DesignJet 5000 and 5500 Series
Large-Format Printers
Safety Symbols
DesignJet 5000 and 5500 Series
Readership Part Numbers
Using this Manual
Purpose
Conventions
Table of Contents
Table of Contents
Troubleshooting
Introduction
Guide to Troubleshooting the Printer
Troubleshooting System Error Codes
Phone Support
Troubleshooting Calibration Error Codes
Performing a Service Test on a Failed Assembly
Performing the Necessary Service Calibrations
Solving Image Quality Problems
Troubleshooting Ink Supplies Error Codes
Troubleshooting Initialization Self Diagnostic Errors
Printer does not Power on
Status LED’s
When clearing a media jam, sometimes media is stuck
Troubleshooting Media Jams/Printhead Crashes
If using HP Coated Media when problem occurred, please also
ALL the Front-Panel LEDs are Lit but Nothing Else Happens
Attempting any procedures to resolve the problem
Troubleshooting Shutdowns User Message
Each case, make sure that you power OFF the Printer before
Check Printhead Cleaner Path
Check Paper Path
Check Printhead Path
Replace Message xx15 Replace and xx16 Replace
Problems with Vacuum
Vacuum suction much lower at high altitudes
Color differences in different HP DesignJet Printers
Banding with unsupported Media
Banding due to Ink Cartridge replacement while printing
Banding at variable extreme environmental conditions
Hue shift on HP Colorfast Adhesive Vinyl media
Black Smearing on HP Photo Imaging Gloss
Dry Cockle on High Density Prints Using Paper Based Media
Worm marks cockle on part of plots on paper based media
User message Media loaded incorrectly. Remove media
Media Skew when Printing a Banner Plot
Drying Time Too Long for HP Studio Canvas
User message Power Supply Error #1
User message Warning Incorrect type of tubes system
Page
Cutter Assembly Problems
This problem is solved in any A.02.xx firmware release
Carriage and Scan-Axis Problems
Media-Axis Problems
Electronics Problems
Setting while the Printer is in the stand-by mode might be
Network configuration
Temperature reading to adjust the printing speed. This is
Configuration 192Mbyte for C6096A and 128Mbytes for
Language Selection is blocked in a brand new printer
Firmware Upgrade Does Not Work Through the Parallel Port
This problem is solved in any A.02.xx firmware release
Dry time at the end of the print is longer
Typical Failures After Exchanging the Ink Tubes
Solving Media-Handling Problems
How to Navigate through the Front Panel Menus
Setup Menu
Setup
Utilities Menu
Short, Full
Internal RIP Settings Menu
DIC
Queuing and Nesting Menu
HP-GL/2 Settings Menu
Format Menu
ISO
Demos Menu
Roll/Sheet Info Vendor Name
Ink Cartridge Menu
Ink Level Capacity Part Number Manufacture Date Yes, No
Printhead Menu
Press Enter
Service Configuration Print
Printer Setup Options
How to Use the Service Configuration Print
Press Up and Enter
Lower
General Printer Information
These are maximum mechanical printing speeds and do not
Troubleshooting Take-Up-Reel Problems
Issue Main Reason Action/Check
System Error Codes
System Error Codes
System Error Codes
XXXXXX-YYYYZZZZ
To troubleshoot the problem
Continuable and Non-Continuable Error Codes
System Error Groups
Even though the customer can continue working with a
Ffff ffff 02b301b0
There is a problem with the I/O Card happens during power-up
Ffff ffff 01dcxxxx
01002D Non-Continuable
Ffff ffff
Ffff ffff 036e0136
System Error 010023 Non-Continuable
Different power socket
010041
ProblemError in Paper-axis Motor Encoder
040000 01E603D9
06030C
Bad Line Sensor
System Error Problem Description Corrective Action
Try the following
Problem in Depressurizing Air System
0A0030
0A0050 Non-Continuable
0A0070 Continuable
0B0001
System Error Problem Description Corrective Action
Unable to detect Fan X = 7 Vacuum, 8 Cooling, 9 Aerosol
Primer Shutdown Error
0B000X
0B0010 xxxxxxxx Non-Continuable
System Error Problem Description Corrective Action
0B000F Continuable Only applicable to DesignJet 5500 Series
System Error 0C0032 Continuable
XX21 Replace
0C1000
0D0003 xxxxxxxx Non-Continuable
0D0000 Continuable
0D0000 033f019C
0D0004 xxxxxxxx Non-Continuable
0D0005 03180382 Non-Continuable
Firmware Error has occurred
Refer to System Error Code ffff ffff
0FXXXX Non-Continuable
0F0200 01E603d2
0F0100 03180382 Non-Continuable
E50000
HP Ink Supplies Troubleshooting
Ink Cartridges
Printheads and Printhead Cleaners
What are HP Ink Supplies?
