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
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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.
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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
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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
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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.
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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.
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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.
1
2
6. Twist the 3 latches at the rear of the
Ink Cartridge Tube Connector and release the complete Assembly.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
2
1
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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.
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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.
2
1
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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Removal and Installation
13. Disconnect the Electrical Cable from
the rear of the Ink Cartridge Tube Connector.
14. Disconnect the Air Tube.
1
2
15. Twist the 3 latches at the rear of the
Ink Cartridge Tube Connector and release the complete Assembly.
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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.
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Removal and Installation
NOTE When the Ink Tubes System is replaced, to restart the Printer
perform the following procedures.
1. Install the Setup Printheads (refer to
the Users Guide).
2. Connect the Power Cable and turn on
the main Power Switch at the rear of the Printer.
3. The Front Panel warns that there are
no Ink Cartridges installed.
INK STARTUP
Initializing Printer Please wait 60 sec
4. Install the Ink Cartridges (refer to the
Users Guide for details).
5. The Front Panel displays the message
shown.
6. Wait about 60 seconds for the next
instruction.
7. Remove the Setup Printheads from the
Printhead Carriage.
8. Install the Printheads and the
Printhead Cleaners (refer to the User’s Guide for details).
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Removal and Installation

EMC Covers

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.
NOTE The EMC Cover is composed of three parts; T op, Lower Left and
Lower Right. Procedures below describe removal of the EMC Covers as; one assembly, the Top only , the Lower Right only . The procedure you select depends on the part you want to access.
EMC Covers as one assembly
1. Remove the Top Cover - Refer to
Page 8-5.
2. Remove the Back Cover - Refer to Page 8-23.
3. Remove Right Rear Cover - Refer to Page 8-16.
4. Remove Left Rear Cover - Refer to Page 8-15.
5. Remove Electronics Module - Refer to Page 8-97.
6. Disconnect connector from Ink Leak Detector and remove 1 T-15 screw (Type B) to remove Ink Leak Detector cable clamp.
NOTE The Ink Leak Detector is
NOT present in the DesignJet 5500 Series and in some DesignJet 5000 Series printers.
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Removal and Installation
7. Remove the following screws (Type
N) from the Top EMC Cover.
n 8 T-15 screws for the 60" Model. n 6 T-15 screws for the 42" Model.
8. Loosen 4 T-15 screws (Type L) on
Lower Covers and remove all Covers as one assembly.
Lower Right Cover
1. Do steps 1 to 5 of the EMC Covers as
one assembly procedure.
2. Remove 2 T-15 screws (Type B) and
loosen 2 T -15 bottom screws (Type L) to remove cover.
Top EMC Cover
1. Do steps 1, 2 and 6 of the EMC
2. Remove the following screws (Type
3. Lift the Top EMC Cover off Printer.
HP DesignJet 5000 and 5500 Series Printers Service Manual
Covers as one assembly procedure.
B and N) screws from the Top EMC
Cover.
n 13 T-15 screws for 60" Model. n 11 T-15 screws for 42" Model.
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Removal and Installation

Encoder Strip

Removal

WARNING Switch off the Printer and remove the Power 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 Top Cover - Refer to Page 8-5.
4. Remove the Back Cover - Refer to Page 8-23.
5. Remove the Top EMC Cover - Refer to Page 8-32.
1. Apply Pressure
6. Remove the 5.5 mm nut from the left
hand side of the Printer that attaches the Encoder Strip to the Spring Clip.
TIP The next step is performed
by putting pressure on the Spring Clip as shown.
7. Release the Encoder strip from the
Spring Clip.
2. Release Encoder Strip
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Removal and Installation
8. Remove the 5.5 mm nut from the right
hand side of the Printer.
9. Remove the Encoder Strip from the
Printer.
2 Pull strip out
1 Lift off pins

Installation of Encoder Strip

WARNING When Installing the Encoder Strip, make sure it is placed in the
Encoder Sensor on the rear of the Carriage Assembly as shown below.
Insert Encoder Strip
HP DesignJet 5000 and 5500 Series Printers Service Manual
Encoder Sensor
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Removal and Installation

