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.

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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

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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

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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.

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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.

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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

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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

Troubleshooting

Create Pattern

Measure Pattern

Restore factory

Recalibrate

Auto, Manual

Yes , N o

Short, Full

Print usage, View usage

Printhead alignment

Accuracy

Color Calibration

Print Quality

Usage report

Service config.

HP-GL/2 config.

Ram present, Service ID

Hark disk, Co de Rev.

Up, Down

PS Code Rev, PS Font code

Track Media Length

Utilities

Usage

Menu Mode

Calibrations

Reset Web Svr Passwd

Test print

Statistics

Default Menu

Clean Platen

Display Contr ast

Lens Maintenance

HP DesignJet 5000 Series Printers Service Manual

1-19

Troubleshooting

255 - 1, 0

0.13mm _ 12.0mm

Color

Width

Pen number 0 _ 15

Factory

Palette A,

Palette B,

Palette A

Software, factory.

Palette

HP-GL/2 Settings

Palette B

Define Palette

Off, On

Merge

1-20

HP DesignJet 5000 Series Printers Service Manual

Native sRGB

Apple RGB

Adobe RGB

Color Match RGB

Native, Euroscale,

SWOP, TOYO @

Troubleshooting

Width, Length

99 .. 1, 0

@ - Postscript models only

Move to top,

Statistics

Copies

99 .. 2, 1 min

Delete page

#...

RGB @

CMYK @

Off, On

Optimized, immediately

After processing

Start Printing

Ink Emulation @

Internal RIP S ettings

Color calibration

Off, On

Black Replacement

Off, On

100%..419%, Fit to Page @

PS Scale

Enhanced res

ASCII

Binary

Software

PS Encoding

Off

In order

Nest

Queue mgmt

Queueing & Nesting

HP DesignJet 5000 Series Printers Service Manual

1-21

Troubleshooting

1.0x1.4m, 42x59in., 44x62in.,

Inked area,

Software

Size

Page format

Over A2, Over A1

54x76in., 60x100in.

1.2x1.7m, 52x73in.,

Oversize

Extrawide

Best JIS B

Best ANSI,

Best ISO A,

ANSI A .. E

JIS B4 .. B1

Best ARCH

ARCH A .. E1

JIS

ARCH

ANSI

ISO A4 .. A0

ISO

0 .. 270

Normal, Extended

Margins

Rotate

30 .. 5, 0 mm

On, OffMirroring

Manual

Automatic

Nest Spacing

Samples, Palette

Demos

1-22

HP DesignJet 5000 Series Printers Service Manual

Media Options

Troubleshooting

Vendor Name

Type of Media

Width

Printable Area

Profile Revision

Roll/Sheet Info.

HW Coated (Economy)

HW Coated

Coated Paper

Photo Imaging Gloss

Colorfast Vinyl

Paper Semi-Gloss

Poster Paper

Studio Canvas

*HW Coated (Economy)

*HW Coated

*Coated Paper

*Photo Imaging Gloss

*Colorfast Vinyl

*Paper Semi-Gloss

Media Selection

Delete Media

Move Media

Yes, No

and more.......

TUR Loaded=

*Poster Paper

*Studio Canvas

and more.......

Yes, No

Form Feed & Cut

HP DesignJet 5000 Series Printers Service Manual

1-23

Troubleshooting

Ink Cartridge Info

HP No. 81 Ink Cartridge

Ink Level

Capacity

Part Number

Manufacture Date

Light Cyan cart Info

Light Magenta cart Info

Yellow cart. Info

Cyan cart Info

Magenta cart Info

Yes, No

Replace Ink Cartridge

Black cart Info

1-24

HP DesignJet 5000 Series Printers Service Manual

Printhead Info

Troubleshooting

Printhead Info

Recover Printheads

Replace Printheads

Light Cyan Info Light Magenta Info Yellow Info Cyan Info Magenta Info Black Info

All Printheads Cyan Magenta Yellow Black Light C Light M

Yes, No

HP DesignJet 5000 Series Printers Service Manual

1-25

Troubleshooting

Service Configuration Print

The Service Configuration Print is a useful tool for troubleshooting the Printer. The Service Configuration Print contains the following information about the Printer:

n General Configuration n Printhead Info. n Ink Cartridge Info. n Operating Conditions. n Calibrations. n Maintenance. n I/O Configuration.

How to Print the Service Configuration Print

1. Load media (Roll media or at least an A0 Sheet) into the Printer.

2. Once the message “Ready” is displayed on the front-panel, scroll to

the “Printer Setup Options” icon and press the Enter key.

Ready

Roll Hewlett Packard

Photo Imaging Gloss

Ink OK Printheads OK

Printer Setup Options

3. Once inside the “Printer Setup Options” menu, use the Arrow keys

to scroll to the “Utilities” menu display and press the Enter key.

Printer setup options

Device setup... I/O setup...

Utilities... Internal RIP settings... Queueing & Nesting... HP-GL/2 settings...

Top

Back

↑ ↓

Enter

Make Selection

Press Enter

1-26

HP DesignJet 5000 Series Printers Service Manual

Troubleshooting

4. Once inside the “Utilities” menu, use the Arrow keys to scroll to the “Test prints” menu display and press the Enter key.

Utilities

Utilities Display Contrast ...

Calibrations ... Reset WebAccess paswd

Contrast ...

Test Prints

Statistics ...

...

Default menu

Test Prints ...

Display contrast . . .

Top

Back

↑ ↓

Enter

Press Up and Enter

5. Use the Arrow keys to scroll to “Service Config.” and press the Enter key to print the Service Configuration Print.

How to Use the Service Configuration Print

The Service Configuration Print is divided into 7 different areas where you can find information to troubleshoot the Printer.

n General Configuration - In this area you can find information

regarding the general configuration of the Printer, for example, the firmware version, amount of memory installed or the capacity of the Hard Disk Drive.

n Printhead Info - In this area you can find all the information

regarding the Printheads, for example, the part number, the manufacturing date or the number of times a certain Printhead has been inserted in the carriage. This information is useful for troubleshooting Printhead problems and even knowing if the Printheads have been used with Non-HP Ink Cartridges.

n Cartridge Info - In this area you can find all the information

regarding the Ink Cartridges, for example, the part number, the manufacturing date or the ink level. This area also shows you if the customer is using Non-HP Ink Cartridges.

n Operating Conditions - In this area you can find the level of

humidity and the temperature that the Printer is working in.

n Calibrations - In this area you can find information on certain

calibrations that have been performed on the Printer. It will also tell you if a required calibration was performed or not.

n Maintenance - In this area you can find information relating to

maintenance, for example, the number times the Printer has been powered ON, the number of Carriage cycles or the last System Error Code that was triggered.

n I/O Configuration - In this area you can find information on the

configuration of the JetDirect Card.

HP DesignJet 5000 Series Printers Service Manual

1-27

Troubleshooting

1-28

HP DesignJet 5000 Series Printers Service Manual

System Error Codes 2

System Error Codes 2-2

01002D (Non-Continuable) 2-4 010023 (Non-Continuable) 2-4 010040 2-4 010041 2-5 010042 2-5 010090 (Continuable) 2-6 010091 (Continuable) 2-6 010092 (Continuable) 2-6 011000 2-6 06030C 2-7 0A0000 2-7 0A0010 2-8 0A0030 2-8 0A0040 2-8 0A0050 (Non-Continuable) 2-9 0A0060 (Non-Continuable) 2-9 0A0070 (Continuable) 2-9 0C0030 2-10 0C0032 (Continuable) 2-10 0C0040 2-10 0C1001 2-11 0D0000 (Continuable) 2-11 0D0002 (Continuable) 2-11 0FXXXX (Non-Continuable) 2-11 System Error Codes During Initialization 2-12

HP DesignJet 5000 Series Printers Service Manual

2-1

System Error Codes

Introduction

NOTE Before troubleshooting System Errors, if possible, repeat the

procedure performed when the error was reported.

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

supply the full Error Code and the firmware version (displayed during the initialization process when powering ON the Printer

or available in the User’s Printer Setup menu).

The following pages contain 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.

⇒ Utilities ⇒ St at i st i c s

System Error Codes consist of two groups of alphanumerics:

[XXXXXX]-[YYYYZZZZ]

The first set of 6 alphanumeric characters consists of the System Error and the second set of 8 digits, when present, refer to the internal error data.

NOTE If the YYYY digits in the second set of 8 characters are zero

[0000ZZZZ], this indicates a LAN Card System Error. The last four digits [ZZZZ] of the Error Code must be reported to the vendor support organization:

n For HP JetDirect Cards, this error code must be reported to

the iIPS Division Support.

n For 3rd party LAN Cards, the HP support organization s hould

communicate to the customer that they should address it through the 3rd party vendor support structure.

2-2

HP DesignJet 5000 Series Printers Service Manual

System Error Codes

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.

The Current configuration sheet.

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

etc.).

Continuable and Non-Continuable Error Codes

Some of the Error Codes are continuable, which means you can press Enter on the front-panel and continue working with the Printer. Non-Continuable Error Codes do not allow you to continue working with the Printer , in this case power the Printer OFF and ON again and see if the System Error disappears. If the Error Code reappears, then the Printer requires an on-site visit in order to resolve the problem.

NOTE Even though the customer can continue working with a

Continuable Error Code, an on-site visit should still be planned to troubleshoot the problem.

HP DesignJet 5000 Series Printers Service Manual

2-3

System Error Codes

System Error: 01002D (Non-Continuable) Problem

Description: Corrective Action: Try the following:

System Error: 010023 (Non-Continuable) Problem

Description: Corrective Action: n Replace the Main PCA ⇒ Page 8-77.

The Main PCA cannot communicate with the Carriage.

n Check the Trailing Cable is connected correctly. n Replace the Trailing Cable ⇒ Page 8-36. n Replace the Carriage Assembly ⇒ Page 8-46.

EEROM Test failure.

