HP deskjet 5000 schematic

DesignJet 5000 SeriesHP Large-Format Printers

Service Manual

For HP Internal Use Only

©Copyright Hewlett-Packard Company 2000

This document con ta ins proprietary information that is protected by copyright. All rights are reserved. No part of this document may be photocopied, reproduced, or transla te d to another language without the prior written consent of HewlettPackard Company.

First Edition, August 2000

Warranty

The information contained in this document is subject to change without notice.

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 contai ne d herein or for incidental or consequentia l damages in connection with the furnishing, performan ce, or use of this material.

WARNING

The procedures descr ibed in this manual are to be performe d by HP-qualified service pe rsonnel only.

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 eart h (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 th e enclosure.

Electrostatic Discharge

Refer to the beginning of Chapter 8 of this manual, for precautions you should take to prevent damage to the Printer circ ui ts from electrostatic discharge.

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.

CAUTION

The Caution symbol calls attention to an operating procedure, practice, or the like, which, if not corre ct ly performed or adhered to, could result in damage to or destructio n of part or all of the product. Do not proceed beyond a Caution symbol until the indicated conditions are fully understood and met.

T echn ical Marketing, Barcelona Division,

Hewlett-Packard Espanola, S.A. Avda. Graells, 501 08190 Sant Cugat del Valles Spain

Safety Symbols

General definitions of safety symbols are given immediately after the table of contents .

DesignJet 5000 SeriesHP 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) n HP DesignJet 5000 Printer - 60” Model (P/N C6095A) n HP DesignJet 5000PS Printer - 42” Model (P/N C6091A) n HP DesignJet 5000PS Printer - 60” Model (P/N C6096A)

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.

HP DesignJet 5000 Series Printers Service Manual

Table of Contents 1

Troubleshooting 1-1

Introduction 1-2 Phone Support 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 1-5 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 1-7 Problems with Vacuum 1-9 Vacuum suction much lower at high altitudes 1-10 Printhead Crashes/Smears on High Density Prints Using Coated Media 1-10 Color differences in different HP DesignJet Printers 1-11 Banding at variable extreme environmental conditions 1-11 Banding with unsupported Media 1-11 Banding due to Ink Cartridge replacement while printing 1-12 Hue shift on HP Colorfast Adhesive Vinyl media 1-12 Black Smearing on HP Photo Imaging Gloss 1-12 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 T ake Up Reel 1-13 Dry Cockle on High Density Prints Using Paper Based Media 1-14 Wrinkles and scratches (cockle) when using HP Coated and Heavyweight Coated Media. 1-14 Worm marks (cockle) on part of plots on paper based media 1-15 Drying Time Too Long for HP Studio Canvas 1-15 Media Skew when Printing a Banner Plot 1-15 Solving Media-Handling Problems 1-16 How to Navigate through the Front Panel Menus 1-18 Service Configuration Print 1-27

HP DesignJet 5000 Series Printers Service Manual

Table of Contents

System Error Codes 2-1

Introduction 2-2 Continuable and Non-Continuable Error Codes 2-3 System Error Codes During Initialization 2-12

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

HP DesignJet 5000 Series Printers Service Manual

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

Table of Contents

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

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 Media 6-19 Printed surface smearing roll 6-19 Warped Lines on Media 6-19 Marks and/or scratches on double-sided media 6-20 There are Smears or Scratching on the Printed Media 6-20 Long Term Color Bleeding (Glossy Papers) 6-20

HP DesignJet 5000 Series Printers Service Manual

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

Table of Contents

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 Right Hand Trim 8-20 Left Hand Trim 8-22

