HP Designjet 5000, 5500 service manual

Removal and Installation8

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 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 Line Sensor 8-53 Scan-Axis Motor 8-57 Cutter Assembly 8-60 Ink Suppl y St ation (ISS) 8-64 Air Pressurization System (APS) 8-67 Service Station Assembly 8-69 Drop Detector Assembly 8-72 Hard Disk Drive (HDD) 8-74 LAN Card 8-76 Memory and BootROM DIMM’s 8-77 Electronics Module Cover 8-79 Main PCA 8-81 PCI-to-IDE PCA 8-85 Power Supply Unit (PSU) 8-88 Ink Suppl y St ation (ISS) PCA 8-91 Ink Leak Detector - If Present (Only Applicable to the 5000 Series) 8-93 Cooling Fans 8-95 Electronics Module (as one complete Assembly) 8-97 Pinch-Wheels 8-98 Pinch-Wheel Cam 8-100 Vacuum Fan 8-103 Paper-Axis Motor Assembly 8- 105 Booster Fan 8-108 Media Sensor 8-109 Entry Roller 8-111 Center Guide Assembly 8-112 Drive Roller Gear 8-114 Front Platen Assembly (Only Applicable to the 5000 Series) 8-115 Center Platen Assembly 8-117 Deflectors (Only Applicable to the 5000 Series) 8-119 Heater Assembly (Only Applicable to the 5500 Series) 8-120 Tube Guide Door 8-124

HP DesignJet 5000 and 5500 Series Printers Service Manual

8-1

Removal and Installation

Introduction

This chapter is a step by step guide to the removal and installation of the key components in the Printer. You may find it useful to tick off the steps as they are performed. Use the illustration at each procedure to identify the parts referred to in the text.

The procedur es appear in or der of removal. So the whole machine can be stripped down by starting at the beginning of this chapter and working through the subsequent procedures.

NOTE

THE INSTRUCTIONS IN THIS CHAPTER APPLY BOTH TO THE DESIGNJET 5000 AND 5500 SERIES UNLESS OTHERWISE NOTED. EVEN THOUGH THE ILLUSTRATIONS ARE SHOWN USING THE DESIGNJET 5000 SERIES, THESE ARE ALSO APPLICABLE TO THE DESIGNJET 5500 SERIES.

NOTE Before using this chapter to remove and/or replace a component

or assembly, always make sure that you have performed the relevant service test for each component as described in 4, Service Tests and Utilities. If the test passes you will not need to replace the component.

NOTE To install a component perform the removal procedures in

reverse order unless a specific installation procedur e is provided.

NOTE After removing and/or replacing a component, the relative

procedure will state whether any calibrations and/or tests are required (Chapter 5, Service Calibrations).

Safety Precautions

(Safety symbols - Immediately after the table of contents.) Review WARNING and CAUTION symbols and instructions before you service the Printer.

Follow these warnings and cautions for your protection an d to avoid damaging the Printer.

WARNING 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 prote ctive earth

(ground) terminal. Switch the printer off, and di sconnect it from the power source

prior to performing any maintenance. Prevent water or other liquids from running onto electrical

components or circuits, or through openings in the module.

8-2

HP DesignJet 5000 and 5500 Series Printers Service Manual

Removal and Installation

Electrostatic Discharge (ESD) Precautions

To prevent damage to the Printer circuits from high-voltage electrostatic discharge (ESD):

1. Do not wear clothing that is subject to static build-up.

2. Do not handle integrated circuits (ICs) in carpeted areas.

3. Do not remove an IC or a printed circuit assembly (PCA) from its conductive foam

pad or conductive packaging until you are ready to install it.

4. Ground (earth) your body while disassembling and working on the Printer.

5. After removing a cover from the Printer, attach an earthing (ground) lead between

the PCA common and earth ground. Touch all tools to earth ground to remove static charges before using them on the Printer.

6. After removing any PCA from the Printer, pl ace it on a conductive foam pad or into

its conductive packaging to prevent ESD damage to any ICs on the PCA.

Required Tools

The following tools are required to disassemble and repair the Printer.