NOTE After replacing the Main PCA, make sure you perform the

Backup EEROM ⇒ Page 4-31, making sure that you select "Main PCA" when prompted.

System Error: 010040 Problem

Description:

Error in Paper-axis Encoder quadrature.

Corrective Action: Try the following:

n Check that the Paper-Axis Motor cable is NOT broken or

damaged.

n Check that the Paper-Axis Motor cable is correctly connected. n Replace the Paper-Axis Motor ⇒ Page 8-98. n If the Error Code continues, replace the the Main PCA ⇒ Page 8-

77.

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

2-4

HP DesignJet 5000 Series Printers Service Manual

System Error: 010041

System Error Codes

Problem Description:

Corrective Action: Try the following:

Error in Scan-axis Encoder quadrature.

n Check that the Encoder Strip is NOT broken or damaged. n Replace the Encoder Strip ⇒ Page 8-34. n Replace the Carriage Assembly ⇒ Page 8-46. n If the Error Code continues, replace the Main PCA ⇒ Page 8-77.

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

System Error: 010042 Problem

Description: Corrective Action: Try the following:

Error in Service Station-axis Encoder quadrature.

n Check that the Service Station Encoder-Cable is NOT broken or

damaged.

n Check that the Service Station Encoder-Cable is correctly

connected.

n Replace the Service Station ⇒ Page 8-65. n If the Error Code continues, replace the Main PCA ⇒ Page 8-77.

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

HP DesignJet 5000 Series Printers Service Manual

2-5

System Error Codes

System Error: 010090 (Continuable) Problem

Description: Corrective Action: Try the following:

Error in Paper-axis Motor Encoder

n Check that the Paper-Axis Motor cable is NOT broken or

damaged.

n Check that the Paper-Axis Motor cable is correctly connected. n Replace the Paper-Axis Motor ⇒ Page 8-98. n If the Error Code continues, replace the Main PCA ⇒ Page 8-77.

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

System Error: 010091 (Continuable) Problem

Description: Corrective Action: Refer to System Error Code 010090.

Error in Paper-axis Motor Encoder

System Error: 010092 (Continuable) Problem

Description: Corrective Action: Try the following:

Mark Encoder position not detected on Drive Roller.

n Replace the Lens Cover ⇒ Page 9-5. n Clean the Mark Encoder on the Drive Roller using the Turn

DRIVE ROLLER Utility ⇒ Page 4-18.

System Error: 011000 Problem

Description: Corrective Action: Power the Printer OFF and ON again using the Power Switch at the

NIB Crash.

back of the Printer.

2-6

HP DesignJet 5000 Series Printers Service Manual

System Error: 050001 (Continuable)

System Error Codes

Problem Description:

Corrective Action: Try the following:

Lens has problems reading the Mark Encoder on the Drive Roller.

n Clean the Mark Encoder on the Drive Roller using the Turn

DRIVE ROLLER Utility ⇒ Page 4-18

n Replace the Lens Cover Assembly ⇒ Page 9-5.

System Error: 06030C Problem

Description: Corrective Action: Try the following:

Bad Line Sensor.

n Replace the Carriage Assembly ⇒ Page 8-46 n Replace the Trailing Cable ⇒ Page 8-36. n Replace the Main PCA ⇒ Page 8-77.

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

System Error: 0A0000 Problem

Description: Corrective Action: Try the following:

APS Failure.

n Check all the cables of the APS and make sure they are correctly

connected and are NOT damaged.

n Check all the tubes of the APS and Tubes System and make sure

they are correctly connected and are NOT pinched or damaged.

n Check that the Air Tube from the APS is correctly connected to

the Tubes System.

n Replace ONE Ink Cartridge at a time, checking if the System

Error Code disappears.

n Faulty APS. Replace the APS ⇒ Page 8-63.

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

HP DesignJet 5000 Series Printers Service Manual

2-7

System Error Codes

System Error: 0A0010 Problem

Description: Corrective Action: Refer to System Error Code 0A0000.

System Error: 0A0030 Problem

Description: Corrective Action: Try the following:

APS Failure.

Problem in Depressurizing Air System.

n Check the APS for any signs of Ink. Also inspect ALL Ink

Cartridges for any signs of leaking (the bottom valve of the Ink Cartridge will contain ink).

n If there is ink leakage, replace ALL Ink Cartridges, the APS ( ⇒

Page 8-63) and the Tubes System ( ⇒ Page 8-25).

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

System Error: 0A0040 Problem

Description: Corrective Action: Try the following:

APS Failure.

n Check all the cables of the APS and make sure they are correctly

connected and are NOT damaged.

n Check all the tubes of the APS and Tubes System and make sure

they are correctly connected and are NOT pinched or damaged.

n Replace ONE Ink Cartridge at a time, checking if the System

Error Code disappears.

n Faulty APS. Replace the complete APS ⇒ Page 8-63.

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

2-8

HP DesignJet 5000 Series Printers Service Manual

System Error: 0A0050 (Non-Continuable)

System Error Codes

Problem Description:

Corrective Action: Try the following:

The Printer has detected a leak in the Tubes System before the life of the System.

n Check for ink in the Ink Leak Detector and, if present, replace the

complete Tubes System ⇒ Page 8-25.

n The Ink Leak Detector could have been trigggered due to

condensation in the Printer. Power OFF the Printer and allow the Printer to dry for 15 minutes. Power ON and check if the System Error Code has disappeared.

n Replace the ISS PCA ⇒ Page 8-84.

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

System Error: 0A0060 (Non-Continuable) Problem

Description:

The Printer has detected a leak in the Tubes System after the life of the System.

Corrective Action: Refer to System Error Code 0A0050.

System Error: 0A0070 (Continuable) Problem

Description: Corrective Action: Try the following:

The Backup EEROM contents stored in the Hard Disk Drive are not consistent with the ones required by the firmware.

n Perform Backup EEROM ⇒ Page 4-31 and ALL calibrations.

Perform EEROM Setup ⇒ Page 4-24 to reconfigure the Printer.

HP DesignJet 5000 Series Printers Service Manual

2-9

System Error Codes

System Error: 0C0030 Problem

Description: Corrective Action: Try the following:

Drop Detector Failure.

n Check that the Drop Detector Cable is NOT broken or damaged. n Check that the Drop Detector cable is correctly connected to the

Service Station Cable.

n Remove the Drop Detector and make sure that there are no

obstacles inside which are blocking the sensor.

n Replace the Drop Detector Assembly ⇒ Page 8-68. n If the System Error Code continues, replace the Main PCA ⇒

Page 8-77.

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

System Error: 0C0032 (Continuable) Problem

Description:

Drop Detector not Calibrated for all Printheads.

Corrective Action: Try the following:

n Perform the Service Station Calibration ⇒ Page 5-11. n Replace the Drop Detector Assembly ⇒ Page 8-68. n If the System Error Code continues, replace the Main PCA ⇒

Page 8-77.

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

System Error: 0C0040 Problem

Description: Corrective Action: Try the following:

Error in Printhead Drop Detection.

n Recover the Printheads ⇒ Page 6-15. n Replace the Drop Detector ⇒ Page 8-68.

2-10

HP DesignJet 5000 Series Printers Service Manual

System Error: 0C1001

System Error Codes

Problem Description:

Corrective Action: Try the following:

Primer Shutdown Error.

n Check that the Primer Stepper-Motor Cable is NOT broken or

damaged and that the Primer Arm moves freely from side to side.

n Replace the Service Station ⇒ Page 8-65. n If the Error Code continues, replace the Main PCA ⇒ Page 8-77.

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

System Error: 0D0000 (Continuable) Problem

Description: Corrective Action: n Download a media profile for the ink type being used.

System Error: 0D0002 (Continuable) Problem

Description:

No Media Profiles Available.

Insufficient Memory to Initialize HPGL2/RTL.

Corrective Action: n The minimum memory required is 96 Mbytes so verify memory

installed on the printer using the Statistics menu (refer to the User’s Guide).

System Error: 0FXXXX (Non-Continuable) Problem

Description: Corrective Action: Try the following:

A Firmware Error has occurred.

n Power OFF and ON using the Printer Power Switch. n Report the error to the HP Response Center or the nearest HP

Support Office. Have the following information ready:

n Model and Serial Number of the printer. n Which firmware revision the printer is using (displayed during

Printer initialization when powering ON).

n The complete error number. n The Service Configuration Print if possible ⇒ Page 1-26.

The Current configuration sheet.

Which software application the customer is using (name, version, etc.).

HP DesignJet 5000 Series Printers Service Manual

2-11

System Error Codes

System Error Codes During Initialization

The following System Error Codes will only appear during the Initialization process when you power ON the Printer.

System Error: 050000 (Continuable) Problem

Description: Corrective Action: Try the following:

Lens has problems reading the Mark Encoder on the Drive Roller.

n Clean the Mark Encoder on the Drive Roller using the Turn

DRIVE ROLLER Utility ⇒ Page 4-18

n Replace the Lens Cover Assembly ⇒ Page 9-5.

System Error: 0B0000 Problem

Description: Corrective Action: Try the following:

Bad Ambient Temperature measured.

n Make sure that the Ambient temperature is within the allowed

range (between 0 and 55 Degrees Centigrade).

n Replace the Main PCA ⇒ Page 8-77.

System Error: 0B0001 Problem

Description: Corrective Action: Replace the Main PCA ⇒ Page 8-77.

2-12

Bad Humidity read.

HP DesignJet 5000 Series Printers Service Manual

System Error: 0B0002

System Error Codes

Problem Description:

Corrective Action: Try the following:

Bad IDS pressure read.

n Check that the cable from the Ink Supply Station (ISS) PCA to

the Ink Supply Station is correctly connected.

n Check that the Air Pressurization System Sensor Cable is

correctly connected and is NOT damaged.

n Check all the tubes of the APS and make sure they are NOT

pinched or damaged.

n Faulty APS. Replace the APS ⇒ Page 8-63. n If the error code continues, replace the Main PCA ⇒ Page 8-77.