HP DesignJet 5000 Series Printers Service Manual

Table of Contents

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 8-53 Cutter Assembly 8-56 Ink Supply Station (ISS) 8-60 Air Pressurization System (APS) 8-63 Service Station Assembly 8-65 Drop Detector Assembly 8-68 Hard Disk Drive (HDD) 8-70 LAN Card 8-72 Memory and BootROM DIMM’s 8-73 Electronics Module Cover 8-75 Main PCA 8-77 Power Supply Unit (PSU) 8-81 Ink Supply Station (ISS) PCA 8-84 Ink Leak Detector 8-86 Cooling Fans 8-88 Electronics Module (as one complete Assembly) 8-90 Pinch-Wheels 8-91 Pinch-Wheel Cam 8-93 Vacuum Fan 8-96 Paper-Axis Motor Assembly 8-98 Booster Fan 8-101 Media Sensor 8-102 Entry Roller 8-104 Center Guide Assembly 8-105 Drive Roller Gear 8-107 Front Platen Assembly 8-108 Center Platen Assembly 8-110 Deflectors 8-112

HP DesignJet 5000 Series Printers Service Manual

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 System Maintenance 9-11 User Upgrade 9-11 Service Upgrade 9-12

Table of Contents

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

Table of Contents

HP DesignJet 5000 Series Printers Service Manual

Troubleshooting 1

Introduction 1-2 Phone Support 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 1-5 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 1-7 Problems with Vacuum 1-9 Vacuum suction much lower at high altitudes 1-9 Printhead Crashes/Smears on Hi gh Density Prints Using Coated Media 1 -10 Color differences in different HP DesignJet P rinters 1-10 Banding at variable extreme environmental conditions 1-11 Banding with unsupported Media 1-11 Banding due to Ink Cartridge replacement while printing 1-11 Hue shift on HP Colorfast Adhesive Vinyl media 1-12 Black Smearing on HP Photo Imaging Gloss 1-12 Magenta Bleeding on HP Photo Imaging Gloss when using the Take Up Reel 1-12 Loss of Gloss on HP Photo Im aging Gloss when usi ng the T ake Up Reel 1-13 Wrinkles and scratches (cockle) when using HP Coated and Heavyweight

Coated Media. 1-14 Dry Cockle on High Density Prints Using Paper Based Media 1-13 Worm marks (cockle) on part of plots on paper based media 1-14 Drying Time Too Long for HP Studio Canvas 1-15 Media Skew when Printing a Banner Plot 1-15 Solving Media-Handling Problems 1-16 How to Navigate through the Front Panel Menus 1-17 Service Configu ration Print 1-26

HP DesignJet 5000 Series Printers Service Manual

1-1

Troubleshooting

Guide to Troubleshooting the Printer

Introduction

This chapter will guide you through the relevant steps to take when troubleshooting the Printer.

Phone Support

In certain circumstances, a Call Agent can try and troubleshoot the Printer by requesting the Customer to perform a Service Calibration, Test or Utility via the phone. Using this process, it can be determined whether the Printer requires any on-site maintenance.

Troubleshooting System Error Codes

Chapter 2 - System Error Codes - contains a list of system error codes and their respective descriptions and recommended corrective actions. Only try one recommended action at a time and check if the error code has disappeared.

If you have an error code which is not documented in this Service Manual or you have an error which you cannot resolve, then report the error to the HP Response Center or the nearest HP Support Office. When reporting the error, have the following information ready:

n Model and Serial Number of the Printer. n Which firmware revision the Printer is using (See Note below).

Check firmware in Utilities / Statistics / Code rev.

n The complete error number (See Note below). n The Service Configuration Print ⇒ Page 1-26

The Current configuration sheet.

n Which software application the customer is using (name, version,

etc.).

NOTE When reporting the System Error Code, make sure that you

supply the full Error Code (inclu ding the last 8 numb ers where applicable) and the firmware version. Without this information, HP Support Personnel cannot help you.

1-2

HP DesignJet 5000 Series Printers Service Manual

Troubleshooting

Performing a Service Test on a Failed Assembly

If possible, always perform a Service Test on the component/ assembly that you are about to replace, just to make sure that is the component/assembly that has failed.

NOTE If the test on that component/assembly passes, you should NOT

replace it.

For information on the Service Tests and how to use them see Chapter 4, Service Tests and Utilities.

