HP DESIGNJET 5000 manual

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

T echnical Marketing, Barcelona Div ision , 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 Comp an y 2002 This do cument con tains propri etary i nform ation that i s protected by copyr ight. All rights are re serv 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 5 500 S eries Pr inters Ser vice Manual Using this Manual Purpose This Service Manual contains information necessary to test, calibra te and service:  HP DesignJet 5000 Printer - 42” Model (P/N C6090A/V)  HP DesignJet 5000 Printer - 60” Model (P/N C6095A/V)  HP DesignJet 5000PS Printer - 42” Model (P/N C6091A[...]

Table of Cont ents 3 HP DesignJet 5000 and 550 0 Series P rinters Servi ce 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 Functio[...]

Table of Co nten t s 4 HP DesignJ et 5000 and 5 500 S eries Pr inters Ser vice Manual[...]

1-1 HP DesignJ et 5000 and 5500 Series Printers Service Manual T r oubleshooting 1 Introdu ction 1-2 Phone Supp ort 1-2 Which Fi rmware V ersion Rela tes to Whi ch Ink Sy stem 1-2 T roublesho oting Sy stem Error C odes 1-2 Performing a Se rvice T est on a Failed Assembly 1-3 Performing the Necessary Servi ce Calibrations 1-3 T roublesho oting C ali[...]

Troubleshooting 1-2 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Guide to T r oubleshooting 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 Customer [...]

Troubleshooting 1-3 HP DesignJ et 5000 and 5500 Series Printers Service Manual Performing a Se rvice T est on a Failed Assembly If possible, always perform a Service T est on the component/ assembly that you are about to replace, just to make sure that is the component/assembly that has failed. NOTE If the test on that component/assembly passes, yo[...]

Troubleshooting 1-4 HP Design Jet 5000 and 5500 Seri es Printers Service Manual T roubl eshooting I nk Supplies Er ro r Codes Chapter 3, HP Ink Supplies T r oubleshooti ng , contains a list 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 c[...]

Troubleshooting 1-5 HP DesignJ et 5000 and 5500 Series Printers Service Manual The Print er does not Power ON 1. Check that the Power Cord is conne cted co rrectly 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 chec[...]

Troubleshooting 1-6 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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 fi[...]

Troubleshooting 1-7 HP DesignJ et 5000 and 5500 Series Printers Service Manual T roubl eshooting Shut downs - User Mess age "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 by [...]

Troubleshooting 1-8 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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, s o before burn ing the motor or the Main PCA, this warni ng appears. The common reason fo[...]

Troubleshooting 1-9 HP DesignJ et 5000 and 5500 Series Printers Service Manual NOTE Also, after re placing the Scan -Axis Motor , perform the Scan-Axis T est (  Page 4-10  and check that the v alues are within the given limits.  If the Print er st ill fail s, re place the Mai n PCA  Page 8- 81 . Check Printhead Path (2) This is[...]

Troubleshooting 1-10 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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 verify if there really is a problem with V acuum, try the following: 1. W ith t he Printer ON, open the W indow of the [...]

Troubleshooting 1-11 HP DesignJ et 5000 and 5500 Series Printers Service 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 th[...]

Troubleshooting 1-12 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Banding at variable extr em e envir onmental condi tions 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 to[...]

Troubleshooting 1-13 HP DesignJ et 5000 and 5500 Series Printers Service 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 that requi re Magenta. T o solve the problem, try the following:  Reduce the level of humidity (<65%) that the[...]

Troubleshooting 1-14 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Loss of G loss on HP Phot o Imag ing Gloss when us ing 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 decreases. If the printed media is rolled onto a T ake-Up Reel or is c[...]

Troubleshooting 1-15 HP DesignJ et 5000 and 5500 Series Printers Service 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 th[...]

Troubleshooting 1-16 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Drying T ime T oo Long for HP S t udio 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 Ree l and Bin. T o solve the problem try the following: [...]

Troubleshooting 1-17 HP DesignJ et 5000 and 5500 Series Printers Service 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 i nitialization, the media sensor is defective. T o solve this, try the following:  Check that the media sensor cable is connected cor rectl[...]

Troubleshooting 1-18 HP Design Jet 5000 and 5500 Seri es Printers Service Manual T railing Cable connect ion, so just reconnec t the T railin g Cable ag ain to dou ble-check th at the Prin ter now w orks. If, after recon necting the cable, the error appe ars again, either the Carriag e PCA or the T railing Ca ble is defec tive. In this case, first [...]

Troubleshooting 1-19 HP DesignJ et 5000 and 5500 Series Printers Service 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 th e middl[...]

Troubleshooting 1-20 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Carriage and Scan-Axis Pr oblems 1. Printhead continuity problem s. When installing the Ink T ubes System, it is possible tha t the crane (the part of the T ubes Syst em that is connected to the front of the Carriage) is not clipped proper ly . This ca n cause Printhea[...]

Troubleshooting 1-21 HP DesignJ et 5000 and 5500 Series Printers Service Manual Electr onics Pr ob lems 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 external RIP .  The customer should print [...]

Troubleshooting 1-22 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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 printin g is lon[...]

Troubleshooting 1-23 HP DesignJ et 5000 and 5500 Series Printers Service Manual 3. The dry time at the end of the print is longer . Normally the Printer uses the temperature a nd the humidi ty reading 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 readings is +/- 15[...]

Troubleshooting 1-24 HP Design Jet 5000 and 5500 Seri es Printers Service Manual T ypical Fai lur es After Exchanging th e Ink T ubes The following table contains typical failures that could appear after changing the Ink T ubes: Failur e Descript ion Solut ion After completing the initializ ation process, th e Front Panel displays: W A RNING Incorr[...]

Troubleshooting 1-25 HP DesignJ et 5000 and 5500 Series Printers Service Manual Solving Media-H andling Pr oblems NOTE HP Designjet Printer s minimum med ia size is A3 in p ortrait mode. The Front Pan el Keeps Indicating that Media Is Mi saligned or Incorrectly Position ed Roll med ia  The roll may be loaded the wrong way . The pa per should loa[...]

Troubleshooting 1-26 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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 0.[...]

Troubleshooting 1-27 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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 Lo[...]

Troubleshooting 1-28 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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 Test [...]

Troubleshooting 1-29 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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 enc[...]

Troubleshooting 1-30 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Queuing and Nes ting Menu 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 Series Printers Service 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 Only[...]

Troubleshooting 1-32 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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 J[...]

Troubleshooting 1-33 HP DesignJ et 5000 and 5500 Series Printers Service Manual Demos Menu Demos Samples Palette Menu Always Appear Only Appe ar in Full Menu Mode @ PostSc ript Onl y[...]

Troubleshooting 1-34 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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 Medi[...]

Troubleshooting 1-35 HP DesignJ et 5000 and 5500 Series Printers Service 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 Seri es Printers Service Manual 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 Series Printers Service Manual Servi ce Conf igurat ion Prin t The Service Configuration Print is a useful tool for troubleshooting the Printer . The Service Configuration Print contains the following information about the Printer:  General Configuration  Printhead Info.  Ink Cartridge Info.[...]

Troubleshooting 1-38 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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 to [...]

Troubleshooting 1-39 HP DesignJ et 5000 and 5500 Series Printers Service 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 you h[...]

Troubleshooting 1-40 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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. sam e area is printed in less prints > reduction of servicing at the beginning/end of the print). [...]

2-1 HP DesignJ et 5000 and 5 500 Series P rinters Service Manual System Err o r Codes 2 System Erro r Co des 2-3 Introdu ction 2-3 Continuab le and Non-Conti nuable Erro r Codes 2-4 System Erro r Gro ups 2-4 f ff f f ff f xxx xxxxx (General Fi rmware Erro r) 2-5 f ff f f ff f 02b 301b0 2-5 f ff f f ff f 01d cxxxx 2-6 f ff f f ff f 030 d0170 or f f [...]

System Error Codes 2-2 HP DesignJet 5000 and 5500 Series Printers Service Manual 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 -Continu able) 2-18 0B000A 2-18 0B000B 2-19 0B000C 2-19 0B000D 2-19 0B000E 2-19 0B000F (C ontinuable) (O nly appli cable to DesignJet 55 00 Serie s) 2-20 0C0[...]

System Error Codes 2-3 HP Desig nJet 5000 an d 5500 Ser ies Printer s Service Manual System Error Codes Introdu ction NOTE Before tr oubleshooting S ystem 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 th e firmwar e v[...]

System Error Codes 2-4 HP DesignJet 5000 and 5500 Series Printers Service Manual 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. W hen reporting the error , have the following information ready:[...]

System Error Codes 2-5 HP DesignJ et 5000 and 5 500 Series P rinters Service Manual System Error: ffff ffff xxxxxxxx (Gener al Firmware Error) Prob lem Desc ript ion: Al l ffff fff f e rr o rs ar e ge ne r al f i r m wa re er r or s . T h i s does not mean that the firmware has f ailed, but that the firmw are (as a piece o f software) has ex perien[...]

System Error Codes 2-6 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual System Error: ffff ffff 01dcxxxx Prob lem Desc ript ion: There is a problem with the I/O Card (happens during power-up). Corr ective Act ion: T ry the followin g:  Disconnect the Network Cable and check if the error still appears during power-up.  If the err or[...]

System Error Codes 2-7 HP DesignJ et 5000 and 5 500 Series P rinters Service Manual System Error: ffff ffff 03450097 Prob lem Desc ript ion: 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 displayed.[...]