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

System Error: 0B0003 Problem

Description:

ADC0 Internal channels check Failure.

Corrective Action: Replace the Main PCA ⇒ Page 8-77.

System Error: 0B0004 Problem

Description: Corrective Action: Try the following:

APS Failure.

n Check that the cable from the Ink Supply Station (ISS) PCA to

the Ink Supply Station is correctly connected.

n Faulty APS. Replace the APS ⇒ Page 8-63. n If the error code continues, replace the Main PCA ⇒ Page 8-77.

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

HP DesignJet 5000 Series Printers Service Manual

2-13

System Error Codes

System Error: 0B0005 Problem

Description: Corrective Action: Try the following:

APS Failure.

n Check that the cable from the Ink Supply Station (ISS) PCA to

the Ink Supply Station is correctly connected.

n Faulty APS. Replace the APS ⇒ Page 8-63. n If the error code continues, replace the Main PCA ⇒ Page 8-77.

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

System Error: 0B0006 Problem

Description: Corrective Action: Try the following:

The Trailing Cable has been incorrectly connected.

n Power the Printer OFF disconnect the T railing Cable. Replace the

Trailing Cable if the ends are not flat or are damaged. Reconnect the Trailing Cable correctly, making sure it is pushed in firmly (refer to the instructions on page ⇒ Page 8-36). Power ON the Printer and check if the Error Code has disappeared.

n If the Error Code continues, replace the Main PCA ⇒ Page 8-77

taking care when connecting the Trailing Cable.

System Error: 0B0007 Problem

Description: Corrective Action: Try the following:

Unable to detect Vacuum Fan.

n Make sure that the Vacuum Fan is connected correctly to the

Main PCA.

Turn the Printer OFF and disconnect the Vacuum Fan from the Main PCA. Connect a power ON the Printer. If the without any Error Codes then remove the the Printer and install the

n If the New Vacuum Fan does not function correctly either, then

replace the Main PCA ⇒ Page 8-77.

New

Vacuum Fan to the Main PCA and

New

Vacuum Fan functions correctly

Old

Vacuum Fan from

New

one.

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HP DesignJet 5000 Series Printers Service Manual

System Error: 0B0008

System Error Codes

Problem Description:

Corrective Action: Try the following:

Unable to detect Cooling Fan.

n Make sure that both Cooling Fans are correctly connected to the

Power Supply Unit.

n Replace the Main PCA ⇒ Page 8-77.

System Error: 0B0009 Problem

Description: Corrective Action: Try the following:

Unable to detect Aerosol Fan (in the Right Cover).

n Make sure that the Aerosol Fan is connected correctly to the

Main PCA.

Turn the Printer OFF and disconnect the Aerosol Fan from the Main PCA. Connect a Right Cover) to the Main PCA and power ON the Printer. If the

New

Aerosol Fan functions correctly without any Error Codes

then remove the

New

one.

n If the New Aerosol Fan does not function correctly either, then

replace the Main PCA ⇒ Page 8-77.

New

Aerosol Fan (comes with the new

Old

Aerosol Fan from the Printer and install the

System Error: 0B000A Problem

Description: Corrective Action: Try the following:

Primer Shutdown Error.

n Check that the Primer Stepper-Motor Cable is NOT broken or

damaged and that the Primer Arm moves freely from side to side.

n Replace the Service Station ⇒ Page 8-65. n If the Error Code continues, replace the Main PCA ⇒ Page 8-77.

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

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2-15

System Error Codes

System Error: 0B000B Problem

Description: Corrective Action: Try the following:

APS Failure.

n Check that the cable from the Ink Supply Station (ISS) PCA to

the Ink Supply Station is correctly connected.

n Check that the Air Pressurization System Sensor Cable is

correctly connected and is NOT damaged.

n Check all the tubes of the APS and make sure they are NOT

pinched or damaged.

n Faulty APS. Replace the APS ⇒ Page 8-63. n If the error code continues, replace the Main PCA ⇒ Page 8-77.

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. Using this procedure you will be able to determine exactly which component failed.

System Error: 0B000C Problem

Description:

Serial Device ADC test failure.

Corrective Action: Replace the Main PCA ⇒ Page 8-77.

System Error: 0B000D Problem

Description: Corrective Action: Replace the Main PCA ⇒ Page 8-77.

24 V source test failure.

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HP DesignJet 5000 Series Printers Service Manual

HP Ink Supplies Troubleshooting

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

3-1

HP Ink Supplies Troubleshooting

What are HP Ink Supplies?

For each of the six colors used in the Printer, there are three separate components. The Printhead and the Printhead Cleaner are supplied together, the Ink Cartridge is supplied separately. All of these components are called the HP Ink Supplies. They are coded with an HP selection number to help you re-order the correct replacement supplies.The Printhead and the Printhead Cleaner are supplied together, and the Ink Cartridge is supplied separately. These consumables are designed with a lock-out feature that will allow only one color to be inserted into a given slot.

Ink Cartridges

The HP Ink Cartridges for the HP DesignJet 5000 Series Printers require no maintenance or cleaning. As long as each Ink Cartridge is inserted correctly into its slot, the ink will flow to the Printheads.

The front panel displays the status of the Ink Cartridges. With the front panel, detailed information can be checked on the Ink Cartridges.

Printheads and Printhead Cleaners

The HP Printheads for the HP DesignJet 5000 series are extremely durable and do not need to be replaced every time an Ink Cartridge is replaced. They are independent of the Ink Cartridges and will continue giving excellent image quality results even if the Ink Cartridges are low on ink. See page 3-5, When Should You Replace the HP Ink Supplies?

If you notice a decline in print quality such as lines or dots missing from text / graphics, go to page 6-1, Print Quality .

The HP Printhead Cleaners keep the Printheads in good condition and they prevent them from being damaged when the Printer is not active. They service the Printheads, making sure they are always ready to be used.

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HP DesignJet 5000 Series Printers Service Manual

HP Ink Supplies Troubleshooting

Identifying the Components

The following illustration will help you identify the components of the HP Ink Supplies.

Printhead

Ink Cartridge

Printhead Cleaner

General Information About HP Ink Supplies

For optimum results from the Printer and modular ink delivery system always follow these guidelines when handling the HP Ink Supplies:

n Always install the Ink Cartridges, Printheads and Printhead

Cleaners before the expiration date, which is on the packaging.

n Install a new Printhead Cleaner every time you change a

Printhead.

n Allow the Printer and Printhead Cleaners to automatically clean

the Printheads.

n Ink Cartridges, Printheads and Printhead Cleaners are designed

with lock-outs that only allow their installation in their colorcoded slots; they must not be forced.

n Follow the instructions on the Front Panel of the Printer during

installation.

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3-3

HP Ink Supplies Troubleshooting

n Avoid unnecessary removal of the Ink Cartridges and Printheads. n When turning off the Printer always use the softpower Off button

on the Front Panel. The Printheads are then stored correctly which prevents them from drying out.

n The Ink Cartridges should never be removed while the Printer is

printing. They should only be removed when the Printer is ready for you to replace them. The Front Panel will guide you through the removal and installation procedure. See page 3-5, When Should You Replace the HP Ink Supplies?

Some General Precautions When Handling HP Ink Supplies

CAUTION

Do not touch, wipe or attempt to clean the Printhead nozzles. This can damage the Printhead.

Handle the HP Ink supplies with care. In particular the Printhead, which is a high precision device and must be handled carefully.

n Do not touch the Printhead nozzles. n Do not put the Printhead down on the nozzles. n Do not be rough when handling the Printheads. Always set them

down gently.

n Do not drop the Printheads. n Proper handling will assure optimum performance throughout the

Printhead life.

n The Printhead Cleaner should always be handled and stored

upright to avoid a potential spillage of ink.

n Do not touch the end of the Ink Cartridge which is inserted into

the Printer as there may be a small amount of ink on the connection.

n Avoid storing partially used Ink Cartridges on their ends.

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HP DesignJet 5000 Series Printers Service Manual

HP Ink Supplies Troubleshooting

Priming the Ink System

When the customer first receives the Printer, it is suppli ed with a set of six Setup Printheads pre-installed in the Carriage Assembly. These Setup Printheads are used for the priming of the tubes in the modular ink delivery system. The customer must not remove the setup Printheads from the Carriage Assembly without following the procedures in the Setup Guide.

When the Printer is powered ON for the first time, the Printer will automatically perform the priming process. Without the priming process, the customer will NOT be able to use the Printer.

Why does the Printer require priming:

n The Tubes System is empty when the customer receives the

Printer.

n The Tubes System has to be pressurized and filled with ink,

ejecting any air bubbles.

CAUTION If the Printing Printheads are installed in the Carriage during

the priming process, th ey will be rejected and the front panel will show the "(XX11)Replace" message (Refer to 3-12, Error Status Messages ).

When Should You Replace the HP Ink Supplies?

When to change the HP Ink supplies is mostly determined by you with guidance from the front panel. In conjunction with the messages displayed in the front panel and the message explanations in this chapter, you will be able to choose for yourself when is the right time to change the HP Ink supplies.

The Printer will also display the ink level and will tell you when the ink supply is low, very low or empty. This means you have constantly updated information about the HP Ink supplies.

Printhead life is anticipated to be 700ml or twelve months in the Printer, whichever occurs first, provided that the Printhead is used under normal operating conditions (using HP Ink Cartridges only) and its “install before date” has not lapsed. However results vary depending on the print quality setting being used.

HP DesignJet 5000 Series Printers Service Manual

3-5

HP Ink Supplies Troubleshooting

The Front Panel Display

The front panel display has a dedicated area to report the status of your HP Ink supplies. Status messages consist of a code and an action message

Printhead Status

Ready

Roll Hewlett Packard

Photo Imaging Gloss

Ink OK Printheads (1421) REPLACE

Action Message

Ink Cartridge Status

n Ink displays information on the Ink Cartridges. n Printheads displays information on the Printheads and the

Status Code

Printhead Cleaners

n The Status code indicates the exact nature of the HP Supplies

problem ( see 3-10, Status Codes and Messages ).

n The Action Message provides instructions to return to normal

status i.e. OK (see 3-10, Status Codes and Messages ).