Performing the Necessary Service Calibrations

Is the Printer calibrated correctly after replacing a component? Refer to the table on Page 5-2 to determine when a calibration is required.

NOTE Remember that certain Calibrations are required even if an

Assembly has been disassembled to gain access to another Assembly or Component.

For information on the Service Calibrations and how to use them see 5, Service Calibrations.

Troubleshooting Calibration Error Codes

Chapter 5 - Service Calibrations - contains a list of Error Codes that are reported when a Calibration fails.

Calibration error codes consist of a four digit number [XXXX].

n Model and Serial Number of the Printer. n Which firmware revision the Printer is using. n The complete error number. n The Service Configuration Print if possible ⇒ Page 1-26.

HP DesignJet 5000 Series Printers Service Manual

1-3

Troubleshooting

n The Current configuration sheet. n A Diagnostic Print.

The Media being used when the error occurred.

NOTE When reporting the Error Code, make sure that you supply the

full Error Code and the firmware ve rsion (d ispl ayed durin g the initialization process when powering ON the Printer or available in the User’s Printer Setup ⇒ Utilities ⇒ Statistics menu).

Troubleshooting Ink Supplies Error Codes

Chapter 3, HP Ink Supplies Tr oubleshooting, contains a list of Error Codes that are reported for Ink Supplies i.e. Ink Cartridges, Printheads and Printhead Cleaners. The error codes are described and recommended corrective actions are provided. Only try one recommended action at a time and check if the error code has disappeared.

Ink Supplies error codes consist of a four digit number [XXXX].

Troubleshooting Initialization - Self Diagnostic Errors

Chapter 4 - Service Tests and Utilities - describes the Printer initialization sequence and reports errors that may be reported when Printer initialization is performed.

Self Diagnostic error codes consist of seven alphanumeric characters [XXXXXXX].

n Model and Serial Number of the Printer. n Which firmware revision the Printer is using. n The complete error number.

1-4

HP DesignJet 5000 Series Printers Service Manual

Troubleshooting

Solving Image Quality Problems

Whenever an Image Quality problem appears, it is advisable to print the Diagnostic Print. This will help you differentiate between possible Printhead errors and other problems such as incorrect frontpanel selection, driver or RIP configuration or mechanical problems. For information on solving Image Quality problems see Chapter 6, Print Quality.

The Printer does not Power ON

1. Check that the Power Cord is connected correctly to the Printer and

to the Power Socket.

2. Check that the Power Switch on the BACK of the Printer is in the

ON position.

3. Remove the DIMM’s Cover (See ⇒ Page 8-73) and check the green

and red Status LED’s on the Main PCA. If they are both NOT lit, replace the Power Supply Unit ⇒ Page 8-81.

Status LED’s

4. Check that the Front-Panel Cable is correctly connected to the

Electronics Module. Also make sure that the Front-Panel Cable is not damaged.

HP DesignJet 5000 Series Printers Service Manual

1-5

Troubleshooting

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

The BootROM DIMM is NOT correctly installed or is the wrong type.

1. Power OFF the Printer from the back and disconnect the Power

Cord. Reseat the BootROM DIMM (looking from the rear of the Printer, the first slot from the left - See that it is installed correctly.

⇒ Page 8-73) making sure

2. If the problem persists replace the BootROM DIMM

⇒ Page 8-73.

Troubleshooting Media Jams/Printhead Crashes

NOTE If using HP Coated Media when problem occurred, please also

refer to Page 1-10.

The failure modes “media jam” and “head crash” are grouped together because in many c ases a me dia ja m cause s the m edia to li ft up into the carriage path and cause a head crash, thus causing many media jam failures to be reported as head crashes.

1. Did the media jam occur when loading media?

n If the client has had media jams, it is common for pieces of media

to get stuck in the media path. Clear the media path.

NOTE When clearing a media jam, sometimes media is stuck in the

paper path. T o clear this, you must lift the media lever and insert thicker media into the paper path to push out the media that is still stuck there.