System Error Codes 2-8 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual System Error: 010023 ( Non-C ontinuab le) Prob lem Desc ript ion: EEROM T est failure. Corr ective Act ion:  Replace t he Main PCA  Page 8- 81 . NOTE After replacin g the Main PC A, make sure you perform the Back up EEROM  Page 4-30 , making sure that [...]

System Error Codes 2-9 HP DesignJ et 5000 and 5 500 Series P rinters Service Manual System Error: 010041 Prob lem Desc ript ion: Error in Scan-axis Encoder quadrature. Corr ective Act ion: T ry the followin g:  Check that the Encoder Strip is NOT broken or damaged.  Replace the Encoder Strip  Page 8-34 .  Replace th e Carriage Assemb[...]

System Error Codes 2-10 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual System Error: 010090 ( Contin uable) Prob lem Desc ript ion: Error in Paper-axis Motor Encoder Corr ective Act ion: T ry the followin g:  Check that the Paper-Axis Motor cable is NOT broken or damaged.  Check that the Paper-Axis Motor cable is correctly connec[...]

System Error Codes 2-11 HP DesignJ et 5000 and 5 500 Series P rinters Service Manual System Error: 040000 01E603D9 Prob lem Desc ript ion: 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 Pri[...]

System Error Codes 2-12 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual System Error: 06030C Prob lem Desc ript ion: Bad Line Sensor . Corr ective Act ion: T ry the followin g:  Replace the Line Sensor  Page 8-53 .  Replace th e Carriage Assembly  Page 8-46 .  Replace t he T railing Cabl e  P age 8-36 .  Re[...]

System Error Codes 2-13 HP DesignJ et 5000 and 5 500 Series P rinters Service Manual System Error: 0A0000 Prob lem Desc ript ion: APS Failure. Corr ective Act ion: T ry 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 su[...]

System Error Codes 2-14 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual System Error: 0A0030 Prob lem Desc ript ion: Problem in Depressuriz ing Air System. Corr ective Act ion: T ry 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 will[...]

System Error Codes 2-15 HP DesignJ et 5000 and 5 500 Series P rinters Service Manual System Error: 0A0050 (Non-Continuable) Prob lem Desc ript ion: The Printer has detected a lea k in the T ubes Sys tem - Should ONL Y appear in printers with the Ink Leak Detector installed. Corr ective Act ion: T ry the followin g:  Check for ink in the Ink Leak[...]

System Error Codes 2-16 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual System Error: 0B0001 Prob lem Desc ript ion: Bad Humidity Read Corr ective Act ion: T ry the followin g:  Replace t he ISS PCA  Page 8-91   Replace t he Main PCA  Page 8- 81 . W ARNING Only replace one component at a time and check if the err or[...]

System Error Codes 2-17 HP DesignJ et 5000 and 5 500 Series P rinters Service Manual System Error: 0B0004 Prob lem Desc ript ion: APS Failure. Corr ective Act ion: T ry 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 5000 and 5500 Ser ies Printers Service Manual System Error: 0B000X Prob lem Desc ript ion: Unable to detect Fa n (X = 7 - V acuum, 8 - Cooling, 9 - Aerosol). Corr ective Act ion: T ry the followin g:  Make sure that the Fan is connected correc tly to the Main PCA.  T urn the Printer OFF and disconnect the[...]

System Error Codes 2-19 HP DesignJ et 5000 and 5 500 Series P rinters Service Manual System Error: 0B000B Prob lem Desc ript ion: APS Failure. Corr ective Act ion: T ry 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 Sensor[...]

System Error Codes 2-20 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual System Error: 0B000F ( Cont inuabl e ) (Only applicable to DesignJet 5500 Series) Prob lem Desc ript ion: Unable to detect the Heat er - If this error appears, all settings rela ted to the heater will disappear from the front Panel. Corr ective Act ion: T ry the fol[...]

System Error Codes 2-21 HP DesignJ et 5000 and 5 500 Series P rinters Service Manual System Error: 0C0032 ( Contin uable) Prob lem Desc ript ion: Drop Detector not calibrated or the calibration settings h ave been lost. Corr ective Act ion: T ry the followin g:  Perform the EEROM Backup from the HDD to the Main PCA (sel ect Main PC A repla ced).[...]

System Error Codes 2-22 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual System Error: 0C00FF Prob lem Desc ript ion: Print Mask could not be generate d. The mask genera tion 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 exter[...]

System Error Codes 2-23 HP DesignJ et 5000 and 5 500 Series P rinters Service Manual System Error: 0D0000 ( Contin uable) Prob lem Desc ript ion: No Media Profiles A vailable. Corr ective Act ion: Download a media profile for the ink type being used. System Error: 0D0000 033f019C Prob lem Desc ript ion: No Media Profiles A vailable. Corr ective Act[...]

System Error Codes 2-24 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual System Error: 0D0005 03180382 (Non-Continuable) Prob lem Desc ript ion: After cutting the media, the Printer ca nnot deactivate the Cutter . Corr ective Act ion: T ry the followin g:  Check the Cutter and the Carriage Assembly to make sure that they are in stalle[...]

System Error Codes 2-25 HP DesignJ et 5000 and 5 500 Series P rinters Service Manual System Error: 0F0200 01E603d2 Prob lem Desc ript ion: 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 Pri[...]

System Error Codes 2-26 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual System Error: e50000 Prob lem Desc ript ion: 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 ective Act ion: T ry the followin g:  Unplug the Printer , remove [...]

3-1 HP DesignJ et 5000 and 5500 Series Printers Service 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 Sup plies 3-3 Some General P recautions When Han dling HP Ink Sup plies 3- 4 Priming a Br[...]

HP Ink Supplies Troubleshooting 3-2 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual What ar e HP Ink Su pplies? For each of th e six colors used in th e Printer , the re are three s eparate components. The Printhead and the Printhead Cleaner are supplied together , the Ink Cartridge is supplied separately . All of these components are[...]

HP Ink Supplies Troubleshooting 3-3 HP DesignJ et 5000 and 5500 Series Printers Service 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 guid[...]

HP Ink Supplies Troubleshooting 3-4 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual  A void unnece ssary removal of the Ink Cartridges and Printheads.  When turning off the Printer always use the soft-power Off button on the Front Panel. The Printheads are then stored correctly which preve nts them from drying out.  The Ink C[...]

HP Ink Supplies Troubleshooting 3-5 HP DesignJ et 5000 and 5500 Series Printers Service 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 deli[...]

HP Ink Supplies Troubleshooting 3-6 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual The Fr ont 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 in[...]

HP Ink Supplies Troubleshooting 3-7 HP DesignJ et 5000 and 5500 Series Printers Service Manual Obtaini ng Ink Cartridge Information 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 Ink[...]

HP Ink Supplies Troubleshooting 3-8 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual 4. The front panel displays information on the selected Ink Cartridge. The information supplied is:  The make of the Ink Cartr idge ( No.81 for Dy e and No.83 for UV In k). Unkn ow n Ink Car trid ge m ay me a n the use of refilled Ink C a rtri dg es[...]

HP Ink Supplies Troubleshooting 3-9 HP DesignJ et 5000 and 5500 Series Printers Service Manual 3. Press n or p key until the front panel hi ghlights “Printhead info”. Press Enter to view the Printhe ads 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 key[...]

HP Ink Supplies Troubleshooting 3-10 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual S tatus Codes and Messages NOTE Most pr oblems w ith Ink Supp lies will be solved by the us er 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 Series Printers Service 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 a t[...]

HP Ink Supplies Troubleshooting 3-12 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Err or S tatus Mes sages 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 Series Printers Service Manual Printhead Err ors NOTE If you think your Printer is re questing you to replace your Printhe ads to o frequently yo u can c heck Pri nthead n ozzle s tatus by printing the Diagnostic Print  Refer to 6, Print Quality . NOTE Do not touch , wipe or att[...]

HP Ink Supplies Troubleshooting 3-14 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Printhea d Informatio n 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 Asse mbly . T ry the following (verify if the mes sage returns to OK after each one[...]

HP Ink Supplies Troubleshooting 3-15 HP DesignJ et 5000 and 5500 Series Printers Service 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 de grade the Printer will prompt the user to recover the Printhead [ (X X20)Recover ]. At this stage, the customer[...]

HP Ink Supplies Troubleshooting 3-16 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Ink Cartridge Err ors NOTE When r eplacing Ink Cartridges:  Use the Replace item in the In k Cartridg es menu . 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 Series Printers Service Manual S tatus Numbers Error Description Procedur e Ink Cartridge Information XX0 3 Re pla ce The Ink Cartr idge has a leak which prevents the ink pumpin g to the Printer . W ARNING: If the Ink Bag in the Ink Cartridge is leaking, the T ubes m ay be dama ged . [...]

HP Ink Supplies Troubleshooting 3-18 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Printhead Cleaner Err ors (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 Cleaner i s the correct colo r for that slot.  Ensure that the Pr[...]

HP Ink Supplies Troubleshooting 3-19 HP DesignJ et 5000 and 5500 Series Printers Service 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 interco[...]

HP Ink Supplies Troubleshooting 3-20 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Risks with the Ink Cartridg e Delivering T oo Much Ink  Meeting Point Refills: If the cust omer refills withi n the ink meeting point zone, then the ink cartridge will operate “normally .” If the customer refil ls after the meeting point, then [...]

HP Ink Supplies Troubleshooting 3-21 HP DesignJ et 5000 and 5500 Series Printers Service Manual Non-HP Hard war e Detec ted in th e Ink De livery S ystem The following information explains the front panel message flow: Error Message XX08 Unknown Description Use genuine HP components f or excellent image quality f rom your printer . If you choose to[...]

