HP DesignJet 5000 Series Large-Format Printers Service Manual For HP Internal Use Only ©Copyright Hewlett-Packard Company 2000 This document contains proprietary information that is protected by copyright. All rights are reserved. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of HewlettPackard Company. First Edition, August 2000 Second Edition, January 2001 Warranty WARNING WARNING The Warning symbol calls attention to a procedure, practice, or the like, which, if not correctly performed or adhered to, could result in personal injury. Do not proceed beyond a Warning symbol until the indicated conditions are fully understood and met. The information contained in this The procedures described in this document is subject to change manual are to be performed by without notice. HP-qualified service personnel only. Hewlett-Packard makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Hewlett-Packard shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material. Electrical Shock Hazard Serious shock hazard leading to death or injury may result if you do not take the following precautions: - Ensure that the ac power outlet (mains) has a protective earth (ground) terminal. - Disconnect the Printer from the power source prior to performing any maintenance. - Prevent water or any other liquids from running onto electrical components or circuits, or through openings in the enclosure. Electrostatic Discharge Refer to the beginning of Chapter 8 of this manual, for precautions you should take to prevent damage to the Printer circuits from electrostatic discharge. Safety Symbols General definitions of safety symbols are given immediately after the table of contents. CAUTION The Caution symbol calls attention to an operating procedure, practice, or the like, which, if not correctly performed or adhered to, could result in damage to or destruction of part or all of the product. Do not proceed beyond a Caution symbol until the indicated conditions are fully understood and met. Technical Marketing, Barcelona Division, Hewlett-Packard Espanola, S.A. Avda. Graells, 501 08190 Sant Cugat del Valles Spain 1 HP DesignJet 5000 Series Large-Format Printers Service Manual Using this Manual Purpose This Service Manual contains information necessary to test, calibrate and service: n HP DesignJet 5000 Printer - 42" Model (P/N C6090A/V) n HP DesignJet 5000 Printer - 60" Model (P/N C6095A/V) n HP DesignJet 5000PS Printer - 42" Model (P/N C6091A/V) n HP DesignJet 5000PS Printer - 60" Model (P/N C6096A/V) For information about using these printers, refer to the corresponding User and Quick Reference Guides. Readership The procedures described in this Service Manual are to be performed by HP-qualified Service Personnel only. Part Numbers Part Numbers for Printer options, accessories and service parts are located in Chapter 7. Conventions A small arrow is used to indicate other parts of the Service Manual where you can find information related to the topic you are consulting. 2 HP DesignJet 5000 Series Printers Service Manual Table of Contents Table of Contents Troubleshooting 1-1 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 Table of Contents System Error Codes 2-1 Introduction 2-2 Continuable and Non-Continuable Error Codes 2-3 HP Ink Supplies Troubleshooting 3-1 What are HP Ink Supplies? 3-2 Ink Cartridges 3-2 Printheads and Printhead Cleaners 3-2 Identifying the Components 3-3 General Information About HP Ink Supplies 3-3 Some General Precautions When Handling HP Ink Supplies 3-4 Priming the Ink System 3-5 When Should You Replace the HP Ink Supplies? 3-5 The Front Panel Display 3-6 Obtaining Ink Cartridge Information 3-7 Obtaining Printhead Information 3-8 Status Codes and Messages 3-10 Status Messages 3-11 Error Status Messages 3-12 Printhead Errors (First Digit = 0, 1, 4, 5) 3-13 Ink Cartridge Errors (First Digit = 6, 8) 3-16 Printhead Cleaner Errors (First Digit = A or *) 3-18 Major Ink Supplies Problems 3-19 Dry-firing of Printheads 3-19 Printheads Which are Out of Warranty are Indicated as In Warranty 3-19 Replace Message "xx15 Replace" and "xx16 Replace" 3-19 Replace Message "xx16 Replace" for ALL Printheads During Replacement 3-20 4 HP DesignJet 5000 Series Printers Service Manual Table of Contents Service Tests and Utilities 4-1 Introduction 4-2 Phone Support 4-2 Diagnostics - Self Test 4-2 Service Tests (Diagnostics) 4-6 Entering the Service Tests Menu 4-7 Scan Axis Test 4-10 Media Axis Test 4-12 Service Utilities 4-14 Prime TUBES 4-19 Altitude Setup 4-23 EEROM Setup 4-24 If you want to set the Model Number 4-25 If you want to set the Serial Number 4-26 If you want to set the Japanese Fonts 4-27 Reset Life Counters 4-29 Backup EEROM 4-31 Image Quality Warning 4-33 Diagnostic Print 4-34 Service Calibrations 5-1 Introduction 5-2 Phone Support 5-2 Service Calibrations 5-3 Entering the Service Calibrations Menu 5-4 1. Scan-Axis Calibration 5-7 2. Service Station Calibration 5-11 3. Accuracy Calibration 5-14 Carriage Height Calibration 5-18 Calibration Error Codes 5-26 HP DesignJet 5000 Series Printers Service Manual 5 Table of Contents Print Quality 6-1 Print Quality Troubleshooting Checklist 6-2 Print Modes 6-3 How to Use the Diagnostic Print 6-4 What is the Diagnostic Print? 