Trailing Cable

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 Right Rear Cover - Refer to Page 8-16.
3. Remove the Right Hand Cover - Refer to Page 8-10.
4. Remove the Left Hand Cover - Refer to Page 8-6.
5. Slide the Carriage to the left side of the Printer.
6. Unclip and remove the Carriage Cover to access the Trailing Cable in the Carriage.
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HP DesignJet 5000 and 5500 Series Printers Service Manual
Press down in center to release
Removal and Installation
7. Carefully disconnect the Trailing
Cables (3) from the connectors in the Carriage PCA.
NOTE Remove Trailing Cable
Ferrites if they fall into the Carriage
n 3 for 60" Model n 1 for 42" Model
8. Remove the Trailing Cables from the
Trailing Cable Holder.
TIP Press the Trailing Cables
firmly in the center to release.
Slide out
9. Slide the Trailing Cable Guide out of
the Carriage.
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Removal and Installation
10. Carefully disconnect the Trailing Cable from the Main PCA.
NOTE Unclip the Trailing Cable
when disconnecting from the Main PCA.
11. Remove the T-20 screw (Type C)
from the Trailing Cable Clip on the left.
NOTE There is a hole in the Tube
Guide to access the screw.
12. Remove 2 T-10 screws (Type I) from
the Trailing Cable Clip on the right.
NOTE Take care when removing
and inserting these screws as they are easily damaged and not easy to access.
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13. Carefully lift the Clips and the
Trailing Cable from the Printer.

Installation of Trailing Cable

WARNING Do not install damaged Trailing Cables. If the Trailing Cable is
incorrectly installed or it is damaged, a "Power Supply Error #1" message will appear on the Front Panel during ini tialization.
Check edge for damage
WARNING When Installing the Trailing Cable, make sure you install it as
follows:
1. Install the Trailing Cable starting from
the Clip on the left as this will provide a reference point for adjusting the length of the Trailing Cable.
Left Clip
locating pin
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Removal and Installation
2. Insert the Trailing Cable Guide into the Carriage and connect the Trailing Cables.
NOTE Remember to pass the
Trailing Cables through the Ferrite(s).
n 3 for 60" Model. n 1 for 42" Model.
3. Insert the Trailing Cable through the Chassis slot next to the Trailing Cable Clip on the right (see diagram in step
4).
Slot
Right Clip
locating pin
4. Place the Right Trailing Cable Clip in
position and adjust the length of the Trailing Cable.
NOTE This clip has a locating pin so
make sure this is in position and the Trailing Cable is the right length before installing the screw.
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HP DesignJet 5000 and 5500 Series Printers Service Manual
NO BUBBLES
Left Clip locating pin
Removal and Installation
TIP Make sure the Trailing Cable
is flat on the chassis without bubbles.
Right Clip
NOTE Check the cable and clips are
correctly installed by sliding the carriage along the Printer to see if it moves freely.
Install with edges straight on
Strip will not be visible when installed correctly
5. Connect the Trailing Cables to the
Main PCA.
NOTE Make sure the vertical strips
on Trailing Cable ends are fully inserted inside the connectors. The strip should not be visible when inserted correctly.
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Removal and Installation

Tensioner 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. Remove the Left Hand Cover - Refer
to Page 8-6.
2. Remove the Right Hand Cover - Refer to Page 8-10.
3. Remove the 5.5 mm nut from the left hand side of the Printer that attaches the Encoder Strip to the Spring Clip.
1. Apply Pressure
2. Release Encoder Strip
TIP The next step is performed
by putting pressure on the Spring Clip as shown.
4. Release the Encoder Strip from the
retaining pin on the Spring Clip.
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HP DesignJet 5000 and 5500 Series Printers Service Manual
Tighten screw
Tighten screw
Removal and Installation
5. Using a screwdriver, fully tighten the
Spring Release Screw to release the tension on the Belt.
6. From the right-hand side, lift the
Tensioner Belt off the Scan-Axis Motor.
7. Remove 1 T-15 screw (Type L) from
the Tensioner Assembly.
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Removal and Installation
8. Remove the Belt Wheel on the left side.
9. Remove the T ensioner Assembly from the left-hand side.
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Removal and Installation

