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Table of Contents Table of Contents 1 Troubleshooting 1-1 Introduction 1-2 Phone Support 1-2 Which Firmware Version Relates to Which Ink System 1-2 Troubleshooting System Error Codes 1-2 Performing a Service Test on a Failed Assembly 1-3 Performing the Necessary Service Calibrations 1-3 Troubleshooting Calibration Error Codes 1-3 Troubleshooting Ink Supplies Error Codes 1-4 Troubleshooting Initialization - Self Diagnostic Errors 1-4 Solving Image Quality Problems 1-4 The Printer does not Power ON 1-5 ALL the Front-Panel LEDs are Lit but Nothing Else Happens 1-6 Troubleshooting Media Jams/Printhead Crashes 1-6 Troubleshooting Shutdowns - User Message "Warning: Switch Power Off" 1-7 Problems with Vacuum 1-10 Vacuum suction much lower at high altitudes 1-10 Printhead Crashes/Smears on High Density Prints Using Coated Media 1-11 Color differences in different HP DesignJet Printers 1-11 Banding at variable extreme environmental conditions 1-12 Banding with unsupported Media 1-12 Banding due to Ink Cartridge replacement while printing 1-12 Hue shift on HP Colorfast Adhesive Vinyl media 1-13 Black Smearing on HP Photo Imaging Gloss 1-13 Magenta Bleeding on HP Photo Imaging Gloss when using the Take-Up Reel 1-13 Loss of Gloss on HP Photo Imaging Gloss when using the Take-Up Reel 1-14 Wrinkles and scratches (cockle) on HP Coated and Heavyweight Coated Media. 1-15 Dry Cockle on High Density Prints Using Paper Based Media 1-14 Worm marks (cockle) on part of plots on paper based media 1-15 Drying Time Too Long for HP Studio Canvas 1-16 Media Skew when Printing a Banner Plot 1-16 User message "Media loaded incorrectly. Remove media" 1-16 User message "Warning: Incorrect type of tubes system" 1-17 User message "Power Supply Error #1" 1-17 Cutter Assembly Problems 1-19 Carriage and Scan-Axis Problems 1-20 Media-Axis Problems 1-20 Electronics Problems 1-21 Language Selection is blocked in a brand new printer 1-23 Firmware Upgrade Does Not Work Through the Parallel Port 1-23 Typical Failures After Exchanging the Ink Tubes 1-24 Solving Media-Handling Problems 1-25 How to Navigate through the Front Panel Menus 1-26 Service Configuration Print 1-37 General Printer Information 1-39 Troubleshooting Take-Up-Reel Problems 1-40 HP DesignJet 5000 Series Printers Service Manual 3

