HP Indigo 5000 Operating manual
HP Indigo Division Service Instructions
filename: CA294-00570.doc page 1 of 18
2 Million Imp - Preventive Maintenance Guide
Purpose
Routine press maintenance
Service instruction details
Item Details
Scope HP Indigo press 5000, all serial numbers
Document Number CA294-00570
Date 13-Mar-06
Security level HP confidential
Contents
Service instruction details.........................................................................................................................1
Overview...................................................................................................................................................2
Monthly maintenance procedure.........................................................................................................2
2 million impressions maintenance procedure....................................................................................2
Monthly maintenance...............................................................................................................................3
Monthly maintenance (continued)............................................................................................................4
Monthly maintenance (continued)............................................................................................................5
2 million imp. maintenance.......................................................................................................................6
2 million imp. maintenance (continued)....................................................................................................7
Quick check maintenance table ...............................................................................................................8
Special tools and jigs..............................................................................................................................12
Monthly routine parts..............................................................................................................................12
Upon reaching 1 million impressions ................................................................................................12
2 million imp. routine parts .....................................................................................................................12
Mandatory replacement.....................................................................................................................12
Conditional replacement ...................................................................................................................12
Appendix A - Imaging oil pump maintenance.........................................................................................13
Appendix B - Vacuum pump maintenance.............................................................................................14
Appendix C - Grease and oil types.........................................................................................................17
Revision history......................................................................................................................................18
Confidentiality Notice..............................................................................................................................18
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 2 of 18
Overview
The preventive maintenance schedule is based on monthly visits, which include performing
procedures based on the press impression counter according to the following schedule:
Monthly maintenance procedure
To be performed monthly, without regard to the impression counter. The following parts will be
replaced only if 1 million impressions were made since the last replacement:
•Carbon filters
•Cleaning station sponge roller
•Suction cups
2 million impressions maintenance procedure
To be performed when the press has printed 2 million or more impressions since the last 2 million
impression procedure was performed. The 2 million impression procedure is performed in addition to
the monthly impression procedure.
These maintenance routines are complementary to the operator routines, and do not replace them.
The operator will continue the press maintenance on a daily and weekly basis. Check that the press is
properly maintained by the operator. If there are signs of negligence, report back to your regional
manager.
The following 2 million impression kit is available: CA290-00960.
Before every visit, verify that you have all the necessary parts. For your convenience, a short list is
provided on page 12.
Note that some of the parts are included as ‘conditional’ - subject to replacement, if needed, following
inspection. Order and replace if needed.
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 3 of 18
Monthly maintenance
Date: Time spent:
HP Indigo press 5000 S/N: Service person:
Customer name: Country/State:
Required parts Complete CE kit. See page 12.
General inspection
Check for external dirt, leakage and signs of improper
maintenance. Initiate a service call if there is a
leakage problem.
Verify that daily and weekly operator routines have
been performed correctly. See the latest User Guide.
Verify that all lubrication points have been oiled and
greased properly. See the latest User Guide.
Inform your regional manager if the press is not
properly maintained.
Config save Perform Config save to update the customer diskette.
Ink unit
Calibrate the density sensors.
Calibrate the ink conductivity sensors.
Calibrate the ink flow rate.
ITM Drum
Clean ITM slip ring (the bias contacts path) using IPA.
Clean the ITM thermostat slip ring.
Verify the temperature sensor reading, and calibrate,
if required.
Make sure that the surface facing the IR sensor is
clean.
Inspect and thoroughly clean the ITM hood wire mesh
filter on the rear wall using IPA soaked cloth.
Caution: Shut down the press before removing the
mesh.
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 4 of 18
Monthly maintenance (continued)
IMP drum
Inspect grippers area, and pay special attention to
cleanliness.
Check the stop stations for freedom of movement.
Make sure that the gripper cam followers are secured
to the drum.
Make sure that the dummy cam followers move
freely, and inspect the springs.
Oil the dummy cam follower arms and gripper arms.
Perfector If 1 million impressions have been reached, replace
the suction cups.
Scorotrons
Perform a general inspection.