Identifying the Components
General Information About HP Ink Supplies
Some General Precautions When Handling HP Ink Supplies
Priming a Brand New Ink System
When Should You Replace the HP Ink Supplies?
Show the XX11Replace message Refer to 3-12, Error Status
Front Panel Display
Obtaining Ink Cartridge Information
Obtaining Printhead Information
Page
Simply following the instructions in the action message
Most problems with Ink Supplies will be solved by the user
Status Codes and Messages
Status Messages
Insert
Error Status Messages
Status Code Part / Information
Printhead Errors
Printhead Information
Printhead Recovery Procedure
Ink Cartridge Errors
Ink Cartridge Information
Ensure that you have the correct Printhead Cleaner
Printhead Cleaner Errors First Digit = A, B or
When replacing Printhead Cleaners
Ensure that the Printhead Cleaner is the correct color for
Ink Cartridge Delivers Too Much Ink
Refill Information DesignJet 5500 Series Only
Ink-Level Sensing ILS Out of Control
Risks with the Ink Cartridge Delivering Too Much Ink
Non-HP Hardware Detected in the Ink Delivery System
1RQ+3KDUGZDUH Lvghwhfwhg
Risks with Using Non-HP Hardware
ILS Out of Control Detection
ILS Out of Control Warranty Statement
HP Ink Supplies Troubleshooting
Service Tests Utilities
Diagnostics Self Test
Introduction
Self Diagnostics Initialization Sequence
Service Tests and Utilities
Present after replacing a component, remember to Reinstall
Component that was first removed before replacing another
Component
Service Tests Diagnostics
Entering the Service Tests Menu
Press Down Enter Together
Top
Scan Axis Test
Report the values to the nearest HP Response Center or HP
Support Office to determine whether values are within
Media Axis Test
With Media
Service Utilities
Entering the Service Utilities Menu
Press Down and Enter
Service Tests and Utilities
Turn Drive Roller
Detected, the message below is displayed
Prime Tubes
Ink
Initializing printer Please wait. xx sec
INK Startup
Altitude Setup
Over 2000 m
Eerom Setup
All the Eerom parameters
If you want to set the Model Number
If you want to set the Serial Number
Encoded in the Eerom
If you want to set the Japanese Fonts
Press Back
Make Selection
Reset Life Counters
Counter for a component when it has not been replaced
Back Press Back
Backup Eerom
Series Only
Press Back to return to the Service Utilities menu
That color
Image Quality Warning
If you use degraded Printheads, the print quality may be
You need
Diagnostic Print
Printer does not print the complete Diagnostic Print
Enter to print it
Sleep Mode DesignJet 5500 Series Only
Service Calibrations
Refer to the following page for the relevant Calibration
Service Calibrations
Entering the Service Calibrations Menu
Press Up Enter Together
Press Down Enter Together
Service Calibrations
Scan-Axis Calibration
That is the full width of the Printer
Use the ID 00 and for the 5500 Series use the ID
Make Selection
Can be located on the label on the side of the Line Sensor
If Scan Axis Calibration is performed without inserting
Correct Line Sensor Id., each time the user performs a Color
After the Calibration has been performed, print the Service
Refer to page 5-26, Calibration Error Codes to troubleshoot
Error codes
EEROM. For information on the Service Config Print Ÿ
Service Station Calibration
