HP (Hewlett-Packard) 5000 manual

Service Manual DesignJet 5000 and 5500 Series HP Large-Format Printers[...]

T echnical Marketing, Barcelona Divisi on , Hewlett-Packard Espanola, S.A. A vda. Graells, 501 08190 S ant Cugat del V alles Spain For HP Internal Use Only ©Copy right He wlett-P ackard Compan y 2002 This do cum ent con tains propri etary i nformat ion that i s protected by copyr ight. All rights are rese rv ed. No pa rt of this docume nt may be p[...]

1 DesignJet 500 0 and 5500 Series HP Large-Forma t Pri nters Service Manual[...]

2 HP DesignJ et 5000 and 5500 Series Pr inters Service Manu al Using this Manual Purpose This Service Manual contains information necessary to test, calibra te and servi ce:  HP DesignJet 5000 Printer - 42” Model (P/N C6090A/V)  HP DesignJet 5000 Printer - 60” Model (P/N C6095A/V)  HP DesignJet 5000PS Printer - 42” Model (P/N C6091A/[...]

Table of Cont ents 3 HP DesignJet 5000 and 550 0 Series Printers Service Manual T able of Contents 1 Troubleshooting 1-1 System Error Codes 2-1 HP Ink Supplies Troubleshooting 3-1 Service Tests and Uti lit ies 4-1 Service Calibrations 5-1 Print Quality 6-1 Parts and Diagrams 7-1 Removal and Installation 8-1 Preventive Mai nte n a nc e 9-1 Functiona[...]

Table of C o nten ts 4 HP DesignJ et 5000 and 5500 Series Pr inters Service Manu al[...]

1-1 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual T r oubleshooting 1 Introdu ction 1-2 Phone Supp ort 1-2 Which Fi rmware V ersio n Rela tes to Whi ch Ink Sy stem 1-2 T roubl eshootin g System Er ror Codes 1- 2 Performing a Se rvice T est on a Fai led Assembly 1-3 Performing the Necessary Servi ce Calibrations 1-3 T roubl eshootin [...]

Troubleshooting 1-2 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Guide to T r oubleshoot ing the Printer Introdu ction This chapter will guide you through th e relevant steps to take when troubleshooting the Printer . Phone Support In certain circumstances, a Call Age nt can try and troubleshoot the Printer by requesting the Custom[...]

Troubleshooting 1-3 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Performing a Se rvice T est on a Failed Asse mbly If possible, always perform a Service T est on t he 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 passe[...]

Troubleshooting 1-4 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual T roubleshoot ing Ink Suppli es Err or Code s Chapter 3, HP Ink Supplies T r oubleshooting , contains a l ist of Error Codes that are reported for Ink Supplies i.e. Ink Cartridges, Printheads and Printhead Cleaners. The error codes ar e described and recommended corre[...]

Troubleshooting 1-5 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual The Print er does not Power ON 1. Check that the Power Cord is conne cted corre ctly to the Printer and to the Powe r Socket. 2. Check tha t the Power Switc h on the BACK of the Printer is in the ON position. 3. Remove the DIMM’ s Cover (See  Page 8-77 ) and c[...]

Troubleshooting 1-6 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual ALL the Fr ont-Pan el LEDs ar e Lit but Nothing Else Happens The BootROM DIMM is NOT correctly instal led or is the wro ng type. 1. Power OFF the Printer from the back and disconnect the Powe r Cord. Reseat the BootROM DIMM (looking from the rear of the Printer , the [...]

Troubleshooting 1-7 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual T roubleshoot ing Shutdowns - Use r Message "W arning: Switch Power Off" If a shutdown occurs, you will get the message “W arning: Switch Power Off” followed by:  Check Printhead Cleaner Path.  Check Paper Path.  Check Printhead Path (followed b[...]

Troubleshooting 1-8 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Check Pape r Path This warning appears w hen ever the friction o n 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 th e motor or the Main PCA, this warni ng appears. The common reason [...]

Troubleshooting 1-9 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual NOTE Also, after re placing th e Scan-Axis Mo tor , perform the Scan-Axis T est (  Page 4-10  and check that the v alues are within the gi ven limits.  If the Prin ter s till fa ils, repla ce the Main PCA  Page 8- 81 . Check Printhead Path (2) Thi[...]

Troubleshooting 1-10 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Problems with V acuum If you have problems loading either Roll or Sheet Media, then there could be a problem with the V acuum Fan or Booster Fan. T o ver ify if there really is a problem with V acuum, try the following: 1. W ith the Printer ON, ope n the W indow of t[...]

Troubleshooting 1-11 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Printhead Crashes/Smears on High Density Prints Using Coated M edia 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[...]

Troubleshooting 1-12 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Banding at variable extr em e envir onmental conditi ons The Accuracy Calibration has bee n done at normal environmental conditions, therefore printing in extreme environmental conditions will cause banding because the advance of the Drive Roller does not correspond [...]

Troubleshooting 1-13 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Hue shift on HP Co lorfast Adhesive V inyl media Under high humidity conditions (approx. >65%) the colors tend to fade over time, parti cularly colors tha t require Magent a. T o solve the problem, try the following:  Reduce the level of humidity (<65%) that[...]

Troubleshooting 1-14 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Loss of G loss on HP Phot o Im aging Gloss when using the T ake-Up Reel Under high humidity conditions (approx. >70%) the polymer chain in the co ating of this media relaxe s and the drying rate de creases. If the printed media is rolled onto a T a ke-Up Reel or i[...]

Troubleshooting 1-15 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual W rinkles and scratche s (cockle) on HP Coated and Heavyweight Coat ed Media. Images may be damaged if prints are not handled with care, particularly when handling wide plots. This can happen when images are placed on top of one another and ther e is movement between[...]

Troubleshooting 1-16 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Drying T ime T oo Long for HP S tudio Canvas Under conditions of high humidity (> 70%) HP St udio Canvas retains a high amount of water and takes too long to dry , also creating problems in using the T ake-Up Reel and Bin. T o solve the problem try the following: [...]

Troubleshooting 1-17 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual 2. The media sensor is defective. T o verify this, remove the media and re-boot the Printer . If the me ssage comes up dur ing initialization, the media sensor is defective. T o solve this, try the following:  Check that the media sensor cable is connected cor rec[...]

Troubleshooting 1-18 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual T railing Cable con nection, so just recon nect the T railing C able again to dou ble-check th at the Pr inter now works. If, aft er reconnect ing the cable, the error appe ars again, either the Carr iage PCA or the T railing Ca ble is defec tive. In th is case, firs[...]

Troubleshooting 1-19 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Cutter Assembly Pr oblems 1. The Printer does not cut (even when using the Form Feed & Cut option in the Front Panel). In this case it is very likely tha t the cutter is disabled in the EEROM. This can happen whenever the D iagnostic Print is cancelled in the mid[...]

Troubleshooting 1-20 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Carriage and Scan-Axis Pr oblems 1. Printhead continuity problem s. When installing the Ink T ubes System, it is possible that the crane (the part of the T ubes Syst em that is connected to the front of the Carriage) is not clipped pr operly . This ca n cause Printhe[...]

Troubleshooting 1-21 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Electr onics Pr oblems 1. The Printer hangs with the front panel completely blank and the three Image Quality LED’ s lit. The firmware has a bug that cr eates this situation whenever the Printer is rece iving data from an exte rnal RIP .  The customer should pri[...]

Troubleshooting 1-22 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual 3. The Printer is printing slower compared to another HP DesignJet 5000. It is important first to determine whether the differences are during receiving/processing, during printing or once the print is finished. 1. The time th e printer take s to start prin ting is l[...]

Troubleshooting 1-23 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual 3. The dry time at the end of the print is longer . Normally the Printer uses the temperature and the humidity readi ng from the ISS PCA to c alculate the dry time, whic h is required for the print to dry before being cut. The spec ification of these re adings is +/-[...]

Troubleshooting 1-24 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual T ypical Failur es After Exchangi ng the Ink T ubes The following table contains typical failures that could appear after changing the Ink T ubes: Failur e Descript ion Sol ution After completing the initializ ation proce ss, the Front Panel displays: W ARNING Incorr[...]

Troubleshooting 1-25 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Solving Media-H andling Pr oblems NOTE HP Designjet Printer s minimum med ia size is A3 in portrait mode. The Front Pan el Keeps Indicating that Media I s Misaligned or Incorrectly Position ed Roll med ia  The roll may be loaded the wrong way . The paper should lo[...]

Troubleshooting 1-26 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual How to Navigate through th e Fron t Panel Menus Shaded boxes always appear in th e front panel. White boxes appe ar only in Full menu mode. I/O Setup Menu I/O setup Card Setup No I/O card found Card ID Card ID Card Setup Configuration Advanced Reset Card I/O timeout [...]

Troubleshooting 1-27 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Device Setup Menu Device Setup Cutter Lang TUR Installed NO,YES On, Off Reduced Margins On, Off PostScript@, Automatic HP-GL/2 Drying Time Manual Automatic, None 255 .. 2, 1 min Always Appear Only Appear in Full Menu Mode @ PostScript Onl y Only Appear if TUR is Not [...]

Troubleshooting 1-28 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Utilitie s M enu Utilities Replace Ink System Usage No (Continue) , Yes (Replace) Print usage, View usage Track Media Length Yes, No Menu Mode Short, Full Printhead alignment, Accuracy Calibrations Recalibrate Restore factory Reset Web Svr Passwd Lens Maintenance Tes[...]

Troubleshooting 1-29 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Internal RIP Settings Menu Ink Emulation PS scale RGB@ Optimized, Immediately CMYK Off,On Off,On Off,On 100% .. 419%, Fit to page Internal RIP Settings Start printing After processing Native, sRGB, Apple RGB, Adobe RGB, ColorMatch RGB Color calibration @ @ @ @ @ PS e[...]

Troubleshooting 1-30 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Queuing and Nes ting Men u Nest Off # .... Nesting Queue mgmt Move to top, Delete Page Copies 99 .. 1,0 Statistics width, Length In order ... 99 .. 2, 1 min Alway s Appe ar Only Appea r in Full Menu Mo de @ PostScript Only[...]

Troubleshooting 1-31 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual HP-GL/2 Settings Menu Define Palette Pen no. 0 … 15 Pen no. 0 … 15 0.13 ... 12.0mm 255 .. 1, 0 Width Width Palette HPGL/2 settings Merge Palette A, Palette B Factory Software, Factory, Palette A, B On/Off Always Appear Only Appear in Full Menu Mode @ PostScript O[...]

Troubleshooting 1-32 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Page Format Menu Page Format Extrawide Oversize Size Inked Area, Software 1.0X1.4m 42inX59in 44X62in 1.2X1.7m 52X73in 54X76 60X100in Over A2, Over A1 Arch Best ARCH, ARCH A.. E1 JIS ANSI ISO Rotate 0 .. 270 Margins Best ISO A, ISO A4 .. A0 Nest Spacing Automatic Best[...]

Troubleshooting 1-33 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Demos Menu Demos Samples Palette Menu Always Appear Only Appe ar in Full Menu Mode @ PostSc ript Only[...]

Troubleshooting 1-34 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Media Menu Media Selection Move Media HW Coated (Economy) HW Coated Coated Paper Photo Imaging Gloss Colorfast Vinyl Paper Semi-Gloss Poster Paper Studio Canvas and more....... Vendor Name Roll/Sheet Info. Type of Media Width Printable Area Profile Revision Delete Me[...]

Troubleshooting 1-35 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Ink Cartridge Menu Replace Ink Cartridge Yes, No HP No. 81 Ink Cartridge Ink Level Capacity Part Number Manufacture Date Light Cyan cart Info Light Magenta cart Info Yellow cart. Info Cyan cart Info Magenta cart Info Black cart Info[...]

Troubleshooting 1-36 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Printhead Menu Recover Printheads Light Cyan Info Light Magenta Info Yellow Info Cyan Info Magenta Info Black Info Printhead Info All Printheads Cyan Magenta Yellow Black Light C Light M Replace Printheads Yes, No[...]

Troubleshooting 1-37 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Servi ce Conf igura 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:  General Configuration  Printhead Info.  Ink Cartridge Inf[...]

Troubleshooting 1-38 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual 4. Once inside the “Utilities” menu, use the Arrow keys t o scroll to the “T e st prints” menu display and press the Enter key . 5. Use the Arr ow keys to s croll to “Service Config.” and press the Enter key to print the Service Configuration Print. How t[...]

Troubleshooting 1-39 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual General Pri nter Inf ormation 1. Interaction between start printing and nesting. Of the four possible combinations between "St art Printing = Optimized or After processing" an d "Nesting = In order or OFF" only two are possible. For example, if yo[...]

Troubleshooting 1-40 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual of the print. Perform a manual r ecovery if t he Printhead status is (XX20) RECOVER/ (XX21) REPLACE.  W ith longer plots, average produc tivi ty will increase (i.e. same area is printed in less prints > reduction of servicing at the beginning/end of the print).[...]

2-1 HP DesignJ et 5000 an d 5500 S eries Printer s Service Manu al System Err or Codes 2 System Erro r Co des 2-3 Introdu ction 2-3 Continuab le and Non-Con tinuable Erro r Codes 2-4 System Erro r Gro ups 2-4 f ff f f f f f xxxxxxxx ( General Fir mware Error) 2-5 f ff f f ff f 02b 301b0 2-5 f ff f f f f f 01dcxxx x 2-6 f ff f f ff f 030d0170 or f f[...]

System Error Codes 2-2 HP DesignJet 5000 and 5500 Series Printers Service Man ual 0B0001 2 -16 0B0002 2 -16 0B0003 2 -16 0B0004 2 -17 0B0005 2 -17 0B0006 2 -17 0B000X 2-18 0B0010 xx xxxxxx (Non -Conti nuable) 2-18 0B000A 2-18 0B000B 2-19 0B000C 2-19 0B000D 2-19 0B000E 2-19 0B000F (C ontinuable) ( Only appl icable to Desi gnJet 5500 S eries) 2-20 0C[...]