HP Ink Supplies Troubleshooting 3-22 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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 Series Printers Service Manual ILS Out of Contr ol W arranty S tatement  Printhead and cl eaner warra nty: Un til t he “end of warra nty” date printed on the product is reached, or 700 cc of HP ink is delivered through the printhead, whichever occu rs first.  Ink Cartridge w[...]

HP Ink Supplies Troubleshooting 3-24 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual[...]

4-1 HP DesignJ et 5000 and 5500 Series Printers Service Manual Service T ests and Utilities 4 Introdu ction 4-2 Diagnostics - Self T est 4-2 The Printer hangs and no thing else hap pens 4-3 Error Memory Co nfig :X 4-3 Error Memory T est 4-3 Powe r S upply Error #1 4-3 BootROM chec ksum failed 4-3 Boot Fail ed:1f500XX 4-4 Boot F AILED 4-4 BOOTROM E [...]

Service Tests and Utilities 4-2 HP Design Jet 5000 and 5500 Ser ies Printers Service 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 sur[...]

Service Tests and Utilities 4-3 HP DesignJ et 5000 and 5500 Series Printers Service Manual W ARNING Only replace one component at a time and check if 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 anot[...]

Service Tests and Utilities 4-4 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual Spin ning up d is k Boot Fai led:1f 500XX 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 th at t he t wo ca b[...]

Service Tests and Utilities 4-5 HP DesignJ et 5000 and 5500 Series Printers Service Manual Service T ests (Diagnostics) The following is a list of all interna l Service T ests available in the Printer . Instructions for enter ing the Service T e sts menu are given on Page 4-6 . 1. Scan Axis T est  Page 4-9 The purpose of this Service T est is to[...]

Service Tests and Utilities 4-6 HP Design Jet 5000 and 5500 Ser ies Printers Service 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 access ing the complet e list of Service T ests a O[...]

Service Tests and Utilities 4-7 HP DesignJ et 5000 and 5500 Series Printers Service 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 disp[...]

Service Tests and Utilities 4-8 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual If your Firmware does not support Service T ests, the following message is displayed. Y ou should press Enter to exit. If you need the Service T ests, download the la test Firmware and repeat the whole procedure to enter the Ser vice T e sts menu. NOTE If th[...]

Service Tests and Utilities 4-9 HP DesignJ et 5000 and 5500 Series Printers Service 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 moving[...]

Service Tests and Utilities 4-10 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual NOTE Report the values to the nearest HP Response Center or HP Suppor t Office to determ ine 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 Series Printers Service 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 Axis [...]

Service Tests and Utilities 4-12 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual NOTE Report the values to the nearest HP Response Center or HP Suppor t Office to determ ine 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 Series Printers Service 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 are given on Page 4-14 . 1. T urn DRIVE ROLLER  Page 4-17 The purpose of this S ervice Uti[...]

Service Tests and Utilities 4-14 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual Entering the Ser vice Utili ties 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 access ing the complet e list of Service Uti l[...]

Service Tests and Utilities 4-15 HP DesignJ et 5000 and 5500 Series Printers Service 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 is[...]

Service Tests and Utilities 4-16 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual NOTE If the Prin ter is not used for 3 minutes, the Print er exits the Service Utilitie s Menu and you mu st repe at the above steps to enter Service Utilities again. NOTE In some cases a quick pr ess of a button may not be r ecognized by the Prin ter . Whe[...]

Service Tests and Utilities 4-17 HP DesignJ et 5000 and 5500 Series Printers Service Manual T urn DRIVE ROLLER The purpose of this Servi ce Utility is to rota te 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. Perform t[...]

Service Tests and Utilities 4-18 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual Prime TUBES The purpose of this Servi ce Utility is to prime th e 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 e[...]

Service Tests and Utilities 4-19 HP DesignJ et 5000 and 5500 Series Printers Service 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 indow and remove ALL the Printheads from the Carriage. Inst all the Setup Printhea ds into t[...]

Service Tests and Utilities 4-20 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual 8. The Printer will then begin to prime the T ubes Syste m. 9. Once the T ubes System is pur ged, the following message will be displayed. Lift the W i ndow and remove ALL the Setup Printheads from the Carriage and i nstall the previou sly removed printing [...]

Service Tests and Utilities 4-21 HP DesignJ et 5000 and 5500 Series Printers Service 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 Printhead Ali gnment Pattern and the following message will be displayed on the front panel: 14. [...]

Service Tests and Utilities 4-22 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual Altitude Setu p This Service Utility allows the opera ting altitude to be se t for the Printer for particular opera ti ng conditions when media loa d problems occur . NOTE This utility is r equir ed exclusi vel y for Printer operating altitudes over 2000 m.[...]

Service Tests and Utilities 4-23 HP DesignJ et 5000 and 5500 Series Printers Service Manual EEROM Setup NOTE This test is only necessary in a situation wher e you have NOT been able to p erform the EEROM backup test and you have lost all the EEROM parame ters. The purpose of this Servi ce Utility is to s et the Pri nter Model, t he Serial Number an[...]

Service Tests and Utilities 4-24 HP Design Jet 5000 and 5500 Ser ies Printers Service 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 and[...]

Service Tests and Utilities 4-25 HP DesignJ et 5000 and 5500 Series Printers Service Manual If you want to set the Ser ial Number NOTE The Se rial Number in the Cur r ent fiel d is only di splayed if it is encoded in the EE ROM. a Select "1.4.2 Set Serial Number" and press the Enter key to view the message below . T o define a new serial [...]

Service Tests and Utilities 4-26 HP Design Jet 5000 and 5500 Ser ies Printers Service 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 Utili ty is not ne cessary . NOTE If the Printer is NOT an HP DesignJet 5000PS or 5500PS, this utility is not avail able and the mess[...]

Service Tests and Utilities 4-27 HP DesignJ et 5000 and 5500 Series Printers Service 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 have se t t he defaul t font type to Japa nese[...]

Service Tests and Utilities 4-28 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual Reset Life Counters The purpose of this Servi ce Utili ty is to reset the pre ventive 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 warning[...]

Service Tests and Utilities 4-29 HP DesignJ et 5000 and 5500 Series Printers Service Manual The front panel message displays the following information:  Color (Printhead Insertions only); the Printhead color for which the counter is being reset.  Limit; the number of c ycles when the part re quires replacing.  Current; the current number o[...]

Service Tests and Utilities 4-30 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual Backup EEROM This Service Utility is used to restore the contents of the EEROM 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 Main PC[...]

Service Tests and Utilities 4-31 HP DesignJ et 5000 and 5500 Series Printers Service Manual 3. If you select "Main PCA" a message confirming the selection is displayed. Press Ente r to confirm and e xit this utility or pre ss Back to cance l. 4. If you select "Hard Disk Drive (HDD )" a message confirming selection is displayed. [...]

Service Tests and Utilities 4-32 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual Image Qu ality 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 pa nel will display a warning: Y ou can [...]

Service Tests and Utilities 4-33 HP DesignJ et 5000 and 5500 Series Printers Service 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" and[...]

Service Tests and Utilities 4-34 HP Design Jet 5000 and 5500 Ser ies Printers Service Manual Sleep Mode (DesignJ et 5500 Series Only) The purpose of this Servi ce Utility is to disable th e 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 "1[...]

5-1 HP DesignJ et 5000 and 5500 Series Printers Service Manual Service Calibrations 5 Servic e Calibrat ions 5-3 Entering the Serv ice Calib rations Me n u 5-4 1. Scan -Axis Calibrati on 5-7 2. Servic e Station Calibr ation 5 - 11 3. Accuracy Cali bration 5-14 Carriage Hei ght Calibra tion 5-18 Calibra tion Er ror Codes 5-26 User Calibrati ons 5-42[...]

Service Calibrations 5-2 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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 Series Printers Service Manual Service Calibrations The following is a list of all inte rnal Service Calibrat ions availabl e 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 Calibra[...]

Service Calibrations 5-4 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Entering the Ser vice Calibrati ons 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 access ing the complet e list of Service Cali bratio[...]

Service Calibrations 5-5 HP DesignJ et 5000 and 5500 Series Printers Service 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 disp[...]

Service Calibrations 5-6 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual NOTE If the Prin ter is not used for 3 minute s, the Print er exits out of the Servic e Calibrat ions Menu and you must r epeat the above steps to enter Service Calibrations again. NOTE In some cases a quick pr ess of a button may not be r ecognized by the Prin t[...]

Service Calibrations 5-7 HP DesignJ et 5000 and 5500 Series Printers Service 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 Plate n Assembly . This Calibration also allows you to calibrate the Li ne Sensor and define the Line Sensor ID. The Scan-Axis Calibrat[...]

Service Calibrations 5-8 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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 re turn[...]

Service Calibrations 5-9 HP DesignJ et 5000 and 5500 Series Printers Service 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 continu[...]

Service Calibrations 5-10 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual 7. The Printer then perform s the Printhead to media spac ing calibration and displays the following message: During this stage the Printer will pri nt the following patte rn. 8. On successfully completing the Calibration, the following message is displayed: 9. [...]

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

Service Calibrations 5-12 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual 2. If the correct media is loaded, the following message is displayed. Press Ente r to confirm or Back to re turn to t he Servic e Calibra tions menu. 3. Once the media is detected, the calibrat ion starts and the following message is displayed: During this stag[...]