Service Station Press Enter to confirm or Back to correct
Press Back
Perform the Accuracy Calibration as follows
Codes for its description and resolution
Accuracy Calibration
Media apart from HP High Gloss Photo Paper
Do not use any other type of media apart from HP High Gloss
Photo Paper
Press Load/Unload Media
Codes
Carriage Height Calibration
Procedure should be carried out using the Carriage Height
Assembly or Center Platen Assembly
Tool See below that came with the new Carriage
Service Calibrations
With the Carriage itself See below
Page
Screws should not be removed
Page
Page
Page
Page
Calibration Error Codes Introduction
Line Sensor error
This code is not an error. See the other codes reported
Pen voltage error
0000
User
Power the Printer OFF and on using the power switch at
Paper Axis Error
Light Magenta Pattern
Media Profile Error
Service Calibrations
Firmware Error
3130
Out of memory
Service
Service, 4006 Service and 4007 Service
Black Printhead failure
Could not detect pattern
Service and 5012 Service
Drop Detector not working
Drop Detector failed to uncap pens Refer to Error Code
Calibration failed for Light Cyan Printhead
Service
User Calibrations
Printhead Alignment
Close-Loop-Color CLC Calibration
Banding Calibration
Their original media advance settings
Accuracy Calibration applies only to the media type
Service Calibrations
Print Quality
Print Quality Troubleshooting Checklist
Print Quality
Photo Paper when performing the Service Accuracy
Calibration
Considerations for Printing the Diagnostic Print
How to Use the Diagnostic Print
What is the Diagnostic Print?
Printing the Diagnostic Print
Press Down and Enter
For Firmware Version A.02.xx in the 5000 Series and on
Series, the Printer does not print the complete Diagnostic
Print Quality
That you need
Overall Print Quality Test
What is Banding?
Solving the Banding Problem
Productivity and Max. Speed modes. If you use Max. Quality
Printer has automatic procedures to hide many Printhead
Defects. This type of problem affects print quality mostly
Be hidden and image quality may not be affected
High quality modes media advance problems may not appear
Or graininess will appear in all the colors
Solving the Color Alignment Problem
Color Alignment Print Test
Solving Bidirectional Alignment Problems
Bidirectional Alignment
Vertical Line Straightness
Solving Vertical Line Straightness
Modes
Nozzle Print Test
Affects print quality mostly in Productivity and Max. Speed
How to fix the Nozzle Defects
No Printing Defects Found in the Diagnostic Print
Print Quality Problems
Solving Color Accuracy problems
Solving Color Consistency problems
Prints are Too Short DesignJet 5000 Series Only
Color Accuracy Configuration
Blurred Lines Ink Bleeds from Lines
Colors are not as Expected
Banding at the Top
Printed surface smearing roll DesignJet 5000 Series Only
Vertical Banding
Media
There are Smears or Scratching on the Printed Media
Warped Lines on Media
Marks and/or scratches on double-sided media
Objective and Description
Using the Color Print
How to Evaluate the Print
How to Interpret the Result
Enrichment Issue
Issues Description
Cause
Page
Workarounds
Problem statement
Ink Marks on Printouts
Cause 1 Aerosol Aerosol Background
Aerosol What customers see
WKH3ULQWRXW
Which printers are affected by this?
What can you see?