System Error Codes 2-3 HP Desig nJet 500 0 and 5500 Series Pri nters Serv ice Manual System Error Codes Introdu ction NOTE Before tr oubles hooting System Errors, if possible, r epeat the procedure performed wh en the error was reported. NOTE When re porting the System Error Code, make sur e that you supply the full Err or Code and the fi rmwar e v[...]

System Error Codes 2-4 HP DesignJet 5000 and 5500 Series Printers Service Man ual 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 near est HP Support Of fice. When re porting the error , have the following information ready[...]

System Error Codes 2-5 HP DesignJ et 5000 an d 5500 S eries Printer s Service Manu al System Error: ffff ff ff xxxxxxxx (Ge neral Firmware Er ror) Prob lem Desc rip tion: Al l ffff fff f er ro r s ar e ge n er a l f i r m wa re e rr o r s. T h is does not mean that the firmware has f ailed, bu t that the firmware (as a piece of software) has ex per[...]

System Error Codes 2-6 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual System Error: ffff ff ff 01dcxxxx Prob lem Desc rip tion: Ther e is a problem with the I/O Card (happens during power-up). Corr ectiv e Action: T r y the followin g:  Disconnect the Network Cable and check if the error still appears during power-up.  If the e[...]

System Error Codes 2-7 HP DesignJ et 5000 an d 5500 S eries Printer s Service Manu al System Error: ffff ff ff 03450097 Prob lem Desc rip tion: If the W indow 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 (fff f f ff f 03450097) may be display[...]

System Error Codes 2-8 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual System Error: 010023 ( Non-C ontinuab le) Prob lem Desc rip tion: EER OM T est failure. Corr ectiv e Action:  Replace t he Main PCA  Page 8-81 . NOTE After replacin g the Main PCA, make sure you perform the Back up EEROM  Page 4-30 , making sur e tha[...]

System Error Codes 2-9 HP DesignJ et 5000 an d 5500 S eries Printer s Service Manu al System Error: 010041 Prob lem Desc rip tion: Error in Scan-axis Encoder quadrature. Corr ectiv e Action: T r y the followin g:  Check that the Encoder Strip is NOT broken or damaged.  Replace the Encoder Strip  Page 8-34 .  Replace th e Carriage Ass[...]

System Error Codes 2-10 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual System Error: 010090 ( Contin uable) Prob lem Desc rip tion: Error in Paper -axis Motor Encoder Corr ectiv e Action: T r y the followin g:  Check that the Paper-Axis Motor cable is NOT broken or damaged.  Check that the Paper-Axis Motor cable is correctly co[...]

System Error Codes 2-11 HP DesignJ et 5000 an d 5500 S eries Printer s Service Manu al System Error: 040000 01E603D9 Prob lem Desc rip tion: This is an error that is related to the Parallel Port. It happens n o rmally in New Printers and only o nce (it is unlikely to appear again). Even if the error app ears again, there is nothing wrong with the P[...]

System Error Codes 2-12 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual System Error: 06030C Prob lem Desc rip tion: Bad Line Sensor . Corr ectiv e Action: T r y the followin g:  Replace the Line Sensor  Page 8-53 .  Replace th e Carriage Assembl y  Page 8-46 .  Replace t he T railing Cabl e  Pa ge 8-36 . ?[...]

System Error Codes 2-13 HP DesignJ et 5000 an d 5500 S eries Printer s Service Manu al System Error: 0A0000 Prob lem Desc rip tion: APS Failure. Corr ectiv e Action: T r y the followin g:  Check all the cables of the APS and make sure they are correctly connected and are NOT dama ged.  Check all the tubes of the APS and T ubes System and make[...]

System Error Codes 2-14 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual System Error: 0A0030 Prob lem Desc rip tion: Pr oblem in Depressurizing Air System. Corr ectiv e Action: T r y the followin g:  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 w[...]

System Error Codes 2-15 HP DesignJ et 5000 an d 5500 S eries Printer s Service Manu al System Error: 0A0050 (Non-Continuable) Prob lem Desc rip tion: The Printer has de tected a leak in the T ubes System - Should ONL Y appear in printers with the Ink Leak Detector installed. Corr ectiv e Action: T r y the followin g:  Check for ink in the Ink Le[...]

System Error Codes 2-16 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual System Error: 0B0001 Prob lem Desc rip tion: Bad Humidity Read Corr ectiv e Action: T r y the followin g:  Replace t he ISS PC A  Page 8-91   Replace t he Main PCA  Page 8-81 . W ARNING Only r eplace one component at a time and check i f the e[...]

System Error Codes 2-17 HP DesignJ et 5000 an d 5500 S eries Printer s Service Manu al System Error: 0B0004 Prob lem Desc rip tion: APS Failure. Corr ectiv e Action: T r y the followin g:  Check that the cable from the Ink Supply Station (ISS ) PCA to the Ink Supply Station is correctly connected.  Faulty APS. Replace the APS  Page 8-67[...]

System Error Codes 2-18 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual System Error: 0B000X Prob lem Desc rip tion: Unable to de tect Fan (X = 7 - V acuum, 8 - Cooling, 9 - Aerosol). Corr ectiv e Action: T r y the followin g:  Make sure that the Fan is connected correc tly to the Main PCA.  T urn the Printer OFF and disconnect [...]

System Error Codes 2-19 HP DesignJ et 5000 an d 5500 S eries Printer s Service Manu al System Error: 0B000B Prob lem Desc rip tion: APS Failure. Corr ectiv e Action: T r y the followin g:  Check that the cable from the Ink Supply Station (ISS ) PCA to the Ink Supply Station is correctly connected.  Check that the Air Pressurization System Sen[...]

System Error Codes 2-20 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual System Error: 0B000F ( Cont inuabl e ) (Only applicable to DesignJet 5500 Series) Prob lem Desc rip tion: Unable to detect the Heat er - If this error appears, all settings relate d to the heater will disappear from the front Panel. Corr ectiv e Action: T r y the [...]

System Error Codes 2-21 HP DesignJ et 5000 an d 5500 S eries Printer s Service Manu al System Error: 0C0032 ( Contin uable) Prob lem Desc rip tion: Drop Detector not calibrated or the calibration settings h ave been lost. Corr ectiv e Action: T r y the followin g:  Perform the EEROM Backup from the HDD to the Main PCA (sel ect Main PC A rep lace[...]

System Error Codes 2-22 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual System Error: 0C00FF Prob lem Desc rip tion: Pr int Mask could not be generate d. The mask generation algorithm could not generate the print mas k. Possible cause s are memory corruption, print mode definiti on incompatible wit h mask restrictions (if using an ext[...]

System Error Codes 2-23 HP DesignJ et 5000 an d 5500 S eries Printer s Service Manu al System Error: 0D0000 ( Contin uable) Prob lem Desc rip tion: No Media Profiles A vailable. Corr ectiv e Action: Download a media profile for the ink type being used. System Error: 0D0000 033f019C Prob lem Desc rip tion: No Media Profiles A vailable. Corr ectiv e [...]

System Error Codes 2-24 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual System Error: 0D0005 03180382 (Non-Continuable) Prob lem Desc rip tion: After cutting the media, the Printer cannot deactivate the Cutter . Corr ectiv e Action: T r y the followin g:  Check the Cutter and the Carriage Assembly to make sure that they are in stal[...]

System Error Codes 2-25 HP DesignJ et 5000 an d 5500 S eries Printer s Service Manu al System Error: 0F0200 01E603d2 Prob lem Desc rip tion: This is an error that is related to the Parallel Port. It happens n o rmally in New Printers and only o nce (it is unlikely to appear again). Even if the error app ears again, there is nothing wrong with the P[...]

System Error Codes 2-26 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual System Error: e50000 Prob lem Desc rip tion: This is an error that is related to the Hard Disk Drive, either the connections are bad or that the Hard Disk Drive or the Main PCA are defective. Corr ectiv e Action: T r y the followin g:  Unplug the Printer , remo[...]

3-1 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual HP Ink Supplies T r oubleshooting 3 What are HP In k Supplie s? 3-2 Ink Cartridg e s 3-2 Printheads and Printhead Cleane rs 3-2 Iden ti f yi ng the Componen ts 3-3 General In formation About HP Ink Supplies 3-3 Some General P recautions W hen Handling HP Ink Supplies 3-4 Priming a Br[...]

HP Ink Supplies Troubleshooting 3-2 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual What ar e HP Ink Supplies ? For each of th e six colors used in th e Printer , ther e are three s eparate components. The Printhead and the Printhead Cleaner are supplied together , the I nk Cartridge is supplied separately . All of these components ar[...]

HP Ink Supplies Troubleshooting 3-3 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Identifyi ng the Components The following illustration will help you i dentify the components of the HP Ink Supplies. General Information About HP Ink Supp lies For optimum results from the Print er and modular ink delivery system always follow these g[...]

HP Ink Supplies Troubleshooting 3-4 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual  A void unnecessary re moval of the Ink Cartridges and Printheads.  When turning off the Printer always use the soft-power Off button on the Front Panel. The Printheads are then stored correctly which preve nts them from drying out.  The Ink C[...]

HP Ink Supplies Troubleshooting 3-5 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Priming a Brand New Ink System When the customer first receives the Printer , it is supplied with a set of six Setup Printhea ds pre-installed in th e Carriage Assembly . These Setup Printheads are used for the priming of the tubes in the modular ink d[...]

HP Ink Supplies Troubleshooting 3-6 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual The Fr on t Panel Display The front panel display has a dedicated area to report the status of your HP Ink supplies. S tatus messa ges consist of a code and an action message  Ink displays information on the Ink Cartridges.  Printheads displays i[...]

HP Ink Supplies Troubleshooting 3-7 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Obtaini ng Ink Cartridge Informat ion 1. T o get information on the Ink Car tridges press the To p key on the front panel to go to the main menu. 2. Press the n or p key to select the cartridges icon and view status bars indicating ink levels in the[...]

HP Ink Supplies Troubleshooting 3-8 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 4. The front panel displays information on the selected Ink Cartridge. The information supplied is:  The make of the Ink Car trid ge ( No.81 for Dy e and No.83 for UV In k). Unkn ow n Ink C ar trid ge m ay mea n the use of refilled In k C a rtri dg [...]

HP Ink Supplies Troubleshooting 3-9 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual 3. Press n or p key until the front panel hi ghlights “Printhead info”. Press Enter to view the Printhea ds information . 4. Press the n or p key until the front panel highlights the color that you want to see information on. Press the Enter [...]

HP Ink Supplies Troubleshooting 3-10 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual S tatus Codes and Messages NOTE Most pr oble ms with Ink Su pplies wil l 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 Ink Supplies Troubleshooting 3-11 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual S tatus Message s These messages provide only an action message for the user to perform. For information on ac cessing detailed information on consumables refer to 3-7, Obtaining Ink Cartridge Information and 3-8, Obtaining Printhead Information . St [...]

HP Ink Supplies Troubleshooting 3-12 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Err or S tat us Messages Error status messages consist of the HP S tatus Code and the action message. The following tables gr oup error messages acc ording to the consumable, the ac tion message (i.e. all Replace errors are grouped together), and then[...]

HP Ink Supplies Troubleshooting 3-13 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Printhead Err ors NOTE If you think your Printer is re questing you to replace your Printhe ads to o frequently you can check Printhe ad nozz le sta tus by printing the Diagnostic Print  Refer to 6, Print Quality . NOTE Do not touch , wipe or at[...]

HP Ink Supplies Troubleshooting 3-14 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Printhea d Informa tion St a t u s Numbers Error Description Proc edure XX02 Reseat XX06 Reseat XX08 Reseat Continuity problem be tween the Printhead and the Carriag e Ass embly . T ry the following (verify if the m essage returns to OK after each one[...]

HP Ink Supplies Troubleshooting 3-15 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Printhea d Recovery Procedure The Printer regularly performs a series of controls on the he alth of the Printhea ds and when they st art to degrade the Printer will prompt the user to recover the Printhead [ (X X20)Recover ]. At this stage, the custom[...]

HP Ink Supplies Troubleshooting 3-16 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Ink Cartridge Err ors NOTE When r eplacing Ink Cartridges:  Use the Replace item in the In k Cartrid ges me nu. This will release all air from the Ink Cartridge and avoid pr oblems in its removal.  Ensur e that you have the correct Ink Cartridge[...]

HP Ink Supplies Troubleshooting 3-17 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual S tatus Numbers Error Description Procedur e Ink Cartridge Information XX0 3 Re pl ace The Ink Cartr idge has a leak which prevents the ink pumpin g to the Printer . W ARN ING: If the Ink Bag in the Ink Cartridge is leaking, the T ubes may be da mage [...]

HP Ink Supplies Troubleshooting 3-18 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Printhead Cleaner Err o rs (First Digit = A, B or * ) NOTE When re placing Printhead Cleaners:  Ensur e that you have the correct Printhead Cleaner .  Ensure that the Prin thead Clean er is the c orr ect col or for that slot.  Ensure that the[...]

HP Ink Supplies Troubleshooting 3-19 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Replace Message "xx16 Replace " for ALL Printheads During Replacement During Printhead replacement, the message "xx16 Replace" can appear for ALL the Printheads due to a firmware bug.  Clean the Printheads and the Carriag e inte[...]

HP Ink Supplies Troubleshooting 3-20 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Risks with the Ink Cartridg e Delivering T oo Muc h Ink  Meeting Point Refills: If the customer refi lls within the ink meeting point zone, then the ink cartridge will operate “normally .” If the custome r refills after the meeting point, the n[...]

HP Ink Supplies Troubleshooting 3-21 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Non-HP Hard war e Det ected in the In k Deliv ery Sy stem The following information explains the front panel message flow: Error Message XX08 Unknown Description Use genuine HP components f or excellent image qua lity from your printer . If you choose[...]

HP Ink Supplies Troubleshooting 3-22 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Risks with Using Non-HP Hardware The risks in using non-hp hardware refill systems are:  Printhead dry fire.  Probable empty ink tubes. These issues can be caused by:  Cartridge not refilled to 100%. A customer could perform a counter reset w[...]