1-6

2. Is the customer using non-HP media?

n The use of non-HP media can easily be the cause of media jams

and head crashes (especially head crashes because HP media is specially formulated to avoid cockle, one of the primary causes of head crashes). If the media is not HP approved, advise the customer to use HP media and check to see if the problem is now solved.

3. The Carriage is at the incorrect height in relation to the Center

Platen. Adjust the carriage to the correct height ⇒ Page 5-18 and try to load the media again.

4. Check that the Vacuum Fans work correctly - Refer to Page 1-9, Problems with Vacuum .

HP DesignJet 5000 Series Printers Service Manual

Troubleshooting

Troubleshooting Shutdowns

If a shutdown occurs, you will get the message “Switch Power Off” followed by:

n Check Printhead Cleaner Path. n Check Paper Path. n Check Printhead Path (followed by (1), (2) or (3)).

A shutdown in each path will require different steps to resolve the problem as explained as follows.

WARNING In each case, make sure that you power OFF the Printer be fore

attempting any procedures to resolve the problem.

Printhead Cleaner Path

1. Open the right door of the Printer and check for any visible

obstacles restricting the movement of Service Station. Manually move the Service Station, checking for smooth and free movement.

Media Path

When a shutdown occurs in the Media path, you will get the message “Switch Power Off / Check Media Path (*). The (*) will be a number, which will give an indication on where the failure occurred:

1. Open the Window and check for any visible obstacles restricting the

movement of the Drive Roller. If there is a wrinkled mass of media inside the paper path, lift the Pinch wheels (using the Media Lever) and clear the obstruction. If you cannot reach the media remove the Entry Roller (⇒ Page 8-104) to gain better access.

2. If this shutdown happens at the end of a Roll of Media, it could be

because the media is stuck firmly to the Roll. Lift the Pinch wheels (using the Media Lever) and pull the media clear.

3. Perform the Media Axis Test

Printhead Path

⇒ Page 4-12.

When a shutdown occurs in the Printhead path, you will get the message “Switch Power Of f / Check Printhead Path (*). The (*) will be a number, which will give an indication on where the failure occurred:

1. Switch the Printer OFF from the rear and open the window.

HP DesignJet 5000 Series Printers Service Manual

1-7

Troubleshooting

2. Look in the area where the Printer was printing at the time of the jam, this is where the media is most likely to be jammed.

3. Raise the media load lever.

4. Carefully remove any of the jammed media which you can lift up

and out from the top of the Printer.

5. Carefully pull the rest of the roll or sheet down and out of the Printer.

6. If you are using a roll of media, trim the media with a knife as shown in the User’s Guide.

7. Reload the media.

8. Switch the Printer ON.

9. If there is some media left behind in the media path, loading paper

can become difficult. This can be cleared by loading a rigid paper type through the Printer media path.

10. If you have image quality problems after a paper jam, this could

indicate that the Printheads have been moved from their correct position in the Carriage. To correct this perform Printhead Alignment - Refer to the User’s Guide.

PWM Shutdown (1) and Energy Shutdown (3)

Clean Slider Rods and Apply Oil along the complete axis of the Slider Rods with the User’s Slider Rods Lubrification Kit applying the Oil, perform the Scan-Axis Test ⇒ Page

⇒

Page

9-8

. After

4-10 and check

that the values are within the given limit s .

2. Replace the Scan-Axis Motor ⇒ Page 8-53.

Velocity Shutdown (2)

1. Open the Window and check for any visible obstacles restricting the

movement of the Carriage Assembly. Try and move the Carriage Assembly manually, checking for smooth and free movement.