Ink accumulation at the bottom edges of the Printheads
See the following image to for an example
Ink accumulation at the bottom of the Carriage Assembly
This is a secondary effect of the ink accumulation
Static Solutions and Workarounds
Parts and Diagrams
Printer Support
Printer Support
Bin and Take-Up Reel
Series
Bin Support
Bin and Take-Up Reel
Right Hand Cover
Right Hand Cover
HP Part Number Quantity Description/Comments Drawing
Left Hand Cover and Rear Door
OEM Logos
Left Hand Cover and Rear Door
Top and Back Covers
Top and Back Covers
Service Station
Service Station
Vacuum Fan
Vacuum Fan
Booster Fan and Media Sensor
Booster Fan and Media Sensor
Paper-Axis Motor
Paper-Axis Motor
Scan-Axis Motor
Scan-Axis Motor
ISS and APS Assembly
ISS and APS Assembly
Ink Tubes System
Ink Tubes System
Boot ROM DIMM, Dram Memory and Covers
OEM Boot ROM Dimm
BootROM, Memory and Covers
Rear Electronics Access Covers
Rear Electronics Access Covers
Hard Disk Drive and Cover
OEM Hard Disk Drive
Hard Disk Drive and Cover
ISS PCA and Main PCA
ISS PCA and Main PCA
Power Supply Unit
Power Supply Unit
Carriage Assembly
Carriage Assembly
Tensioner Assembly and Encoder Strip
Tensioner Assembly and Encoder Strip
Platen Assemblies DesignJet 5000 Series
Series Only
Platen Assemblies DesignJet 5000 Series
Platen Assemblies DesignJet 5500 Series
Platen Assemblies DesignJet 5500 Series
Pinch-Wheels Assembly and Lever
Pinch-Wheels Assembly and Lever
Center Guide 60 Model
Parts and Diagrams
Center Guide and Entry Roller DesignJet 5500 Series
Center Guide and Entry Roller DesignJet 5500 Series
Tubes Guide Assemblies
Tubes Guide Assemblies
EMC Covers
EMC Covers
Spindle and Hub
Spindle and Hub
Rollfeed Brakes
Rollfeed Brakes
Miscellaneous Items
Media Types
Parts and Diagrams
Removal and Installation
Safety Precautions
Electrostatic Discharge ESD Precautions
Required Tools
Chassis screws have a copper washer and should never be
Removed
Top Cover Assembly
Removal
Printer
Switch off the Printer and remove the power cable
Remove ALL the Ink Cartridges from
Page
Page
When inserting the Left Hand Cover, be careful not to pinch
Installation of Left Hand Cover
When handling the Tubes make sure you do not damage them by
Twisting
Right Hand Cover
P24
Page
Page
Installation of Right Hand Cover
Front Panel Assembly
Switch off the Printer and remove the Power Cord
Left Rear Cover
Right Rear Cover
Remove 4 T-15 screws Type B from
Extension Cover 60 Model only
Remove the Left Rear Cover Refer
Extension Cover
Media Lever Assembly
Spring in the Trim
Installation of the Media Lever Assembly
Sideplate in the UP position to avoid damaging the Lever
Right Hand Trim
P27
Lever in the UP position to avoid damaging the Lever spring
Installation of Right Hand Trim
When installing the Media Lever in the Trim, install with
Trim
Left Hand Trim
Back Cover
Number onto it
Installation of the Back Cover
Label has been applied, copy the product number and serial
Out the Printhead Cleaner Carriage
Open the Right Cover door and pull
Page
Page
Page
Page
Installation of Ink Tubes System
Perform the following procedures
INK Startup Initializing Printer Please wait 60 sec
EMC Covers
Lower Right Cover
Encoder Strip
Release Encoder Strip
Below
Installation of Encoder Strip
When Installing the Encoder Strip, make sure it is placed
Trailing Cable
Slide out
Ferrites if they fall into Carriage
When disconnecting from Main PCA
Guide to access the screw
Installation of Trailing Cable
Check edge for damage
Trailing Cables through Ferrites
Right Clip Slot Locating pin
Is flat on the chassis without
Removal and Installation
Make sure the Trailing Cable
Bubbles
Tensioner Assembly
Tighten screw
Page
Installation of Tensioner Assembly
Carriage Assembly and Belt
Page
Page
Page
Slide out
Page
Installation of Carriage and Belt
Line Sensor
Page
Installation
3XVKKHUH
Scan-Axis Motor
P23
Encoder Sensor on the rear of the Carriage Assembly
Installation of the Scan-Axis Motor