Installation of Tensioner Assembly

NOTE Before installation, clean and oil the Slider Rods using the User’ s
Slider Rods Lubrification Kit (Refer to Page 9-8).
WARNING Be careful not to twist the Belt when installing the Tensioner
Assembly.
WARNING When installing the Enco der Strip, make sure it is in serted in the
Encoder Sensor on the rear of the Carriage Assembly as shown below.
Insert Encoder Strip
Encoder Sensor
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Removal and Installation

Carriage Assembly and Belt

Removal

WARNING Switch off the Printer and remove the 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.
4. Remove the Tensioner Assembly ­Refer to Page 8-42.
5. Pull out Printhead Cleaner Carriage.
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6. Slide Carriage Assembly to position shown.
HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation
7. Lift up the Carriage Cover and
remove ALL the Printheads and close the Carriage Cover.
8. Slide the Carriage along the Printer to
the position shown.
9. Push in the 2 retaining clips either side
of the Printhead Tube Connector.
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Removal and Installation
10. Pull the Printhead Tube Connector towards you.
11. Push the button to release the Printhead Tubes in the Carriage.
12. Release the retaining clip by pulling it away from the holding brackets.
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13. Pull the Printhead Tube Connector up
between the two Tube Guides.
14. Slide the Carriage to the left side of
the Printer.
15. Unclip and remove the Carriage
Cover to access the Trailing Cable in the Carriage.
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Removal and Installation
Press down in center to release
16. Carefully disconnect the Trailing
Cables (3) from the connectors in the Carriage PCA.
NOTE Remove Trailing Cable
Ferrites if they fall into the Carriage
n 3 for 60" Model. n 1 for 42" Model.
17. Remove the Trailing Cables from the Trailing Cable Holder.
TIP Press the Trailing Cables
firmly in the center to release.
Slide out
18. Slide the Trailing Cable Guide out of
the Carriage.
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19. Slide the Carriage (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.
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Removal and Installation

Installation of Carriage and Belt

NOTE Before installation, clean and oil the Slider Rods using the User’s
Slider Rods Lubrification Kit (Refer to the Users Guide).
WARNING Make sure you install the Carriage Assembly and Belt as follows:
1. Insert belt as indicated on the
underside of Carriage.
TIP An arrow on the bottom of
the Carriage indicates position and direction.
2. Line up the Carriage Guide, on the
underside of the carriage, with the Slider Rods on the Printer.
NOTE Perform the following
Service Calibrations after the installation of the Carriage Assembly:
n Carriage Height Page 5-18. n Service Station Page 5-11. n Scan Axis Page 5-7.
8-52
n Printhead Alignment User Guide. n Color Calibration User Guide.
HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation

Line Sensor

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 Carriage Assembly -
Refer to Page 8-46.
2. Unclip the Carriage Cover from both
sides of the Carriage Assembly.
3. Remove the Carriage Cover.
NOTE Make sure both sides of the
cover are unclipped before removing. Also make sure the cover is removed vertically, if not the Cover Retaining Pins can be broken.
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-53
Removal and Installation
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 sides are also released.
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HP DesignJet 5000 and 5500 Series Printers Service Manual

Installation

Removal and Installation
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 into place.
NOTE Make sure the Line Sensor is
clipped correctly and
securely, if not the Line Sensor will malfunction.
3. Connect the Line Sensor Connector to
the Carriage PCA.
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-55
Removal and Installation
3XVKKHUH
4. Install the Carriage Cover.
NOTE Make sure the cover is
installed vertically, if not the Cover Retaining Pins can be broken.
5. Clip the Carriage Cover on both sides
of the Carriage Assembly by pushing the clip downwards (with force if necessary).
NOTE Make sure the clips are
locked correctly, if not the Carriage Cover could become loose and cause major damage to the printer.
NOTE You must perform the
following Calibration when the Line Sensor is replaced:
n Scan Axis Calibration Page 5-7.
8-56
HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation

Scan-Axis Motor

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 Right Rear Cover - Refer
to Page 8-16.
2. Remove the Left Hand Cover - Refer
to Page 8-6.
3. Remove the Right Hand Cover - Refer
to Page 8-10.
4. Remove the 5.5 mm nut from the left
hand side of the Printer that attaches the Encoder Strip to the Spring Clip.
TIP The next step is performed
5. Release the Encoder strip from the
1. Apply Pressure
2. Release Encoder Strip
HP DesignJet 5000 and 5500 Series Printers Service Manual
by putting pressure on the Spring Clip as shown.
Spring Clip.
8-57
Removal and Installation
Tighten screw
6. Using a screwdriver, fully tighten the
Spring Release Screw to release the tension on the Belt.
7. Disconnect the Scan-Axis Motor Cable from position P23 on the Main PCA.
P23
8. Unclip the Scan-Axis Motor Cable
from underneath the Service Station.
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HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation
9. From the right-hand side, lift the
Tensioner Belt off the Scan-Axis Motor.
10. While supporting the Scan-Axis
Motor, remove 2 T-15 screws (Type
B).
11. Lower the Scan-Axis Motor and
remove from the Printer.

Installation of the Scan-Axis Motor

NOTE Before installation, clean and oil the Slider Rods using the User’s
Slider Rods Lubrification Kit (Refer to Page 9-8).
WARNING When installing the Enco der Strip, make sure it is in serted in the
Encoder Sensor on the rear of the Carriage Assembly.
Note: When installing the Belt, make sure that it is not twisted.
Insert Encoder Strip
Encoder Sensor
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-59
Removal and Installation

Cutter 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. Open the Top Cover.
2. 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.
8-60
HP DesignJet 5000 and 5500 Series Printers Service Manual
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.
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-61
Removal and Installation
7. Push the button to release the Printhead Tubes from the Carriage.
8. Release the retaining clip by pulling it away from the holding brackets.
9. Remove 1 T-8 screw (Type V) and washer that attaches the Cutter to the Carriage.
8-62
HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation
10. Slide the Cutter towards you and
remove from the Printer.
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-63
Removal and Installation

Ink Supply St ation (ISS)

Removal

WARNING Switch off the Printer and remove the Power Cord.
1. Remove the Left Hand Cover - Refer
to Page 8-6.
2. Remove the Left Rear Cover - Refer to Page 8-15.
3. Remove the Back Extension Cover (Only for the 60" Model) - Refer to Page 8-17.
4. Disconnect APS Cables (P5, P4 and P3) from the ISS PCA.
P5 P4
P3
Press here
5. T o remove the ISS, stand at the end of
the Printer and press in the retaining clip on the ISS.
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HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation
INSIDE VIEW FRONT
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 ISS to the left and pull out
2
the left side to remove from the Printer.
INSIDE VIEW REAR
1
1
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-65
Removal and Installation

Installation of ISS

NOTE If the ISS is to be replaced, make sur e you remove the APS from
the old ISS and, after installing the Grounding Plate, reinstall it on the new ISS.
WARNING When replacing the ISS re member to insert the Ground ing Plate
into the slot as shown (before reinstalling the APS).
8-66
HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation

Air Pressurization System (APS)

Removal

WARNING Switch off the Printer and remove the Power Cord.
1. Remove the Left Hand Cover - Refer
to Page 8-6.
2. Remove the Left Rear Cover - Refer
to Page 8-15.
3. Remove the Back Extension Cover
(Only for the 60" Model) - Refer to Page 8-17.
4. Remove the ISS - Refer to Page 8-64.
5. Remove the cables and tube from the
slot on the ISS.
n For the 42" Model, open the Cable
Clip under the ISS holding the APS Cables to the ISS.
NOTE When removing the APS
from the ISS, take care with the tube and cabl es attached to the ISS.
6. Push the retaining clips on the left side
of the APS to release it from the ISS.
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-67
Removal and Installation