Service Calibrations 5-13 HP DesignJ et 5000 and 5500 Series Printers Service 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 followin[...]

Service Calibrations 5-14 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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 control the exact movement of the media in order to avoid prin[...]

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

Service Calibrations 5-16 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual 6. The Printer will unload the media a nd request you to remove it from the Printer . Press Ente r 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 Series Printers Service 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 been performed, print the Service Confi gurati on print to be sure that [...]

Service Calibrations 5-18 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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 Series Printers Service Manual NOTE During the Carr iage Height Calibrat ion procedure the Carriage Assembly has to be moved along the length of t he Printer f or corr ec t calib ration . Make sur e tha t the Ca rriag e Assem bly is only ever moved by pulling the Be lt and never by dir ect conta[...]

Service Calibrations 5-20 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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 Series Printers Service 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 the [...]

Service Calibrations 5-22 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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 Series Printers Service Manual 11 . Raise the Carriage Assembly slightly , by turning the T9 screw (shown below) clockwise . 12. Check that there is no longer a scraping sound.[...]

Service Calibrations 5-24 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual 13. When the s craping has been elimina ted it is importa nt to leave th e Carria ge Assembly as close as possible to the Cent er Platen: move the Carriage Assembly back and forth a cross the area where the scraping sound was, gently lowe ring and raising the Ca[...]

Service Calibrations 5-25 HP DesignJ et 5000 and 5500 Series Printers Service 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 Series Print ers Serv ice Manual Calibration Err or Cod es Introdu ction NOTE Calibration Error Codes are continuable, wh ich means you can press Enter on the Front Panel to continue working with th e Printer . If you have a Print Quality pr oblem you must troublesh oot the error to restor e qu[...]

Service Calibrations 5-27 HP DesignJ et 5000 and 5500 Series Printers Service 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 ript ion: Pen voltage er ror . Corr ective Act ion: T ry the followin g:  Power the Printer OFF and ON again using the Power Switch [...]

Service Calibrations 5-28 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Calibrat ion Err or: 0020 Prob lem Desc ript ion: Line Sensor error . Corr ective Act ion: Check the me dia used for the Calibrat ion is WHITE.  Replace the Lens Cover Assembly  Page 9-5 . Calibrat ion Err or: 0021 Prob lem Desc ript ion: Line Sensor er[...]

Service Calibrations 5-29 HP DesignJ et 5000 and 5500 Series Printers Service Manual Calibrat ion Err or: 1002 (User) Prob lem Desc ript ion: The Line Sensor pattern is not printed. Firmware er ror . Corr ective Act ion: T ry the followin g:  Power the Printer OFF and ON (u sing the power switch at the back of the printer) to reset the memory . [...]

Service Calibrations 5-30 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Calibrat ion Err or: 1005 (User) Prob lem Desc ript ion: Pa per Axis Error . Corr ective Act ion: T ry 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 Series Printers Service Manual Calibrat ion Err or: 1042 (User) Prob lem Desc ript ion: Scan-Axis Alignment Error in "slow" speed se ction in Light C yan and Light Magenta Pattern. Corr ective Act ion: T ry the followin g:  Perform Printhead Recovery (  Page 6-15 ).  Perfor[...]

Service Calibrations 5-32 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Calibrat ion Err or: 2004 (User) Prob lem Desc ript ion: Media Profile Error . Corr ective Act ion: T ry the followin g:  Download a Media Profile for the current medium.  Power the P rinter OFF a nd ON from the rear of the P rinter .  Download a Firmwa[...]

Service Calibrations 5-33 HP DesignJ et 5000 and 5500 Series Printers Service Manual Calibrat ion Err or: 2101 (through to 2607) (User) Prob lem Desc ript ion: Firmware Er ror . Corr ective Act ion: T ry the followin g:  Repeat the Closed Loop Color calibration (  See the User ’ s Guide).  Download the latest Firmware  Page 9-13[...]

Service Calibrations 5-34 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Calibrat ion Err or: 3130 Prob lem Desc ript ion: Firmware Er ror . Corr ective Act ion: T ry 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 Series Printers Service Manual Calibrat ion Err or: 4003 (Service) Prob lem Desc ript ion: Line Detection Error . Corr ective Act ion: T ry the followin g:  Check that the Lens Cover is clean.  Replace the Lens Cover Assembly  Page 9-5 .  Download the Firmware  Page 9-13 . C[...]

Service Calibrations 5-36 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Calibrat ion Err or: 5002 (Service) Prob lem Desc ript ion: Black Printhead failure. Corr ective Act ion: T ry the followin g:  Perform Recovery for Black Printhead  Page 6-15 .  Replace t he Black Print head. Calibrat ion Err or: 5003 (Service) Prob le[...]

Service Calibrations 5-37 HP DesignJ et 5000 and 5500 Series Printers Service Manual Calibrat ion Err or: 5010 (Service) Prob lem Desc ript ion: T oo many Black Printhead nozzles not working. Corr ective Act ion: T ry the followin g:  Recover the Black Printhead (  Page 6-15 ) and if the problem persists replace the Black Printhead. Calibr[...]

Service Calibrations 5-38 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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 ript ion: Drop Detector not working. Corr ective Act ion: T ry the followin g:  T urn the Printer OFF and ON [...]

Service Calibrations 5-39 HP DesignJ et 5000 and 5500 Series Printers Service Manual Calibrat ion Err or: 6006 (Service) Prob lem Desc ript ion: Drop Detector f ailed to reach position for calibration. Corr ective Act ion: Refer to Error Code 6005. Calibrat ion Err or: 6007 (Service) Prob lem Desc ript ion: Drop Detector f ailed to uncap pens. Corr[...]

Service Calibrations 5-40 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Calibrat ion Err or: 6012 (Service) Prob lem Desc ript ion: Calibration failed for Lig ht Cyan Printhead. Corr ective Act ion:  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 Series Printers Service Manual Calibrat ion Err or: 6018 (Service) Prob lem Desc ript ion: Calibration position out of range for Light Cyan Printhead. Corr ective Act ion: Replace the Drop Detector A ssembly  Page 8-72 . Calibrat ion Err or: 6019 (Service) Prob lem Desc ript ion: Calibrati[...]

Service Calibrations 5-42 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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 Series Printers Service Manual Printhead Alignment The printer will normally perfor m an alignmen t automatical ly whenever any printhead is replace d. However , you can turn Of f t his automatic alignment by choosing the printe r icon , then Interna l RIP Setting > Align Calibration > Of [...]

Service Calibrations 5-44 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Banding Calib ration The banding calibra tion is intended t o eliminate the probl em 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 [...]

Service Calibrations 5-45 HP DesignJ et 5000 and 5500 Series Printers Service 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 xpl[...]

Service Calibrations 5-46 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual[...]

6-1 HP DesignJ et 5000 and 5500 Series Printers Service Manual Print Quality 6 Print Qu ality 6-2 Print Quali ty T roubl eshooting Ch ecklist 6-2 How to Use the D iagno stic Print 6-4 What is the Di a gnostic Print? 6 -4 Considerat ions for Printing the Diagnost ic Print . 6-4 Printin g the Diag nostic P rint 6-5 Overall Pri nt Quality T est - Page[...]

Print Qual ity 6-2 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al Print Quality Print Quality T r oubleshooting Checkl ist 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 s[...]

Print Qual ity 6-3 HP DesignJ et 5000 and 5500 Series Printers Service Manual 6 Driver print quality configuration: T o cla rify if the reason of the pr obl em is relate d with the print mode defined with the Non-HP Driver try the following:  Print the same sample using the Non-HP driver and their normal media.  Print one of the internal demo[...]

Print Qual ity 6-4 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al How to Use th e Diagnostic Print 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 specific[...]

Print Qual ity 6-5 HP DesignJ et 5000 and 5500 Series Printers Service 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 “ Utilities?[...]

Print Qual ity 6-6 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al 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 Series Printers Service Manual NOTE For Firmware V e rsion A.02.xx in the 5000 Series and on the 5500 Series, the Printer DOES NOT print the complete Diagnost ic 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 n[...]

Print Qual ity 6-8 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al Overal l Prin t Qualit y T est - Page 1 This test pattern checks for banding in the print mode and media that is being used. What is Band ing? 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 Series Printers Service Manual In the following exam ple, there is a prob lem in the Mag enta 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 y[...]

Print Qual ity 6-10 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al 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 instead. The bandi ng or grainin ess will appear i n all the colors. 1 If the image is grainy , this could also be a symptom [...]

Print Qual ity 6-11 HP DesignJ et 5000 and 5500 Series Printers Service 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 and[...]

Print Qual ity 6-12 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al 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 Printhe ad color except yellow . Ea ch s[...]

Print Qual ity 6-13 HP DesignJ et 5000 and 5500 Series Printers Service Manual V ertical Line S traightness - Page 4 If a Printer has V er tical Line S traightness 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 straightnes[...]

Print Qual ity 6-14 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al 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 r esults. T he Printer has automatic pr ocedur es t o hide ma ny nozzle defects. This type of p rob lem affects print quality mostly i[...]

Print Qual ity 6-15 HP DesignJ et 5000 and 5500 Series Printers Service Manual How to fix the Nozzle Defects NOTE The Prin ter will aut o matically request you to r ecover Printheads with a number of defective nozzles that may affect print quality , or repl ace them if the Printhead defect cannot be r ecovered. NOTE If your Printer has nozzle de fe[...]

Print Qual ity 6-16 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al No Printing Defects Fou nd in the Diagnostic Pri nt If all the test patterns from the Diagnostic Print are corre ct and you still experienc e print quality problems, he re 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 Series Printers Service 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 Col[...]