To view information for a specific Ink Cartridge color or Printhead you must access the cartridge and Printhead menus ( See 3-7,

Obtaining Ink Cartridge Information and 3-8, Obtaining Printhead Information ). The overlay indicates the color related to the Ink

Cartridge and Printhead menu information.

Press ENTER for

cartridges menu

LIGHT CYAN

LIGHT MAGENTA

YELLOW

CYAN

MAGENTA

BLACK

Ink

LOW

3-6

overlay colors

The Ink Cartridges Menu

HP DesignJet 5000 Series Printers Service Manual

HP Ink Supplies Troubleshooting

Obtaining Ink Cartridge Information

1. To get information on the Ink Cartridges press the Top key on the

front panel to go to the main menu.

Ink info.

Ready

Light Cyan cart. info...

Roll

Light Magenta cart. info...

Hewlett Packard Photo Imaging Gloss

Ink OK

Magenta cart info...

Printheads OK

Black cart info...

2. Press the ↑ or ↓ key to select the catridges icon and view status bars indicating ink levels in the Ink Cartridges.

Press ENTER for cartridges menu

LIGHT CYAN

LIGHT MAGENTA

YELLOW

CYAN

MAGENTA

BLACK

Ink

LOW

Ink Cartridges Menu

The front panel displays six horizontal bars. These bars represent how much ink is remaining in the Ink Cartridges: as ink is used up the bars get shorter in length. The Ink Cartridge color on the overlay indicates the Ink Cartridge color related to each bar.

Press the Enter key to view the Ink Cartridges menu.

3. Press the ↑ or ↓ key until the front panel highlights the color that you want to see information on. Press the Enter key.

Ink cartridge info.

Light Magenta cart. info... Yellow cart. info... Cyan cart info... Magenta cart info... Black cart info...

Replace ...

HP DesignJet 5000 Series Printers Service Manual

3-7

HP Ink Supplies Troubleshooting

4. The front panel displays information on the selected Ink Cartridge.

Yellow cart. info

HP No.81 ink cartridge Ink level=87% Capacity=680ml

Part number=C4934AW

Part number=C4934A Mfg.month=12/1999

Mfg. month=5/1999

The information supplied is:

n The make of the Ink Cartridge. n The percentage of how much ink is remaining. n Original capacity of the Ink Cartridge in milliliters. n Re-order part number of the Ink Cartridge. n The month and year that the Ink Cartridge was manufactured.

Obtaining Printhead Information

1. To get information on your Printheads, press the Top key on the

front panel to go to the main menu.

Ink cartridge info.

Ready

Light Cyan cart. info...

Roll

Light Magenta cart. info...

Hewlett Packard Photo Imaging Gloss

Ink OK

Magenta cart info...

Printheads OK

Black cart info...

2. Press the ↑ or ↓ key to select the Printheads icon and view

information on the Printheads..

Press ENTER for

LIGHT CYAN

LIGHT MAGENTA

YELLOW

CYAN

MAGENTA

BLACK

printheads menu

OK OK

(1421) REPLACE

OK OK

Printheads

Printhead Menu

3-8

HP DesignJet 5000 Series Printers Service Manual

HP Ink Supplies Troubleshooting

3. Press ↑ or ↓ key until the front panel highlights “Printhead info”. Press Enter to view the Printheads information

Printhead info

Printhead info... Recover printheads Replace printheads

4. Press the ↑ or ↓ key until the front panel highlights the color that you want to see information on. Press the Enter key.

Printhead info.

Light Cyan cart. info... Light Magenta cart. info...

Yellow cart. info... Cyan cart info...

Magenta cart info... Black cart info...

5. The front panel displays information on the selected Printhead.

Cyan printhead info

HP No.81 printhead Status=OK IN Warranty Part Number=C4821AW Usage time=50h Ink consume d=3ml Mfg. month=5/1998

The information supplied is:

n The make of the Printheads. n The current status of the Printhead. n The Printhead warranty status. n Re-order part number of the Printhead. n The time (hours) the Printhead has been operating in the Printer. n How much ink has been consumed by the Printhead. Note: It is

possible for a Printhead to consume more than one Ink Cartridge.

n The year and the month that the Printhead was manufactured.

HP DesignJet 5000 Series Printers Service Manual

3-9

HP Ink Supplies Troubleshooting

Status Codes and Messages

NOTE Most problems with Ink Supplies will be solved by the user

simply following the instructions in the action message.

If a problem persists, a Call Agent can try and troubleshoot Consumables problems by requesting the HP Status code from the Customer via the phone. Using this process, it can be determined whether the Printer requires any on-site maintenance.

Press ENTER for

LIGHT CYAN

LIGHT MAGENTA

YELLOW

CYAN

MAGENTA

BLACK

printheads menu

OK OK OK OK

(1421) REPLACE

Printheads

Printhead Menu

HP ID Code

Status Number Action Message

HP Status Code

The HP Status Code is made up of 4 digits: the first two digits are the HP ID Code that identify the consumable and its color. The last two digits are the status number indicating the nature of the problem.

The tables in the next few pages describe the messages and status codes for HP Ink Supplies.

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HP DesignJet 5000 Series Printers Service Manual

HP Ink Supplies Troubleshooting

Status Messages

These messages provide only an action message for the user to perform. For information on accessing detailed information on consumables refer to 3-7, Obtaining Ink Cartridge Information and 3-8, Obtaining Printhead Information .

Status Description Procedure OK The ink system is working correctly None

Insert There is no consumable installed Insert the correct consumable.

If the correct consumable is inserted, check the Carriage Tube Connector is correctly connected to the Carriage.

Setup The setup message is displayed

when new tubes have been installed into the Printer and you have installed the correct setup Printheads.

Low Ink Cartridge Level has reached it’s

low limit (100 ml.). This is an early warning.

Very Low

Empty Ink Cartridge is empty. The Printer

Ink Cartridge Level has reached it’s very low limit (50 ml.)

stops.

When the setting up of the tube system is complete, the front panel will display a message (XX04)Replace asking you to remove them and replace them with ‘normal Printheads’.

New supplies should be obtained ready to replace the particular color

Overnight printing should not be attempted. Priming of the Ink Tubes should not be attempted. A new Ink Cartridge is strongly recommended to prevent the Printer from interrupting a print.

A new Ink Cartridge is required. Check image quality of prints in progress.

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HP Ink Supplies Troubleshooting

Error Status Messages

Error status messages consist of the HP Status Code and the action message. The following tables group error messages according to the consumable, the action message (i.e. all Replace errors are grouped together), and then the status number i.e. last two digits.

The first digit in the HP ID code (see table below), identifies the consumable and/or provides specific consumables information.

Status Code

First Digit

0 HP No.81 Printhead in warranty 1 HP No.81 Printhead out of warranty 4 Setup Printhead 5 Printhead Smartchip error

A HP No.81 Printhead Cleaner

6 HP No.81 Ink Cartridge 8 Ink Cartridge Unknown

Printhead Cleaner Detection Error

Part / Information

The second digit identifies the color (see table below), for the Printhead, Printhead Cleaner or cartridge.

Status Co de

Second Digit

5 Light Cyan

Color

3-12

4 Light Magenta 3 Yellow 2Cyan 1 Magenta 0 Black

HP DesignJet 5000 Series Printers Service Manual

HP Ink Supplies Troubleshooting

Printhead Errors (First Digit = 0, 1, 4, 5)

NOTE If you think your Printer is requesting you to replace your

Printheads too frequently you can check Printhead nozzle status by printing the Diagnostic Print ⇒ Refer to 6, Print Quality.

NOTE Do not touch, wipe or attempt to clean the Printhead nozzles.

This can damage the Printhead and reduce print quality (See Page 9-6 for Maintenance Procedures).

NOTE When replacing Printheads:

n Ensure that you have the correct Printhead. n Ensure that the Printhead is the correct color for that slot. n Ensure that the protective cap is removed from the

Printhead.

n Check the empty slots to see if they need cleaning. In extreme

circumstances, when a Printhead is inserted, it is possible that the Printer will not recognize it due to the build-up of ink on the electrical connection between the Printhead and the Printhead carriage.

NOTE If all 6 Printheads present the same error message, check the

following:

n All Printheads installed are NOT wrong type i.e. wrong

model, Setup Printheads instead of normal etc.

n If you replace or reseat Printheads one at a time and the

error persists for all Printheads, this indicates a hardware failure. Do the following:

1 Check that the Carriage Tube Connector is correctly connected

to the Carriage.

2 Check that the Trailing Cable connections between the

Carriage Assembly and the Main PCA and if the cable is

damaged, replace it ⇒ Page 8-36. 3 Replace the Carriage Assembly ⇒ Page 8-46. 4 Replace the Main PCA ⇒ Page 8-77.

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HP Ink Supplies Troubleshooting

Status

Numbers

XX02 Reseat XX06 Reseat XX08 Reseat

XX10 Reseat Electrical failure.

XX03 Replace Printhead smartchip failure. Replace Printheads. XX04 Replace Setup Printhead installed. Install normal Printheads. XX05 Replace Used setup Printheads

XX09 Replace Electrical failure. 1. Replace the Printhead(s).

XX11 Replace Incorrect type of Printhead

XX12 Replace Printhead does not match the

Printhead Information

XX13 Replace Printhead smart chip failure. Replace the Printhead(s). XX14 Replace The Printhead has an internal XX15 Replace XX16 Replace The Printer was printing: XX17 Replace

XX18 Replace The Printhead smartchip

XX20 Recover The Printhead has detected

XX21 Replace The Printhead has detected a

Error Description Procedure

Continuity problem between the Printhead and the Carriage Assembly.

installed.

rest of the ink consumables.

electric al failure.

Printhead short

detects an unapproved manufacturer.

nozzle failure.

significant number of bad nozzles that affects print quality.