Section	Page
Using this Manual	4
Purpose	4
Readership	4
Part Numbers	4
Conventions	4
Table of Contents	5
Troubleshooting	13
Guide to Troubleshooting the Printer	14
Introduction	14
Phone Support	14
Which Firmware Version Relates to Which Ink System	14
Troubleshooting System Error Codes	14
Performing a Service Test on a Failed Assembly	15
Performing the Necessary Service Calibrations	15
Troubleshooting Calibration Error Codes	15
Troubleshooting Ink Supplies Error Codes	16
Troubleshooting Initialization - Self Diagnostic Errors	16
Solving Image Quality Problems	16
The Printer does not Power ON	17
ALL the Front-Panel LEDs are Lit but Nothing Else Happens	18
Troubleshooting Media Jams/Printhead Crashes	18
Troubleshooting Shutdowns - User Message \	19
Problems with Vacuum	22
Vacuum suction much lower at high altitudes	22
Printhead Crashes/Smears on High Density Prints Using Coated Media	23
Color differences in different HP DesignJet Printers	23
Banding at variable extreme environmental conditions	24
Banding with unsupported Media	24
Banding due to Ink Cartridge replacement while printing	24
Hue shift on HP Colorfast Adhesive Vinyl media	25
Black Smearing on HP Photo Imaging Gloss	25
Magenta Bleeding on HP Photo Imaging Gloss when using the Take-Up Reel	25
Loss of Gloss on HP Photo Imaging Gloss when using the Take-Up Reel	26
Dry Cockle on High Density Prints Using Paper Based Media	26
Wrinkles and scratches (cockle) on HP Coated and Heavyweight Coated Media.	27
Worm marks (cockle) on part of plots on paper based media	27
Drying Time Too Long for HP Studio Canvas	28
Media Skew when Printing a Banner Plot	28
User message \	28
User message \	29
User message \	29
Cutter Assembly Problems	31
Carriage and Scan-Axis Problems	32
Media-Axis Problems	32
Electronics Problems	33
Language Selection is blocked in a brand new printer	35
Firmware Upgrade Does Not Work Through the Parallel Port	35
Typical Failures After Exchanging the Ink Tubes	36
Solving Media-Handling Problems	37
How to Navigate through the Front Panel Menus	38
I/O Setup Menu	38
Device Setup Menu	39
Utilities Menu	40
Internal RIP Settings Menu	41
Queuing and Nesting Menu	42
HP-GL/2 Settings Menu	43
Page Format Menu	44
Demos Menu	45
Media Menu	46
Ink Cartridge Menu	47
Printhead Menu	48
Service Configuration Print	49
General Printer Information	51
Troubleshooting Take-Up-Reel Problems	52
System Error Codes	53
System Error Codes	55
Introduction	55
Continuable and Non-Continuable Error Codes	56
HP Ink Supplies Troubleshooting	77
What are HP Ink Supplies?	78
Ink Cartridges	78
Printheads and Printhead Cleaners	78
Identifying the Components	79
General Information About HP Ink Supplies	79
Some General Precautions When Handling HP Ink Supplies	80
Priming the Ink System	81
When Should You Replace the HP Ink Supplies?	81
The Front Panel Display	82
Obtaining Ink Cartridge Information	83
Obtaining Printhead Information	84
Status Codes and Messages	86
Status Messages	87
Error Status Messages	88
Printhead Errors (First Digit = 0, 1, 2, 3, 4, 5)	89
Ink Cartridge Errors (First Digit = 6, 7, 8)	92
Printhead Cleaner Errors (First Digit = A, B or *)	94
Major Ink Supplies Problems	95
Dry-firing of Printheads	95
Printheads Which are Out of Warranty are Indicated as In Warranty	95
Replace Message \	95
Replace Message \	96
Service Tests and Utilities	97
Introduction	98
Phone Support	98
Diagnostics - Self Test	98
Service Tests (Diagnostics)	102
Entering the Service Tests Menu	103
For On-Site Engineers accessing the complete list of Service Tests	103
For Call Agents requesting the User to access a limited number of Service Tests	104
Scan Axis Test	106
Media Axis Test	108
Service Utilities	110
Entering the Service Utilities Menu	111
For On-Site Engineers accessing the complete list of Service Utilities	111
For Call Agents requesting the User to access a limited number of Service Utilities	112
Turn DRIVE ROLLER	114
Prime TUBES	115
Altitude Setup	119
EEROM Setup	120
If you want to set the Model Number	121
If you want to set the Serial Number	122
If you want to set the Japanese Fonts	123
Reset Life Counters	125
Backup EEROM	127
Image Quality Warning	129
Diagnostic Print	130
Service Calibrations	131
Introduction	132
Phone Support	132
Service Calibrations	133
Entering the Service Calibrations Menu	134
For On-Site Engineers accessing the complete list of Service Calibrations	134
For Call Agents requesting the User to access a limited number of Service Calibrations	135
1. Scan-Axis Calibration	137
2. Service Station Calibration	141
3. Accuracy Calibration	144
Carriage Height Calibration	148
Calibration Error Codes	156
Introduction	156
Print Quality	175
Print Quality	176
Print Quality Troubleshooting Checklist	176
Print Modes	177
How to Use the Diagnostic Print	178
What is the Diagnostic Print?	178
Considerations for Printing the Diagnostic Print.	178
Printing the Diagnostic Print	179
For On-Site Engineers accessing the complete list of Service Utilities	179
For Call Agents requesting the User to print the Service Diagnostic print	180
Overall Print Quality Test	182
What is Banding?	182
Solving the Banding Problem	182