Print Qual ity 6-18 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al Color Accurac y Configurat ion The configurations of the Printer , the driver , and the software RIPs define how ink is applied to each type of media . Use the information in the following table to configure the Printer and software for best color accur acy. Blurr ed[...]

Print Qual ity 6-19 HP DesignJ et 5000 and 5500 Series Printers Service Manual length by severa l centimeters . Depending on the type of probl em, 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 ma[...]

Print Qual ity 6-20 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al 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 Banding Some prints[...]

Print Qual ity 6-21 HP DesignJ et 5000 and 5500 Series Printers Service 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 specificat ions (Refer to the User ’ s Guide)  2 St or [...]

Print Qual ity 6-22 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al Using the Color Print Objective an d Descripti on The objective of the Color Print is to determine whether the printer hardware has any color reproductio n problem s. Before starting, lo ad a roll of HP High- Gloss Photo Paper or HP Heavy weight Co ated Paper . T o s[...]

Print Qual ity 6-23 HP DesignJ et 5000 and 5500 Series Printers Service Manual Bear in mind that the transition could happen anywhere along the line. T rust your perception! How to In terpr et the Resu lt 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 than 4[...]

Print Qual ity 6-24 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al 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 Series Printers Service Manual See the f ollowing ima ge: 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 th e ink). 2 This ink is contained on the printhead n[...]

Print Qual ity 6-26 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al evaporates partially , which leaves the ink on the nozzle with more pigments. Therefore, the initial drops e jected from those nozz les will be darker (they have more pigment) than the following ones. This leads to the second issue ( darker border ). If we take the p[...]

Print Qual ity 6-27 HP DesignJ et 5000 and 5500 Series Printers Service Manual W orkaround s This image quality problem i s a product limitation. So, it has NO solution. Anyway , due to the limited cases wher e the problem could appear , large amounts of comp laints are not expected. If any customer complains about this problem, provide the followi[...]

Print Qual ity 6-28 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al Y ou will see that rep lacing any printer ’ s hardware 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 printout s is caused by two different iss ues each with a differe[...]

Print Qual ity 6-29 HP DesignJ et 5000 and 5500 Series Printers Service 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 occurrence t hat customers would see. Because of this occurre nce HP included cleaning and maintenance inst[...]

Print Qual ity 6-30 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al 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 Series Printers Service 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 of[...]

Print Qual ity 6-32 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al 2 Presence of ink smears or even drops on the printout. See the f ollowing image t o see an example. These marks are ca used due by the fact t hat the static charge of the media forces th e aerosol to accum ulate at the e dges of the printheads and at the bottom of t[...]

Print Qual ity 6-33 HP DesignJ et 5000 and 5500 Series Printers Service 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 image t o for an example. Ink accumulation at the botto m of the Car riage Assembly .[...]

Print Qual ity 6-34 HP Desig nJet 5000 an d 5500 Se ries Printer s Service Manu al S tatic: Solutions an d W orkarounds 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 P rinters Servi ce 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 St ation 7-12 V acuum Fan 7-14 Booster Fa n and Media S ensor 7-16 Paper -Axis Mot or 7-18 Scan-Axis Motor 7- 20 ISS and APS [...]

Parts and Diagrams 7-2 HP Design Jet 5000 and 5500 Series Printe rs Service Manual Printer Sup port Printer Support 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-B[...]

Parts and Diagrams 7-3 HP DesignJet 5000 and 550 0 Series P rinters Servi ce Manual Figure 3: Printer Support 1 4 1 2 2 3[...]

Parts and Diagrams 7-4 HP Design Jet 5000 and 5500 Series Printe rs Service Manual Bin and T ake -Up Ree l 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 Support) 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 P rinters Servi ce Manual Figure 4: Bin and T ake-Up Reel 1 8 3 4 5 6 7 9 2 Bin Su pport[...]

Parts and Diagrams 7-6 HP Design Jet 5000 and 5500 Series Printe rs Service Manual Right Hand Cover Right Hand Cover Reference on Drawing HP Part Number Quan tity Description/Comme nts 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 P rinters Servi ce 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 Printe rs Service Manual Left Hand Cover and Rear Door Left Hand Cover and Rear Door Reference on Drawing HP Part Number Quan tity Descriptio n/Comments DJ 5000 Series DJ 5500 Serie s 1 C6090-60039 1 Left Hand Cover (inclu des doo r) 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 P rinters Servi ce 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 Printe rs Service Manual T op and Back Covers T op and Back Covers Reference on Drawing HP Part Number Qu anti ty Desc ription/ Comm ents 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 T op[...]

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

Parts and Diagrams 7-12 HP Design Jet 5000 and 5500 Series Printe rs Service Manual Service S tation Servi ce S tat ion Ref er enc e on Drawing HP Part Number Quantity Descrip tion/Commen ts 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 Scre w 3 0515-1743 1 Scre w[...]

Parts and Diagrams 7-13 HP DesignJet 5000 and 550 0 Series P rinters Servi ce 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 Printe rs Service Manual V a c uum Fan V acuum Fan Reference on Drawing HP Part Nu mber Quantity Description/Comm ents DJ 5000 Series D J 5500 Seri es 1 C6090-60095 1 V acuum Fan 2 0515-2248 4 Screw[...]

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

Parts and Diagrams 7-16 HP Design Jet 5000 and 5500 Series Printe rs Service Manual Booster Fan and Media Sensor Booster Fan and Media Sensor Reference on Drawing HP Part Num ber Quantity De script ion/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 P rinters Servi ce Manual Figur e 10: Booster Fan and Media Sensor 2 3 1[...]

Parts and Diagrams 7-18 HP Design Jet 5000 and 5500 Series Printe rs Service Manual Paper -Axi s Motor Paper -Axis Motor Reference on Drawing HP Part Number Quant ity Descri ption/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 P rinters Servi ce Manual Figure 1 1: Paper -Axis Motor 2 3 1[...]

Parts and Diagrams 7-20 HP Design Jet 5000 and 5500 Series Printe rs Service Manual Scan-Axis Motor Scan-Axis Motor Reference on Drawing HP Part Numb er Quantity De scription/Comments 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 P rinters Servi ce Manual Figur e 12: Scan-Axis Motor 2 1[...]

Parts and Diagrams 7-22 HP Design Jet 5000 and 5500 Series Printe rs Service Manual ISS and APS Ass e m 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 P rinters Servi ce Manual Figure 13: ISS and APS Assembly 2 1[...]

Parts and Diagrams 7-24 HP Design Jet 5000 and 5500 Series Printe rs Service Manual Ink T ubes System Ink T ubes System Reference on Drawing HP Part Number Quant ity Desc ript ion/ Comme nts 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 ube[...]

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

Parts and Diagrams 7-26 HP Design Jet 5000 and 5500 Series Printe rs Service 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 Descript ion/Comm ents 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 0515-22[...]

Parts and Diagrams 7-27 HP DesignJet 5000 and 550 0 Series P rinters Servi ce 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 Printe rs Service Manual Rear Electr onics Access Covers Rear Electronics Access Covers Reference on Drawing HP Part Number Quant ity Descri ption/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 Rear Cover 4 0515-0382 1 Scre[...]

Parts and Diagrams 7-29 HP DesignJet 5000 and 550 0 Series P rinters Servi ce Manual Figur e 16: Rear Electronics Access Covers 1 2 3 4 6 5 7 8[...]

Parts and Diagrams 7-30 HP Design Jet 5000 and 5500 Series Print ers Serv ice Manual Hard Disk Drive and Cover Hard Disk Drive and Cover Reference on Drawing HP Par t Number Quan tity Description/Comme nts DJ 5000 Serie s DJ 5500 Series 1 C6 091-60255 - 1 Hard Disk Drive PS A.02.12 (includes data cable and pow er cable ) C6090-60303 - 1 Hard Disk D[...]

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

Parts and Diagrams 7-32 HP Design Jet 5000 and 5500 Series Printe rs Service Manual ISS PCA and Main PCA ISS PCA and Main PCA Reference on Drawing HP Par t Number Quan tity Descript ion/Comment s DJ 5000 Series DJ 5500 Series 1 C 6090-60012 Q1251-60030 1 Main PCA 2 0515-2200 1 1 Screw 3 C6090-60041 1 ISS PCA (Includes ISS PCA cable ) 4 0515-2200 5 [...]

Parts and Diagrams 7-33 HP DesignJet 5000 and 550 0 Series P rinters Servi ce 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 Printe rs Service Manual Power Supp ly Unit Power Suppl y Unit Reference on Drawing HP Part Number Quantity Descript ion/Comment s DJ 5000 Serie s DJ 5500 Series 1 C 6090-60028 C6090-60315 1 P ower Supply Unit 2 0515-2200 7 Screw 3 C6090-60029 2 Cooling Fans 4 0515-2278 4 Screw 5 C 6090-600[...]

Parts and Diagrams 7-35 HP DesignJet 5000 and 550 0 Series P rinters Servi ce 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 Printe rs Service Manual Carriage Assembly Carriage Assembly Ref er enc e on Drawing HP Part Num ber Quantity Description/Comm ents 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 P rinters Servi ce Manual Figur e 20: Carriage Assembly 5 3 2 1 4[...]

Parts and Diagrams 7-38 HP Design Jet 5000 and 5500 Series Printe rs Service Manual T ensioner Assembly and Enco de r S trip T ensio ner Assembl y and Enc oder S trip Reference on Drawing HP Part Number Quanti ty Descri ption/C omment s DJ 5000 Series DJ 5500 Series 1 C6090-60088 1 T ensioner Assembly (Includes Pulley Assembly , Pulley Spring, W ed[...]