Try the following (verify if the message returns to OK after each one).

1. Reseat the Printhead.

2. Remove the Printhead and clean the interconnect, refer to 9-6, Carriage Interconnect Wiper .

3. Replace the failing Printhead.

4. Check the Carriage Tube Connector is correctly connected to the Carriage.

5. Check Trailing Cable connections between the Carriage Assembly and the Main PCA and replace the Trailing Cable if damaged

6. Replace the Carriage Assembly

If priming Tubes install new Setup Printheads otherwise install normal Printheads.

2. Check Trailing Cable connections between the Carriage Assembly and the Main PCA and replace the Trailing Cable if damaged

3. Replace the Carriage Assembly

4. Replace the Main PCA If Tubes system is priming: install Setup

Printhead(s) Ensure that you have HP No. 81 Printheads

installed. Ensure that all the ink consumables are HP No. 81

1. Replace the Printhead(s).

2. Replace the Carriage Assembly Select YES to replace Printheads or NO to finish

print job without the failed Printhead (print quality is affected). You must replace the Printhead after the print job.

Install HP No. 81 Printheads.

1. You can continue using the Printhead unless the (XX21)Replace message is displayed (the affect on print quality depends on the print mode).

2. Perform the Recovery procedure Select YES to replace Printheads or NO to finish

the print job without the failed Printhead (print quality may be affected). The message will be displayed for every print job until you replace the Printhead.

1. Attempt the Recovery procedure

2. If the message persists replace the Printhead(s).

⇒ Page 8-36.

⇒ Page 8-46.

⇒ Page 8-36.

⇒ Page 8-46.

⇒ Page 8-77.

⇒ Page 8-46.

⇒ Page 6-15.

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HP DesignJet 5000 Series Printers Service Manual

HP Ink Supplies Troubleshooting

Printhead Recovery Procedure

The Printer regularly performs a series of controls on the health of the Printheads and when they start to degrade the Printer will prompt the user to recover the Printhead [(XX20)Recover].

Ready

LIGHT CYAN

LIGHT MAGENTA

YELLOW

CYAN

MAGENTA

BLACK

Printheads

(1520) RECOVER OK OK OK OK OK

At this stage, the customer should obtain new Printheads. Depending on the print mode being used (Max. Quality, Productivity or Max. Speed) the Printer may still be able to print with an acceptable print quality. Refer to Page 6-15 for details on performing Printhead recovery.

If the Printer is printing a job and the Printhead health degrades to a significant degree [(XX16) and (XX17)

REPLACE], the front panel

will display a warning.

Warning! Printhead quality degrading select YES to replace failing printhead(s)

YES (Replace) NO (Continue )

Press the ↓ or ↑ down key to select YES or NO and press the Enter key. If you select YES the print job will be cancelled and Printhead replacement will be started. If you select NO, the Printer will finish the current print job.

NOTE This message will be displayed each time you send a print job to

the Printer until you replace the failing Printhead(s).

WARNING If you select NO the Printer finishes the current print job

WITHOUT using the failed Printhead i.e. without using that color.

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3-15

HP Ink Supplies Troubleshooting

Ink Cartridge Errors (First Digit = 6, 8)

NOTE When replacing Ink Cartridges:

n Use the Replace item in the Ink Cartridges menu. This will

release all air from the Ink Cartridge and avoid problems in its removal.

n Ensure that you have the correct Ink Cartridge. n Ensure that the Ink Cartridge is the correct color for that

slot.

n Ensure that the Ink Cartridge is the correc t or ient a tio n, w it h

the color coded label at the top.

NOTE If all 6 Ink Cartridges present the same error message, check the

following:

n All Ink Cartridges installed are NOT of the wrong type i.e.

wrong model.

n If you replace or reseat Ink Cartridges one at a time and the

error persists for all cartridges, this indicates a hardware problem. Do the following:

1 Check ISS cable connections on the rear of the Ink Supply

Station and the ISS PCA.

2 Remove the Service Station and check that the connections on

the floaters are clean. 3 Replace the Ink Tubes System ⇒ Page 8-60. 4 Replace the ISS PCA ⇒ Page 8-84.

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HP DesignJet 5000 Series Printers Service Manual

HP Ink Supplies Troubleshooting

Status Numbers Error Description Procedure XX03 Replace The Ink Cartridge has a leak which

prevents the ink pumping to the Printer.

WARNING: If the Ink Bag in the Ink Cartridge is leaking, the Tubes may be damaged.

Ink Cartridge Information

XX04 Replace Smart chip error. You can not

continue to use this Ink Cartridge.

XX05 Replace Incorrect Ink Cartridge Check correct Ink Cartridge is installed.

XX06 Replace The Printer detects that the Ink

Cartridge does not match th e rest of the Ink System already installed.

XX08 Unkn own The Ink Cartridge smart chip

indicates that the Ink Cartridge installed is not supported by HP.

XX02 Reseat Continuity problem between Ink

Cartridge and Ink Supply Station.

1. Remove the Ink Cartridge immediately.

2. Open the Door at the rear of the Left Cover and check the Air Tubes for Ink and do the following:

3. If there is no ink in the Air Tubes: a) Replace the Ink Cartridge and, if the XX03Replace error reappears for any Ink Cartridge, go to step 5.

4. If there is ink in the Air Tubes: a) Remove all the Ink Cartridges to allow the ink to drain from the Tubes. b) Replace the faulty Ink Cartridge and reinsert the other Ink Cartridges.

If the XX03Replace error reappears for any Ink Cartridge, do the following:

5. Remove the Ink Cartridge and check for ink on the Air Connector on the rear of the Ink Cartridge.

6. If there is ink present, do the following: a) Press the sides of the Ink Cartridge to see if ink is leaking from the Air Connector and replace the Ink Cartridge if it is faulty. b) If the Ink Cartridge is not faulty, replace the Ink Tubes System

7. If there is no ink present, do the following: a) Verify ISS cable connections. b) Remove the ISS Station and check that the slots and connections on the floaters are clean. c) Replace the Ink Tubes S ystem

60. d) Replace the ISS PCA

1. Remove the Ink Cartridge and reinstall.

2. Replace the Ink Cartridge

Replace with approved Ink Cartridge. Ensure that the Printheads and the Ink

Cartridges are HP No. 81.

1. Press Enter to continue or:

2. Replace with a genuine HP No. 81 Ink Cartridge.

1. Remove the Ink Cartridge and reinsert.

2. Replace the Ink Cartridge.

3. Remove the Ink Supply Statio n and check contacts on floaters.

⇒ Page 8-60.

⇒ Page 8-84.

⇒ Page 8-

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HP Ink Supplies Troubleshooting

Printhead Cleaner Errors (First Digit = A or *)

NOTE When replacing Printhead Cleaners:

n Ensure that you have the correct Printhead Cleaner. n Ensure that the Printhead Cleaner is the correct color for

that slot.

n Ensure that the Printhead Cleaner is the correct orientation.

NOTE If all 6 Printhead Cleaners present the same error message,

check the following:

n All Printhead Cleaners installed are NOT wrong type i.e.

wrong model, unapproved etc.

n Replace Printhead Cleaners when Printheads are replaced.

NOTE The message status for Printhead Cleaners will not change until

the door is closed; there is no sensor detecting removal and insertion.

Status Numbers Printhead Cleaner Error

Description

*X03 Replace

XX05 Replace The Printhead detects that the

XX06 Replace The Printer detects an incorrect

Printhead Cleaner Information

There is a Printhead Cleaner detection failure (you may continue to use the Printhead Cleaner)

Printhead Cleaner does not match the rest of the ink system already installed.

Printhead Cleaner

Procedure

Try the following:

1. Ensure that genuine HP No. 81 Printhead Cleaners are installed.

2. Reseat the Printhead Cleaner.

3. Check the lens is clean and perform Lens Maintenance if required 9-5.

4. Replace the Printhead Cleaner. Ensure that you have replaced the

Printhead Cleaner together with the Printhead. Ensure that genuine HP No. 81 Printhead Cleaners are installed.

⇒ Page

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HP DesignJet 5000 Series Printers Service Manual

Service Tests and Utilities

Introduction 4-2 Diagnostics - Self Te st 4-2

The Printer hangs and nothing else happens 4-3 Error Memory Config:X 4-3 Error Memory Test 4-3 Power Supply Error #1 4-3 BootROM checksum failed 4-3 Boot Failed::1f500XX 4-4 Boot FAILED 4-5 BOOTROM ERROR: 4-5 COMPONENT MISMATCH: 4-5

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

Entering the Servic e Utilities Menu 4-15 Turn DRIVE ROLLER 4-18 Prime TUBES 4-1 9 Altitude Setup 4-23 EEROM Setup 4-24 Reset Life Counters 4-29 Backup EEROM 4-31 Image Quality Warning 4-33 Diagnostic Print 4-34

HP DesignJet 5000 Series Printers Service Manual

4-1

Service Tests and Utilities

Introduction

This chapter explains how to use the built-in Service Tests and Service Utilities and what to do if any of the Service Tests fail. If possible, always perform a Service Test on the component that you are about to replace, just to make sure that is the component that has failed. If the test on that component passes, there is no need to replace it.

Phone Support

In certain circumstances, a Call Agent can try and troubleshoot the Printer by requesting the Customer to perform a Service Test or Utility via the phone. Using this process, it can be determined whether the Printer requires any on-site maintenance. In Phone Support the user will have access to a limited number of Service Tests or Utilities.

Diagnostics - Self Test

Initialization Sequences

Whenever the Printer is switched ON, it automatically performs a series of internal self tests and mechanical initialization sequences. If any of the parts fail, an error code will appear. Below is a description of the initialization sequence, describing front panel messages and the sequence of the Print Quality LEDs, the error messages and error codes that may appear, and the corrective action.

NOTE Because of the speed at which the initialization sequence is

performed, some of the steps described in the intialization process may not be visible unless they are interrupted by an error code.

