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DesignJets 5000 and 5500 Series Large-Format Printers Service Manual and Parts Manual

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SERVICE MANUAL TABLE OF CONTENTS

1. Troubleshooting
Introduction
Phone Support
Which Firmware Version Relates to Which Ink System
Troubleshooting System Error Codes
Performing a Service Test on a Failed Assembly
Performing the Necessary Service Calibrations
Troubleshooting Calibration Error Codes
Troubleshooting Ink Supplies Error Codes
Troubleshooting Initialization – Self Diagnostic Errors
Solving Image Quality Problems
The Printer does not Power ON
ALL the Front-Panel LEDs are Lit but Nothing Else Happens
Troubleshooting Media Jams/Printhead Crashes
Troubleshooting Shutdowns – User Message “Warning: Switch Power Off”
Problems with Vacuum
Vacuum suction much lower at high altitudes
Printhead Crashes/Smears on High Density Prints Using Coated Media
Color differences in different HP DesignJet Printers
Banding at variable extreme environmental conditions
Banding with unsupported Media
Banding due to Ink Cartridge replacement while printing
Hue shift on HP Colorfast Adhesive Vinyl media
Black Smearing on HP Photo Imaging Gloss
Magenta Bleeding on HP Photo Imaging Gloss when using the Take-Up Reel
Loss of Gloss on HP Photo Imaging Gloss when using the Take-Up Reel
Wrinkles and scratches (cockle) on HP Coated and Heavyweight Coated Media.
Dry Cockle on High Density Prints Using Paper Based Media
Worm marks (cockle) on part of plots on paper based media
Drying Time Too Long for HP Studio Canvas
Media Skew when Printing a Banner Plot
User message “Media loaded incorrectly. Remove media”
User message “Warning: Incorrect type of tubes system”
User message “Power Supply Error #1”
Cutter Assembly Problems
Carriage and Scan-Axis Problems
Media-Axis Problems
Electronics Problems
Language Selection is blocked in a brand new printer
Firmware Upgrade Does Not Work Through the Parallel Port
Typical Failures After Exchanging the Ink Tubes
Solving Media-Handling Problems
How to Navigate through the Front Panel Menus
Service Configuration Print
General Printer Information
Troubleshooting Take-Up-Reel Problems

2. System Error Codes
Introduction
Continuable and Non-Continuable Error Codes
System Error Groups
ffff ffff xxxxxxxx (General Firmware Error)
ffff ffff 02b301b0
ffff ffff 01dcxxxx
ffff ffff 030d0170 or ffff ffff 030d0171
ffff ffff 031609xx
ffff ffff 03450097
ffff ffff 036000bd
ffff ffff 036e0136
01002D (Non-Continuable)
010023 (Non-Continuable)
010030 034c095e
010040
010041
010042
010090 (Continuable)
010091 (Continuable)
010092 (Continuable)
011000
040000 01E603D9
050000 (Continuable)
050001 (Continuable)
06030C
06040C
0A0000
0A0010
0A0020
0A0030
0A0040
0A0050 (Non-Continuable)
0A0060 (Non-Continuable)
0A0070 (Continuable)
0B0000
0B0001
0B0002
0B0003
0B0004
0B0005
0B0006
0B000X
0B0010 xxxxxxxx (Non-Continuable)
0B000A
0B000B
0B000C
0B000D
0B000E
0B000F (Continuable) (Only applicable to DesignJet 5500 Series)
0C0030
0C0032 (Continuable)
0C0040
0C00FF
0C1000
0C1001
0D0000 (Continuable)
0D0000 033f019C
0D0002 (Continuable)
0D0003 xxxxxxxx (Non-Continuable)
0D0004 xxxxxxxx (Non-Continuable)
0D0005 03180382 (Non-Continuable)
0FXXXX (Non-Continuable)
0F0200 00b007bc
0F0200 00b007E5
0F0200 01E603d2
0F0100 03180382 (Non-Continuable)
1f500XX (Boot Failed)
e50000