Color Alignment Print Test	185
Solving the Color Alignment Problem	185
Bidirectional Alignment	186
Solving Bidirectional Alignment Problems	186
Vertical Line Straightness	187
Solving Vertical Line Straightness	187
Nozzle Print Test	188
How to fix the Nozzle Defects	189
No Printing Defects Found in the Diagnostic Print	190
Print Quality Problems	190
Solving Color Accuracy problems	191
Solving Color Consistency problems	191
Color Accuracy Configuration	192
Blurred Lines (Ink “Bleeds” from Lines)	192
The Prints are Too Short	192
Colors are not as Expected	193
Bad Color to Color Alignment in the Media-Axis	193
Banding at the Top of the Page	194
Vertical Banding	194
Media	195
Printed surface smearing roll	195
Warped Lines on Media	195
Marks and/or scratches on double-sided media	196
There are Smears or Scratching on the Printed Media	196
Long Term Color Bleeding (Glossy Papers)	196
Parts and Diagrams	197
Printer Support	198
Bin and Take-Up Reel	200
Right Hand Cover	202
Left Hand Cover and Rear Door	204
Top and Back Covers	206
Service Station	208
Vacuum Fan	210
Booster Fan and Media Sensor	212
Paper-Axis Motor	214
Scan-Axis Motor	216
ISS and APS Assembly	218
Ink Tubes System	220
Boot ROM DIMM, DRAM Memory and Covers	222
Rear Electronics Access Covers	224
Hard Disk Drive and Cover	226
ISS PCA and Main PCA	228
Power Supply Unit	230
Carriage Assembly	232
Tensioner Assembly and Encoder Strip	234
Platen Assemblies	236
Pinch-Wheels Assembly and Lever	238
Center Guide, Deflector and Entry Roller	240
Tubes Guide Assemblies	242
EMC Covers	244
Spindle and Hub	246
Miscellaneous Items	248
Media Types	249
Removal and Installation	251
Introduction	252
Safety Precautions	252
Electrostatic Discharge (ESD) Precautions	253
Required Tools	253
Screw Types	254
Top Cover Assembly	255
Removal	255
Left Hand Cover	256
Removal	256
Installation of Left Hand Cover	259
Right Hand Cover	260
Removal	260
Installation of Right Hand Cover	263
Front Panel Assembly	264
Removal	264
Left Rear Cover	265
Removal	265
Right Rear Cover	266
Removal	266
Extension Cover (60\	267
Removal	267
Media Lever Assembly	268
Removal	268
Installation of the Media Lever Assembly	269
Right Hand Trim	270
Removal	270
Installation of Right Hand Trim	271
Left Hand Trim	272
Removal	272
Back Cover	273
Removal	273
Installation of the Back Cover	274
Ink Tubes System	275
Removal	275
Installation of Ink Tubes System	280
EMC Covers	282
Removal	282
Encoder Strip	284
Removal	284
Installation of Encoder Strip	285
Trailing Cable	286
Removal	286
Installation of Trailing Cable	289
Tensioner Assembly	292
Removal	292
Installation of Tensioner Assembly	295
Carriage Assembly and Belt	296
Removal	296
Installation of Carriage and Belt	302
Scan-Axis Motor	305
Removal	305
Installation of the Scan-Axis Motor	307
Cutter Assembly	308
Removal	308
Ink Supply Station (ISS)	312
Removal	312
Installation of ISS	314
Air Pressurization System (APS)	315
Removal	315
Installation of APS	316
Service Station Assembly	317
Removal	317
Drop Detector Assembly	320
Removal	320
Hard Disk Drive (HDD)	322
Removal	322
Installation of Hard Disk Drive	323
LAN Card	324
Removal	324
Memory and BootROM DIMM’s	325
Removal	325
Installation of DIMM’s	326
Electronics Module Cover	327
Removal	327
Installation of the Electronics Module Cover	328
Main PCA	329
Removal	329
Installation of Main PCA	332
Power Supply Unit (PSU)	333
Removal	333
Installation of the Power Supply Unit (PSU)	335
Ink Supply Station (ISS) PCA	336
Removal	336
Installation of the ISS PCA	337
Ink Leak Detector	338
Removal	338
Cooling Fans	340
Removal	340
Electronics Module (as one complete Assembly)	342
Removal	342
Pinch-Wheels	343
Removal	343
Installation of Pinch-Wheels	344
Pinch-Wheel Cam	345
Removal	345
Installation of Cam	347
Vacuum Fan	348
Removal	348
Installation of Vacuum Fan	349
Paper-Axis Motor Assembly	350
Removal	350
Installation of Paper-Axis Motor Assembly	352
Booster Fan	353
Removal	353
Media Sensor	354
Removal	354
Installation of Media Sensor	355
Entry Roller	356
Removal	356
Center Guide Assembly	357
Removal	357
Drive Roller Gear	359
Removal	359
Installation of Gear	359
Front Platen Assembly	360
Removal	360
Center Platen Assembly	362
Removal	362
Installation of the Center Platen Assembly	363
Deflectors	364
Removal	364
Preventive Maintenance	365
Introduction	366
Service Preventive Maintenance	366
Warning/Stop Triggers	367
Routine Maintenance	369
Lens Maintenance	369
Carriage Interconnect Wiper	370
Roller Lubrification Kit	371
Slider Rods Lubrification Kit	372
Cleaning the Platen	373
Moisture on the Printer	374
Noisy Carriage Bushing	374
Belt Swelling	374
General Cleaning	374
Firmware Upgrade	375
Upgrade Instructions	376
Functional Overview	377
Introduction	378
Electrical System	378
Front Panel	379
Scan Axis	379
Paper Axis	380
Ink Delivery System (IDS)	381
Ink Cartridge	381
Ink Supply Station (ISS)	382
Tubes System	382
Printheads	383
Air Pressurization System (APS)	384
Leak Detect System (LDS)	384
Service Station	385
Print Head Cleaner (PHC)	385
Printer Specifications	386
Printable Area	389
Interface Specifications	389
Glossary	391
Index	395