HP Ink Supplies Troubleshooting 3-23 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual ILS Out of Contr ol W arranty S tatement  Printhead and cl eaner wa rranty: Un t il the “end of warranty” date printed on the product is reached, or 700 cc of HP ink is delivered through the printhead, whichever occu rs first.  Ink Cartridge[...]

HP Ink Supplies Troubleshooting 3-24 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual[...]

4-1 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Service T ests and Utilities 4 Introdu ction 4- 2 Diagnostics - Self T est 4-2 The Printer hangs and no thing el se happens 4- 3 Error Memory Co nfig :X 4-3 Error Memory T est 4- 3 Powe r S upp ly Error #1 4- 3 BootROM chec ksum failed 4-3 Boot Fail ed:1f500XX 4- 4 Boot F AILED 4-4 B[...]

Service Tests and Utilities 4-2 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual Intr oduction This chapter explains how to use the built-in Service T ests and Service Utiliti es and what to do if any of t he Service T ests fail. If possible, always perform a Service T est on the component that you are about to replace , just to make s[...]

Service Tests and Utilities 4-3 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual W ARNING Only r eplace one component at a time and check i f the err or has gone before r eplacing another component. If the error is still present after replacing a component, remember to REINST A LL the compon ent that was first re moved before replacing[...]

Service Tests and Utilities 4-4 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual Spin ning up d isk Boot Fai led:1 f500XX This is an error related to the Hard Di sk Drive, eithe r the connect ions are ba d or the Hard Disk Drive or the Main PCA are defective.  Unplug the Printer, remove the HDD cove r an d ch eck that th e tw o cab [...]

Service Tests and Utilities 4-5 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Service T ests (Diagnostics) The following is a list of all inte rnal Service T e sts availa ble in the Printer . Instructions for entering the Serv ice T ests menu are given on Page 4-6 . 1. Scan Axis T est  Page 4-9 The purpose of this Service T est i[...]

Service Tests and Utilities 4-6 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual Entering the Ser vice T ests Menu 1. Once the message "Ready" is displayed on the front-panel, scroll to the "Printer Setup Options" icon and press the Enter key . For On-Site Engi neers acce ssing th e complete li st of Service T ests [...]

Service Tests and Utilities 4-7 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual For Call Agents requ esting th e User to access a limit ed number of Service T ests a Once inside the "Printer Setup Options" menu and the "Device setup" menu is highlighted, press the following key combination: 2 The message below is d[...]

Service Tests and Utilities 4-8 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual If your Firmware does not support Service T ests, the following message is displayed. Y ou should press Ente r to exit. If you need the Service T ests, download the la test Firmware and repe at the whole procedure to enter the Ser vice T e sts menu. NOTE I[...]

Service Tests and Utilities 4-9 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Scan Axis T est The purpose of this test is to verify:  Carriage movement al ong the Printer axis.  Scan-Axis mot or . This test measure s the maximum a nd the avera ge current require d to move the Scan Axis parts in order to verify if parts are mov[...]

Service Tests and Utilities 4-10 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual NOTE Report the values to the nearest HP Response Center or HP Suppor t Office to deter mine whether values ar e within the accepted range. When re porting the values, have the following information r eady:  Model and Serial Nu mber of the Printer . ?[...]

Service Tests and Utilities 4-11 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Media Axis T est The purpose of this test is to verify:  Overdrive Roller movement.  Paper -Axis motor . This test measures the current required to move the Media Axis parts in order to verify if parts are moving freely or not. Perform the Medi a Ax[...]

Service Tests and Utilities 4-12 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual NOTE Report the values to the nearest HP Response Center or HP Suppor t Office to deter mine whether values ar e within the accepted range. When re porting the values, have the following information r eady:  Model and Serial Nu mber of the Printer . ?[...]

Service Tests and Utilities 4-13 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Service Uti lities The following is a list of al l intern al Servi ce Utilities available in the Printers. Instructions for ent ering the Service Uti lities menu ar e given on Page 4-14 . 1. T ur n DRIVE ROLLER  Page 4-17 The purpose of this S ervic[...]

Service Tests and Utilities 4-14 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual Entering the Ser vice Uti lities Men u 1. Once the message "Ready" is displayed on the front-panel, scroll to the "Printer Setup Options" icon and press the Enter key . For On-Site Engi neers acce ssing th e complete li st of Service U[...]

Service Tests and Utilities 4-15 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual For Call Agents requ esting th e User to access a limit ed number of Service Util ities a Once inside the "Printer Setup Options" menu and the "Device setup" menu is highlighted, press the following key combination. 2 The message below[...]

Service Tests and Utilities 4-16 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual NOTE If the Prin ter is not used for 3 minutes, the Printer exits th e Service Utilitie s Menu and you mu st rep eat the above steps to enter Service Utilities again. NOTE In some cases a quick press of a button may not be r ecognized by the Prin ter . Wh[...]

Service Tests and Utilities 4-17 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual T urn DRI VE ROLLER The purpose of this Servi ce Utility is to rotate the Overdrive, Drive Roller and Roller Mark in order to clean them. NOTE Remove the media before performing this operation. If medi a is detected, the message below is displayed. Perfor[...]

Service Tests and Utilities 4-18 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual Prime TUBES The purpose of this Servi ce Utility is to prime t he T ubes when the tubes are NOT new and they need to be reprim ed or automatic priming was not completed. NOTE Remember that the p riming process is automatically perfor med when NEW tubes ar[...]

Service Tests and Utilities 4-19 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual 4. The following message will be disp layed on the front panel while the printer verifies the Ink Cartridges:. 5. When the following message is displayed, lift the W i ndow and remove ALL the Printheads from the Carriage. Inst all the Se tup Printhea ds i[...]

Service Tests and Utilities 4-20 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual 8. The Printer will then begin to prime the T ubes S ystem. 9. Once the T ubes System is pur ged, the following message will be displayed. Lift the W indow a nd remove ALL the Setup Printheads from the Carriage and i nstall the previou sly removed printin[...]

Service Tests and Utilities 4-21 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual 12. If media is not loaded, the following message appears on the front panel and you must load media into the Printer . 13. The Printer will start to print th e Printhe ad Alignment Patte rn and the following message will be displayed on the front panel: [...]

Service Tests and Utilities 4-22 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual Altitude Setu p This Service Utility allows the operating altitude t o be set for the Printer for particular opera ti ng conditions when media load problems occur . NOTE This utility is r equir ed exclusi vel y for Printe r operating altitude s over 2000 [...]

Service Tests and Utilities 4-23 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual EEROM Setup NOTE This test is only necessary in a situation wher e you have NOT been able to p erform the E EROM backup test and you have lost all the EEROM pa rameters. The purpose of this Servi ce Utility is to s et the P rinter Model, t he Serial Numbe[...]

Service Tests and Utilities 4-24 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual 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 a[...]

Service Tests and Utilities 4-25 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual If you want to set the Ser ial Number NOTE The Se rial Number in the Cur r ent field is only disp layed if i t is encoded in the E EROM. a Select "1.4.2 Set Serial Number" and press the Enter key to view the message below . T o define a new seri[...]

Service Tests and Utilities 4-26 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual If you want to set the Jap anese Fonts NOTE If the customer is not using any internal Japanese PS Fonts, then this Ser vice Util ity is not necessary . NOTE If the Printer is NOT an HP DesignJet 5000PS or 5500PS, this utility is not avail able and the mes[...]

Service Tests and Utilities 4-27 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual b If you select Ye s the message below wi ll be displayed. Press Enter to comple te loading and return to the EEROM Setup utilit y or press Bac k to return to the previous message. 1.4.2 Set Japanes e Fonts Y ou ha ve set t he defaul t font type to Japa n[...]

Service Tests and Utilities 4-28 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual Reset Life Counters The purpose of this Servi ce Utili ty is to reset the preventive maintenance counters when par ts have been replaced. When you reset a preventive maint enance c ounter for a part, the Printer will stop displaying the maintenance warnin[...]

Service Tests and Utilities 4-29 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual The front panel message displays the following information:  Color (Printhead Insertions only); the Printhead colo r for which the counter is being reset.  Limit; the number of c ycles when the part re quires replacing.  Current; the current numb[...]

Service Tests and Utilities 4-30 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual Backup EEROM This Service Utility is used to res tore the contents of the EER OM when a service enginee r has replaced the Main PCA or the Hard Disk Drive. If the Ma in PCA is replaced the EEROM content, backed up on the hard disk, is rest ored to the Mai[...]

Service Tests and Utilities 4-31 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual 3. If you select "Main PCA" a message confirming the selection is displayed. Press Ente r to con firm and exit this utilit y or press Back to cance l. 4. If you select "Hard Disk Drive (HDD )" a message confirming selection is displaye[...]

Service Tests and Utilities 4-32 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual Image Qu alit y W arning This Service Utility is used to turn the Im age Quality W arning On or Of f. If the printer is about to print a job and Printhead health status means that a Printhe ad is not usable, the front panel will displa y a warning: Y ou c[...]

Service Tests and Utilities 4-33 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Diagnostic Print This Service Utility al lows you to pr int a Diagnostic print that will help you to troubleshoot image quality problems and verify printhead nozzl e status. 1. In the Service Utilities submenu, sc roll to "1.8 Diagnostic Print" [...]

Service Tests and Utilities 4-34 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual Sleep Mode (DesignJ et 5500 Series Only) The purpose of this Servi ce Utility is to disable t he Sleep Mode so that the P rinter is never switched OFF automaticall y if not used after a certain period. 1. In the Service Utilities submenu, sc roll to "[...]

5-1 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Service Calibrations 5 Servic e Calibrat ions 5- 3 Entering the Se rvice Cal ibration s Menu 5-4 1. Scan -Axis Calibra tion 5-7 2. Servic e Station Calibr ation 5 -1 1 3. Accuracy Cali bration 5-14 Carriage Hei ght Calibra tion 5- 18 Calibra tion Er ror Codes 5-26 User Calibrati ons [...]

Service Calibrations 5-2 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Intr oduction The Printer has seve ral calibrati on procedures that must be performed under cer tain conditions. Refer to the table on the next page to determine when calibrations are require d. Phone Support In certain circumstances, a Call Age nt can try and tr[...]

Service Calibrations 5-3 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Service Calibrations The following is a list of all inte rnal Service Ca librations avail able in the Printers. Instructions for entering the Service Calibrations menu are given on Page 5-4 . 1. Scan Axis Calib ration  Page 5-7 The purpose of this Service Cali[...]

Service Calibrations 5-4 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Entering the Ser vice Cali brations Menu 1. Once the message "Ready" is displayed on t he front-panel, scroll to "Printer Setup Options" icon and press the Enter key . For On-Site Engi neers acce ssing th e complete li st of Service Cali brati[...]

Service Calibrations 5-5 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual For Call Agents requ esting th e User to access a limit ed number of Service Cal ibrations a Once inside the "Printer Setup Options" menu and the "Device setup" menu is highlighted, press the following key combination: 2 The message below is d[...]

Service Calibrations 5-6 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual NOTE If the Prin ter is not used for 3 minu tes, the Printer exi ts out of the Servic e Calibr ations 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 r ecognized by the Prin ter[...]

Service Calibrations 5-7 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual 1. Scan-Axis Calibrat ion The purpose of this Service Calibrati on is to calibrate the Printhead in relation to the me dia and the Pla ten Assembly . This Calibration also allows you to calibrate the Li ne Sensor and define the Line Sensor ID. The Scan-Axis Calib[...]

Service Calibrations 5-8 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual If the Media loaded is not the right size, the following message is displayed. Press Enter to exit. Load the correct media and r epeat the procedure. 2. If the correct media is loaded, the following message is displayed. Press Ente r to confirm or Back to return [...]

Service Calibrations 5-9 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual 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 Ba ck to modify the number . 5. If you do not insert correct values the message below is displayed. Press Enter to cont[...]

Service Calibrations 5-10 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 7. The Printer then perform s the Printhead to media spacing calibration and displays the following message: During this stage the Printer will pri nt the fol lowing pattern. 8. On successfully completing the Calibration, the following message is displayed: 9. P[...]

Service Calibrations 5-11 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual 2. Service S tation Calibration The purpose of this Servi ce Calibration is to calibrate the Service St ation in relation to the Carriage Assembly . The Service Station Calibration performs the following calibrations:  Line Sensor to Black Pen.  Drop Detec[...]

Service Calibrations 5-12 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 2. If the correct media is loaded, the following message is displayed. Press Ente r to confirm or Back to return to the Service Calibrations menu. 3. Once the media is detected, the calibrat ion starts and the following message is displayed: During this stage th[...]

Service Calibrations 5-13 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual 5. On completing the Drop Detector calibration, the following message is displayed: 6. On completing the calibration successfully , the following message is displayed. 7. Press Back to return to the Service Ca librations menu. If the Calibration fails, the follo[...]

Service Calibrations 5-14 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 3. Accuracy Calibration The purpose of this Accuracy Calibration is to set the nominal advance of the media, changing the factory default values stored on the EEROM. This calibra tion is necessary to c ontrol the exact movement of the media in order to avoid pri[...]

Service Calibrations 5-15 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual 3. If media is not loaded, the following message appears on the front panel and you must load media into the Printer . Pre ss the Load/ Unload Media button (see the User ’ s Guide for detailed information on loading media). NOTE Do NOT use any other type of me[...]

Service Calibrations 5-16 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 6. The Printer will unload the media a nd request you to remove it from the Printer . Press Enter to continue. 7. The following message is displayed. Press Load/Unload Medi a to start the load procedure for the printed sheet. 8. When loading, rotate the pattern [...]

Service Calibrations 5-17 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual If the Calibration fails the following message is displayed. Press Enter to continue. NOTE Refer to 5-26, Calibrati on Error Codes to troubleshoot err or codes. NOTE After the Cal ibration has be en performed, p rint the Servic e Confi gurat ion pri nt to be sur[...]