Parts and Diagrams 7-39 HP DesignJet 5000 and 550 0 Series P rinters Servi ce 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 Printe rs Service Manual Platen Assemblies - DesignJet 5000 Series Platen Assemblies - DesignJet 5000 Series Reference on Drawing HP Part Numb er Quantity De scription/Comments 1 C6095-60174 1 Front Platen Assembly (including screws) (60" Model) C6090-60079 1 Front Platen Assembly (inc[...]

Parts and Diagrams 7-41 HP DesignJet 5000 and 550 0 Series P rinters Servi ce 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 Printe rs Service Manual Platen Assemblies - DesignJet 5500 Series Platen Assemblies - DesignJet 5500 Series Reference on Drawing HP Part Numb er Quantity De scription/Comments 1 Q1253-6001 1 1 Heater Assembly (including screws) (60" Model) Q1251-60031 1 Heater Assembly (including scre[...]

Parts and Diagrams 7-43 HP DesignJet 5000 and 550 0 Series P rinters Servi ce 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 Printe rs Service Manual Pinch-Whee ls Asse mbly and Lever Pinch-Wheels Assembly and L ever Reference on Drawing HP Part Number Quantity Description/ Comments DJ 5000 Series DJ 5500 Series 1 C6095-60181 1 Pinch Assembly (60" Model) C6090-60073 1 P inch Assembly (42" Model) 2 C6095[...]

Parts and Diagrams 7-45 HP DesignJet 5000 and 550 0 Series P rinters Servi ce 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 Printe rs Service 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 Quantity De scription/Comments 1 C 6095-60180 1 Center Guide (60" Model) C6090-60075 1 C[...]

Parts and Diagrams 7-47 HP DesignJet 5000 and 550 0 Series P rinters Servi ce 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 Printe rs Service 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 Quantity De scription/Comments 1 C 6095-60180 1 Center Guide (60" Model) C6090-60075 1 Center Guide (42" Model[...]

Parts and Diagrams 7-49 HP DesignJet 5000 and 550 0 Series P rinters Servi ce Manual Figure 26: C enter 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 Printe rs Service Manual T ubes Guide Assemblies T ubes Guide Assemblies Reference on Drawing HP Part Numb er Quant ity Descript ion/Comments DJ 5000 Serie s DJ 5500 Series 1 C6095-60176 1 Ba ck T ube Guide Assembly (60" Model) (Includes Saf ety Arm for T op Cover) C6095-60078 1 Back T[...]

Parts and Diagrams 7-51 HP DesignJet 5000 and 550 0 Series P rinters Servi ce 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 Printe rs Service Manual EMC Covers EMC Covers Reference on Drawing HP Part Num ber Qua nti ty Descri ption/ Comme nts 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 to[...]

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

Parts and Diagrams 7-54 HP Design Jet 5000 and 5500 Series Printe rs Service Manual Spindle and Hub Spindl e and Hu b Reference on Drawing HP Par t Number Quantity Descript ion/Comment s 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 C6090-601 12 2 3" Spi[...]

Parts and Diagrams 7-55 HP DesignJet 5000 and 550 0 Series P rinters Servi ce Manual Figur e 29: Spindle and Hub 1 3 2[...]

Parts and Diagrams 7-56 HP Design Jet 5000 and 5500 Series Printe rs Service Manual Rollfeed Brakes Rollfeed Brake s Reference on Drawing HP Par t Number Quantity Descript ion/Comment s 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 P rinters Servi ce 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 Printe rs Service Manual Miscellaneous Items Miscellaneous Items Reference on Drawing HP Part Number Quanti ty Descripti on/Comments DJ 5000 Series DJ 5500 Series - C6090-60081 Q1251-60073 1 Service Preventive Maintenance Kit (for both 42" and 60" Models) - C6090-60314 1 User Main[...]

Parts and Diagrams 7-59 HP DesignJet 5000 and 550 0 Series P rinters Servi ce Manual Media T ypes ' H 89[...]

Parts and Diagrams 7-60 HP Design Jet 5000 and 5500 Series Printe rs Service Manual[...]

8-1 HP DesignJ et 5000 and 5 500 Series Printe rs Service Manu al 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 e r 8-15 Right Re ar Cover 8-16 Extension C over (60" M odel only ) 8-17 Media Lever Assembly 8-1 8 Right Hand T rim 8-20 L[...]

Removal and Installa tion 8-2 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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 performed. Use the illustration at each pr ocedure to identify the par ts r[...]

Removal and Installa tion 8-3 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Electr ostatic Dis charge (ESD) Pr ecautions T o pr event damage to the Printer cir c uits fr om high-voltage electr ostatic 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 [...]

Removal and Installa tion 8-4 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Screw T ypes W ARNING Chassis screws have a copp er 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 y pe 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 0515-22[...]

Removal and Installa tion 8-5 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual T op Cover Assembly Removal W ARNING Sw itch off the Pr inter and remove th e power cabl e. 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 Series Print ers Serv ice Manual Left Hand Cover Removal W ARNING Sw itch off the Pr inter and remove th e power cabl e. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove ALL the Ink Cartridges from the Printer . 2. Open the T op Cover . 3. Open the door at the [...]

Removal and Installa tion 8-7 HP Design Jet 5000 and 5500 Series Printers Se rvice 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 rear 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 Series Print ers Serv ice Manual 7. Remove the Ink Cartridge T ube Connector and place safely on the window . 8. Remove 1 T -15 screw ( Ty p e F ) from the Left Hand Cover (rea r). 9. Close the Left Back door and remove 1 T - 25 screw ( Ty p e U ) from bottom side (rear) of Lef t Hand Cover[...]

Removal and Installa tion 8-9 HP Design Jet 5000 and 5500 Series Printers Se rvice 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 handlin g the T ubes make sure you do not damage them by twisting. W ARNING Whe n insert[...]

Removal and Installa tion 8-10 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Right Hand Cover Removal W ARNING Sw itch off the Pr inter and remove the Powe r 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 informati[...]

Removal and Installa tion 8-11 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual 4. Remove 1 T -15 screw ( Ty p e F ) and 1 T -25 screw ( 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 Series Print ers Serv ice Manual NOTE T ake car e n ot to dr op the Cover when removing the screws. Su pport the Cover thr oughout the next ste p. 7. Remove 3 T -15 ( Ty p e F ) scre ws from the front of the Right Hand Cover . 8. T o release the c ables, car efully pull out the Right Hand [...]

Removal and Installa tion 8-13 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual TIP T o check cor r ect fun ctioning of serviced parts on the Printer axis you can do the following: a Reinsert the top T -15 screw ( Ty p e F ) at the rear of the Pri nter . 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 Series Print ers Serv ice Manual Fr ont Pane l Assembly Removal W ARNING Sw itch off the Pr inter and remove the Powe r 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[...]

Removal and Installa tion 8-15 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Left Rear Cover Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove one T -15 screw ( Ty p e B ) from the Left Rear Cover . NOTE Support the Cover as it is r elea[...]

Removal and Installa tion 8-16 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Right Rear Cover Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove one T -15 screw ( Ty p e B ) from the Right Rear Cover . NOTE Support the Cover as it is r [...]

Removal and Installa tion 8-17 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Extension Cove r (60" Model only) Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove the Left Rear Cover - Refe r to Page 8-15 . 2. Remove 4 T -15 sc rews ([...]

Removal and Installa tion 8-18 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Media Lever Assembly Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Only applicabl e to the DesignJet 5000 Series - Remove the Deflector closest to the Right Cove[...]

Removal and Installa tion 8-19 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual 5. Remove 1 T -15 screw ( 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 , y ou mus t in sert it in the T rim and Sideplate in the UP positi[...]

Removal and Installa tion 8-20 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Right Hand T rim Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w 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 Series Printers Se rvice Manual 6. Carefully remove the Right Hand Tr i m . Installation of R ight Hand T rim W ARNING When installing the M edia Lever 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 Series Print ers Serv ice Manual Left Hand T rim Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove 4 T -15 screws ( Ty p e F ) and 1 T -20 screw ( Ty p e L ) from t he Le ft Hand T rim. 2. Ca[...]

Removal and Installa tion 8-23 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Back Cover Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove the T op Cover - Refer to Page 8-5 . 2. Remove the following ( Ty p e B ) screws from the upper par[...]

Removal and Installa tion 8-24 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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 app lied, co py the product number and s erial [...]

Removal and Installa tion 8-25 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Ink T ubes System Removal W ARNING Sw itch off the Pr inter and remove the Powe r 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 Series Print ers Serv ice 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 Series Printers Se rvice Manual 7. Push the button to rele ase the Printhea d T ubes 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 Series Print ers Serv ice 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 Series Printers Se rvice 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 rear 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 Series Print ers Serv ice 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 the Ink T ubes System it is very important that the T ubes are NOT TWI[...]

Removal and Installa tion 8-31 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual NOTE When the Ink T ubes System is r eplace d, to rest art the Pri nter perform the following procedur es. 1. Install the S etup Printheads (refer 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 Series Print ers Serv ice Manual EMC Covers Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. NOTE The EMC Cover is composed of th ree parts; T op, Lower Lef t and Lower Right. Procedures below describ[...]

Removal and Installa tion 8-33 HP Design Jet 5000 and 5500 Series Printers Se rvice 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 screws ( Ty p e L ) on Lower Covers and remove all Covers as one assembly . Lower Rig[...]

