508 UNKNOWN 6408 UNKNOWN 6308 UNKNOWN 6208 UNKNOWN 6108 UNKNOWN 6008 UNKNOWN 5 Webserver will show gray IC bars Error Message XX08 Unknown Description Use genuine HP components for excellent image quality from your printer If you choose to continue printing with this ink supply you may not have a properly functioning or reliable ink level indicator The solid bar showing the ink level will be replaced by a patterned bar 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 Any damage resulting from use of this supply or non HP ink is not covered under your printer watranty Recovery Action Select Yes to replace the Ink Cartridge with a genuine HP No 81 83 Ink Cartridge or No to continue HP DesignJet 5000 and 5500 Series Printers Service Manual 3 21 HP Ink Supplie
255. to Chapter 7 Parts and Diagrams of this Service Manual Refer to Chapter 8 Removal and Installation of this Service Manual as a guide to replace the necessary parts 9 4 HP DesignJet 5000 and 5500 Series Printers Service Manual Preventive Maintenance Warranty Statement 1 2 3 User Maintenance 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 Routine printer maintenance operations such as cleaning and preventive maintenance services including parts contained in the preventive maintenance kit and HP service engineer visits are not covered by HP s limited warranty but in some countries may be covered under a separate support contract User s receive a User Maintenance Kit when they purchase the Printer The Kit provides the User with all the tools and instructions required to perform routine maintenance procedures This Kit consists of the following Lens Maintenance Kit m Carriage Interconnect Wiper Kit m Roller Lubrification Kit m Slider Rods Lubrification Kit m Platen cleaning instructions Service Engineers should perform these procedures only when troubleshooting Printer problems Lens Maintenance To perform Lens Main
256. tral processing units and controls most of the motors and sensors in the printer The motors and sensors themselves are located throughout the printer and are connected to the main electronics via cables m Carriage Connected to the Printheads this block supplies power to them as well as monitoring and protecting them from damage It also has the ability to control warming and to perform continuity checking as well as controlling the Line Sensor The Carriage Encoder is also located in this block E Ink Supply Station The Ink Supply Station is connected to the Ink Cartridge supplies and controls air pressure pump sensor and valve as well as monitoring ink levels and the supply latch sensor E Service Station Contains the electronics needed to perform drop detection a DC motor encoder for capping wiping and spitting and a stepper motor for priming Front Panel is the user interface It consists of an LCD display a key panel and four LEDs 10 2 HP DesignJet 5000 Series Printers Service Manual 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 gr
257. ual 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 lt ase Fe 5 Remove 15 T 15 screws Type B from the Electronics Module Cover HP DesignJet 5000 and 5500 Series Printers Service Manual 8 79 Removal and Installation NOTE Lift the Parallel Port Clips before removing the Cover 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 8 80 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 PCI to IDE PCA WARNING If you are working with an hp designjet 5000 C6090A V I C6091A V C6095A V I C6096A
258. uality Marks caused by 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 Leading Edge marks Marks caused by due to ink accumulation a dirty Cutter Wheel on the platen aO ae A the Pinchwheels FRONT SIDE of the Printout SS Printing Direction PrweveZ So as you have seen we can have marks caused by the ink accumulation on m The center platen and overdrive m The pinch wheels m The cutter wheel Our recommendation is to clean the printer once per roll Cause 2 Static Static Background Over the past few years HP has been improving image quality by using smaller and smaller drops of inks Without this it would have been impossible to achieve a level of photo quality unmatched by any other printer in its class For example the DesignJet 5X00 fires 12 pl drops when using dye based ink and 18 pl drops with the UV inks compared to the 24 or 40 pl used in previous DesignJet printers However reducing the size of the drops has made them more susceptible to m Airflow and or E Static charges Any of these two effects may force the ink drops to deviate from its trajectory causing them to position at the wrong place of the media 6 30 HP DesignJet 5000 and 5500 Series Printers Service Manual Print Quality The HP DesignJet 5X00 series is already optimized to minim
259. ular color warning Very Ink Cartridge Level has reached it s Overnight printing should not be Low very low limit 50 ml attempted Priming of the Ink Tubes should not be attempted A new Ink Cartridge is strongly recommended to prevent the Printer from interrupting a print Empty Ink Cartridge is empty The Printer A new Ink Cartridge is required stops Check image quality of prints in progress HP DesignJet 5000 and 5500 Series Printers Service Manual 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 Part Information First Digit 0 HP No 81 Printhead in warranty 1 HP No 81 Printhead out of warranty 2 HP No 83 Printhead in warranty 3 HP No 83 Printhead out of warranty 4 Setup Printhead 5 Printhead Smartchip error A HP No 81 Printhead Cleaner B HP No 83 Printhead Cleaner T Printhead Cleaner Detection Error 6 HP No 81 Ink Cartridge 7 HP No 83 Ink Cartridge 8 Ink Cartridge Unknown The second digit identifies the color see table below for the Prin