Long Torx Screwdriver with the indicated attachments

T8 T10 T15 T20

T25

Nut driver with the

indicated attachments

Small flat-blade screwdriver

HP DesignJet 5000 and 5500 Series Printers Service Manual

8-3

Removal and Installation

Screw Types

WARNING Chassis screws have a copper washer and should never be

removed.

Type Torx Length

(mm)

Head Type Thread Type Part Number

A T-20 17 Pan Taptite 0515-1743 B T-15 12 Pan Machined 0515-0382 C T-20 10 Pan Taptite 0515-2282 D T-15 12.5 Pan Washer Plastite 0515-3040 E T-15 12.7 Pan Plastite 0624-0769

F T-15 20 Pan Plastite 0624-0771 G T-8 12.7 Pan Plastite 0624-0768 H T-15 9.5 Pan Plastite 0515-2981

I T-10 7.5 Flat Taptite 0515-2984

J T-15 27.4 Pan Machined 0515-2986 K T-10 8 Pan Taptite 0515-2200 L T-20 14 Pan Taptite 0515-2248

M T-15 - Flat Taptite 0515-2250

N T-15 24 Flat Machined C6071-20026 O T-15 10 Pan Washer Machined 0515-0380

P T-10 8 Pan Machined 0515-2246 Q T-20 10 Pan Washer Taptite 0515-2278 R T-10 8 Flat Countersunk 2200-1294

S T-25 54 Pan Machined C6071-20005 T T-20 20 Pan Machined C3180-20001 U T-25 10 Pan Taptite 0515-4268 V T-8 14 Pan Machined 0624-0737

8-4

HP DesignJet 5000 and 5500 Series Printers Service Manual

Removal and Installation

Top Cover Assembly

Removal

WARNING Switch off the Printer and remove the power cable.

1. Open the Top Cover and lift UP and

remove from Printer (see detail of hinge mechanism below).

NOTE Detail of hinge mechanism.

HP DesignJet 5000 and 5500 Series Printers Service Manual

8-5

Removal and Installation

Left Hand Cover

Removal

WARNING Switch off the Printer and remove the power cable.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove ALL the Ink Cartridges from

the Printer.

2. Open the Top Cover.

3. Open the door at the back of the Left

Hand Cover.

8-6

HP DesignJet 5000 and 5500 Series Printers Service Manual

Removal and Installation

4. Disconnect the Electrical Cable from

the rear of the Ink Cartridge Tube Connector.

5. Disconnect the Air Tube.

6. Twist the 3 latches at the rear of the

Ink Cartridge Tube Connector and release the complete Assembly.

HP DesignJet 5000 and 5500 Series Printers Service Manual

8-7

Removal and Installation

7. Remove the Ink Cartridge Tube

Connector and place safely on the window.

8. Remove 1 T-15 screw (Type F) from

the Left Hand Cover (rear).

9. Close the Left Back door and remove 1 T- 25 screw (Type U) from bottom side (rear) of Left Hand Cover.

8-8

HP DesignJet 5000 and 5500 Series Printers Service Manual

Removal and Installation

10. Remove 3 T-15 screws (Type F) from

the Left Hand Cover (front).

11. Remove the Left Hand Cover from the

Printer.

Installation of Left Hand Cover

WARNING When handling the Tubes make sur e you do not damage the m by

twisting.

WARNING When inserting the Left Hand Cover, be careful not to pinch/

twist the air tube or the electrical cable.

HP DesignJet 5000 and 5500 Series Printers Service Manual

8-9

Removal and Installation

Right Hand Cover

Removal

WARNING Switch off the Printer and remove the Power Cord.

WARNING T o r emove the Right Hand Cover you must open the Right Cover

door and push in the Printhead Cleaner Carriage.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove the Right Rear Cover - Refer

to Page 8-16.

2. Remove the Ferrite (if present) and disconnect the Front Panel cable from the Main PCA (P24) from the left side of the Electronics Module.

P29

P30

P24

3. On the Main PCA, disconnect the

Aerosol Fan cable from position P30 and the service station door from position P29.