NOTE Before troubleshooting error codes try the following:

n Check that the BootROM DIMM, the DRAM DIMM’s and

the Hard Disk Drive are correctly installed.

n Try powering the Printer Off and On to see if the error code

disappears.

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HP DesignJet 5000 Series Printers Service Manual

Service Tests and Utilities

Max. Quality Productivity

Max. Speed

Max. Quality Productivity

Max. Speed

Max. Quality Productivity

Max. Speed

Max. Quality Productivity

Max. Speed

WARNING Only replace one component at a time and check if the error has

gone before replacing another component. If the error is still present after replacing a component, remember to REINSTALL the component that was first removed before replacing another component.

Self Diagnostics - Initialization Sequence

LED’s Front Panel Message Printer Error - Error

Message/Code

The Printer hangs and nothing else happens

Self Test Please Wait

End Self Test

Initializing Power Supply Erro r

Error Memory Config:X (sometimes only the error code is displayed)

Error Memory Test Replace the DRAM DIMM’s ⇒ Page 8-73.

#1 Contact HP Representative

Corrective Action

Install the BootROM or replace it if already installed ⇒ Page 8-73.

If X = 7 reseat the DRAM DIMM’s, otherwise replace the DRAM DIMM’s ⇒ Page 8-73.

The Trailing Cable is not connected correctly. Reconnect the Trailing Cable ⇒ Page 8-36.

Initializing IO devs BootROM checksum

failed

HP DesignJet 5000 Series Printers Service Manual

Replace the BootROM ⇒ Page 8-73.

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Service Tests and Utilities

Max. Quality Productivity

Max. Speed

Self Diagnostics - Initialization Sequence

LED’s Front Panel Message Printer Error - Error

Message/Code

Spinning up disk Boot Failed::1f500XX Depending on the last two digits, do the

Corrective Action

following:

NOTE: If the error is still present after replacing a co mponent, remember to REINSTALL the component that was first removed before replacing another component.

01 - Replace the Hard Disk Drive ⇒ Page

8-70. Replace the Main PCA ⇒ Page 8-77.

07 - Replace the Hard Disk Drive ⇒ Page

8-70. Replace the Main PCA ⇒ Page 8-77.

0E - Replace the Hard Disk Drive ⇒ Page

8-70. Replace the Main PCA ⇒ Page 8-77.

02 - Install the Hard Disk Drive ⇒ Page 8-

70. Replace the Main PCA ⇒ Page 8-

77.

03 - Replace the Hard Disk Drive ⇒ Page

8-70. Replace the BootROM DIMM

⇒ Page 8-73. Replace the Main PCA ⇒ Page 8-77.

04 - Replace the Hard Disk Drive ⇒ Page

8-70. Replace the BootROM DIMM

⇒ Page 8-73. Replace the Main PCA ⇒ Page 8-77.

05 - Replace the DRAM DIMM’s ⇒ Page

8-73. Replace the BootROM DIMM

⇒ Page 8-73. Replace the Main PCA ⇒ Page 8-77.

06 - Replace the BootROM ⇒ Page 8-73.

Replace the Main PCA ⇒ Page 8-77.

09 - Replace the BootROM DIMM ⇒ Page

8-73. Replace the Main PCA ⇒ Page 8-77.

0A - Replace the BootROM DIMM ⇒

Page 8-73. Replace the Main PCA ⇒ Page 8-77.

0B - Replace the Hard Disk Drive ⇒ Page

8-70. Replace the BootROM DIMM

⇒ Page 8-73. Replace the Main PCA ⇒ Page 8-77.

0C - Replace the BootROM DIMM ⇒

Page 8-73. Replace the Main PCA ⇒ Page 8-77.

0D - Replace the Hard Disk Drive ⇒ Page

8-70. Replace the BootROM DIMM

⇒ Page 8-73. 0F - Replace the Main PCA ⇒ Page 8-77. 10 - Replace the Main PCA ⇒ Page 8-77. 11 - Replace the Main PCA ⇒ Page 8-77.

4-4

Spinning up disk...OK

HP DesignJet 5000 Series Printers Service Manual

Service Tests and Utilities

Max. Quality Productivity

Max. Speed

Max. Quality Productivity

Max. Speed

Max. Quality

Productivity

Max. Speed

Self Diagnostics - Initialization Sequence

LED’s Front Panel Message Printer Error - Error

Message/Code

Loading firmware.fmw

Initializing

Initializing L2C Initializing CLK

Initializing IO

Boot FAILED

BOOTROM ERROR: Current Version:XXX Necessary Version:XXX Replace and Restart

COMPONENT MISMATCH: You are running a XXX printer with a XXX disk Insert XXX disk and restart.

Corrective Action

Download the Firmware file to the Printer ⇒ Page 9-12.

The BootROM ver s ion and the Firmware version do not match. Download the BootROM version indicated by the "Necessary Version" message.

The Hard Disk Drive, or the Firmware on the Hard Disk Drive, does not match the BootROM Printer Model. For RTL Printers (Part No. C6090A and C6095A - see label on the Back Cover): Make sure RTL Hard Disk Drives and Firmware are used. For Part Numbers see Page 7-1. For Postscript Printers (Part No. C6091A and C6096A - see label on the Back Cover): Make sure Postscript Hard Disk Drives and Firmware are used. For Part Numbers see Page 7-1.

Initializing Please Wait Code rev:XXXXXX BootROM:XXXXX RAM present:XXX MB Hard Disk:XXXX MB PS Code rev:XXXXX

Ready or Ready for Media

HP DesignJet 5000 Series Printers Service Manual

4-5

Service Tests and Utilities

Service Tests (Diagnostics)

The following is a list of all internal Service Tests available in the Printer. Instructions for entering the Service Tests menu are given on Page 4-7.

1. Scan Axis Test ⇒ Page 4-10

The purpose of this Service Test is to verify the correct functioning of parts relating to Carriage movement along the Printer axis.

2. Media Axis Test ⇒ Page 4-12

The purpose of this Service Test is to verify the correct functioning of parts relating to Media movement through the Printer.

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HP DesignJet 5000 Series Printers Service Manual

Service Tests and Utilities

Entering the Service Tests Menu

1. Once the message "Ready" is displayed on the front-panel, scroll to

the "Printer Setup Options" icon and press the Enter key.

Ready

Roll Hewlett Packard

Photo Imaging Glos s

Ink OK Printheads OK

Top

Back

↑ ↓

Enter

Make Selection

Press Enter

For On-Site Engineers accessing the complete list of Service Tests

a Once inside the "Printer Setup Options" menu, use the Arrow keys

to scroll to the "Utilities" menu and press the Enter key.

Printer setup options

Device setup... I/O setup...

Utilities... Internal RIP settings... Queueing & Nesting... HP-GL/2 settings...

Top

Back

↑ ↓

Enter

Make Selection

Press Enter

b Once inside the "Utilities" Menu, press the following key

combination to access the complete list of Service Test menus.

Utilities

Usage ... Menu Mode = Full

Calibrations ... Reset WebAccess paswd Test Prints ...

Statistics ...

Top

Back

↑ ↓

Enter

Press Up and Enter

HP DesignJet 5000 Series Printers Service Manual

4-7

Service Tests and Utilities

For Call Agents request ing the User to acces s a limit ed number of Service Tests

a Once inside the "Printer Setup Options" menu and the "Device

setup" menu is highlighted, press the following key combination:

Printer setup options

Device setup... I/O setup...

Utilities... Internal RIP settings... Queueing & Nesting... HP-GL/2 settings...

Top

Back

↑ ↓

Enter

Press Down and Enter

2 The message below is displayed. Select Yes to continue.

Warning!

This mode should NOT be

used without having the guidance of a HP representative person

Yes... No

Top

Back

↑ ↓

Enter

Press Enter

3. You are now in the Service Menu. Use the Arrow keys to scroll to the "3 Service Tests" menu and press the Enter key.

Top

Service Menu

Back

1 Service Utilities... 2 Service 3 Service Tests...

3 Service Tests...

Calibrations...

↑ ↓

Enter

Make Selection

Press Enter

4. Use the Arrow keys to scroll through the "Service T ests" selections.

Top

3 Service Tests

Back

↑

3.1 Scan Ax i s

3.2 Media Axis

↓

Enter

Make Selection

Press Enter

5. Press the Enter key to begin a specific operation when the required Service Test is highlighted.

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HP DesignJet 5000 Series Printers Service Manual

Service Tests and Utilities

If your Firmware does not support Service Tests, the following message is displayed. You should press Enter to exit. If you need the Service Tests, download the latest Firmware and repeat the whole procedure to enter the Service Tests menu.

3. Service Tests Error!!

Svs Test not available. Upgrade Firmware rev.

Press Ent er to continue

Top

Back

↑ ↓

Enter

Press Enter

NOTE If the Printer is not used for 3 minutes, the Printer exits the

Service Tests Menu and you must repeat the above steps to enter Service Tests again.

NOTE In some cases a quick press of a button may n ot be recognized by

the Printer. When pressing a button, be sure to press it deliberately and all the way to the bottom of its travel.

NOTE If the Printer hangs up during an operation, switch the Printer

OFF and restart from step 1.

HP DesignJet 5000 Series Printers Service Manual

4-9

Service Tests and Utilities

Scan Axis Test

The purpose of this test is to verify:

n Carriage movement along the Printer axis. n Scan-Axis motor.

This test measures the maximum and the average current required to move the Scan Axis parts in order to verify if parts are moving freely or not.

Perform the Scan Axis Test as follows:

1. In the "3 Service Tests" menu, scroll to "3.1 Scan Axis" and press Enter.

3 Service Tests

Top

Back

↑

3.1 Scan Ax i s

3.2 Media Axis

↓

Enter

Make Selection

Press Enter

2. The test will start and the following message will appear on the front panel as the test is performed.

Top

3.1 Scan Axis

Max. PWM: Avg. PWM:

xxx

Analyzing Data...

xxx

Back

↑ ↓

Enter

3. When the test has completed, the Maximum and Average Pulse Modulation Values are displayed for each direction (left and right). Press Enter to return to the Service Tests menu.