3. HP Ink Supplies Troubleshooting
What are HP Ink Supplies?
Priming a Brand New Ink System
Obtaining Ink Cartridge Information
Status Codes and Messages
Error Status Messages
Printhead Errors
Ink Cartridge Errors
Printhead Cleaner Errors

4. Service Tests and Utilities
Introduction
Diagnostics
Service Tests (Diagnostics)
Service Utilities

5. Service Calibrations
Entering the Service Calibrations Menu
Scan-Axis Calibration
Service Station Calibration
Accuracy Calibration
Carriage Height Calibration
Calibration Error Codes
User Calibrations
Printhead Alignment
Close-Loop-Color (CLC) Calibration
Banding Calibration
Accuracy Calibration

6. Print Quality
Print Quality Troubleshooting Checklist
How to Use the Diagnostic Print

7. Parts and Diagrams
Printer Support
Bin and Take-Up Reel
Right Hand Cover
Left Hand Cover and Rear Door
Top and Back Covers
Service Station
Vacuum Fan
Booster Fan and Media Sensor
Paper-Axis Motor
Scan-Axis Motor
ISS and APS Assembly
Ink Tubes System
Boot ROM DIMM, DRAM Memory and Covers
Rear Electronics Access Covers
Hard Disk Drive and Cover
ISS PCA and Main PCA
Power Supply Unit
Carriage Assembly
Tensioner Assembly and Encoder Strip
Platen Assemblies – DesignJet 5000 Series
Platen Assemblies – DesignJet 5500 Series
Pinch-Wheels Assembly and Lever
Center Guide, Deflectors and Entry Roller – DesignJet 5000 Series
Center Guide and Entry Roller – DesignJet 5500 Series
Tubes Guide Assemblies
EMC Covers
Spindle and Hub
Rollfeed Brakes
Miscellaneous Items
Media Types

8. Removal and Installation
Screw Types
Top Cover Assembly
Left Hand Cover
Right Hand Cover
Front Panel Assembly
Left Rear Cover
Right Rear Cover
Extension Cover (60″ Model only)
Media Lever Assembly
Right Hand Trim
Left Hand Trim
Back Cover
Ink Tubes System
EMC Covers
Encoder Strip
Trailing Cable
Tensioner Assembly
Carriage Assembly and Belt
Line Sensor
Scan-Axis Motor
Cutter Assembly
Ink Supply Station (ISS)
Air Pressurization System (APS)
Service Station Assembly
Drop Detector Assembly
Hard Disk Drive (HDD)
LAN Card
Memory and BootROM DIMM’s
Electronics Module Cover
Main PCA
PCI-to-IDE PCA
Power Supply Unit (PSU)
Ink Supply Station (ISS) PCA
Ink Leak Detector – If Present (Only Applicable to the 5000 Series)
Cooling Fans
Electronics Module (as one complete Assembly)
Pinch-Wheels
Pinch-Wheel Cam
Vacuum Fan
Paper-Axis Motor Assembly
Booster Fan
Media Sensor
Entry Roller
Center Guide Assembly
Drive Roller Gear
Front Platen Assembly (Only Applicable to the 5000 Series)
Center Platen Assembly
Deflectors (Only Applicable to the 5000 Series)
Heater Assembly (Only Applicable to the 5500 Series)
Tube Guide Door

9. Preventive Maintenance
Introduction
Service Preventive Maintenance
Warning/Stop Triggers
User Maintenance
Lens Maintenance
Carriage Interconnect Wiper
Roller Lubrification Kit
Slider Rods Lubrification Kit
Cleaning the Platen
Noisy Carriage Bushing
Belt Swelling
General Cleaning
Firmware Upgrade

10. Functional Overview
Introduction
Electrical System
Front Panel
Scan Axis
Paper Axis
Ink Delivery System (IDS)
Ink Supply Station (ISS)
Tubes System
Printheads,
Air Pressurization System (APS)
Service Station
Print Head Cleaner (PHC)

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