2. Check that the Encoder Strip is clean. If necessary, clean the Encoder Strip using a damp cloth.

1-8

HP DesignJet 5000 Series Printers Service Manual

Troubleshooting

Problems with Vacuum

If you have problems loading either Roll or Sheet Media, then there could be a problem with the Vacuum Fan or Booster Fan. To verify if there really is a problem with Vacuum, try the following:

1. With the Printer ON, open the Window of the Printer and place a

sheet of HP High Gloss Photo Paper (must be D-Size), aligned with the blue lines on the Center Platen. If the Vacuum holds the sheet in place, and then loads it c orrectly, then the Fans function correctly. If the Vacuum does not hold the sheet in place (no suction), then try the following:

n Check that the holes in the Center Platen are NOT blocked.

Clean the Overdrive using the Platen Cleaning Utility ⇒ Page

n Check that the Vacuum and Booster Fans are installed correctly. n Replace the Vacuum Fan ⇒ Page 8-96. n Replace the Booster Fan ⇒ Page 8-101.

2. If the Vacuum held the sheet in place, but couldn’t correctly load it,

then there could be a problem with the Overdrive. In this case, replace the Center Platen Assembly

⇒ Page 8-110.

9-9

Vacuum suction much lower at high altitudes

At altitudes above 2,000 meters, the vacuum force holding down the media will be lower, therefore the media will not be held in place properly causing:

n Ink Smearing on the Media. n Printhead crashes against the Media. n Cut Sheet loading problems (high probability). n Roll Media loading problems (low probability).

To solve the problem, try the following:

n Using the “1.3 Altitude Setup” in the Service Utilities, set the

altitude to “1.3.2 2000 m or more” (see Altitude Setup 4-23).

HP DesignJet 5000 Series Printers Service Manual

1-9

Troubleshooting

Printhead Crashes/Smears on High Density Prints Using Coated Media

High density prints can cause cockle mainly on HP Coated Media. This causes two main problems:

1. Cockling in the borders - Because the Printer places too much ink on the Coated Media, the borders of the print become raised, causing the Printhead to crash against the media. To solve the problem, try the following:

n Check in the Front Panel if print mode is Max. Quality. If it is

selected, then change print mode to Productivity to reduce ink density.

n Change the paper margins to “Extended” in the Printer Setup

menu/Page Format/Margins or in the Driver. If the customer is printing PostScript images, send them a PPD file containing the extended margins.

2. Cockling within the print - If the Printer places too much ink within the print, the media starts to ripple, causing the Printhead to smear against the media. To solve the problem, try the following:

n Check in the Front Panel if print mode is Max. Quality. If it is

selected, then change print mode to Productivity to reduce ink density.

n Never use HP Coated Media for High Density prints. As a

substitute use HP Heavy Weight Coated or Heavy W e ight Coated (Economy) Media.

Color differences in different HP DesignJet Printers

Color differences between one image printed on the HP DesignJet 5000 Series and the rest of the DesignJet platforms are due to the different chemistry of the 5000 series inks compared with the rest of the inks for other printers. This color variability among different HP DesignJet Series Printers has been always present. You can try to achieve consistent colors with the following:

n Select the same color emulation settings in your Postscript Driver

as the one used by the printer you want to emulate.

n Select the correct Ink Emulation from the Printer Setup Menu/

Internal RIP Settings.

1-10

HP DesignJet 5000 Series Printers Service Manual

Troubleshooting

Banding at variable extreme environmental conditions

The Accuracy Calibration has been done at normal environmental conditions, therefore printing in extreme environmental conditions will cause banding because the advance of the Drive Roller does not correspond to the same conditions that the calibration was done in. To solve the problem, try the following:

n Perform the Accuracy Calibration in the new environmental

conditions (Refer to the User’s Guide - Media Solutions).

Banding with unsupported Media

The Accuracy Calibration has not been done for the Media now loaded. Banding may occur because the advance of the Drive Roller does not correspond to the same conditions that the calibration was done in. To solve the problem, try the following:

n Select the Media loaded in the “Media Options” menu and

perform the Accuracy Calibration (Refer to the User’s Guide Media Solutions).