Service Calibrations 5-18 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 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 preve nt problems like Printhead crashes. Perform the Carriage Height Cal[...]

Service Calibrations 5-19 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual NOTE During the Carr iage Height Cal ibration procedure the Carriage Assembly has to be moved along the length of t he Printer f or corr ect calib ration . Mak e sur e tha t th e Carri age As sembl y is only ever moved by pulling the Be lt and never by dir ect c[...]

Service Calibrations 5-20 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 5. Insert the Carriage Height T ool into the black Printhead slot. 6. Close the Carriage Cover .[...]

Service Calibrations 5-21 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual 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 t[...]

Service Calibrations 5-22 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 9. Lower the C arriage Assembly slightly , by turning the T9 screw shown below anti-clockwise and then check f or 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 scra[...]

Service Calibrations 5-23 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual 11 . Raise the Ca rriage Assembly slightly , by turning the T9 screw (shown below) clockwise . 12. Check that there is no longer a scraping sound.[...]

Service Calibrations 5-24 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 13. When the s craping has been el iminated it i s important to leav e the Carria ge Assembly as close a s possible to th e Center Plat en: move the Carriage Assembly back and forth a cross the area where the scraping sound was, gently lowe ring and raising the [...]

Service Calibrations 5-25 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual 15. When the complete length of the Printer is calibrated (c lear of any scraping sound), tighten the two T10 screws at the back of the Carriage Assembly to secure the c urrent position. 16. Remove the Carriage Height T ool.[...]

Service Calibrations 5-26 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Calibration Err or Codes Introdu ction NOTE Calibration Error Codes are continuable, wh ich means you can press Enter on the Front Panel to continue working with the Printer . If you have a Print Quality prob lem you must troublesh oot the error to r estore qual[...]

Service Calibrations 5-27 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Calibrat ion Err or: 0000 NOTE This code is not an err or . See the other codes reported. Calibrat ion Err or: 0001 Prob lem Desc rip tion: Pe n voltage error . Corr ectiv e Action: T r y the followin g:  Power the Printer OFF and ON again using the Power Swi[...]

Service Calibrations 5-28 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Calibrat ion Err or: 0020 Prob lem Desc rip tion: Line Sensor er ror . Corr ectiv e Action: Check the me dia used for the Ca libration is WHITE.  Replace the Lens Cover Assembly  Page 9-5 . Calibrat ion Err or: 0021 Prob lem Desc rip tion: Line Sensor e[...]

Service Calibrations 5-29 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Calibrat ion Err or: 1002 (User) Prob lem Desc rip tion: The Line Sensor pa ttern is not printed. Firmware error . Corr ectiv e Action: T r y the followin g:  Power the Printer OFF and ON (u sing the power switch at the back of the printer) to reset the memor[...]

Service Calibrations 5-30 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Calibrat ion Err or: 1005 (User) Prob lem Desc rip tion: Pa per Axis Er ror . Corr ectiv e Action: T r y the followin g:  Perform Printhead Recovery (  Page 6-15 ).  Reseat ALL the Printheads and repeat the Printhead Alignment (  See the User ?[...]

Service Calibrations 5-31 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Calibrat ion Err or: 1042 (User) Prob lem Desc rip tion: Scan-A xis Alignment Error in "slow" speed section in Light Cyan and Light Magenta Pattern. Corr ectiv e Action: T r y the followin g:  Perform Printhead Recovery (  Page 6-15 ).  Per[...]

Service Calibrations 5-32 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Calibrat ion Err or: 2004 (User) Prob lem Desc rip tion: Media Profile Er ror . Corr ectiv e Action: T r y the followin g:  Download a Media Profile for the current medium.  Power the P rinter OFF a nd ON from the rear of t he Printer .  Download a Firm[...]

Service Calibrations 5-33 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Calibrat ion Err or: 2101 (through to 2607) (User) Prob lem Desc rip tion: Firmwa re Error . Corr ectiv e Action: T r y the followin g:  Repeat the Closed Loop Color calibration (  See the User ’ s Guide).  Download the latest Firmware  Page [...]

Service Calibrations 5-34 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Calibrat ion Err or: 3130 Prob lem Desc rip tion: Firmwa re Error . Corr ectiv e Action: T r y the followin g:  Power the Printer OFF and ON again using the Power Switch at the back of the Printer to rese t the memory .  Upgrade the F irmware  Page 9[...]

Service Calibrations 5-35 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Calibrat ion Err or: 4003 (Service) Prob lem Desc rip tion: Line De tection Error . Corr ectiv e Action: T r y the followin g:  Check that the Lens Cover is clean.  Replace the Lens Cover Assembly  Page 9-5 .  Download the Firmware  Page 9-1[...]

Service Calibrations 5-36 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Calibrat ion Err or: 5002 (Service) Prob lem Desc rip tion: Bla ck Printhead failure. Corr ectiv e Action: T r y the followin g:  Perform Recovery for Black Printhead  Page 6-15 .  Replace t he Black Prin thead. Calibrat ion Err or: 5003 (Service) Prob [...]

Service Calibrations 5-37 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Calibrat ion Err or: 5010 (Service) Prob lem Desc rip tion: T oo many Black Printhead nozzles not working. Corr ectiv e Action: T r y the followin g:  Recover the Black Printhead (  Page 6-15 ) and if the problem persists replace the Black Printhead. Ca[...]

Service Calibrations 5-38 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Calibrat ion Err or: 6000 (Service) NOTE This code is not an err or . See the other codes reported. Calibrat ion Err or: 6001 (Service) Prob lem Desc rip tion: Drop De tector not working. Corr ectiv e Action: T r y the followin g:  T urn the Printer OFF and O[...]

Service Calibrations 5-39 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Calibrat ion Err or: 6006 (Service) Prob lem Desc rip tion: Drop De tector failed to reach position for calibration. Corr ectiv e Action: Refer to Error Code 6005. Calibrat ion Err or: 6007 (Service) Prob lem Desc rip tion: Drop De tector failed to uncap pens. C[...]

Service Calibrations 5-40 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Calibrat ion Err or: 6012 (Service) Prob lem Desc rip tion: Calibration failed for Ligh t Cyan Printhead. Corr ectiv e Action:  Recover the Light Cyan Printhead  Page 6-15 .  Replace the Light Cyan Printhead. Calibrat ion Err or: 6013 (Service) Prob [...]

Service Calibrations 5-41 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Calibrat ion Err or: 6018 (Service) Prob lem Desc rip tion: Calibration position out of range for Light Cyan Printhead. Corr ectiv e Action: Replace the Drop Detector A ssembly  Page 8-72 . Calibrat ion Err or: 6019 (Service) Prob lem Desc rip tion: Calibr[...]

Service Calibrations 5-42 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual User Calibrations The following is a list of internal User Calibrations available in the Print ers. 1. Printhead Alignment  Page 5-43 2. Close-Loop-Color Calibration  Page 5-43 3. Banding Calibration  Page 5-44 4. Accuracy Cali bration  Page 5-45[...]

Service Calibrations 5-43 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Printhead Alignment The printer will normally perfor m an alignmen t automatic ally whenever any printhead is replace d. However , you can turn Of f t his automatic alignment by choosing the printe r icon , then Internal RIP Setting > Align Calibration > O[...]

Service Calibrations 5-44 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Banding Calib ration The banding calibra tion is intended t o eliminate the problem of banding, by optimizing the media a dvance settings to suit the printing material, and the environmental conditions such as humidity and temperature. It is available only for p[...]

Service Calibrations 5-45 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Accuracy Calibration The printer is cali brate d a t the factory to e nsure that it opera tes wit h the greatest ac curacy in norma l environmental conditions. If the printer is operated unde r significantly diff erent conditions, it should be recalibrated as e [...]

Service Calibrations 5-46 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual[...]

6-1 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Print Quality 6 Print Qu ality 6 -2 Print Quali ty T ro ubleshooting Checklist 6 -2 How to Use the D iagno stic Print 6-4 What is the Di a gnostic Print? 6-4 Considerat ions for Printi ng the Dia gnostic Pr int. 6-4 Printin g th e Dia gnosti c Print 6- 5 Overall Pri nt Quality T est [...]

Print Qual ity 6-2 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual Print Quality Print Quality T roubles hooting Checklist When faced with a Print Quality problem, use the following checklist as a guide in troubleshooting the problem: 1 Problem reproduction  Reproduce the problem that the customer is seeing using their original se[...]

Print Qual ity 6-3 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual 6 Driver print quality configuration: T o cla rify if the reason of the pr obl em is related with the print m ode defined with the Non-HP Driver try the following:  Print the same sample using the Non-HP driver and their normal media.  Print one of the internal d[...]

Print Qual ity 6-4 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual How to Use th e Diagnos tic Pri nt What is the Diagnos tic Print? The Printer contains internal Dia gnostic 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 specif[...]

Print Qual ity 6-5 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Printing the Diagnosti c Print 1 Once the message “Rea dy” is displa yed on the Front Panel, scroll to the “Printer Setup Options” icon and press the Enter key . 2 Once inside the “Printer Setup Options” menu, use the Arrow keys to scroll to the “ Utiliti[...]

Print Qual ity 6-6 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual For Call Agents r equesting the User to print the Service Di agnostic print a Once inside the “Printer Setup Options” menu and the “Device setup” menu is highlighted, pre ss the followin g key combination . 2 The message below is displayed. Select Ye s to cont[...]

Print Qual ity 6-7 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual NOTE For Firmware V ersion A.02.xx in the 5000 Series and on the 5500 Series, the Printer DOES NOT print the complete Diagn ostic Print. Instead you must select wh ich part of the Diagnostic Print that you need. 5 Use the Arr ow keys to s elect the page that you need a[...]

Print Qual ity 6-8 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual Overal l Pri nt Qual ity T est - Page 1 This test pattern checks for banding in the print mode and media that is being used. What is Ban ding? Banding is when you see repetiti ve horizontal bands within the printed image (these may appear as light or dark bands). This[...]

Print Qual ity 6-9 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual In the following exam ple, there is a prob lem in the Magenta Printhead. There will be clear repetitive bands (perhaps white) in the magenta column. NOTE The Print er has automatic procedur es to hide m any Printhead defects. This typ e of pr oblem affects print qualit[...]

Print Qual ity 6-10 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual Banding in all of the colors NOTE In high qual ity modes media advance problems may not appear as lines of bandi ng, they may ap pear grain y inste ad. The b anding or grainin ess will appear i n all the color s. 1 If the image is grainy , this could also be a sympto[...]

Print Qual ity 6-11 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Color Alignment Print T est - Page 2 This part of the Diagnostic Print T est is designed to check the color alignment. It produces five crosses: one for e ach color compared to magenta. All lines are printed in one direction. If there is misalignment between Magen ta [...]

Print Qual ity 6-12 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual Bidir ectional Alignment - Page 3 If a Printer has Bidirectional alignment problems, lines are not straight. The pattern shown below is designed to highlight t his kind of problem. A pair of vertical lines is printed with each Pri nthead color except yellow . Each se[...]

Print Qual ity 6-13 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual V ertical Line S traightness - Page 4 If a Printer has V ertical 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 printe d in each direction, comparing line straightne[...]

Print Qual ity 6-14 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual Nozzle Print T est - Page 5 NOTE If your Printer has nozzle defe cts, it does not mean that you will not get p erfect p rint quality results. The Pr inter has autom atic pr ocedur es to hide ma ny nozzle defec ts. This typ e of pr oblem affects print quality mostly i[...]

Print Qual ity 6-15 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual How to fix the Nozzle Defects NOTE The Prin ter will auto matically request you to r e cover Printheads with a number of defective nozzles that may affect print quality , or repl ace them if the Printhead defect cannot be recovered. NOTE If your Printer has nozzle de [...]

Print Qual ity 6-16 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual No Printing Defects Fou nd in the Diagnosti c Print If all the test patterns from the Diagnostic Print are corre ct and you still experienc e print quality proble ms, here are some of the more likely causes to check:  The print mode used in the Printer is not righ[...]

Print Qual ity 6-17 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual  If the problem persists check the lens and if it is dirty replace the Lens Cover Assembly (  Page 9-5  and repeat the ca librations.  Perform the Printhead Alignment  Page 5-43 .  Perform the Banding Calibration  P age 5-44 . Solving [...]

Print Qual ity 6-18 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual Color Accurac y Configurat ion The configurations of the Printer , the driver , and the softwa re RIPs define how ink is applied to each type of media . Use the information in the following table to configure the Printer and software for best color accur acy. Blurr e[...]

Print Qual ity 6-19 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual length by severa l 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 diff erence because the w ay the margi ns and the crop [...]

Print Qual ity 6-20 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual 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. V ertical Band ing Some print[...]

Print Qual ity 6-21 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Warped Lines on Media The media itself may be warped. T his can happen if it has been used or stored in an extreme environment. 1 Make sure the Environmental C onditions your Printer is operating in are withi n specifi cations (Refer t o the User ’ s Guide)  2 St[...]

Print Qual ity 6-22 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual Using the Color Print Objective an d Descrip tion The objective of the Color Print is to determine whether the printer hardware has any color reproduct ion pro blems. Be fore start ing, load a roll of HP Hi gh-Gloss Photo Paper or HP Heavyweigh t Coat ed Paper . T o [...]

Print Qual ity 6-23 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Bear in mind that the transition could happen anywhere along the line. T r ust your perception! How to In terpr et the Result If you get a number in the range 4.5 to 9.5, your printer is with in the expected color reproduction a ccuracy . If you get a number lower tha[...]

Print Qual ity 6-24 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual Enrichment I ssue Issues Description There can be some li ght color ar ea fills that have two dif ferent (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 f ill (~ 2-4mm hig[...]

Print Qual ity 6-25 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual See the f ollowing i mage: 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 t he ink). 2 This ink is contained on the printhea[...]

Print Qual ity 6-26 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual evaporates partially , which leaves the ink on the nozz le with more pigments. Therefore, the initial dr ops ejected fr om those nozzles will be darker (they have more pigment) than the f ollowing ones. This leads to the second issue ( darker bor der). If we take the[...]