Installation of APS

WARNING When Installing the Air Pressurization System make sure the
tube and wires are placed in the dedicated slots and perform the following steps:
1. Before installing the APS on the ISS,
insert first the 3 cables and then the tube in the dedicated slot.
2. Install the APS on the ISS.
3. For the 42" Model, secure the APS
Cables to the ISS using the Cable Clip under the ISS.
NOTE Before installing the ISS on
the Printer, make sure the cable and tube are inserted in the ISS slot.
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HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation

Service St at ion 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. Remove the Right Rear Cover - Refer
to Page 8-16.
2. Remove the Right Hand Cover - Refer
to Page 8-10.
3. Remove the Printhead Cleaners.
4. Manually slide the Carriage out of
the Service Station.
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-69
Removal and Installation
5. Disconnect the Service Station Cable from the Main PCA (P15).
P15
6. Unclip the Scan-Axis Motor Cable
from the Service Station.
NOTE Follow the instructions in
step 7 carefully; LOOSEN the screw and DO NOT remove.
7. Loosen the T-20 screw (Type A)
securing the Service Station to the side plate.
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HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation
8. Remove 2 T-15 screws (Type F)
between the two slider rods that attach the Service Station to the Chassis.
9. Standing in front of the Service
Station, lift it off the loosened screw.
10. Pull the assembly out towards you and
remove from the Printer.
NOTE Perform the following
Service Calibration if the Service Station Assembly is replaced:
n Service Station Page 5-11.
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-71
Removal and Installation

Drop Detector Assembly

Removal

WARNING Switch off the Printer and remove the Power 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 Service Station Asse mbly
- Refer to Page 8-69.
4. Disconnect the Drop Detector cable from the Service Station Cable.
Press clip to disconnect
5. Release the cable from the Service
Station.
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HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation
6. Remove the T-15 screw (Type F) that
attaches the Drop Detector Assembly to the Service Station.
7. Remove the Drop Detector from the
Service Station.
NOTE Move the Drop Detector
1
2
towards the front of the Service Station until the locating pin reaches the end.
Pin
8. Lift the Foam from the Service
Station.
NOTE The Foam may be full of ink
so be careful when ha ndling it.
NOTE If you replace the Drop
Detector you must perform the following Service Calibration:
n Service Station Page 5-11.
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-73
Removal and Installation

Hard Disk Drive (HDD)

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 6 T -15 screws (Type B) from
the HDD Access Cover. Remove the HDD Access Cover.
2.
Remove the HDD with its foam holder.
3. Disconnect the HDD Cable and Power Supply Cable from the HDD.
8-74
HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation

Installation of Hard Disk Drive

NOTE If you replace the Main PCA and the HDD at the same time you
must perform ALL Service Calibrations (Page 5-3) and the EEROM Setup Service Utility (Page 4-23).
WARNING When Installing the Hard Disk Drive make sure the holder is
placed in the right position so that it cannot move.
NOTE When the Hard D isk D r ive is
replaced perform the following Service Utility:
n Backup EEROM (select HDD
replaced) Page 4-30.
NOTE
If you have to replace the HDD Cable, refer to the following drawing:
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&$86(620(,17(50,77(17352%/(06
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-75
Removal and Installation

LAN Card

Removal

WARNING Switch off the Printer and remove the Power 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 attach the LAN Card to the Printer.
3. Remove the LAN Card and store in a safe place.
8-76
HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation

Memory and BootROM DIMM’s

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-10 screws (Type P) from
the DIMM Access Cover. Remove the DIMM Access Cover.
2. To remove a DIMM, first push down
2
1
the lower locking tab and then push up the upper locking tab to release the DIMM.
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-77
Removal and Installation
3. Pull out the DIMM. Take care that it does not fall out.