Removal and Installa tion 8-34 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Encoder S trip Removal W ARNING Sw itch off the Pr inter and remove the Powe r 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 [...]

Removal and Installa tion 8-35 HP Design Jet 5000 and 5500 Series Printers Se rvice 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 Insta lling the E ncoder S trip, make sur e it is placed in the Encoder Sensor on the rear of the Ca[...]

Removal and Installa tion 8-36 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual T railing Cable Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w 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 Series Printers Se rvice 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 fall int o the Carriage  3 for 60" Model  1 for 42" Model 8. Remove the T railing Cables from the T railing[...]

Removal and Installa tion 8-38 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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 Series Printers Se rvice Manual 13. Carefully lift the Cli ps and the T raili ng Cable from the Printer . Installation of T railing Ca ble W ARNING Do not install damag ed T railing Cables. If the T railing Cab le is incorr ectl y 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 Series Print ers Serv ice 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 Series Printers Se rvice Manual TIP Make sur e the T railing Cable is flat on the chassis without bubble s. NOTE Check the cable and c lips are corr ectly in stalled by s liding the carriage along the Printer to see if it moves freely . 5. Connect the T railing C ables to the Main PCA. NOTE[...]

Removal and Installa tion 8-42 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual T ensioner Assembly Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w 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 Series Printers Se rvice 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 of f the Scan-Axis Motor . 7. Remove 1 T -15 screw ( Ty p e L ) from the T ensioner Assembly . Ti ghten[...]

Removal and Installa tion 8-44 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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 Series Printers Se rvice Manual Installat ion of T ensioner As sembly NOTE Before install ation, clean and oil the Slider Rods using the User’s Slider Rods Lu brificatio n Kit (Refer to Page 9-8 ). W ARNING Be car eful not to twist the Belt when installing the T ensioner Assembly . W ARNI[...]

Removal and Installa tion 8-46 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Carriage Assembly and Be lt Removal W ARNING Sw itch off the Pr inter and remove th e power cord . 1. Remove the Left Hand Cover - Refer to Page 8-6 . 2. Remove the Right Rear Cover - Refer to Page 8-16 . 3. Remove the Right Hand Cover - Refer to Page 8-10 [...]

Removal and Installa tion 8-47 HP Design Jet 5000 and 5500 Series Printers Se rvice 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 Series Print ers Serv ice Manual 10. Pull the Printhead T ube Connector towards you. 11 . Push the button to release the Printhea d T ubes in the Carriage. 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 Series Printers Se rvice 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 Series Print ers Serv ice 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 fall int o the Carriage  3 for 60" Model.  1 for 42" Model. 17. Remove the T railing Cables from the T r[...]

Removal and Installa tion 8-51 HP Design Jet 5000 and 5500 Series Printers Se rvice 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 Series Print ers Serv ice Manual Installati on of Carriage a nd Belt NOTE Before install ation, clean and oil the Slider Rods using the User’s Slider Rods Lu brificatio n Kit (Refer to the User’ s Guide ). W ARNING Make sure you in stall the Carriage Assembly and Belt as follows: 1. In[...]

Removal and Installa tion 8-53 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Line Sensor Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove the Carriage Assembly - Refer to Page 8-46 . 2. Unclip the Carriage Cover from both sides of the C[...]

Removal and Installa tion 8-54 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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, rotate 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 Series Printers Se rvice 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 Series Print ers Serv ice 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 Series Printers Se rvice Manual Scan-Axis Motor Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w 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 Series Print ers Serv ice 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 Series Printers Se rvice Manual 9. From the right-hand side, lift the T ensioner Belt of f the Scan-Axis Motor . 10. While supporting the Scan-Axis Motor , remove 2 T - 15 screws ( Ty p e B ). 11 . Lower the Scan-Axis Motor and remove from the Print er . Installation of the Scan-Axis Motor [...]

Removal and Installa tion 8-60 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Cutter Assembly Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Open the T op Cover . 2. Pull the Carriage out along t he Printer to the position shown. 3. Lift up[...]

Removal and Installa tion 8-61 HP Design Jet 5000 and 5500 Series Printers Se rvice 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 Series Print ers Serv ice 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 screw ( 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 Series Printers Se rvice 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 Series Print ers Serv ice Manual Ink Supply S t ation (ISS) Removal W ARNING Sw itch off the Pr inter and remove the Powe r 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&qu[...]

Removal and Installa tion 8-65 HP Design Jet 5000 and 5500 Series Printers Se rvice 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 Series Print ers Serv ice 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 replacing the ISS remember to insert the Gr ounding Plate into th[...]

Removal and Installa tion 8-67 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Air Pressurization System (APS) Removal W ARNING Sw itch off the Pr inter and remove the Powe r 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 Series Print ers Serv ice Manual Installation of A PS W ARNING When Installing th e Air Pr essuri zation System make sur e 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 IS S, insert first th e 3 cables and then[...]

Removal and Installa tion 8-69 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Service S t at ion Assembly Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove the Right Rear Cover - Refer to Page 8-16 . 2. Remove the Right Hand Cover - Refer[...]

Removal and Installa tion 8-70 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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 nstructions in step 7 carefully; LOOSE N the screw and DO NOT r emove. 7. Loosen the T -20 screw ( Ty p e A[...]

Removal and Installa tion 8-71 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual 8. Remove 2 T -15 screws ( Ty p e F ) between the two slider rods that a ttach the Service S tat ion 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 Pri[...]

Removal and Installa tion 8-72 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Drop Detector Assembly Removal W ARNING Sw itch off the Pr inter and remove the Powe r 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 St ation Assembly - Refer to Pa g[...]

Removal and Installa tion 8-73 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual 6. Remove the T -15 screw ( Ty p e F ) that attaches th e Drop Detector Assembl y to the Service Station. 7. Remove the Drop Detector from the Servic e S tatio n. NOTE Move the Drop Detector towards the front of the Service S tation until the locati ng pin r [...]

Removal and Installa tion 8-74 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Hard Disk Drive (HDD) Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove 6 T -15 sc rews ( Ty p e B ) from the HDD Access Cover . Remove the HDD Access Cover .[...]

Removal and Installa tion 8-75 HP Design Jet 5000 and 5500 Series Printers Se rvice 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 Calibr ations (  Page 5-3 )  and the EEROM Se tup Servic e Utility (  Page 4-23 ). W ARNING When Installing the Hard [...]

Removal and Installa tion 8-76 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual LAN Card Removal W ARNING Sw itch off the Pr inter and remove the Powe r 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. [...]

Removal and Installa tion 8-77 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Memory a nd BootROM DIMM’ s Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove 4 T -10 screws ( Ty p e P ) from the DIMM Access Cover . Remove the DIMM Access [...]

Removal and Installa tion 8-78 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual 3. Pull out the DIMM. T ake car e that it does not fall out. Installation of D IMM’ s W ARNING When installing the DIMM’ s make sur e they ar e in the corr ect 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 Series Printers Se rvice Manual Electr onics Module Cover Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w 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 Series Print ers Serv ice Manual NOTE Lift the Par allel Port Clips before r emoving the Cover . 6. Remove the Electronics Module Cover . Installation of the Electr o nics Module Cover NOTE When Installin g the Electr onics Modul e Cover make sur e the paralle l port connec tor clips are i[...]

Removal and Installa tion 8-81 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Main PCA W ARNING This assembly d oes NOT include the PCI-t o-IDE PCA (the small PCA that conne c ts the Main PCA to the Hard Disk Drive) as it used to in the past. When instal ling the new Main PCA, make sure that you reuse the PCI-to-IDE PCA that was disass[...]

Removal and Installa tion 8-82 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w 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 Rig[...]

Removal and Installa tion 8-83 HP Design Jet 5000 and 5500 Series Printers Se rvice 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 ) f rom 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 Series Print ers Serv ice 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 Backup EEROM  Page 4-30 . NOTE If you re place the Main P[...]

Removal and Installa tion 8-85 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual PCI-to-IDE PCA Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w 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. R[...]

Removal and Installa tion 8-86 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Installation of the PCI- to-IDE PCA NOTE When installin g the new 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 CON NECT OR ON THE MAIN PCA (even if th e P1 1 conn ector is pr ese[...]

Removal and Installa tion 8-87 HP Design Jet 5000 and 5500 Series Printers Se rvice 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'LV N' U L YH 6KRUW & RQQ HFW R UFR QQH[...]

Removal and Installa tion 8-88 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Power Supply Unit (PSU) Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove the LAN Card - Refe r to Page 8-76 . 2. Remove the Left Rear Cover - Refe r to Page [...]

Removal and Installa tion 8-89 HP Design Jet 5000 and 5500 Series Printers Se rvice 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 screws ( 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 Series Print ers Serv ice Manual Installation of the Power Supply Unit (PSU) W ARNING Aft er installin g the Power S upply Unit, remember to place th e plastic protective cover over the unit. NOTE The Power S upply Unit c onnections are illustrat ed below . PS Fans PS Sw it c h PS Socket[...]

Removal and Installa tion 8-91 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Ink Supply S t ation (ISS) PCA Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove the LAN Card - Refe r to Page 8-76 . 2. Remove the Left Rear Cover - Refe r to [...]

Removal and Installa tion 8-92 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Installation of the ISS PC A NOTE The ISS PCA co nnections ar e illustr ated below . * 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. J[...]

Removal and Installa tion 8-93 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Ink Leak Detector - If Pr es ent (Only Applicable to the 5000 Series) Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove the Left Rear Cover - Refe r to Page 8-1[...]