Print Qual ity 6-27 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual W orkar ounds This image quality problem i s a product limitation. S o, it has NO solution. Anyway , due to the limited cases wher e the problem could appear , lar ge amounts of comp laints are not expected. If any customer complains about this problem, provide the fo[...]

Print Qual ity 6-28 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual Y ou will see that r eplacing any printer’ s hardwar e part can not solve these problems . Let’ s go problem by problem… Pr oblem descr iption: As we have already e xplained be fore, ink marks on printouts is caused by two different iss ues each with a differen[...]

Print Qual ity 6-29 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual Given that the DesignJet 5X00 series printer is a production speed printer and customer usage was expected to be a t high volume; aerosol affects were a n expected occurrenc e that customers would see. Because of this occurre nce HP included cleaning and maintenance i[...]

Print Qual ity 6-30 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual 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: So, as you have seen, we can have marks ca used by the ink accumulation on:  The center platen (a nd overdrive).  [...]

Print Qual ity 6-31 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual The HP DesignJe t 5X00 series is al re ady op timiz e d t o m inimi ze t he static build up within the printer , i.e. the spindle is connected to ground, the print zone i s made out of carbon filled plastic to make it conductive, there is an antistatic br ush in front[...]

Print Qual ity 6-32 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual 2 Presence of ink smears or even drops on the printout. See the f ollowing imag e to see an example . These marks are ca used due by the fact that the static cha r ge of the media forces th e aerosol to ac cumulate at th e edges of the printheads and at the bottom of[...]

Print Qual ity 6-33 HP DesignJ et 5000 and 5500 Se ries Pri nters Servi ce Manual 3 Ink stains on the media after changing/reseating the printheads NOTE This is a secondary effect of the ink accumulation. See the f ollowing imag e to for an exa mple. Ink accumulation at the botto m of the Carriage Assembly .[...]

Print Qual ity 6-34 HP Desig nJet 500 0 and 5500 Se ries Prin ters Serv ice Manual S tatic: Solutions and W orkar ounds The following options resolve the issue:  Use HP DesignJet 5X00 Series approved media  Use 3rd party media types with ANTI-ST A TIC BACK COA TING If these options are not possible, and they still want to continue printing wi[...]

7-1 HP DesignJet 5000 and 550 0 Series Printers Service Manual Parts and Diagrams 7 Printer S upport 7-2 Bin and T ake-Up Reel 7- 4 Right Hand C over 7-6 Left Hand C over and Rear Door 7-8 T op and Back Covers 7-10 Servic e S tation 7-12 V acuum Fan 7-14 Booster Fa n and Media S ensor 7- 16 Paper -Axis M otor 7-18 Scan-Axis Motor 7- 20 ISS and APS [...]

Parts and Diagrams 7-2 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Printer Sup port Printer Suppor t Reference on Drawing HP Part Number Quantity Description/Comments DJ 5000 Series DJ 5500 Series 1 C6090-60049 2 Foot Assembly 2 C6090-60047 2 Legs Assembly 3 C6095-60167 1 T op X-Brac e Assembly (60" Model) C6090-60055 1 T op X[...]

Parts and Diagrams 7-3 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figure 3: Printer Support 1 4 1 2 2 3[...]

Parts and Diagrams 7-4 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Bin and T ake-U p Reel Bin an d T ake-Up Reel Reference on Drawing HP Part Number Quantity Description/Comments DJ 5000 Seri es DJ 5500 Serie s 1 C 7770-60148 1 42" Bin (includes the Bin S upport) 2 C6095-60 282 1 T ake-Up Reel Spindle ( 60" Model ) C6090-[...]

Parts and Diagrams 7-5 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figure 4: Bin and T ake-Up Reel 1 8 3 4 5 6 7 9 2 Bin Su ppor t[...]

Parts and Diagrams 7-6 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Right Hand Cover Right Hand Cover Reference on Drawing HP Part Number Quanti ty Description/ Comments DJ 5000 Series DJ 5500 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 T rim[...]

Parts and Diagrams 7-7 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figur e 5: Right Hand Cover 4 7 8 1 5 2 6 3 2 9[...]

Parts and Diagrams 7-8 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Left Hand Cover and Rear Door Left Hand Cover and Rear Door Reference on Drawing HP Part Number Quantity Descri ption/Comm ents DJ 5000 Series DJ 5500 Serie s 1 C6090-60039 1 Left Hand Cover (inc ludes door) 2 0624-0771 4 Screw 3 0515-4268 1 Screw 4 C6090-60042 1 Le[...]

Parts and Diagrams 7-9 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figur e 6: Left Hand Cover and Rear Door 4 5 6 2 2 1 8 2 3 9 7 11 10 12[...]

Parts and Diagrams 7-10 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual T op and Back Co ve r s T op and Back Covers Reference on Drawing HP Part Number Qu anti ty Descri ption/ Comme nts DJ 5000 Seri es DJ 5500 Seri es 1 C6095-60278 - 1 T op Cover ( 60" Model ) C6090-60291 - 1 T op Cover ( 42" Model ) - Q1253- 60012 1 Black [...]

Parts and Diagrams 7-11 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figure 7: T op and Back Covers 1 2 4 3[...]

Parts and Diagrams 7-12 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Service S tation Servi ce S tat ion Ref er en ce on Drawing HP Part Number Quantity Descrip tion/Comm ents DJ 5000 Series DJ 5500 Series 1 C6090-60083 1 Service S tation Assembly (Includes Drop D etector and Primer Assembly) 2 0624-0771 2 Screw 3 0515-1743 1 Screw [...]

Parts and Diagrams 7-13 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figur e 8: Service S tation 4 5 2 1 3 2[...]

Parts and Diagrams 7-14 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual V acuum Fan V acuum Fan Reference on Drawing HP Part Nu mber Qu antity Description/Comm ents DJ 5000 Series D J 5500 Seri es 1 C6090-60095 1 V ac uum Fan 2 0515-2248 4 Screw[...]

Parts and Diagrams 7-15 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figure 9: V acuum Fan 1 2[...]

Parts and Diagrams 7-16 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Booster Fan and Media Sensor Booster Fan and Media Sensor Reference on Drawing HP Part Num ber Quanti ty Desc ription/ Comm ents DJ 5000 Series DJ 5500 Series 1 C6090-60093 1 Booster Fan 2 0515-2248 2 Screw 3 C6090-60103 1 Media Sensor[...]

Parts and Diagrams 7-17 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figur e 10: Booster Fan and Media Sensor 2 3 1[...]

Parts and Diagrams 7-18 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Paper -Axis Motor Paper -Axis Motor Reference on Drawing HP Part Number Quant ity Descript ion/Com ments DJ 5000 Seri es DJ 5500 Series 1 C6072-60160 1 Paper-Axis Motor Assembly (includes Helical Gear and Grease ) 2 0515-2248 3 Screw 3 0515-1743 2 Screw ( Helical g[...]

Parts and Diagrams 7-19 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figure 1 1: Paper -Axis Motor 2 3 1[...]

Parts and Diagrams 7-20 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Scan-Axis Motor Scan-Axis Motor Reference on Drawing HP Part Numb er Quantity Description/Comm ents DJ 5000 Serie s DJ 5500 Series 1 C6090-60092 1 Scan-Axis Motor Assembly 2 0515-0382 2 Screw[...]

Parts and Diagrams 7-21 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figur e 12: Scan-Axis Motor 2 1[...]

Parts and Diagrams 7-22 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual ISS and APS A ss em bly ISS and AP S Assembly Reference on Drawing HP Part Number Quantity Description /Comments DJ 5000 Series DJ 5500 Series 1 C6090-60085 1 Ink Supply Station (ISS) (Includes Grounding Strip) 2 C6090-60084 1 Air Pressurization System (APS)[...]

Parts and Diagrams 7-23 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figure 13: ISS and APS Assembly 2 1[...]

Parts and Diagrams 7-24 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Ink T ubes System Ink T ubes System Reference on Drawing HP Part Number Quant ity Desc ript ion /Comm ent s DJ 5000 Series DJ 5500 Series 1 C6095-60186 1 Dye Ink T ubes System ( 60" Model ) (Includes Setup Printheads and Carrier Clip) C6090-60058 1 Dye Ink T u[...]

Parts and Diagrams 7-25 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figure 14: Ink T ubes System 2 1[...]

Parts and Diagrams 7-26 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Boot ROM DIMM, DRAM Memory an d Covers Boot ROM DIMM, DRAM Me mory and Covers Reference on Drawing HP Part Numb er Quantity Descri ption/Com ment s DJ 5000 Series DJ 5500 Series 1 J6057-61001 1 EIO Card (615N) 2 - 1 EIO Card Cover 3 C6072-60176 1 DIMM Cover 4 0515-[...]

Parts and Diagrams 7-27 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figure 15: BootROM, Memory and Covers 4 6 5 2 1 3[...]

Parts and Diagrams 7-28 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Rear Electr onics Access Covers Rear Electronics Access Covers Reference on Drawing HP Part Number Quant ity Descript ion/Com ments DJ 5000 Seri es DJ 5500 Series 1 Q1251-60085 1 Right Rear Cover 2 0515-0382 1 Screw 3 Q1251-60086 1 Left Rea r Cover 4 0515-0382 1 Sc[...]

Parts and Diagrams 7-29 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figur e 16: Rear Electron ics Access Covers 1 2 3 4 6 5 7 8[...]

Parts and Diagrams 7-30 HP Design Jet 5000 and 55 00 Series P rinters S ervice Manual Hard Disk Drive and Cover Hard Disk Drive and Cover Reference on Drawing HP Par t Number Qua nti ty Description/ Comments DJ 5000 Serie s DJ 5500 Series 1 C6 091-60255 - 1 Ha rd Disk Drive PS A.02.12 (includes data cable and pow er cable ) C6090-60303 - 1 Hard Dis[...]

Parts and Diagrams 7-31 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figur e 17: Hard Disk Drive and Cover 1 3 2[...]

Parts and Diagrams 7-32 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual ISS PC A and Mai n PC A ISS PCA and Main PCA Reference on Drawing HP Par t Number Quantity Description/Comme nts DJ 5000 Series DJ 5500 Series 1 C 6090-60012 Q1251-60030 1 Main PCA 2 0515-2200 1 1 Scre w 3 C6090-60041 1 ISS PCA (Includes ISS PCA cable ) 4 0515-2200[...]

Parts and Diagrams 7-33 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figure 18: ISS PCA and Main PCA 3 4 2 1 2 5[...]

Parts and Diagrams 7-34 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Power Supp ly Unit Power Suppl y Unit Reference on Drawing HP Part Number Quantity Desc ription/ Comments DJ 5000 Serie s DJ 5500 Series 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[...]

Parts and Diagrams 7-35 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figur e 19: Power Supply Unit 5 1 2 6 3 4[...]

Parts and Diagrams 7-36 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Carriage Assembly Carriage Assembly Ref er en ce on Drawing HP Part Num ber Quantity Description/ Comments DJ 5000 Series DJ 5500 Series 1 C6090- 60236 Q1251-60070 1 Carriage Assembly (Includes Carriage Height T ool, Cutter Assembly and Line Sensor) 2 C6090-60094 1[...]

Parts and Diagrams 7-37 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figur e 20: Carriage Assembly 5 3 2 1 4[...]

Parts and Diagrams 7-38 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual T ensioner Ass emb ly and Enc oder S trip T ensioner Asse mbly and E ncoder S trip Reference on Drawing HP Part Number Quanti ty Descri ption/ Comme nts DJ 5000 Series DJ 5500 Series 1 C6090-60088 1 T ensioner Assembly (Includes Pulley Assembly , Pulley Spring, W e[...]

Parts and Diagrams 7-39 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figure 21: T ensioner Assembly and Encoder S trip 2 4 5 3 1[...]

Parts and Diagrams 7-40 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Platen Assemblies - DesignJet 5000 Series Platen Assemblies - DesignJet 5000 Series Reference on Drawing HP Part Numb er Qu antity Description/Comm ents 1 C6095-60174 1 Fr ont Platen Assembly (including screws) (60" Model) C6090-60079 1 Front Platen Assembly ([...]

Parts and Diagrams 7-41 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figure 22: Platen Assemblies - DesignJet 5000 Series 1 3 4 5000 Series Only 2[...]

Parts and Diagrams 7-42 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Platen Assemblies - DesignJet 5500 Series Platen Assemblies - DesignJet 5500 Series Reference on Drawing HP Part Numb er Qu antity Description/Comm ents 1 Q1253-6001 1 1 Hea ter Assembly (including screws) (60" Model) Q1251-60031 1 Heater Assembly (including s[...]

Parts and Diagrams 7-43 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figure 23: Platen Assemblies - DesignJet 5500 Series 1 3 4 2 5500 Series Only[...]

Parts and Diagrams 7-44 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Pinch-Whee ls Asse mbly and Lever Pinch-Wheels Assembly and L ever Reference on Drawing HP Part Number Quantity Descr iption/Comme nts DJ 5000 Series DJ 5500 Series 1 C6095-60181 1 Pinch Assembly (60" Model) C6090-60073 1 Pinch Assembly ( 42" Model) 2 C60[...]

Parts and Diagrams 7-45 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figure 24: P inch-Wheel s Assembly and Lever 5 3 7 6 4 2 1[...]

Parts and Diagrams 7-46 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Center Guide, Deflecto rs an d Entry Roller - DesignJet 5000 Series Center Guide, Deflectors and En try Roller - De signJet 5000 Series Reference on Drawing HP Part Numb er Qu antity Description/Comm ents 1 C 6095-60180 1 Center Guide (60" Model) C6090-60075 1[...]

Parts and Diagrams 7-47 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figur e 25: Center Guide, Deflectors and Entry Roller - DesignJet 5000 Series 2 1 7 2 3 6 4 5 5000 Series Only[...]