260. uracy Calibration refer to the Accuracy calibration for service Page 5 14 HP DesignJet 5000 and 5500 Series Printers Service Manual 5 45 Service Calibrations 5 46 HP DesignJet 5000 and 5500 Series Printers Service Manual Print Quality 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 6 4 Printing the Diagnostic Print 6 5 Overall Print Quality Test Page 1 6 8 What is Banding 6 8 Solving the Banding Problem 6 8 Color Alignment Print Test Page 2 6 11 Solving the Color Alignment Problem 6 11 Bidirectional Alignment Page 3 6 12 Solving Bidirectional Alignment Problems 6 12 Vertical Line Straightness Page 4 6 13 Solving Vertical Line Straightness 6 13 Nozzle Print Test Page 5 6 14 How to fix the Nozzle Defects 6 15 No Printing Defects Found in the Diagnostic Print 6 16 Print Quality Problems 6 16 Solving Color Accuracy problems 6 17 Solving Color Consistency problems 6 17 Blurred Lines Ink Bleeds from Lines 6 18 The Prints are Too Short DesignJet 5000 Series Only 6 18 Colors are not as Expected 6 19 Banding at the Top of the Page 6 19 Vertical Banding 6 20 Media 6 20 Printed surface smearing roll DesignJet 5000 Series Only 6 20 Warped Lines on Media 6 21 Marks and or scratches on double sided media 6 21 There are Smears or Scratching on the Printed Media 6 21 Using the
261. ver Installation of Ink Tubes System WARNING NOTE NOTE 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 Do not install NEW Ink Tubes System with Ink Cartridges that indicate Low or Very Low ink levels Before installing the new Ink Tubes System make sure that the Ink Type Dye or UV of the Tubes is the same as the ones that you are replacing 8 30 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 5 The Front Panel displays the message INK STARTUP ate 6 Wait about 60 seconds for the next Initializing Printer instruction Ple ase Wait 60 sec 7 Remove the Setup Printheads from the Printhead Carriage 8 Install the Printheads and the Printhead Cleaners refer to the User s Guide for details HP DesignJet 5000 and 5500 Series Printers Service Manual 8 31 Removal an
262. very procedure gt Page 6 15 XX21 Replace The Printhead has detected a Select YES to replace Printheads or NO to finish significant number of bad the print job without the failed Printhead print nozzles that affects print quality may be affected quality The message will be displayed for every print job until you replace the Printhead 1 Attempt the Recovery procedure Page 6 15 2 If the message persists replace the Printhead s 3 14 HP DesignJet 5000 and 5500 Series Printers Service Manual HP Ink Supplies Troubleshooting NOTE WARNING 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 LIGHT CYAN 1520 RECOVER LIGHT MAGENTA OK YELLOW CYAN MAGENTA BLACK At this stage the customer should obtain new Printheads Depending on the print mode being used Max Quality Productivity or Max Speed the Printer may still be able to print with an acceptable print quality Refer to Page 6 5 for details on performing Printhead recovery If the Printer is printing a job and the Printhead health degrades to a significant degree XX16 and XX17 REPLACE the front panel will display a warning Warning Printhead quality degrading select YES to replace failing printhead s NO Continue Press the 4 or down key to select YES or N
263. view Tubes to Printhead ey A Connection gt Tubes Joint for Ink Leak Detection 3 CON a lt gai DI ko 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 Printheads The Printheads are high precision devices that place the ink on the media The Printheads are designed with m Smart chip storing Printhead information Em Ink inlet to receive ink from the Tubes m Nozzle plate with 512 Nozzles to deliver ink on to the media E Ink Type lockouts that avoid Printheads of the wrong type Setup Printheads or Ink type being installed in the Carriage m Color lockouts that will allow only one color to be inserted into a given slot Smart Chip Ink Inlet Printhead Interconnect Nozzle Plate HP DesignJet 5000 and 5500 Series Printers Service Manual 10 7 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 ra
264. xis Calibration 5 7 2 Service Station Calibration 5 11 3 Accuracy Calibration 5 14 Carriage Height Calibration 5 18 Calibration Error Codes 5 26 User Calibrations 5 42 Printhead Alignment 5 43 Close Loop Color CLC Calibration 5 43 Banding Calibration 5 44 Accuracy Calibration 5 45 HP DesignJet 5000 and 5500 Series Printers Service Manual 5 1 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 no Phone Support SY wo In certain circumstances a Call Agent can try and troubleshoot the Printer by requesting the Customer to perform a Service Calibration via the phone In Phone Support the user will have access to a limited number of Calibrations on site repair calibrations are excluded If a Service Calibration fails a four digit xxxx calibration error code is reported which can be used to determine whether the Printer requires any on site maintenance Up to three error codes can be reported for each Calibration To troubleshoot Service Calibration Error Codes refer to the Page 5 26 NOTE If a calibration fails the Printer will use the previous successful calibration If you have a Print Quality problem you must troubleshoot the error to restore quality WARNING REMEMBER THAT CERTAIN CALIBRATIONS ARE REQUIRED EVEN IF AN ASSEMBLY HAS BEEN DISA

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