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Table of Contents

HP DesignJet 5000 Series Printers Service Manual

Table of Contents

Troubleshooting 1-1

Introduction

1-2

Phone Support

1-2

Which Firmware Version Relates to Which Ink System

1-2

Troubleshooting System Error Codes

1-2

Performing a Service Test on a Failed Assembly

1-3

Performing the Necessary Service Calibrations

1-3

Troubleshooting Calibration Error Codes

1-3

Troubleshooting Ink Supplies Error Codes

1-4

Troubleshooting Initialization - Self Diagnostic Errors

1-4

Solving Image Quality Problems

1-4

The Printer does not Power ON

1-5

ALL the Front-Panel LEDs are Lit but Nothing Else Happens

1-6

Troubleshooting Media Jams/Printhead Crashes

1-6

Troubleshooting Shutdowns - User Message "Warning: Switch Power Off"

1-7

Problems with Vacuum

1-10

Vacuum suction much lower at high altitudes

1-10

Printhead Crashes/Smears on High Density Prints Using Coated Media

1-11

Color differences in different HP DesignJet Printers

1-11

Banding at variable extreme environmental conditions

1-12

Banding with unsupported Media

1-12

Banding due to Ink Cartridge replacement while printing

1-12

Hue shift on HP Colorfast Adhesive Vinyl media

1-13

Black Smearing on HP Photo Imaging Gloss

1-13

Magenta Bleeding on HP Photo Imaging Gloss when using the Take-Up Reel

1-13

Loss of Gloss on HP Photo Imaging Gloss when using the Take-Up Reel

1-14

Wrinkles and scratches (cockle) on HP Coated and Heavyweight Coated Media.

1-15

Dry Cockle on High Density Prints Using Paper Based Media

1-14

Worm marks (cockle) on part of plots on paper based media

1-15

Drying Time Too Long for HP Studio Canvas

1-16

Media Skew when Printing a Banner Plot

1-16

User message "Media loaded incorrectly. Remove media"

1-16

User message "Warning: Incorrect type of tubes system"

1-17

User message "Power Supply Error #1"

1-17

Cutter Assembly Problems

1-19

Carriage and Scan-Axis Problems

1-20

Media-Axis Problems

1-20

Electronics Problems

1-21

Language Selection is blocked in a brand new printer

1-23

Firmware Upgrade Does Not Work Through the Parallel Port

1-23

Typical Failures After Exchanging the Ink Tubes

1-24

Solving Media-Handling Problems

1-25

How to Navigate through the Front Panel Menus

1-26

Service Configuration Print

1-37

General Printer Information

1-39

Troubleshooting Take-Up-Reel Problems

1-40