Parts and Diagrams 7-48 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Center Guide and Entry Ro ller - DesignJet 5500 Series Center Guide and Entry Roller - DesignJet 5500 Series Reference on Drawing HP Part Numb er Qu antity Description/Comm ents 1 C 6095-60180 1 Center Guide (60" Model) C6090-60075 1 Center Guide (42" Mod[...]

Parts and Diagrams 7-49 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figure 26: Center Guide and Entry Roller - DesignJet 5500 Series 4 5 3 2 2 1 5000 Series Only[...]

Parts and Diagrams 7-50 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual T ubes Guide Assem blies T ubes Guide Assemblies Reference on Drawing HP Part Numb er Qu anti ty Description/ Comments DJ 5000 Serie s DJ 5500 Series 1 C6095-60176 1 B ack T ube Guide Assembly (60" Model) (Includes Saf ety Arm for T op Cover) C6095-60078 1 Ba [...]

Parts and Diagrams 7-51 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figur e 27: T ubes Guide Assemblies 3 4 5 6 7 1 2[...]

Parts and Diagrams 7-52 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual EMC Covers EMC Covers Reference on Drawing HP Part Num ber Qua nti ty Descri ption/ Comm ents DJ 5000 Serie s DJ 5500 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 t[...]

Parts and Diagrams 7-53 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figure 28: EMC Covers 1 2 1 1 3[...]

Parts and Diagrams 7-54 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Spindle and Hub Spindl e and Hu b Reference on Drawing HP Par t Number Quantity Desc ription/Comme nts DJ 5000 Series DJ 5500 Series 1 C6095-60182 1 Spindle (60" Model) C6090-60074 1 Spindle (42" Model) 2 C6090-60105 1 Blue Hub 3 C 6090-601 12 2 3" S[...]

Parts and Diagrams 7-55 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figur e 29: Spind le and Hub 1 3 2[...]

Parts and Diagrams 7-56 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Rollfeed Brakes Rollfeed Brake s Reference on Drawing HP Par t Number Quantity Desc ription/Comme nts DJ 5000 Series DJ 5500 Series 1 C6072-60158 1 Left Rollfeed Module 2 C6072-60155 1 Right Rollfeed Module 3 C6072-60156 1 Right Rollfeed Brake 4 0624-0704 1 Screw 5[...]

Parts and Diagrams 7-57 HP DesignJet 5000 and 550 0 Series Printers Service Manual Figur e 30: Rollfeed Brakes 1 Left Hand Side Right Hand Side 2 3 and 4 5 and 6[...]

Parts and Diagrams 7-58 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual Miscellaneous Items Miscellaneous Items Reference on Drawing HP Part Number Quanti ty Descriptio n/Comments DJ 5000 Series DJ 5500 Series - C6090-60081 Q1251-60073 1 Service Preve ntive Maintenance Kit (for both 42" and 60" Models) - C6090-60314 1 Use r M[...]

Parts and Diagrams 7-59 HP DesignJet 5000 and 550 0 Series Printers Service Manual Media T ypes ' H 89[...]

Parts and Diagrams 7-60 HP Design Jet 5000 and 5500 Series P rinters Se rvice Manual[...]

8-1 HP DesignJ et 5000 and 5500 Seri es Pr inters Ser vice Manual Removal and Installation 8 Screw T ypes 8-4 T op Cover Assembly 8-5 Left Ha nd Cover 8- 6 Right Hand C over 8-10 Front Pane l Assembly 8-14 Lef t Rea r Cov er 8-15 Right Re ar Cover 8-1 6 Extension C over ( 60" Model on ly) 8-17 Media Lever Assembly 8- 18 Right Hand T rim 8-20 L[...]

Removal and Installa tion 8-2 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Intr oduction This chapter is a step by step guide to th e r emoval and installation of the key components in the Printer . Y ou may find it useful to tick off the steps as they ar e pe rformed. Use the illustration at each pr ocedure to i dentify the parts [...]

Removal and Installa tion 8-3 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Electr ostati c Discharge (ESD) Pr ecautions T o pr event damage to the Printer cir cuits fr om high-voltage electros tatic dischar ge (ESD): 1. Do not wear clothing that is subject to static build-up. 2. Do not handle integrated circu its (IC s) in carpeted a[...]

Removal and Installa tion 8-4 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Screw T ype s W ARNING Chassis scr ews have a copper washer and should never be r emoved. Ty p e To r x L e n g t h (mm) Head T ype Thr ead T ype Part Number A T -20 17 Pan T aptite 0515-1743 B T -15 12 Pan Machined 0515-0382 C T -20 10 Pan T aptite 0515-228[...]

Removal and Installa tion 8-5 HP Design Jet 5000 and 5500 Seri es Printers Service Manual T op Cover Assembly Removal W ARNING Switch off the Pri nter and remove the p ower cable . 1. Open the T op Cover and lift UP and remove from Printer (see detail of hinge mechanism below). NOTE Detail of hinge mechanism.[...]

Removal and Installa tion 8-6 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Left Hand Cover Removal W ARNING Switch off the Pri nter and remove the p ower 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 T op Cover . 3. Open the door at the ba[...]

Removal and Installa tion 8-7 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 4. Disconnect the Electrical Cable from the rear of the Ink Cartridge Tube Connec tor . 5. Disconnect the Air T ube. 6. T wist the 3 latches at the rea r of the Ink Cartridge T ube Connector and release the compl ete Assembly . 2 1[...]

Removal and Installa tion 8-8 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 7. Remove the Ink Cartridge T ube Connector and place safely on the window . 8. Remove 1 T -15 scr ew ( Ty p e F ) from the Left Hand Cover (rea r). 9. Close the Left Back door and remove 1 T - 25 scre w ( Ty p e U ) from bottom side (rear) of Lef t Hand Cov[...]

Removal and Installa tion 8-9 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 10. Remove 3 T -15 screws ( Ty p e F ) from the Left Hand Cover (front). 11 . Remove the Left H and Cover from the Printer . Installation of Le ft Hand Cover W ARNING When hand ling the T ubes make sur e you do not dam age them by twisting. W ARNING When inser[...]

Removal and Installa tion 8-10 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Right Hand Cover Removal W ARNING Switch off the Pri nter and remove the Power Cord . W ARNING T o remove the Right Hand Cover you must open the Right Cover door and push in the Printhead Cl eaner Carriage. NOTE Refer to the table on Page 8-4 for informatio[...]

Removal and Installa tion 8-11 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 4. Remove 1 T -15 scr ew ( Ty p e F ) and 1 T -25 scr ew ( Ty p e U ) (bottom) from the rear of the Right Hand Cover . 5. Open the T op Cover . 6. Raise the Medi a Lever .[...]

Removal and Installa tion 8-12 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual NOTE T ake ca re no t to dr op t he Cover when removing the screws. Su pport the Cover thr oughout the next st ep. 7. Remove 3 T -15 ( Ty p e F ) scre ws from the front of the Right Hand Cover . 8. T o re lease the c ables, car efully pull out the Right Han[...]

Removal and Installa tion 8-13 HP Design Jet 5000 and 5500 Seri es Printers Service Manual TIP T o ch eck correct fun ctioning of serviced parts on the Printer axis you can do the following: a Reinsert the top T -15 scr ew ( Ty p e F ) at the rear of the P rinter . b Hang the Cover on the screw . c Connect all cables at the Rear of the Right Cover [...]

Removal and Installa tion 8-14 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Fr ont Panel Assembly Removal W ARNING Switch off the Pri nter 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 s[...]

Removal and Installa tion 8-15 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Left Rear Cover Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove one T -15 scre w ( Ty p e B ) from the Left Rear Cover . NOTE Support the Cover as it is r eleas[...]

Removal and Installa tion 8-16 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Right Rear Cover Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove one T -15 scre w ( Ty p e B ) from the Right Rear Cover . NOTE Support the Cover as it is r e[...]

Removal and Installa tion 8-17 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Extension Cove r (60" Model only) Removal W ARNING Switch off the Pri nter 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 - Refe r to Page 8-15 . 2. Remove 4 T -15 screws ( Ty[...]

Removal and Installa tion 8-18 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Media Lever Assembly Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Only applicabl e to the DesignJet 5000 Series - Remove the Deflector closest to the Right Cover [...]

Removal and Installa tion 8-19 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 5. Remove 1 T -15 scr ew ( Ty p e H ) that attaches the Le ver Arm to the Lever . 6. Remove the Media Lever . Installation of the Media Lever Assembl y W ARNING When installing the Media Lever , you mu st i nse rt it in th e T rim and Sideplate in the UP posi[...]

Removal and Installa tion 8-20 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Right Hand T rim Removal W ARNING Switch off the Pri nter 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. [...]

Removal and Installa tion 8-21 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 6. Carefully remove the Right Hand Tr i m . Installation of R ight Hand T rim W ARNING When in stalling the Media L ever in the T rim, install with the Lever in the UP position to avoid damagin g the Lever spring in the T rim. Remove carefully 1 2[...]

Removal and Installa tion 8-22 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Left Hand T rim Removal W ARNING Switch off the Pri nter 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 ( Ty p e F ) and 1 T -20 scre w ( Ty p e L ) from t he L eft Hand T rim. 2. Car[...]

Removal and Installa tion 8-23 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Back Cover Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the T op Cover - Refe r to Page 8-5 . 2. Remove the following ( Ty p e B ) screws from the upper part[...]

Removal and Installa tion 8-24 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 4. Remove the Back Cover . Installation of the Back Cov er NOTE If the Back Cover is r eplaced, remember to apply a new Printer Label to the new Back Cover before it is installed. O nce the new labe l has been a pplie d, copy the produ ct number and seri al[...]

Removal and Installa tion 8-25 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Ink T ubes System Removal W ARNING Switch off the Pri nter and remove the Power Cord . 1. Open the Right Cover door and pull out the Printhead Cleaner Carriage. 2. Open the T op Cover and pull the Carriage out along the Printer to the position shown. 3. Lift [...]

Removal and Installa tion 8-26 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 4. Slide the Carria ge to the position shown. 5. Push in the 2 reta ining clips either side of the Printhead T ube Connector . 6. Pull the Printhead T ube Connector towards you.[...]

Removal and Installa tion 8-27 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 7. Push the button to rele ase the Printhea d T ub es in the Carriage. 8. Release the Retaining Clip by pulling it away from the holding brackets. 9. Pull the Printhead T ube Connector up between the two T ube Guides.[...]

Removal and Installa tion 8-28 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 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 Lef t Cover .[...]

Removal and Installa tion 8-29 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 13. Disconnect the Electrical Cable from the rear of the Ink Cartridge Tube Connec tor . 14. Disconnect the Air T ube. 15. T wist the 3 latches at the rea r of the Ink Cartridge T ube Connector and release the compl ete Assembly . 2 1[...]

Removal and Installa tion 8-30 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 16. The complete assembly can now be removed by sliding the Ink Cartridge Connector out from the rear of the Left Hand Cover . Installation of I nk T ubes System W ARNING When installing th e Ink T ubes System it is very important that the T ubes are NOT TW[...]

Removal and Installa tion 8-31 HP Design Jet 5000 and 5500 Seri es Printers Service Manual NOTE When the Ink T ubes System is replac ed, to r estart th e Printer perform the following procedur es. 1. Install the S etup Printheads (re fer to the User ’ s Guide). 2. Connect the Power Cable and turn on the main Power Switch a t the rear of the Print[...]

Removal and Installa tion 8-32 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual EMC Covers Removal W ARNING Switch off the Pri nter 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; T op , Lower Lef t and Lower Right. Procedures below describe [...]

Removal and Installa tion 8-33 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 7. Remove the following screws ( Ty p e N ) from the T op EMC Cover .  8 T - 15 screws for the 60" Model.  6 T - 15 screws for the 42" Model. 8. Loosen 4 T -15 scr ews ( Ty p e L ) on Lower Covers and remove all Covers as one assembly . Lower [...]

Removal and Installa tion 8-34 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Encoder S trip Removal W ARNING Switch off the Pri nter 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 T op Cover - Refer to Page 8-5 . 4. Remove the Back C[...]

Removal and Installa tion 8-35 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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 S trip W ARNING When In stallin g the Enco der S trip, make sur e i t is placed in the Encoder Sensor on the rear of the [...]

Removal and Installa tion 8-36 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual T railing Cable Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the T op Cover - Refer to Page 8-5 . 2. Remove the Right Rear Cover - Refer to Page 8-16 . 3. [...]

Removal and Installa tion 8-37 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 7. Carefully disconnect the T railing Cables (3) from the connectors in the Carriage PCA. NOTE Remove T railing Cable Ferr ites if they fal l into t he Carriage  3 for 60" Model  1 for 42" Model 8. Remove the T railing Cables from the T r aili[...]

Removal and Installa tion 8-38 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 10. Carefully disconnect the T railing Cable from the Main PCA. NOTE Unclip the T railing Cable when disconnectin g from the Main PCA. 11 . Remove the T -20 screw ( Ty p e C ) from the T rai ling Cable Clip on the left. NOTE Ther e is a hole in the T ube Gu[...]

Removal and Installa tion 8-39 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 13. Carefully lift the Cli ps and the T r ailing Ca ble from the Printer . Installation of T railing Ca ble W ARNING Do not install d amaged T railing Cabl es. If the T railing Cable is incorr ectly installed or it is damaged, a "Power Supply Err or #1&q[...]

Removal and Installa tion 8-40 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 2. Insert the T railing Cable Guide into the Carriage and connect the Trailing Cables. NOTE Remember to pass the T railing Cables thr ough the Ferrit e(s).  3 for 60" Model.  1 for 42" Model. 3. Insert the T railing Cable through the Chassis[...]

Removal and Installa tion 8-41 HP Design Jet 5000 and 5500 Seri es Printers Service Manual TIP Make sur e the T railing Cable is flat on the chassis without bubble s. NOTE Check the cable an d clips are corr ectly in stalle d by slidi ng the carriage along the Printer to see if it moves freely . 5. Connect the T ra iling Cables t o the Main PCA. NO[...]

Removal and Installa tion 8-42 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual T ensioner Ass emb ly Removal W ARNING Switch off the Pri nter 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[...]