Banding due to Ink Cartridge replacement while printing

A user has removed the Ink Cartridge while the Printer was printing, which has caused the Printer to stop. If the user does not replace the Ink Cartridge immediately, when the Printer starts to print again, a band will appear in the position where the pri nting restarte d. This is because the wet ink interacts with the dried ink on the media causing the band to appear. To solve the problem, try the following:

n Do NOT remove the Ink Cartridge while the Printer is Printing.

Only replace/remove Ink Cartridges in between Prints.

n If the Ink Cartridge was replaced due to the “Empty” status on the

Front Panel, then advise the customer to replace the Ink Cartridge when the “Very Low” status is showing on the Front Panel.

HP DesignJet 5000 Series Printers Service Manual

1-11

Troubleshooting

Hue shift on HP Colorfast Adhesive Vinyl media

Under high humidity conditions (approx. >65%) the colors tend to fade over time, particularly colors that require Magenta. To solve the problem, try the following:

n Reduce the level of humidity (<65%) that the Printer is working

in. To find the humidity level, print the Service Configuration Print (Printer Setup Menu / Utilities / Test prints / Service config).

n Laminate the prints.

Black Smearing on HP Photo Imaging Gloss

Narrow black lines can smear on this type of media, particularly if the lines are narrow and have white gaps in between them. Try the following:

n Increase the Dry Time using the Front Panel (Refer to the User’s

Guide).

n Laminate the prints.

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

Under high humidity conditions (approx. >70%) this media reduces its capacity to absorb Magenta because of this color’s particular characteristics. When an area fill with magenta is printed and then rolled onto the Take Up Reel the ink that is not completely dry moves laterally on the media. To solve the problem, try the following:

n Reduce the level of humidity (<70%) that the Printer is working

in. To find the humidity level, print the Service Configuration Print (Printer Setup Menu / Utilities / Test prints / Service config).

n Increase the Dry Time using the Front Panel (Refer to the User’s

Guide).

n Do not use the Take Up Reel or Bin for this media when humidity

levels are high.

1-12

HP DesignJet 5000 Series Printers Service Manual

Troubleshooting

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

Under high humidity conditions (approx. >70%) the polymer chain in the coating of this media relaxes and the drying rate decreases. If the printed media is rolled onto a Take Up Reel or is covered by another print, the contact between the two surfaces could cause blotches in the gloss. Try the following:

n Reduce the level of humidity (<70%) that the Printer is working

in. To find the humidity level, print the Service Configuration Print (Printer Setup Menu / Utilities / Test prints / Service config).

n Increase the Dry Time using the Front Panel (Refer to the User’s

Guide).

n Do not use the Take-Up Reel or Bin for this media when

humidity levels are high.

Dry Cockle on High Density Prints Using Paper Based Media

High density prints can cause dry cockle mainly on Paper Based Media.

To solve the problem do the following:

n Use the Take Up Reel and Take Up Reel deflectors. n Set the Printer to Productivity mode to reduce the ink density. n Select Coated media modes.

If the problem persists, try the following:

n Laminate the prints. n Use a heavier media that is more suitable to high ink density,

such as HP Paper based Semi-Gloss or HP Poster Paper.

HP DesignJet 5000 Series Printers Service Manual

1-13

Troubleshooting

Wrinkles and scratches (cockle) when using HP Coated and Heavyweight Coated Media.

Images may be damaged if prints are not handled with care, particularly when handling wide plots. This can happen when images are placed on top of one another and there is movement between them, causing friction and loss of ink from the surface if it is not completely attached. Also, if plots are rolled up wrinkles can occur. To avoid this problem try the following:

n Always handle plots with care. n Use of the Take-Up Reel eliminates handling and avoids

wrinkles.

n Use heavier media. n Select faster print modes such as Heavyweight Coated

(Economy) for Media selection and/or Productivity Print mode.

n If damage is slight, Lamination will help towhead’ defects. n Use of Fixative Sprays immediately after printing may protect the

image.

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

At high temperatures and under dry conditions worm marks may occur on initial parts of plots when printing solid fill areas in medium tone colors. Try the following:

n Advance the media manually by 15 mm. n Select Heavy Coated for Media setting. n Select Productivity mode to reduce ink density.