Installation of DIMM’s

WARNING When installing the DIMM’s make sure they are in the correct
position as shown in the diagram.
NOTE Note the position of the BootROM and the SDRAM (memory)
modules.
J6 - Boot ROM
J7 - SDRAM
J8 - SDRAM
8-78
HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation

Electronics Module 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 LAN Card - Refer to
Page 8-76.
2. Remove Left Rear Cover - Refer to
Page 8-15.
3. Remove Right Rear Cover - Refer to
Page 8-16.
4. If present, remove the Ferrites from
the Ferrite Holder on the right side.
Push clip to release Ferrite (if present)
5. Remove 15 T-15 screws (Type B)
from the Electronics Module Cover.
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-79
Removal and Installation
Lift clips
NOTE Lift the Parallel Port Clips
before removing the Cover.
6. Remove the Electronics Module
Cover.

Installation of the Electronics Module Cover

NOTE When Installing the Electronics Module Cover make sure the
parallel port connector clips are in closed position i.e. UP, so that they pass through the slot in the Cover.
Lift clips
8-80
HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation

Main PCA

WARNING This assembly does NOT include the PCI-to-IDE PCA (the small
PCA that connects the Main PCA to the Hard Disk Drive) as it used to in the past. When installing the new Main PCA, mak e sure that you reuse the PCI-to-IDE PCA that was disassembled previously.
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WARNING If you are working with an hp designjet 5000 (C6090A/V/I,
C6091A/V, C6095A/V/I, C6096A/V) and the new Main PCA has the following connectors, you do NOT need to use them (they can be ignored):
127QHHGHG
3
3+HDWHU
127QHHGHG
HP DesignJet 5000 and 5500 Series Printers Service Manual
21/<RQKSGHVLJQMHW
8-81
Removal and Installation

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 LAN Card - Refer to
Page 8-76.
2. Remove the Left Rear Cover - Refer to Page 8-15.
3. Remove the Right Rear Cover - Refer to Page 8-16.
4. Remove the Electronics Module Cover - Refer to Page 8-79.
5. Disconnect and remove the Hard Disk Drive for safety reasons - Refer to Page 8-74.
6. Remove ALL Firmware/Memory DIMMs - Refer to Page 8-77.
NOTE 0DNHVXUH\RX UHLQVWDOO WKH
)LUPZDUH0HPRU\ ',00V RQWKHQHZ0DLQ3&$
7. Disconnect ALL Cables from the Electronics Module.
8. Remove 2 T-10 screws (Type K) to remove the PCI-to-IDE PCA.
8-82
HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation
9. Disconnect the PCI-to-IDE PCA and
remove from the Printer.
NOTE Make sure you reuse the
PCI-to-IDE PCA when reassembling.
10. Remove 6 T -10 screws (Type K) from
the Main PCA.
11. Loosen 2 T-10 screws on the Main
PCA.
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-83
Removal and Installation
12. Remove by sliding the Main PCA to the left and lifting out (see detail below).
NOTE Detail of Main PCA removal.

Installation of Main PCA

NOTE When the Main PCA has been replaced, perform the Backup
EEROM Page 4-30.
NOTE If you replace the Main PCA and the HDD at the same time you
must perform ALL Service Calibrations (⇒ Page 5-3) and the EEROM Setup Service Utility (⇒ Page 4-23).
NOTE If you are not sure how the cables are connected on th e Main
PCA, each connector is labelled with the name of the assembly to which it is connected.
NOTE
When installing the Hard Disk Drive, please refer to the instructions for the instal la tio n of th e P CI- to -ID E PC A ( R efe r to P ag e the installation of the HDD Cable (Refer to Page
8-87
8-86
) and
).
8-84
HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation

PCI-to-IDE PCA

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 LAN Card - Refer to
Page 8-76.
2. Remove the Left Rear Cover - Refer
to Page 8-15.
3. Remove the Right Rear Cover - Refer
to Page 8-16.
4. Remove the Electronics Module
Cover - Refer to Page 8-79.
5. Disconnect and remove the HDD for
safety reasons - Refer to Page 8-74.
6. Remove 2 T-10 screws that secure the
PCI-to-IDE PCA.
7. Disconnect the PCI-to-IDE PCA and
remove from the Printer.
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-85
Removal and Installation

Installation of the PCI-to-IDE PCA

NOTE When installing the new PCI-to-IDE PCA, CONNECT THE
HDD POWER CABLE TO THE P36 CONNECTOR (IF PRESENT) ON THE PCI-TO-IDE PCA AND NOT TO THE P11 CONNECTOR ON THE MAIN PCA (even if the P11 connector is present and the HDD Power Cable was connected there previously).
2.
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12
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7+,6&211(&725
,)7+(3
&211(&725,6
35(6(17217+(
3&,WR,'(3&$
8-86
HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation

Installing the HDD Cable

When installing the HDD Cable between the HDD and the PCI-to-IDE PCA, make sure you connect the correct ends as follows:
/RRSHG(QGFRQQHFWVWR
6KRUW&RQQHFWRUFRQQHFWV
WKH+DUG'LVN'ULYH
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,)7+(+''&$%/(,6127&211(&7('&255(&7/<,70$<
&$86(620(,17(50,77(17352%/(06
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-87
Removal and Installation

Power Supply Unit (PSU)

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 LAN Card - Refer to
Page 8-76.
2. Remove the Left Rear Cover - Refer to Page 8-15.
3. Remove the Right Rear Cover - Refer to Page 8-16.
4. Remove the Electronics Module Cover - Refer to Page 8-79.
PCA PS Connector
5. Disconnect and remove the Hard Disk Drive for safety reasons - Refer to Page 8-74.
6. Disconnect the PCA Power Supply connector from the Main PCA.
8-88
HP DesignJet 5000 and 5500 Series Printers Service Manual
PS Fans
Removal and Installation
7. Remove the plastic protective cover
from the Power Supply Unit.
8. Disconnect ALL Cables from the PSU
(see Installation of PSU for connections).
Press
PS Switch
PS Socket
9. Remove 7 T-10 screws (Type K) and
remove the PSU.
HP DesignJet 5000 and 5500 Series Printers Service Manual
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Removal and Installation

Installation of the Power Supply Unit (PSU)

WARNING After installing the Power Supply Unit, remember to place the
plastic protective cover over the unit.
NOTE The Power Supply Unit connections are illustrated below.
PS Fans
PS Socket
PS Switch
8-90
HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation

Ink Supply St ation (ISS) PCA

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 LAN Card - Refer to
Page 8-76.
2. Remove the Left Rear Cover - Refer
to Page 8-15
3. Remove the Right Rear Cover - Refer
to Page 8-16.
4. Remove the Electronics Module
Cover - Refer to Page 8-79.
5. Disconnect ALL Cables from the ISS
PCA (see installation of ISS PCA for connections).
6. Remove 5 T -10 screws (Type K) from
the ISS PCA.
7. Remove the ISS PCA.
HP DesignJet 5000 and 5500 Series Printers Service Manual
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Removal and Installation

Installation of the ISS PCA

NOTE The ISS PCA connections are illustrated below.
P5
P6
P4
J3
P3
P2
J1
J Position
J1 J3
Connection Connector
Color
ISS Cable white
Main PCA white
P Position
P2*
P3
P4 P5** P6**
Connection Connector
Color Ink Leak Detector white APS Temperature white
APS Valve red
APS Pump white
APS Pump (Spare) white
* The Ink LeakDetector has been discontinued so this connector is no longer used.
** There are 2 connectors available for the APS Pump and any one of them can be used.
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HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation

Ink Leak Detector - If Present (Only Applicable to the 5000 Series)