8-10

HP DesignJet 5000 and 5500 Series Printers Service Manual

Removal and Installation

4. Remove 1 T-15 screw (Type F) and 1

T-25 screw (Type U) (bottom) from the rear of the Right Hand Cover.

5. Open the Top Cover.

6. Raise the Media Lever.

HP DesignJet 5000 and 5500 Series Printers Service Manual

8-11

Removal and Installation

NOTE Take care not to drop the

Cover when removing the screws. Support the Cover throughout the next step.

7. Remove 3 T-15 (Type F) screws from

the front of the Right Hand Cover.

8. To release the cables, carefully pull out the Right Hand Cover until the cables can be accessed.

8-12

9. Remove the Right Hand Cover.

HP DesignJet 5000 and 5500 Series Printers Service Manual

Removal and Installation

TIP To check cor rect functioning

of serviced parts on the Printer axis you can do the following:

a Reinsert the top T -15 screw (Type F) at

the rear of the Printer.

b Hang the Cover on the screw. c Connect all cables at the Rear of the

Right Cover and turn on the Printer.

Installation of Right Hand Cover

NOTE Make sure the Front Panel cable and the Aerosol Fan cables are

secured inside the Right Hand Cover with cable clamps and retaining pins.

WARNING Make sure cables pass through slot at re ar of chassis on the right

hand side otherwise the Cover cannot be properly installed and cables may be damaged.

HP DesignJet 5000 and 5500 Series Printers Service Manual

8-13

Removal and Installation

Front Panel Assembly

Removal

WARNING Switch off the Printer and remove the Power Cord.

1. Remove Right Rear Cover - Refer to

Page 8-15.

2. Remove Right Hand Cover - Refer to Page 8-10.

3. Disconnect the cable from Front Panel.

Lift towards you

4. Unclip Front Panel supports inside the

Right Hand Cover and remove.

8-14

HP DesignJet 5000 and 5500 Series Printers Service Manual

Removal and Installation

Left Rear Cover

Removal

WARNING Switch off the Printer and remove the Power Cord.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove one T -15 screw (Type B)

from the Left Rear Cover.

NOTE Support the Cover as it is

released.

2. Remove the Left Rear Cover.

HP DesignJet 5000 and 5500 Series Printers Service Manual

8-15

Removal and Installation

Right Rear Cover

Removal

WARNING Switch off the Printer and remove the Power Cord.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove one T -15 screw (Type B)

from the Right Rear Cover.

NOTE Support the Cover as it is

released.

2. Remove the Right Rear Cover.

8-16

HP DesignJet 5000 and 5500 Series Printers Service Manual

Removal and Installation

Extension Cover (60" Model only)

Removal

WARNING Switch off the Printer and remove the Power Cord.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove the Left Rear Cover - Refer

to Page 8-15.

2. Remove 4 T -15 screws (Type B) from

the Extension Cover.

3. Lift the Cover and remove from the

Printer.

HP DesignJet 5000 and 5500 Series Printers Service Manual

8-17

Removal and Installation

Media Lever Assembly

Removal

WARNING Switch off the Printer and remove the Power Cord.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Only applicable to the DesignJet 5000 Series - Remove the Deflector

closest to the Right Cover - Refer to Page 8-119.

2. Remove the Right Hand Cover - Refer to Page 8-10.

3. Raise the Media Lever.

8-18

4. Remove 1 T-15 screw (Type D) from the support that attaches the Media Lever to the Sideplate.

HP DesignJet 5000 and 5500 Series Printers Service Manual

Removal and Installation

5. Remove 1 T-15 screw (Type H) that

attaches the Lever Arm to the Lever.

6. Remove the Media Lever.

Installation of the Media Lever Assembly

WARNING When installing the Media Lever, you must insert it in the Trim

and Sideplate in the UP position to avoid damaging the Lever Spring in the Trim.

HP DesignJet 5000 and 5500 Series Printers Service Manual

8-19

Removal and Installation

Right Hand Trim

Removal

WARNING Switch off the Printer and remove the Power Cord.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove Right Rear Cover - Refer to

Page 8-16.