Removal and Installa tion 8-43 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 5. Using a screwdriver , fully tighten the Spring Release S crew to rele ase the tension on the Belt. 6. From the right-hand side, lift the T ensioner Belt off the Scan-Axis Motor . 7. Remove 1 T -15 scr ew ( Ty p e L ) from the T ensioner Assembly . Ti ghten[...]

Removal and Installa tion 8-44 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 8. Remove the Be lt Wheel on the l eft side. 9. Remove the T ensioner Assembly from the left-hand side.[...]

Removal and Installa tion 8-45 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Installat ion of T ensioner Assembly NOTE Before install ation, clean and oil the Slider Rods using the User’s Slider Rods Lu brificati on Kit (Refer to Page 9-8 ). W ARNING Be car e ful n ot to twi st the Belt wh en installin g the T ensioner Assembly . W [...]

Removal and Installa tion 8-46 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Carriage Assembly and Be lt Removal W ARNING Switch off the Pri nter and remove the p ower cord. 1. Remove the Left Hand Cover - Refer to Page 8-6 . 2. Remove the Right Rear Cover - Refer to Page 8-16 . 3. Remove the Right Hand Cover - Refer to Page 8-10 . [...]

Removal and Installa tion 8-47 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 7. Lift up the Carriage Cover and remove ALL the Pri ntheads and close the Carriage Cover . 8. Slide the Carriage along the Printer to the position shown. 9. Push in the 2 reta ining clips either side of the Printhead T ube Connector .[...]

Removal and Installa tion 8-48 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 10. Pull the Printhead T ube Connector towards you. 11 . Push the button to release the Printhea d T ubes in the Carriag e. 12. Release the retaining clip by pulling it away from the holding brackets.[...]

Removal and Installa tion 8-49 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 13. Pull the Printhead T ube Connector up between the two T ube Guides. 14. Slide the Carria ge to the left si de of the Printer . 15. Unclip and remove the Carriage Cover to ac cess the T railing Cabl e in the Carriage.[...]

Removal and Installa tion 8-50 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 16. Carefully disconnect the T railing Cables (3) from the connectors in the Carriage PCA. NOTE Remove T railing Cable Ferr ites if they fal l into t he Carriage  3 for 60" Model.  1 for 42" Model. 17. Remove the T railing Cables from the T [...]

Removal and Installa tion 8-51 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 19. Slide the Ca rriage (inclu ding the Belt) to the left and out of the Printer . 20. Remove the Belt from the Carriage by releasing it from the retaining clips underneath the Carriage.[...]

Removal and Installa tion 8-52 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Installati on of Carriage a nd Bel t NOTE Before install ation, clean and oil the Slider Rods using the User’s Slider Rods Lu brificati on Kit (Refer to the Use r ’ s Guide). W ARNING Make sure you install the Carriage Assembly an d Belt as follows: 1. [...]

Removal and Installa tion 8-53 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Line Sensor Removal W ARNING Switch off the Pri nter 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 Car[...]

Removal and Installa tion 8-54 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 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, rota te the Line Sensor downwards so that the locating pins on both si des are also[...]

Removal and Installa tion 8-55 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Installa tion 1. When installing the new Line Sensor , make sure you insert the Line Sensor Cable through the correct hole (as highlighted). 2. Install the Line Sensor by first inserting the 2 locating pins and then rotating upwards so that the clip locks int[...]

Removal and Installa tion 8-56 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 4. Install the Ca rriage Cover . NOTE Make sure the cover i s installed vertically , if not the Cover Retaining Pins can be br oken. 5. Clip the C arriage Cove r on bot h sides of the Carriage Assembly by pushing the clip downwards (with force if necessary)[...]

Removal and Installa tion 8-57 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Scan-Axis Motor Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Right Rear Cover - Refer to Page 8-16 . 2. Remove the Left Hand Cover - Refe r to Page 8-6 .[...]

Removal and Installa tion 8-58 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 6. Using a screwdriver , fully tighten the Spring Release S crew to rele ase the tension on the Belt. 7. Disconnect the Scan-Axis Motor Cable from positio n P23 on the Main PCA. 8. Unclip the S can-Axis Motor C able from underneath the Service Station. Tigh[...]

Removal and Installa tion 8-59 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 9. From the right-hand side, lift the T ensioner Belt off the Scan-Axis Motor . 10. While supporting the Scan-Axis Motor , remove 2 T -15 screw s ( Ty p e B ). 11 . Lower the Scan-Axis Motor and remove from the Print er . Installation of the Scan-Axis Motor N[...]

Removal and Installa tion 8-60 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Cutter Assembly Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Open the T op Cover . 2. Pull the Carriage out along t he Printer to the position shown. 3. Lift up t[...]

Removal and Installa tion 8-61 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 4. Slide the Carria ge to the position shown. 5. Push in the 2 reta ining clips either side of the Printhead T ube Connector . 6. Pull the Printhead T ube Connector towards you.[...]

Removal and Installa tion 8-62 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 7. Push the button to rele ase the Printhead T ubes from the Carriage . 8. Release the retaining clip by pulling it away from the holding brackets. 9. Remove 1 T -8 scr ew ( Ty p e V ) and washer that atta ches th e Cutter to the Carriage.[...]

Removal and Installa tion 8-63 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 10. Slide the Cutter towards you and remove from the Print er .[...]

Removal and Installa tion 8-64 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Ink Supply S t ation (ISS) Removal W ARNING Switch off the Pri nter and remove the Power Cord . 1. Remove the Left Hand Cover - Refer to Page 8-6 . 2. Remove the Left Rear Cover - Refe r to Page 8-15 . 3. Remove the Back Extension Cover (Only for the 60&quo[...]

Removal and Installa tion 8-65 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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 IS S to the left a nd pull out the left side to rem ove from the Printer . INSIDE VIEW FRONT INSIDE VIEW REAR 1[...]

Removal and Installa tion 8-66 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Installation of I SS NOTE If the ISS is to be r eplaced, make sur e you r emove the APS from the old ISS and, after installing the Groundi ng Plate, reinstall it on the new ISS. W ARNING When r eplacing the ISS r emember to insert the Grou nding Plate into [...]

Removal and Installa tion 8-67 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Air Pressurization System (APS) Removal W ARNING Switch off the Pri nter and remove the Power Cord . 1. Remove the Left Hand Cover - Refer to Page 8-6 . 2. Remove the Left Rear Cover - Refe r to Page 8-15 . 3. Remove the Back Extension Cover (Only for the 60&[...]

Removal and Installa tion 8-68 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Installation of A PS W ARNING When In stalling the Air Pr essuri zation System make su re the tube and wir es ar e placed in th e dedicated slots and perform the following steps: 1. Before instal ling the APS on the ISS, insert first th e 3 cables and then [...]

Removal and Installa tion 8-69 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Service S t at ion Assembly Removal W ARNING Switch off the Pri nter 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 t[...]

Removal and Installa tion 8-70 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 5. Disconnect the Service Station Cable from the Main PCA (P15) . 6. Unclip the S can-Axis Motor C able from the Serv ice S tation. NOTE Follow the i nstruction s in step 7 carefully; LOOSE N the screw and DO NOT r emove. 7. Loosen the T -20 sc rew ( Ty p e[...]

Removal and Installa tion 8-71 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 8. Remove 2 T -15 scr ews ( Ty p e F ) between the two slider rods that a ttach the Service S tation to the Chassis. 9. St anding in front of the Service St ation, lift it off the loosened screw . 10. Pull the assembly out towards you and remove from the Prin[...]

Removal and Installa tion 8-72 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Drop Detector Assembly Removal W ARNING Switch off the Pri nter 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 Se rvice S tation Asse mbly - Refer to Pa g[...]

Removal and Installa tion 8-73 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 6. Remove the T -15 scr ew ( Ty p e F ) that attaches th e Drop Detector A ssembly to the Service Sta tion. 7. Remove the Drop Detector from the Servic e S tat ion. NOTE Move the Drop Detector towards the front of the Service S tation until the locati ng pin [...]

Removal and Installa tion 8-74 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Hard Disk Drive (HDD) Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove 6 T -15 screws ( Ty p e B ) from the HDD Access Cover . Remove the HDD Access Cover . 2.[...]

Removal and Installa tion 8-75 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Installation of Hard Di sk Drive NOTE If you re place the Main PCA and the HDD at the same time you must perf orm ALL Ser vice Cal ibrations (  Page 5-3 )  and the EEROM Se tup Serv ice Utility (  Page 4-23 ). W ARNING When Installin g the Hard[...]

Removal and Installa tion 8-76 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual LAN Card Removal W ARNING Switch off the Pri nter 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 atta ch the LAN Card to the Printer . 3. R[...]

Removal and Installa tion 8-77 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Memory a nd BootROM DIMM’ s Removal W ARNING Switch off the Pri nter 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 ( Ty p e P ) from the DIMM Access Cover . Remove the DIMM Access Co[...]

Removal and Installa tion 8-78 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 3. Pull out the DIMM. T ake care that it does not fall out. Installation of D IMM’ s W ARNING When in stalling the DIMM’ s make sur e they a re in the cor rect position as shown i n the diagram. NOTE Note the position of the B ootROM and the SDRAM (m em[...]

Removal and Installa tion 8-79 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Electr onics Module Cover Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the LAN Card - Refe r to Page 8-76 . 2. Remove Left Rear Cover - Refer to Page 8-15 . [...]

Removal and Installa tion 8-80 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual NOTE Lift the Par allel Port Clips before r emoving the Cover . 6. Remove the Electronics Module Cover . Installation of the Electr onics Module Cover NOTE When Installin g the Electr onics Mo dule Cover mak e sure the paralle l port connec tor clips are in[...]

Removal and Installa tion 8-81 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Main PCA W ARNING This asse mbly does NOT inclu de the PCI-to-IDE PCA (t he small PCA that conne c ts the Main PCA to the Hard Disk Drive) as it used to in the past. Wh en inst alling th e new Mai n PCA, make sure that you reuse the PCI-to-IDE PCA that was di[...]

Removal and Installa tion 8-82 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the LAN Card - Refe r to Page 8-76 . 2. Remove the Left Rear Cover - Refe r to Page 8-15 . 3. Remove the Right[...]

Removal and Installa tion 8-83 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 9. Disconnect the PCI-to-IDE PCA and remove from the Print er . NOTE Make sur e you re use the PCI-to-IDE PCA when r eassembling. 10. Remove 6 T -10 screws ( Ty p e K ) from the Main PCA. 11 . Loosen 2 T -10 screws on the Main PCA.[...]

Removal and Installa tion 8-84 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 12. Remove by sliding the Main PCA to the left and lifting out (see detail below). NOTE Detail of Main PCA removal. Installation of M ain PCA NOTE When the Main PCA has been replaced, perf orm the Back up EEROM  Page 4-30 . NOTE If you re place the Main [...]

Removal and Installa tion 8-85 HP Design Jet 5000 and 5500 Seri es Printers Service Manual PCI-to-IDE PCA Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the LAN Card - Refe r to Page 8-76 . 2. Remove the Left Rear Cover - Refe r to Page 8-15 . 3. Rem[...]

Removal and Installa tion 8-86 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Installation of the PCI- to-IDE PCA NOTE When installin g the ne w PCI-to-IDE PCA, CONNECT THE HDD POWER CABLE T O THE P36 CONNECT OR (IF PRESENT) ON THE PCI-T O-IDE PCA AND NOT T O THE P1 1 CONNEC T OR ON THE MAIN PCA (even if the P1 1 conn ecto r is pr es[...]

Removal and Installa tion 8-87 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Installin g the HD D Cable When installing the HDD Cable between the H DD and the PCI-to-IDE PCA, make sure you connect the correct ends a s follows: / RRSHG (QGFRQQH FWVWR WKH +DU G' LVN ' U L YH 6KRUW & R QQHF W RU FRQQ[...]

Removal and Installa tion 8-88 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Power Supply Unit (PSU) Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the LAN Card - Refe r to Page 8-76 . 2. Remove the Left Rear Cover - Refe r to Page 8-[...]

Removal and Installa tion 8-89 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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 scr ews ( Ty p e K ) and remove the PSU. PS Fans PS Switch PS Socket Press[...]

Removal and Installa tion 8-90 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Installation of the Power Supply Unit (PSU) W ARNING After in stalling t he Power Sup ply Unit, remember to place th e plastic protective cover over the unit. NOTE The Power S upply Unit c onnecti ons are illustrated bel ow . PS Fans PS Sw it c h PS Socket[...]

Removal and Installa tion 8-91 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Ink Supply S t ation (ISS) PCA Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the LAN Card - Refe r to Page 8-76 . 2. Remove the Left Rear Cover - Refe r to Pa[...]

Removal and Installa tion 8-92 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Installation of the ISS PC A NOTE The ISS PCA co nnections ar e illu strated be low . * The Ink LeakDetector has been discontinued so this connector is no longer use d. ** There are 2 connec tors available for the A PS Pump and any one of them can be used. [...]

Removal and Installa tion 8-93 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Ink Leak Detector - If Pr es ent (Only Applicable to the 5000 Series) Removal W ARNING Switch off the Pri nter 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 - Refe r to Page 8-15 [...]

Removal and Installa tion 8-94 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 6. Press the ret aining clip on the Ink Leak D etecto r and r eleas e it. TIP A screwdriver can be used to press the retaining clip down. 7. Remove the Ink Leak Detector f rom the Printer .[...]

Removal and Installa tion 8-95 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Cooling Fans Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the LAN Card - Refe r to Page 8-76 . 2. Remove the Left Rear Cover - Refe r to Page 8-15 . 3. Remov[...]

Removal and Installa tion 8-96 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 7. Remove the plastic Protective Cover from the Power Supply Unit. 8. Disconnect the Cooling Fan Cables from the Power Supply Unit. 9. Remove the Cooling Fans from the Printer .[...]

Removal and Installa tion 8-97 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Electr onics Module (as one complete Assembly) Removal W ARNING Switch off the Pri nter 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 - Refe r to Page 8-15 . 2. Remove the Right R[...]