1-14

HP DesignJet 5000 Series Printers Service Manual

Troubleshooting

Drying Time Too Long for HP Studio Canvas

Under conditions of high humidity (> 70%) HP Studio Canvas retains a high amount of water and takes too long to dry, also creating problems in using the Take-Up Reel and Bin. To solve the problem try the following:

n Reduce the level of humidity (<70%) that the Printer is working

in. To find the humidity level, print the Service Configuration Print (Printer Setup Menu / Utilities / Test prints / Service config).

n Increase the drying time using the Front Panel settings (Refer to

the User’s Guide).

n Do not use the Take-Up Reel or Bin under conditions of high

humidity.

Media Skew when Printing a Banner Plot

When printing banners, media skew occurs. This is particularly noticeable in the first plot when media is not perfectly aligned. To solve this problem do the following:

n Use extended margins for banner plots (Refer to the User’s

Guide).

HP DesignJet 5000 Series Printers Service Manual

1-15

Troubleshooting

Solving Media-Handling Problems

NOTE HP Designjet Printers minimum media size is A3 in portrait

mode. The Front Panel Keeps Indicating that Media Is Misaligned or

Incorrectly Positioned

Roll media n The roll may be loaded the wrong way. The paper should load

over the roll toward you.

n The media may be crumpled or warped or have irregular edges. n The paper may be loaded at an angle. The right-hand edge must

be parallel to the blue line on the paper entry roller.

WARNING Ensure that the paper is wrapped tightly on the roll. This is a

very important step to remember because if this is not done, the media may be loaded at an angle, causing the media to be rejected.

n Perform the manual alignment procedure (Refer to the User’s

Guide).

n Check that the paper is correctly loaded onto the spindle.

Sheet media n It must be loaded with the right-hand edge against the blue

perforated line on the Printer.

n Align the media against the trailing edge coming out of the

Printer.

n The media may be crumpled or warped or may have irregular

edges.

n If you are using hand-cut media, the edges may not form a right-

angle or they may be rough. Do not use hand-cut media. Use only purchased sheet media.

n If the media you are trying to load is very slippery, hold the

media with both hands, and gently push the media into the Printer until it buckles upwards in the middle, this will help the P rinter to load it.

n If the Overdrive is covered in dust, it will have problems picking

up the sheet media during the load process. Clean the Overdrive using the Platen Cleaning Utility ⇒ Page 9-7.

Prints Do Not Stack Properly in the Media Bin

n The Printer may be too close to the end of the roll. The natural

curl near the end of the roll can cause stacking problems. Load a new roll or remove prints manually as they are completed.

1-16

n If you are mixing prints or nesting sets of several different sizes,

you may have stacking problems because of the different sizes of media in the bin.

HP DesignJet 5000 Series Printers Service Manual

Troubleshooting

How to Navigate through the Front Panel Menus

Shaded boxes always appear in the front panel. White boxes appear only in Full menu mode.

Printer Setup Options

NO, YES

TUR installed

Device Setup

255 - 2, 1 min

Postscript,

On, Off

Cutter

Automatic

Automatic,

Manual

None

HP-GL/2, CALS/G4

Language

Drying time

No I/O Card found,

I/O Setup

Card ID,

Card Setup

Reset card

Advanced

Configuration

Card Setup

0.5 min ... 30 min

I/O timeout

HP DesignJet 5000 Series Printers Service Manual

1-17

Troubleshooting

@ - Postscript models only

255 - 2, 1 min

NO, YES

On, Off

Cutter

TUR installed

Device Setup

Postscript, @Automatic

Automatic,

Manual

HP-GL/2, CALS/G 4

Language

None

Drying time

Card ID,

Card Setup

No I/O Card found,

I/O Setup

Reset card

Advanced

Configuration

Card Setup

0.5 min ... 30 min

I/O timeout

1-18

HP DesignJet 5000 Series Printers Service Manual

+ 348 hidden pages