When installing the Encoder Strip, make sure it is inserted
Slider Rods Lubrification Kit Refer to
Cutter Assembly
Open the Top Cover
Page
Page
Page
Ink Supply Station ISS
Inside View Front
Installation of ISS
Switch off the Printer and remove the Power Cord
Air Pressurization System APS
Following steps
Installation of APS
When Installing the Air Pressurization System make sure
Remove the Right Rear Cover Refer
Service Station Assembly
Remove the Printhead Cleaners
P15
Page
Drop Detector Assembly
Press clip to disconnect
Move the Drop Detector
Hard Disk Drive HDD
Installation of Hard Disk Drive
If you have to replace HDD Cable, refer to the following
LAN Card
Memory and BootROM DIMM’s
Modules
Installation of DIMM’s
Position as shown in the diagram
Electronics Module Cover
They pass through the slot in the Cover
Installation of the Electronics Module Cover
When Installing the Electronics Module Cover make sure
Main PCA
Remove the Electronics Module
Page
Installation of Main PCA
PCI-to-IDE PCA
P11 Connector on the Main PCA even if the P11
Installation of the PCI-to-IDE PCA
When installing the new PCI-to-IDE PCA, Connect
Connector is present and the HDD Power Cable was connected
Installing the HDD Cable
Power Supply Unit PSU
PCA PS Connector
Press PS Fans PS Switch PS Socket
Power Supply Unit connections are illustrated below
Installation of the Power Supply Unit PSU
After installing the Power Supply Unit, remember to place
Plastic protective cover over the unit
Ink Supply Station ISS PCA
Installation of the ISS PCA
J3 P3
Removal
Remove the Ink Leak Detector from the Printer
Cooling Fans
Page
Electronics Module as one complete Assembly
Pinch-Wheels
Wheels at each end of the Printer axis
Installation of Pinch-Wheels
During installation, make sure you install the White Pinch
Pinch-Wheel Cam
Page
Installation of Cam
Vacuum Fan
P19
Installation of Vacuum Fan
Guides in the Sideplate
Paper-Axis Motor Assembly
P10 P12
106
Apply grease to the Helical Gear
Installation of Paper-Axis Motor Assembly
Screws are tight
Booster Fan
Media Sensor
Shown in the diagram
Installation of Media Sensor
When installing the Media Sensor, insert the moving part as
Entry Roller
Center Guide Assembly
Page
Remove the Drive Roller Gear
Installation of Gear
Drive Roller Gear
Fully tightened
Front Platen Assembly Only Applicable to the 5000 Series
Remove the Left Hand Trim Refer to
116
Center Platen Assembly
Removing the Platen Assembly
Installation of the Center Platen Assembly
Deflectors Only Applicable to the 5000 Series
Disconnect the Heater Cable from
Heater Assembly Only Applicable to the 5500 Series
Remove the Right Cover Refer to
Page
122
Installing the Heater
Tube Guide Door
Preventive Maintenance
Utilities/Service Configuration Print
Service Preventive Maintenance
Maintenance information can be obtained from Printer Setup
Ink Tube Maintenance Advised
Have Ink Tube Replaced or Risk Printer Damage
Ink Tube Maintenance Required Now
If Printing is , the Tubes can break causing a
Contact HP
User Maintenance
Lens Maintenance
Do not handle or attempt to clean the Nozzles on the bottom
Printhead
Roller Lubrification Kit
This procedure is for Service Engineers only. Users should
Perform the procedure described in the User’s Guide
Avoid oil spills and make sure you remove any excess oil
Power Off the Printer and remove the Power Cord
Slider Rods Lubrification Kit
Cleaning the Platen
Preventive Maintenance
Noisy Carriage Bushing
General Cleaning
Moisture on the Printer
Belt Swelling
Firmware Upgrade
Button and look for Programs HP DesienJet folder and run it
Upgrade Instructions 5000 Series only
Upgrade process may take several minutes. Do not Power
From there
Functional Overview
Electrical System
Front Panel
Scan Axis
Paper Axis
Ink Delivery System IDS
Ink Cartridge
Ink Supply Station ISS
Tubes System
Printheads
Air Pressurization System APS
Service Station
Print Head Cleaner PHC
10-10
About this Edition
DesignJet 5000 and 5500 Series