2. Remove Right Hand Cover - Refer to Page 8-10.

3. Remove Media Lever Assembly Refer to Page 8-18.

4. Disconnect the Sensors cable from position P27 on the Main PCA.

P27

5. Remove 1 T -15 screws (Type F) and 1

T-20 (Type L) from the Right Hand Trim.

8-20

HP DesignJet 5000 and 5500 Series Printers Service Manual

Removal and Installation

6. Carefully remove the Right Hand

Trim.

Remove carefully

Installation of Right Hand Trim

WARNING When installing the Media Lever in the Trim, install with the

Lever in the UP position to avoid damaging the Lever spring in the Trim.

HP DesignJet 5000 and 5500 Series Printers Service Manual

8-21

Removal and Installation

Left Hand Trim

Removal

WARNING Switch off the Printer and remove the Power Cord.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove 4 T -15 screws (Type F) and 1

T-20 screw (Type L) from the Left Hand Trim.

Remove carefully

2. Carefully remove the Left Hand Trim.

8-22

HP DesignJet 5000 and 5500 Series Printers Service Manual

Removal and Installation

Back Cover

Removal

WARNING Switch off the Printer and remove the Power Cord.

NOTE Refer to the table on Page 8-4 for information on screw types.

1. Remove the Top Cover - Refer to

Page 8-5.

2. Remove the following (Type B)

screws from the upper part of the Back Cover:

n 8 Screws (T-15) for the 60" Model. n 6 Screws (T-15) for the 42" Model.

NOTE Support the Back Cover as it

is released.

3. Remove 3 T -15 screws (Type N) from

the lower part of the Back Cover.

HP DesignJet 5000 and 5500 Series Printers Service Manual

8-23

Removal and Installation

4. Remove the Back Cover.

Installation of the Back Cover

NOTE If the Back Cover is replaced, remember to apply a new Printer

Label to the new Back Cover before it is installed. Once the new label has been applied, copy the product number and serial number onto it.

8-24

HP DesignJet 5000 and 5500 Series Printers Service Manual

Removal and Installation

Ink Tubes System

Removal

WARNING Switch off the Printer and remove the Power Cord.

1. Open the Right Cover door and pull

out the Printhead Cleaner Carriage.

2. Open the Top Cover and pull the

Carriage out along the Printer to the position shown.

3. Lift up the Carriage Cover and

remove ALL the Printheads and close the Carriage Cover.

HP DesignJet 5000 and 5500 Series Printers Service Manual

8-25

Removal and Installation

4. Slide the Carriage to the position shown.

5. Push in the 2 retaining clips either side of the Printhead Tube Connector.

6. Pull the Printhead Tube Connector towards you.

8-26

HP DesignJet 5000 and 5500 Series Printers Service Manual

Removal and Installation

7. Push the button to release the

Printhead Tubes in the Carriage.

8. Release the Retaining Clip by pulling

it away from the holding brackets.

9. Pull the Printhead Tube Connector up

between the two Tube Guides.

HP DesignJet 5000 and 5500 Series Printers Service Manual

8-27

Removal and Installation

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 Left Cover.

8-28

HP DesignJet 5000 and 5500 Series Printers Service Manual

Removal and Installation

13. Disconnect the Electrical Cable from

the rear of the Ink Cartridge Tube Connector.

14. Disconnect the Air Tube.

15. Twist the 3 latches at the rear of the

Ink Cartridge Tube Connector and release the complete Assembly.

HP DesignJet 5000 and 5500 Series Printers Service Manual

8-29

Removal and Installation

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 Ink Tubes System

WARNING When installing the Ink Tubes System it is very important that

the Tubes are NOT TWISTED. Make sure that the Tubes are correctly routed at the rear of the Left Cover and before powering On the printer, check again that they are NOT TWISTED.

NOTE Do not install NEW Ink Tubes System with Ink Cartridges that

indicate Low or Very Low ink levels.

NOTE Before installing the new Ink Tubes System, make sure that the

Ink Type (Dye or UV) of the Tubes is the same as the ones that you are replacing.

8-30

HP DesignJet 5000 and 5500 Series Printers Service Manual

+ 94 hidden pages