Top

3.1 Scan Axis

Max. PWM: Avg. PWM:

xxx xxx

Press ENTE R to contin ue

xxx

Back

↑ ↓

Enter

Press Enter

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HP DesignJet 5000 Series Printers Service Manual

Service Tests and Utilities

NOTE Report the values to the nearest HP Response Center or HP

Support Office to determine whether values are within the accepted range.

When reporting the values, have the following information ready:

n Model and Serial Number of the Printer. n All values reported in the test. n The Service Configuration Print ⇒ Page 1-26.

If values are not within the accepted ranges, turn the Printer OFF and perform the following steps and repeat the test after each one:

1. Clean Slider Rods and Apply Oil along the complete axis of the

Slider Rods with the User’s Slider Rods Lubrification Kit ⇒ Page 9-8.

2. Check the Encoder Strip and clean it if it is dirty.

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

4. Check the Carriage Belt for excessive wear. If necessary , replace the

Carriage Belt ⇒ Page 8-46.

HP DesignJet 5000 Series Printers Service Manual

4-11

Service Tests and Utilities

Media Axis Test

The purpose of this test is to verify:

n Overdrive Roller movement. n Paper-Axis motor.

This test measures the current required to move the Media Axis parts in order to verify if parts are moving freely or not.

Perform the Media Axis Test as follows:

1. In the "3 Service Tests" menu, scroll to "3.2 Media Axis" and press Enter.

3 Service Tests

Top

Back

↑

3.1 Scan Ax i s

3.2 Media Axis

↓

Enter

Make Selection

Press Enter

2. The test will start and the following message will appear on the front panel as the test is performed.

Top

3.2 Paper Axis

Max. PWM: Avg. PWM:

Analyzing Data...

Back

↑ ↓

Enter

3. When the test has completed the Maximum and the Average Pulse Modulation Values are displayed for each direction (down and up). Press Enter to return to the Service Tests menu.

Top

3.2 Paper Axis

Max. PWM: Avg. PWM:

xx xx

Press ENTE R to contin ue

Back

↑ ↓

Enter

Press Enter

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HP DesignJet 5000 Series Printers Service Manual

Service Tests and Utilities

NOTE Report the values to the nearest HP Response Center or HP

Support Office to determine whether values are within the accepted range.

When reporting the values, have the following information ready:

n Model and Serial Number of the Printer. n All values reported in the test. n The Service Configuration Print ⇒ Page 1-26.

If values are not within the accepted ranges, power the Printer OFF and perform the following steps and repeat the test after each one:

1. Lift the Media Lever and insert thick media into the paper path to

push out any media that may be stuck there.

2. 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.

3. Remove the Paper-Axis Motor (⇒ Page 8-98) and check the Drive

Roller movement is smooth and if it is not, remove the Center Platen (⇒ Page 8-110) to check for any obstructions.

4. Replace the Paper-Axis Motor ⇒ Page 8-98.

HP DesignJet 5000 Series Printers Service Manual

4-13

Service Tests and Utilities

Service Utilities

The following is a list of all internal Se rvice Utilities available in the Printers. Instructions for entering the Service Utilities menu are given on Page 4-15.

1. Turn DRIVE ROLLER ⇒ Page 4-18 The purpose of this Service Utility is to fa cilitate the cleaning of t he

Drive Roller and the Overdrive.

2. Prime TUBES ⇒ Page 4-19 The purpose of this Service Utility is to prime the Tube s when a new

Tubes System has been installed or automatic priming was not completed.

3. Altitude Setup ⇒ Page 4-23 This Service Utility allows the operating altitude to be set for the

Printer.

4. EEROM Setup ⇒ Page 4-24 The purpose of this Service Utility is to set the Printer Model, the

Serial Number and Japanese Fonts.

5. Reset Life Counters ⇒ Page 4-29 The purpose of this Service Utility is to reset the preventive

maintenance counters when parts have been replaced.

6. Backup EEROM ⇒ Page 4-31 The purpose of this Service Utility is to restore the EEROM content

when the Main PCA or Hard Disk Drive are replaced.

7. Image Quality Warning ⇒ Page 4-33 This Service Utility allows you to turn the Image Quality Warning

message On or Off.

8. Diagnostic Print ⇒ Page 4-34 This Service Utility allows you to print a Diagnostic print that will

help you to troubleshoot image quality problems and verify printhead nozzle status.

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HP DesignJet 5000 Series Printers Service Manual

Service Tests and Utilities

Entering the Service Utilities Menu

1. Once the message "Ready" is displayed on the front-panel, scroll to

the "Printer Setup Options" icon and press the Enter key.

Ready

Roll Hewlett Packard

Photo Imaging Gloss Ink OK

Printheads OK

Top

Back

↑ ↓

Enter

Make Selection

Press Enter

For On-Site Engineers accessing the complete list of Service Utilities

a Once inside the "Printer Setup Options" menu, use the Arrow keys

to scroll to the "Utilities" menu and press the Enter key.

Printer setup options

Device setup... I/O setup...

Utilities... Internal RIP settings... Queueing & Nesting... HP-GL/2 settings...

Top

Back

↑ ↓

Enter

Make Selection

Press Enter

b Once inside the "Utilities" Menu, press the following key

combination to access the complete list of Service Utilities.

Utilities

Usage ... Menu Mode = Full

Calibrations ... Reset WebAccess paswd Image quality print ...

Statistics ...

Top

Back

↑ ↓

Enter

Press Up and Enter

HP DesignJet 5000 Series Printers Service Manual

4-15

Service Tests and Utilities

For Call Agents request ing the User to acces s a limit ed number of Service Utilities

a Once inside the "Printer Setup Options" menu and the "Device

setup" menu is highlighted, press the following key combination.

Printer setup options

Device setup... I/O setup...

Utilities... Internal RIP settings... Queueing & Nesting... HP-GL/2 settings...

Top

Back

↑ ↓

Enter

Press Down and Enter

2 The message below is displayed. Select Yes to continue.

Warning!

This mode should NOT be

used without having the guidance of a HP representative person

Yes... No

Top

Back

↑ ↓

Enter

Press Enter

3. You are now in the Service Menu. Use the Arrow keys to scroll to the "Service Utilities" menu and press the Enter key.

Top

Service Menu

Back

1 Service Utilities... 2 Service 3 Service Tests...

3 Service Tests...

Calibrations...

↑ ↓

Enter

Make Selection

Press Enter

4. Use the Arrow keys to scroll through the "Service Utilities" selections.

1. Service Utilities

1.1 Turn DRIVE ROLLER

1.2 Prime TUBES

1.3 Altitude Setup

1.4 EEROM Setup

1.5 Reset Life Counters

1.6 Backup EER OM

Top

Back

↑ ↓

Enter

Make Selection

Press Enter

5. Press the Enter key to begin a specific operation when the required Service Utility is highlighted.

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HP DesignJet 5000 Series Printers Service Manual

Service Tests and Utilities

NOTE If the Printer is not used for 3 minutes, the Printer exits the

Service Utilities Menu and you must re peat the above steps to enter Service Utilities again.

NOTE In some cases a quick press of a button may n ot be recognized by

the Printer. When pressing a button, be sure to press it deliberately and all the way to the bottom of its travel.

NOTE If the Printer hangs up during an operation, switch the Printer

OFF and restart from step 1.

HP DesignJet 5000 Series Printers Service Manual

4-17

Service Tests and Utilities

Turn DRIVE ROLLER

The purpose of this Service Utility is to rotate the Overdrive, Drive Roller and Roller Mark in order to clean them.

NOTE Remove the media before performing this operation. If media is

detected, the message below is displayed.

1.1 Turn DRIVE ROLLER

Please remove media completely

Press ENTER to continue

Perform the Turn DRIVE ROLLER utility as follows:

1. Lift the Window on the printer and deactivate the Window Sensor by inserting a pencil in the Sensor slot on the top of the Right Trim.

2. In the Service Utilities submenu, scroll to "Turn DRIVE ROLLER" and press Enter.

1. Service Utilities

1.1 Turn DRIVE ROLLER

1.2 Prime TUBES

1.3 Altitude Setup

1.4 EEROM Setup

1.5 Reset Life Count ers

1.6 Backup EEROM

Top

Back

↑ ↓

Enter

Make Selection

Press Enter

3. Once the utility starts, the Drive Roller will begin to turn slowly a nd the following message will be displayed. Everytime the Drive Roller completes a turn, the counter will increase by one.

1.1 Turn DRIVE ROLLER

Cancel

Press Cancel

1 turn (s)

Press CANCEL to stop

4. If you want to stop the Drive Roller from turning, press Cancel and the following message will appear on the front panel. P ress Enter if you want to return to the Service Utility menu or press Back if you want to continue turning the Drive Roller.

Top

1.1 Turn DRIVE ROLLER Stopped!

Back

↑

Press ENTER to exit or BACK to resume

↓

Enter

Make Selection

4-18

HP DesignJet 5000 Series Printers Service Manual

Service Tests and Utilities

Prime TUBES

The purpose of this Service Utility is to prime the Tube s when a new Tubes System has been installed or automatic priming was not completed.

NOTE If you are using this Service Utility because automatic priming

has failed, you will need to remove the Setup Printheads used and insert new Setup Printheads.

NOTE Check there is enough ink remaining in the Ink Cartridges

before starting to prime the tubes; if the ink level is LOW or VERY LOW, replace the Ink Cartridges.