6-4 Considerations for Printing the Diagnostic Print. 6-4 Printing the Diagnostic Print 6-5 Overall Print Quality Test 6-8 What is Banding? 6-8 Solving the Banding Problem 6-8 Color Alignment Print Test 6-11 Solving the Color Alignment Problem 6-11 Bidirectional Alignment 6-12 Solving Bidirectional Alignment Problems 6-12 Vertical Line Straightness 6-13 Solving Vertical Line Straightness 6-13 Nozzle Print Test 6-14 How to fix the Nozzle Defects 6-15 No Printing Defects Found in the Diagnostic Print 6-16 Print Quality Problems 6-16 Solving Color Accuracy problems 6-17 Solving Color Consistency problems 6-17 Color Accuracy Configuration 6-18 Blurred Lines (Ink "Bleeds" from Lines) 6-18 The Prints are Too Short 6-18 Colors are not as Expected 6-19 Bad Color to Color Alignment in the Media-Axis 6-19 Banding at the Top of the Page 6-20 Vertical Banding 6-20 Media 6-21 Printed surface smearing roll 6-21 Warped Lines on Media 6-21 Marks and/or scratches on double-sided media 6-22 There are Smears or Scratching on the Printed Media 6-22 Long Term Color Bleeding (Glossy Papers) 6-22 6 HP DesignJet 5000 Series Printers Service Manual Table of Contents Parts and Diagrams 7-1 Printer Support 7-2 Bin and Take-Up Reel 7-4 Right Hand Cover 7-6 Left Hand Cover and Rear Door 7-8 Top and Back Covers 7-10 Service Station 7-12 Vacuum Fan 7-14 Booster Fan and Media Sensor 7-16 Paper-Axis Motor 7-18 Scan-Axis Motor 7-20 ISS and APS Assembly 7-22 Ink Tubes System 7-24 Boot ROM DIMM, DRAM Memory and Covers 7-26 Rear Electronics Access Covers 7-28 Hard Disk Drive and Cover 7-30 ISS PCA and Main PCA 7-32 Power Supply Unit 7-34 Carriage Assembly 7-36 Tensioner Assembly and Encoder Strip 7-38 Platen Assemblies 7-40 Pinch-Wheels Assembly and Lever 7-42 Center Guide, Deflector and Entry Roller 7-44 Tubes Guide Assemblies 7-46 EMC Covers 7-48 Spindle and Hub 7-50 Miscellaneous Items 7-52 Media Types 7-53 Removal and Installation 8-1 Introduction 8-2 Safety Precautions 8-2 Electrostatic Discharge (ESD) Precautions 8-3 Required Tools 8-3 Screw Types 8-4 Top Cover Assembly 8-5 Left Hand Cover 8-6 Right Hand Cover 8-10 Front Panel Assembly 8-14 Left Rear Cover 8-15 Right Rear Cover 8-16 Extension Cover (60" Model only) 8-17 Media Lever Assembly 8-18 HP DesignJet 5000 Series Printers Service Manual 7 Table of Contents Right Hand Trim 8-20 Left Hand Trim 8-22 Back Cover 8-23 Ink Tubes System 8-25 EMC Covers 8-32 Encoder Strip 8-34 Trailing Cable 8-36 Tensioner Assembly 8-42 Carriage Assembly and Belt 8-46 Scan-Axis Motor 8-55 Cutter Assembly 8-58 Ink Supply Station (ISS) 8-62 Air Pressurization System (APS) 8-65 Service Station Assembly 8-67 Drop Detector Assembly 8-70 Hard Disk Drive (HDD) 8-72 LAN Card 8-74 Memory and BootROM DIMM's 8-75 Electronics Module Cover 8-77 Main PCA 8-79 Power Supply Unit (PSU) 8-83 Ink Supply Station (ISS) PCA 8-86 Ink Leak Detector 8-88 Cooling Fans 8-90 Electronics Module (as one complete Assembly) 8-92 Pinch-Wheels 8-93 Pinch-Wheel Cam 8-95 Vacuum Fan 8-98 Paper-Axis Motor Assembly 8-100 Booster Fan 8-103 Media Sensor 8-104 Entry Roller 8-106 Center Guide Assembly 8-107 Drive Roller Gear 8-109 Front Platen Assembly 8-110 Center Platen Assembly 8-112 Deflectors 8-114 8 HP DesignJet 5000 Series Printers Service Manual Table of Contents Preventive Maintenance 9-1 Introduction 9-2 Service Preventive Maintenance 9-2 Warning/Stop Triggers 9-3 Routine Maintenance 9-5 Lens Maintenance 9-5 Carriage Interconnect Wiper 9-6 Roller Lubrification Kit 9-7 Slider Rods Lubrification Kit 9-8 Cleaning the Platen 9-9 Moisture on the Printer 9-10 Noisy Carriage Bushing 9-10 Belt Swelling 9-10 General Cleaning 9-10 Firmware Upgrade 9-11 Functional Overview 10-1 Introduction 10-2 Electrical System 10-2 Front Panel 10-3 Scan Axis 10-3 Paper Axis 10-4 Ink Delivery System (IDS) 10-5 Ink Cartridge 10-5 Ink Supply Station (ISS) 10-6 Tubes System 10-6 Printheads 10-7 Air Pressurization System (APS) 10-8 Leak Detect System (LDS) 10-8 Service Station 10-9 Print Head Cleaner (PHC) 10-9 Printer Specifications 10-10 Printable Area 10-13 Interface Specifications 10-13 Glossary Index HP DesignJet 5000 Series Printers Service Manual 9 Table of Contents 10 HP DesignJet 5000 Series Printers Service Manual Troubleshooting 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 d ...