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 the Top Cover - Refer to
Page 8-5.
3. Remove the Back Cover - Refer to
Page 8-23.
P2
4. Disconnect the Ink Leak Detector
cable at position P2 from the ISS PCA.
5. Remove one T-15 screw (Type B) to
release the cable clip on the Top EMC cover.
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-93
Removal and Installation
6. Press the retaining clip on the Ink
Leak Detector and release it.
TIP A screwdriver can be used to
press the retaining clip down.
7. Remove the Ink Leak Detector from
the Printer.
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HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation

Cooling Fans

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 LAN Card - Refer to
Page 8-76.
2. Remove the Left Rear Cover - Refer
to Page 8-15.
3. Remove the Right Rear Cover - Refer
to Page 8-16.
4. Remove the Electronics Module
Cover - Refer to Page 8-79.
5. Disconnect and remove the Hard Disk
Drive for safety reasons - Refer to Page 8-74.
6. Remove 2 screws for each Cooling
Fan from underneath the Electronics Module.
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-95
Removal and Installation
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.
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HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation
LEFT

Electronics Module (as one complete 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. Remove the Left Rear Cover - Refer
to Page 8-15.
2. Remove the Right Rear Cover - Refer
to Page 8-16.
3. Disconnect ALL Cables from the
Main PCA (Right Rear Cover) and ISS PCA (Left Rear Cover) and remove the Ferrites from the left side.
4. Remove 2 T -15 screws (Type B) from
the both sides of the Electronics Module.
RIGHT
5. Lift the Electronics Module up (to
clear it from the shoulder screws) and remove from the Printer.
1
2
1
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-97
Removal and Installation

Pinch-Wheels

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 Back Cover - Refer to
Page 8-23.
3. Remove the Electronics Module -
Refer to Page 8-97.
4. Remove EMC Covers as one
assembly - Refer to Page 8-32.
NOTE For the next steps place the
Media Lever in the UP position.
5. Remove the following T-20 screws (Type Q):
n For the 60" Model remove 4 screws
from each group of 4 Pinch-Wheels (5 groups in total).
n For the 42" Model remove 4 screws
from each group of 4 Pinch-Wheels (3 groups in total) and 2 screws from the one group with 2 Pinch­Wheels.
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HP DesignJet 5000 and 5500 Series Printers Service Manual
Removal and Installation
6. First remove lateral Pinch-Wheels
with their Coupling Plates.
NOTE For Pinch-Wheel groups
installed around the Mount Brackets do the following:
REMOVE
COUPLING PLATES
7. From the front of the Printer, remove
the Coupling Plate corresponding to the position of the Mount Bracket.
n 3 Mount Brackets in the 60" Model. n 1 Mount Bracket in the 42" Model.
8. From the rear of the Printer, rotate the
group (90 degrees) and pull it through
R
O
T
A
1
T
E
0
9
0
the gap left by the Coupling Plate.
2

Installation of Pinch-Wheels

NOTE During installation, make sure you install the White Pinch-
Wheels at each end of the Printer axis.
HP DesignJet 5000 and 5500 Series Printers Service Manual
8-99
Removal and Installation

Pinch-Wheel Cam

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 Left Rear Cover - Refer to Page 8-15.
3. Remove the Deflectors - Refer to Page 8-119.
4. Remove the Left Hand Cover - Refer to Page 8-6.
5. Remove the Right Hand Cover - Refer to Page 8-10.
6. Remove the Left Hand Trim - Refer to Page 8-22.
7. Remove the Right Hand Trim - Refer to Page 8-20.
8. Remove the Media Lever Assembly ­Refer to Page 8-18.
9. Remove the ISS - Refer to Page 8-64.
10. Remove the Service Station - Refer to
Page 8-69.
11. Remove the Vacuum Fan - Refer to Page 8-103.
12. Remove the Electronics Module ­Refer to Page 8-97.
13. Remove the Booster Fan - Refer to Page 8-108.
8-100
14. Remove the Media Sensor - Refer to Page 8-109.
15. Remove the Entry Roller - Refer to Page 8-111.
HP DesignJet 5000 and 5500 Series Printers Service Manual
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