Prime the TUBES as follows:

1. In the Service Utilities submenu, scroll to "1.2 Prime TUBES" and press Enter.

1. Service Utilities

1.1 Turn DRIVE ROLLER

1.2 Prime TUBES

1.3 Altitude Setup

1.4 EEROM Setup

1.5 Reset Life Counte rs

1.6 Backup EEROM

Top

Back

↑ ↓

Enter

Make Selection

Press Enter

2. The following message will be displayed. Press Enter to confirm.

Top

1.2 Prime TUB ES

Back

↑

Press ENTER to confirm

or BACK to correct

↓

Enter

Press Enter

3. The Printer will begin to startup and in order to continue, press Enter.

Top

INK STARTUP

Printer startup

Back

↑

Press ENTER to

Continue

HP DesignJet 5000 Series Printers Service Manual

↓

Enter

Press Enter

4-19

Service Tests and Utilities

4. The following message will be displayed on the front panel while

the printer verifies the Ink Cartridges:.

5. When the following message is displayed, lift the Window and

remove ALL the Printheads from the Carriage. Install the Setup Printheads into the Carriage.

Ready

Ink

INK STARTUP

Lift window to install SETUP printheads

6. Once all the Setup Printheads are installed, the following message

will appear on the front panel. Close the Carriage Cover and close the Window.

INK STARTUP

All SETUP printheads are OK. Clos e cover and window to continue

7. The following messages will be displayed on the front panel while

the Printer accesses and then stores the Printheads.

INK STARTUP

Accessing Printheads

INK STARTUP

Storing Printhea ds

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HP DesignJet 5000 Series Printers Service Manual

Service Tests and Utilities

8. The Printer will then begin to prime the Tubes System.

INK STARTUP

Initializing printer Please wait. xx sec

9. Once the Tubes System is purged, the following message will be displayed. Lift the Window and remove ALL the Setup Printheads from the Carriage and install the previously removed printing Printheads into the Carriage.

INK STARTUP

Lift window to replace SETUP printheads

10. Once all the Printheads are installed, the following message will

appear on the front panel. Close the carriage cover and close the window.

INK STARTUP

All printheads are OK. Close cover and window to continue

11. Open the Right Door and make sure the Printhead Cleaners are

installed in the Service Station.

INK STARTUP

Open right cover and install printhead cleaners

HP DesignJet 5000 Series Printers Service Manual

4-21

Service Tests and Utilities

12. If media is not loaded, the following message appears on the front

panel and you must load media into the Printer.

13. The Printer will start to print the Printhead Alignment Pattern and

the following message will be displayed on the front panel:

INK STARTUP

Load paper for

calibration

INK STARTUP

Aligning printheads Approximate time remaining x min xx sec

14. Once the Printhead Alignment is completed, the following message will be displayed on the front panel. Press Enter to continue:

INK STARTUP

Printer startup has finished

Press ENTER to Continue

Back

↑ ↓

Enter

Press Enter

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HP DesignJet 5000 Series Printers Service Manual

Service Tests and Utilities

Altitude Setup

This Service Utility allows the operating altitude to be set for the Printer for particular operating conditions when media load problems occur.

NOTE This utility is required exclusively for Printer operating altitu des

over 2000 m.

1. In the Service Utilities submenu, scroll to "1.3 Altitude Setup " and

press Enter.

1. Service Utilities

1.1 Turn DRIVE ROLLER

1.2 Prime TUBES

1.3 Altitude Setup

1.4 EEROM Setup

1.5 Reset Life Counters

1.6 Backup EEROM

Top

Back

↑ ↓

Enter

Make Selection

Press Enter

2. The following options are displayed Use the Arrow keys to make

the selection and then press Enter:

Top

1.3 Altitude Setup

Select an altitude

1.3.1 0-2000m

1.3.2 2000m or more

Back

↑ ↓

Enter

Make Selection

Press Enter

3. Once the option has been selected, the following confirmation

screen is displayed:

1.3 Altitud e S etu p

You have selected th e following altitude:

1.3.2 2000m or more

Press ENTER to confir m

4. Press Enter to confirm and exit this utility or press Back to return to

the altitude settings menu.

HP DesignJet 5000 Series Printers Service Manual

4-23

Service Tests and Utilities

EEROM Setup

The purpose of this Service Utility is to set the Printer Model, the Serial Number and Japanese Fonts. This is required in the following situations:

n The Main PCA and Hard Disk Drive are replaced at the same

time (EEROM empty).

n The Hard Disk Drive and Main PCA are replaced at the same

time and the Main PCA has already been used (valid EEROM content); the Printer backs up the data to the Hard Disk Drive storing wrong values for the current Printer.

n The main PCA EEROM and the Hard Disk Drive EEROM

backup are valid at initialization but data is conflicting because they do not come from the same Printer (they have a different Model Number or Serial Number), and the user has performed the Backup EEROM Utility incorrectly (See Page 4-31).

n Both the Main PCA EEROM and the Hard Disk Drive EEROM

backup are corrupt or fail during Printer initialization.

1. In the Service Utilities submenu, scroll to "1.4 EEROM S etup " and press Enter.

1. Service Utilities

1.1 Turn DRIVE ROLLER

1.2 Prime TUBES

1.3 Altitude Setup

1.4 EEROM Setup

1.5 Reset Life Counters

1.6 Backup EERO M

Top

Back

↑ ↓

Enter

Make Selection

Press Enter

2. The following options are displayed for EEROM setup. Press Enter once you have made your selection:

1.4 EEROM Setup

Top

Back

↑

1.4.1 Set Model Number

1.4.2 Set Serial Number

1.4.3 Set Japanese Font

↓

Enter

Make Selection

Press Enter

4-24

HP DesignJet 5000 Series Printers Service Manual

Service Tests and Utilities

If you want to set the Model Number

a If you want to set the Model Number select "1.4.1 Set Model

Number" and press the Enter key to access the list of possible Model Numbers for the Printer. Select the Model Number using the Up and Down keys and then press Enter.

Top

1.4.1 Set Model Number

Back

↑

1.4.1.1 C60 95 A

1.4.1.2 C60 96 A

↓

Enter

Make Selection

Press Enter

b The following message is displayed. Press Enter to confirm and

return to the EEROM Setup menu or Back to select another Model Number.

Top

1.4.1 Set Model Number Model numb er sele c ted :

C6095A

Back

↑

Make Selection

Press ENTER to confirm or BACK to correct

↓

Enter

HP DesignJet 5000 Series Printers Service Manual

4-25

Service Tests and Utilities

If you want to set the Serial Number

NOTE The Serial Numbe r in the Cur rent field is only displayed if it is

encoded in the EEROM. a Select "1.4.2 Set Serial Number" and press the Enter key to

view the message below. To define a new serial number use the Up and Down keys to scroll through a list of characters in the following ranges: 1...10, A...F (hexadecimal format), ES or SG (site of manufacture), (Backspace).The current parameter is displayed in the New field. To select the current parameter press the Enter key. To delete a character previously confirmed using the Enter key, select the (Backspace character) from the list.

1.4.2 Set Serial Number Current : ESA80035674

New: ES_ Use Up/Down buttons

to scroll

Top

Back

↑

Make Selection

↓

Enter

b When the last digit has been entered, the message below is

displayed. Press Enter to confirm the number and return to the EEROM Setup utility or Back to modify the number.

Top

1.4.2 Set Serial Number Serial number selected:

ESB7531008 Press ENTER to confirm

or BACK to correct

Back

↑

Make Selection

↓

Enter

c If you decided to press Back, the utility will return to the Serial

Number selection menu and the last digit of the Serial Number will be automatically deleted.

4-26

1.4.2 Set Serial Number Serial number selected:

ESB7531008 Press ENTER to confirm

or BACK to correct

Top

Back

↑

Make Selection

↓

Enter

HP DesignJet 5000 Series Printers Service Manual

HP deskjet 5000 schematic

Specifications and Main Features

Frequently Asked Questions

User Manual

Using this Manual

Purpose

Readership

Part Numbers

Conventions

Table of Contents

Troubleshooting 1

Guide to Troubleshooting the Printer

Introduction

Phone Support

Troubleshooting System Error Codes

Performing a Service Test on a Failed Assembly

Performing the Necessary Service Calibrations

Troubleshooting Calibration Error Codes

Troubleshooting Ink Supplies Error Codes

Troubleshooting Initialization - Self Diagnostic Errors

Solving Image Quality Problems

The Printer does not Power ON

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

Troubleshooting Media Jams/Printhead Crashes

Troubleshooting Shutdowns

Problems with Vacuum

Vacuum suction much lower at high altitudes

Printhead Crashes/Smears on High Density Prints Using Coated Media

Color differences in different HP DesignJet Printers

Banding at variable extreme environmental conditions

Banding with unsupported Media

Banding due to Ink Cartridge replacement while printing

Hue shift on HP Colorfast Adhesive Vinyl media

Black Smearing on HP Photo Imaging Gloss

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

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

Dry Cockle on High Density Prints Using Paper Based Media

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

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

Drying Time Too Long for HP Studio Canvas

Media Skew when Printing a Banner Plot

Solving Media-Handling Problems

How to Navigate through the Front Panel Menus

Printer Setup Options

Media Options

Ink Cartridge Info

Printhead Info

Service Configuration Print

System Error Codes 2

System Error Codes

Introduction

Continuable and Non-Continuable Error Codes

System Error Codes During Initialization

HP Ink Supplies Troubleshooting

What are HP Ink Supplies?

Ink Cartridges

Printheads and Printhead Cleaners

Identifying the Components

General Information About HP Ink Supplies

Some General Precautions When Handling HP Ink Supplies

Priming the Ink System

When Should You Replace the HP Ink Supplies?

The Front Panel Display

Obtaining Ink Cartridge Information

Obtaining Printhead Information

Status Codes and Messages

Status Messages

Error Status Messages

Printhead Errors (First Digit = 0, 1, 4, 5)

Ink Cartridge Errors (First Digit = 6, 8)

Printhead Cleaner Errors (First Digit = A or *)

Service Tests and Utilities

Introduction

Phone Support

Diagnostics - Self Test

Service Tests (Diagnostics)

Entering the Service Tests Menu

For On-Site Engineers accessing the complete list of Service Tests

For Call Agents request ing the User to acces s a limit ed number of Service Tests

Scan Axis Test