Removal and Installa tion 8-94 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual 6. Press the ret aining clip on the Ink Leak D etecto r and r elease i t. 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 Series Printers Se rvice Manual Cooling Fans Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w 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 8-96 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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 Series Printers Se rvice Manual Electr onics Module (as one complete Assembly) Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove the Left Rear Cover - Refe r to Page 8-15 . 2. Remove the Right[...]

Removal and Installa tion 8-98 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Pinch-Wheels Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove the T op Cover - Refer to Page 8-5 . 2. Remove the Back Cover - Refer to Page 8-23 . 3. Remove [...]

Removal and Installa tion 8-99 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual 6. First remove lateral P inch-Whe els 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 , remove the Coupling Plate corresponding to the position of the Mount Brac[...]

Removal and Installa tion 8-100 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Pinch-Whee l Cam Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w 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 Series Printers Se rvice 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 screw ( Ty p e F )[...]

Removal and Installa tion 8-102 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice 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 Series Printers Se rvice Manual V acuum Fan Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w 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 Series Print ers Serv ice 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 tigh tly to the Guide s in the S ideplate.[...]

Removal and Installa tion 8-105 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Paper - Axis Motor Assembly Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove the Right Rear Cover - Refer to Page 8-16 . 2. Remove the Right Hand Cover - Refe[...]

Removal and Installa tion 8-106 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual 6. Remove the Hel ical Gear . 7. Remove the 3 T -20 screws ( 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 f[...]

Removal and Installa tion 8-107 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Installation of P aper -Axis Mo tor Assembly W ARNING When rein stalling 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 Series Print ers Serv ice Manual Booster Fan Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove Right Rear Cover - Refer to Page 8-16 . 2. Remove Left Rear Cover - Refer to Page 8-15 . 3. Rem[...]

Removal and Installa tion 8-109 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Media Sensor Removal W ARNING Sw itch off the Pr inter and remove the Powe r 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 C[...]

Removal and Installa tion 8-110 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Installation of M edia Sensor W ARNING When installing the Media Sensor , insert the moving part as shown in the diagram.[...]

Removal and Installa tion 8-111 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Entry Roller Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove Left Hand T rim - Refer to Page 8-22 . 2. Remove the Left Hand Cover - Refer to Page 8-6 . 3. Re[...]

Removal and Installa tion 8-112 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Center Guide Assembly Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove the T op Cover - Refer to Page 8-5 . 2. Remove the Back Cover - Refer to Page 8-23 . [...]

Removal and Installa tion 8-113 HP Design Jet 5000 and 5500 Series Printers Se rvice 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 screws ( Ty p e J ) that secure the Center Guide to t he left Sideplate. 20. Remo[...]

Removal and Installa tion 8-114 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Drive Roller Gear Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove the Left Hand Cover - Refer to Page 8-6 . 2. Remove the Left Rear Cover - Refe r to Page [...]

Removal and Installa tion 8-115 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Fr ont Platen Ass embly (Only A pplicable to the 5000 Series ) Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove the Left Hand T rim - Refe r to Page 8-22 . 2.[...]

Removal and Installa tion 8-116 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual 4. Remove the Pl aten starting from the left side.[...]

Removal and Installa tion 8-117 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Center Plat en Assembly Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Open the T op Cover . NOTE Make sure the Carriage is not in the print Platen ar ea. NOTE Mak[...]

Removal and Installa tion 8-118 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual 3. Remove the c omplete Center Pl aten Assembly (includes the Overdrive Assembly and the Cutter guide). NOTE Y ou mu st perform the following Calibrations when the C enter P laten A ssembly is r eplaced:  Scan Axis Calibration  P age 5-7 .  Car[...]

Removal and Installa tion 8-119 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Deflectors (Only Applica ble to the 5000 Series) Removal NOTE Refer to the table on Page 8-4 for information on scre w 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" Mo[...]

Removal and Installa tion 8-120 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual Heater A ssembly (Only Applicable to the 5500 Series) Removal W ARNING Sw itch off the Pr inter and remove the Powe r Cord. NOTE Refer to the table on Page 8-4 for information on scre w types. 1. Remove the Right Rear Cover - Refer to Page 8-16 . 2. Remove[...]

Removal and Installa tion 8-121 HP Design Jet 5000 and 5500 Series Printers Se rvice 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 Series Print ers Serv ice Manual 8. Before removing the Heather completely , pull out the Heater Cable from the access ho le in the s ideplate. 9. Remove the Hea ter from the Prin ter .[...]

Removal and Installa tion 8-123 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Installing the Heater T o install the Heater , follow the 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 He[...]

Removal and Installa tion 8-124 HP Desig nJet 500 0 and 5500 Series Print ers Serv ice Manual T ube Guide 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&a[...]

9-1 HP Design Jet 5000 and 5500 Series Printers Se rvice Manual Pr eventive Maintenance 9 Introdu ction 9-2 Service Prev entive Maintenan ce 9-2 W arning/Sto p T riggers 9- 3 User Maintenance 9-5 Lens Main tenance 9-5 Carriage Interconnect W iper 9-6 Rolle r Lub rific ation K it 9- 7 Slide r Ro ds Lubr ific ation Kit 9-8 Cleaning the Platen 9-9 Noi[...]

Preventive Ma intenance 9-2 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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 eve ntiv[...]

Preventive Maintenance 9-3 HP DesignJ et 5000 and 5500 Seri es Printe rs Service Manu al W arning/S top T riggers NOTE If the Ink T ubes System needs to be r eplaced, this can be perform ed by th e User . The Printer will advise the User when the Scan- Axis System and/or T ubes need to be replaced by displaying a W arning message. The W arning mess[...]

Preventive Ma intenance 9-4 HP Design Jet 5000 and 5500 Seri es Printers Service Manual If the Ink T ubes reach 7 million cycles, they risk breakage. The Printer is stopped and the following message is displayed: "Ink T ube Maint enance R equir ed No w" If the Ink T ubes are not replaced, the following message is displayed ea ch time a jo[...]

Preventive Maintenance 9-5 HP DesignJ et 5000 and 5500 Seri es Printe rs Service Manu al User Maintenance W arranty S t atement HP’ s limited warranty cover s only those defect s which arise as a result of appr opriate use of the pro duct, and does not appl y to any: a. Improper or inadequate ma intenance or modi fication; b. Software, interfacin[...]

Preventive Ma intenance 9-6 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Carriage Inter connect Wiper NOTE The Ca rriage Interconnect Wiper also comes with 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 the C[...]

Preventive Maintenance 9-7 HP DesignJ et 5000 and 5500 Seri es Printe rs Service Manu al Roller Lubri fication Kit W ARNING This procedur e is for Service Engineers only . Users should perform th e procedure describe d in the User ’ s Guide . W ARNING Prevent water or other liquids fr om running onto electrical components or circuits, or th r oug[...]

Preventive Ma intenance 9-8 HP Design Jet 5000 and 5500 Seri es Printers Service Manual 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 accumulation of ink particle s and dust from the media or the atmosphere in the vicinity of the Slider Rods. Scan-Axis mainte[...]

Preventive Maintenance 9-9 HP DesignJ et 5000 and 5500 Seri es Printe rs Service Manu al Cleaning the Platen W ARNING This procedur e is for Service Engineers only . Users should perform th e procedure describe d in the User ’ s Guide . W ARNING Prevent water or other liquids fr om running onto electrical components or circuits, or th r ough ope [...]

Preventive Ma intenance 9-10 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Moistur e on the Printer Users should use the Printer in an environment between 20% and 80% relative humidity . T o recover from moisture condensation, turn the Printer Off, and, using the main Roller as a reference, wait until the Printer is complete ly dry be[...]

Preventive Maintenance 9-11 HP DesignJ et 5000 and 5500 Seri es Printe rs Service Manu al 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 Printer) when they are re quired. There are 3 ways of upgrading the System Software: 1 Downloading the[...]

Preventive Ma intenance 9-12 HP Design Jet 5000 and 5500 Seri es Printers Service Manual Upgrade Instructi ons - 5000 Series ONL Y 5500 SERIES ONL Y UPGRADE INSTRUC TIONS FOR THE 5500 SERIES CAN BE FOUND IN THE USER’S GUIDE W ARNING The Firmware Upgrade pr ocess will d elete all pending print jobs. NOTE Ensure that the Printer is powered ON and t[...]

10-1 HP DesignJet 5000 and 550 0 Series P rinters Servi ce 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 ( ISS ) , page 10-6 T ubes Syst em, page 10-6 Printheads, pag e 10-7 Air Press[...]

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 5000 and 5500 Ser ies Printers Service 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 displa y has an LED backlight to[...]

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 5000 and 5500 Ser ies Printers Service 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 permane ntly connected tubes to the high throughput Printheads. The IDS consists of six major subsystems:  The Ink Cartridge[...]

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 5000 and 5500 Ser ies Printers Service 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 m etal parts with opposing U-shaped profiles. The T ubes are threaded inside a protec tive extrusion called the T ube Carrier which consists of a base[...]

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 5000 and 5500 Ser ies Printers Service 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 He[...]

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

About this Ed ition This is the 2nd edition of this Serv ice Manual 1st edition, titled HP Desi gnJet 5000 and 50 00PS S ervice Manual - August 2000 2nd edition, titled HP Desi gnJet 500 0 and 50 00PS Se rvice Manual - January 200 1 3rd edition, titled HP Desi gnJet 500 0 and 55 00 Seri es Servic e Manual - S eptember 20 02[...]

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