Removal and Installa tion 8-98 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Pinch-Wheels Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the T op Cover - Refer to Page 8-5 . 2. Remove the Back Cover - Refer to Page 8-23 . 3. Remove th[...]

Removal and Installa tion 8-99 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 6. First remove latera l Pinch-Wh eels with their Coupling Plat es. NOTE For Pinch-Wheel groups installed ar ound the Mount Brackets do the following: 7. From the front of the Printer , r emove the Coupling Plate corresponding to the position of the Mount Bra[...]

Removal and Installa tion 8-100 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Pinch-Whee l Cam Removal W ARNING Switch off the Pri nter 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. [...]

Removal and Installa tion 8-101 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 16. Remove the Center Guide - Refer to Page 8-1 12 . 17. Remove the Pinch-Wheels - Refer to Page 8-97 . 18. Through the slot in the right Sideplate, remove the T -15 screw ( Ty p e H ) retaining the cam lever a rm. 19. Remove the T -15 Cam scr ew ( Ty p e F [...]

Removal and Installa tion 8-102 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Installation of C am 1. T o install the Cam slide it through the left Sideplate and place it in the cam slot in the beam. 2. Hold the Cam Lever Linkage over its slot in the Sideplate and insert the Cam into it. 3. Push the Cam with the Cam Lever Linkage in[...]

Removal and Installa tion 8-103 HP Design Jet 5000 and 5500 Seri es Printers Service Manual V ac uum Fan Removal W ARNING Switch off the Pri nter 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 . [...]

Removal and Installa tion 8-104 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 6. Remove the V acuum Fan. Installation of V acuum Fan W ARNING When installing the V acuum Fan make sur e that it fits tightly to the Guide s in the S ideplate.[...]

Removal and Installa tion 8-105 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Paper -Axis Motor Assembly Removal W ARNING Switch off the Pri nter 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 t[...]

Removal and Installa tion 8-106 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 6. Remove the Hel ical Gear . 7. Remove the 3 T -20 scr ews ( Ty p e L ) that secure th e Paper-Axis Motor Assembly to the S ideplate. 8. Remove the Paper-Axis Mot or Assembly . NOTE When you r eplace the Paper - Axis Motor Assemb ly you must per form the [...]

Removal and Installa tion 8-107 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Installation of P aper -Axis Motor Ass embly W ARNING When r einstallin g parts make su re that the y fit tightly and that screws ar e tight. NOTE Apply gr ease to the Helical Gear .[...]

Removal and Installa tion 8-108 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Booster Fan Removal W ARNING Switch off the Pri nter 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. Remov[...]

Removal and Installa tion 8-109 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Media Sensor Removal W ARNING Switch off the Pri nter and remove the Power Cord . 1. Remove the T op Cover - Refer to Page 8-5 . 2. Remove the Right Rear Cover - Refer to Page 8-16 . 3. Remove the Left Rear Cover - Refe r to Page 8-15 . 4. Remove the Back Co[...]

Removal and Installa tion 8-110 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Installation of M edia Sensor W ARNING When installing th e Media Sensor , insert the moving part as shown in the diagram.[...]

Removal and Installa tion 8-111 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Entry Roller Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove Left Hand T rim - Refer to Page 8-22 . 2. Remove the Left Hand Cover - Refer to Page 8-6 . 3. Remo[...]

Removal and Installa tion 8-112 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Center Guide Assembly Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the T op Cover - Refer to Page 8-5 . 2. Remove the Back Cover - Refer to Page 8-23 . 3.[...]

Removal and Installa tion 8-113 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 16. Remove the Booster Fan - Refer to Page 8-108 . 17. Remove the Media Sensor - Refer to Page 8-109 . 18. Remove the Entry Roll er - Refer to Page 8 - 111 . 19. Remove 3 T -15 scr ews ( Ty p e J ) that secure the Center Guide to t he left Sideplate. 20. Rem[...]

Removal and Installa tion 8-114 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Drive Roller Gear Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Left Hand Cover - Refer to Page 8-6 . 2. Remove the Left Rear Cover - Refe r to Page 8-[...]

Removal and Installa tion 8-115 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Fr ont Platen Ass embly (Only A pplicable to the 5000 Series) Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Remove the Left Hand T rim - Refe r to Page 8-22 . 2. Op[...]

Removal and Installa tion 8-116 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 4. Remove the Pl aten starting from the left side.[...]

Removal and Installa tion 8-117 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Center Plat en Assembly Removal W ARNING Switch off the Pri nter and remove the Power Cord . NOTE Refer to the table on Page 8-4 for information on screw types. 1. Open the T op Cover . NOTE Make sure the Carriage is not in the print Platen ar ea. NOTE Make [...]

Removal and Installa tion 8-118 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 3. Remove the c omplete Cent er Platen Assembly (includes the Overdrive Assembly and the Cutter guide). NOTE Y ou must perform th e following Calibrations when the C enter Platen Assemb ly is r eplaced:  Scan Axis Calibration  P age 5-7 .  Carr[...]

Removal and Installa tion 8-119 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Deflectors (Only Applica ble 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 ( Ty p e M ) screw fr o m each Defl ector .  4 Deflectors in the 60" Mod[...]

Removal and Installa tion 8-120 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual Heater A ssembly (Only Applicable to the 5500 Series) Removal W ARNING Switch off the Pri nter 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 t[...]

Removal and Installa tion 8-121 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 5. Remove 15 screws that secure the Heater from the top of the Printer . NOTE The 42" Printer only has 1 1 screws securing the Heater from the top. NOTE Be very car eful not to forc e the screws as th ey are scr ewed directly to the Print er Chassis. 6.[...]

Removal and Installa tion 8-122 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual 8. Before removing the Heather completely , pull out the Heate r Cable from the access ho le in the s ideplat e. 9. Remove the Hea ter from the Prin ter .[...]

Removal and Installa tion 8-123 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Installing the Heater T o install the Heate r , follow t he removal pro c edures in rever se order , taking care of the following information: 1. When install ing the Heater , place the top lip of the Heater over the Center Platen Assembly and then push the [...]

Removal and Installa tion 8-124 HP Desig nJet 500 0 and 5500 Serie s Printer s Service Manual T ube Gu id e Door The T ube Guide Door kit contains 2 dif ferent types of springs which need to be installed depending on the design of the T ube Guide. Refer to the drawing below to determine which spring needs to be installed. ,IWKH7XEH*XLGH[...]

9-1 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Pr eventive Maintenance 9 Introdu ction 9- 2 Service Prev entive Maintenan ce 9-2 W arning/S top T r iggers 9-3 User Maintenance 9-5 Lens Main tenance 9-5 Carriage Interconnect W iper 9-6 Rolle r Lub rifi catio n Kit 9 -7 Slide r Ro ds Lubr ification Kit 9-8 Cleaning the Platen 9-9 Noi[...]

Preventive Ma intenance 9-2 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Intr oduction This chapter explains how to perform service preventive maintenance procedure s when they are required, and routine maintenance procedures that are r ecommended when Service Engineers perform Removal and Installation procedures. Service Pr e vent[...]

Preventive Maintenance 9-3 HP DesignJ et 5000 and 5500 S eries Pr inters Ser vice Manual W arning/S top T riggers NOTE If the Ink T ubes System needs to b e replaced , this can be perform ed by th e User . The Printer will advise the User when the Scan- Axis System and/or T ube s need to be replaced by displaying a W arning message. The W arning me[...]

Preventive Ma intenance 9-4 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual If the Ink T ubes reach 7 million cycles, they ris k breakage. The Printer is stopped and the following message is displayed: "Ink T ube M aintenanc e Req uir ed Now" If the Ink T ubes are not replaced, the following message is displayed ea ch time a[...]

Preventive Maintenance 9-5 HP DesignJ et 5000 and 5500 S eries Pr inters Ser vice Manual User Maintenance W arranty S tatement HP’ s li mited warranty covers onl y those defects which ari se as a result of appr opriate use of t he pro duct, and does not apply t o any: a. Improper or inadequate ma intenance or modi fication; b. Software, interfaci[...]

Preventive Ma intenance 9-6 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Carriage Inter connect Wiper NOTE The Ca rriage Interconnect Wiper also comes wit h the Carriage. T o clea n the Printheads and Printhead connects select Replace Printheads in the Printhead menu to remove the Printhe ads from the Carriage Assembly: 1 Insert th[...]

Preventive Maintenance 9-7 HP DesignJ et 5000 and 5500 S eries Pr inters Ser vice Manual Roller Lubri fication Kit W ARNING This pr ocedur e is for Service Engineers only . Users should perform th e procedure describe d in the User ’s Guide. W ARNING Pr event water or other liquids from running onto electrical components or circuits, or th r ough[...]

Preventive Ma intenance 9-8 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Slider Rod s Lubrification Ki t In addition to the wea ring of the S can-Axis Motor , the friction in this area can inc rease due to the accumula tion of ink partic les and dust from the media or the atmosphere in the vicinity of the Slider Rods. Scan-Axis mai[...]

Preventive Maintenance 9-9 HP DesignJ et 5000 and 5500 S eries Pr inters Ser vice Manual Cleaning the Platen W ARNING This pr ocedur e is for Service Engineers only . Users should perform th e procedure describe d in the User ’s Guide. W ARNING Pr event water or other liquids from running onto electrical components or circuits, or th r ough ope n[...]

Preventive Ma intenance 9-10 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Moistur e on the Printer Users should use the Printer in an environment between 20% and 80% relative humidity . T o recover from moisture condensa tion, turn the Printer Off, and, using the main Roller as a reference, wait until the Printer is complete ly dry[...]

Preventive Maintenance 9-11 HP DesignJ et 5000 and 5500 S eries Pr inters Ser vice Manual Firmwar e Upgrade This section explains how to perform the System Software (Firmware) Upgrade and the Interna l Demo Prints Upgrade (Only for the PostScr ipt Print er) when they ar e required. There are 3 ways of upgrading the System Software: 1 Downloading th[...]

Preventive Ma intenance 9-12 HP Design Jet 5000 and 5500 S eries Pri nters Service Man ual Upgrade Instructi ons - 5000 Series ONL Y 5500 SERIES ONL Y UPGRADE INSTRUCTIONS FOR THE 5500 SERIES CAN BE FOUND IN THE USER’S GUIDE W ARNING The Firmware Up grade pr ocess will delete all p ending print jobs. NOTE Ensure that the Printer is powered ON and[...]

10-1 HP DesignJet 5000 and 550 0 Series Printers Service Manual Functional Overview 10 Introdu ction, pag e 10-2 Electri cal System, page 10-2 Front Panel, page 10-3 Scan Axis, page 1 0-3 Paper Axis, pa ge 10-4 Ink Delivery System (IDS), page 10-5 Ink S uppl y Statio n (I SS ), p age 10 -6 T ubes System, page 10 -6 Printheads, pag e 10-7 Air Pressu[...]

Functional Overview 10-2 HP DesignJet 5000 Series Printers Service Manual Intr oduction This Chapter contains a simplified description of the HP DesignJet 5000 and 5500 Series Printers. Electric al System The electrical system of the Printer c onsists of six major blocks and their associa ted cabling:  Power Supply Unit: Connected to the mai ns [...]

Functional Overview 10-3 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual Front Panel The Front Panel is used to displa y 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 a t the same time. The display has an LED backlight t[...]

Functional Overview 10-4 HP DesignJet 5000 Series Printers Service Manual Paper Axis The Paper Axis determines the motion of the media through the printer . Its main parts are:  Paper-Axis Mot or - provides traction to the Overdrive.  Center Platen and Overdrive - c ontrols the printing path and expansion of the media.  Pinch-wheels and Le[...]

Functional Overview 10-5 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual Ink Delivery System (IDS) The Ink Delivery System (IDS) delivers ink under pressure from the lar ge capacity off-axis Ink Cart ridges via permanently c onnected tubes to the high throughput Printheads. The IDS consists of six major subsystems:  The Ink Cartrid[...]

Functional Overview 10-6 HP DesignJet 5000 Series Printers Service Manual Ink Supply S tation (ISS) In the Printer , the Ink Ca rtridges re side inside the Ink Sup ply Station (ISS). This module is situated on the left side of the machine. The ISS includes the plastic housing that surrounds t he supplies, the latch mechanism, and the fluid and elec[...]

Functional Overview 10-7 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual The T ubes move back and forth inside the volume defined by the T ube Guides. The T ube Guides are a pair of sheet metal pa rts with opposing U-shaped profiles. The T ubes are threaded inside a protec tive extrusion called the T ube Carrier which consists of a ba[...]

Functional Overview 10-8 HP DesignJet 5000 Series Printers Service Manual Air Pr essurization Sys tem (APS) The APS is the system that provide s and controls t he pressurization of the ink in the Ink Cartridges and is located under the ISS. The ke y purpose of this system is to ensure the minimum required ink pressure at the inlet to e ach Printhea[...]

Functional Overview 10-9 HP Design Jet 500 0 and 5500 Series Pri nters Serv ice Manual Service S tation The Service Station consists of a linear motion mechanism with a chassis containing one PrintHead Cleane r (PHC) for eac h printhead. Attached to the Service Station chassis, one optical drop detector provides nozzle ch eck functionality . Print [...]

Functional Overview 10-10 HP DesignJet 5000 Series Printers Service Manual[...]

About this Ed ition This is the 2nd edition of this Service Manual 1st edition, titled HP Desig nJet 500 0 and 50 00PS Se rvice Manual - August 2000 2nd edition, titled HP Desig nJet 500 0 and 5000 PS Servi ce Manual - January 200 1 3rd edition, titled HP Desig nJet 500 0 and 55 00 Seri es Servic e Manual - Se ptember 20 02[...]

1 What’ s in this Service Manual This manual contains information necessary to test, calibrate and serv ice: - HP De signJet 5000 P rinter - 42” Model ( P/N C609 0A/V) - HP De signJet 5000 P rinter - 60” Model ( P/N C609 5A/V) - HP DesignJet 5000PS Printer - 42” Model (P/N C6091A /V) - HP DesignJet 5000PS Printer - 60” Model (P/N C6096A /[...]