Inspect the inside housing sides for the formation of
insulating layer. Clean with IPA soaked cloth. Use an
abrasive cleaning pad, if required.
Inspect each corona unit for loose or broken grid rails.
Glue or replace, if necessary.
If 1 million impressions have been reached, replace
the four carbon filters.
PTE – air knife
Perform a general inspection, and check for paper
chips.
Clean the PTE shield.
Clean and check the LED operation.
Cleaning station
If 1 million impressions have been reached, clean the
wetting roller.
If 1 million impressions have been reached, replace
the sponge roller.
Check the imaging oil flow rate.
Utility cabinet
Perform general inspection.
Externally clean the heat exchanger, if necessary.
Drain water separator - open service valve for 30
seconds.
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 5 of 18
Monthly maintenance (continued)
Lubrication Make sure that all lubrication points have been oiled
and greased properly. See "Appendix C - Grease and
oil types" on page 17.
BID engage Verify that the BID fans are working properly.
Ventilation system
Make sure that all the Amateks are working
properly:
Scorotron (suction and blower).
ITM input fan.
Air knife (suction and blower).
Bottom cooling.
Print quality
Perform the following:
Print Fine_Tune job, adjust if necessary.
Print a gray_20 job, and verify the quality of the print.
Check writing head deskew, and adjust, if necessary.
Use the gray_20 job to observe banding of ~3.5 mm
along the format that appears due to an incorrect
deskew adjustment.
Print the CATP job. Check the press performance
according to the table of specifications attached to the
job.
Send 2 copies of each job marked with the press
serial number and the date to your service center.
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 6 of 18
2 million imp. maintenance
NOTE: To be performed together with the monthly routines.
Date: Time spent:
HP Indigo press 5000 S/N: Service person:
Customer name: Country/State:
Required parts Complete CE kit. See page 12.
ITM drum
Check the bias carbon brush on the rear wall, and
replace, if required.
Check the ITM overheat thermal fuse carbon brushes
on the front wall, and replace, if required.
Make sure that the housing did not come loose from
the press wall.
Note: See "Conditional replacement" on page 12.
PIP drum
Check the grounding brush, and replace, if required.
Check the condition of the SofSub (PIP underlayer).
IMP drum
Replace the gripper clamps.
Check the grippers magnet gap, and adjust as
required.
Cleaning station
Replace the sponge roller.
Check the drive belt tension.
Paper transport
Clean all rollers and sensors.
Clean paper path.
Clean Feeder elastic bridge conveyor belts with IPA.
Clean Feeder drawer tray.
Clean paper transport sensors.
Replace exit roller and springs.
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 7 of 18
2 million imp. maintenance (continued)
Clean the lower feed roller and pinch rollers (IFR) with
IPA.
Check the duplex conveyor-impression drum gap, and
adjust, if necessary.
Replace perfector suction cups.
Clean Stacker paper path with IPA.
Check Stacker flipping wheels.
Check that the paper buckle is correct. Adjust if
necessary.
Perform the suction cup margin adjustment wizard.
Perform the full placement adjustment wizard.
Utility cabinet
Check oil level in solid air compressor.
Clean vacuum pump filters. See "Appendix B -
Vacuum pump maintenance" on page 14.
Drain water separator - open service valve for 30
seconds.
Chiller unit
Check water level.
Clean the water filter, and replace, if needed. See the
chiller manual.
Inline densitometer
Print a new reference densitometer full calibration
strip if one is not available, and perform the validation
procedure. See the HP Indigo service instruction for
the Inline Densitometer.
Instruct the operator to store the strip in a dark, clean
place.
Lubrication Make sure that all lubrication points have been oiled
and greased properly, including the exit elevator
gears and chains. See "Appendix C - Grease and oil
types" on page 17. For a complete list, check the
User Guide, or view the press On-line documentation
videos (OPD).
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 8 of 18
Quick check maintenance table
Component Mo 2M X Procedure
General inspection 9
9
9
9
Check for external dirt, leakage and signs of improper
maintenance. Initiate a service call if there is a leakage problem.
Verify that daily and weekly operator routines have been
performed correctly. See the latest User Guide.
Verify that all lubrication points have been oiled and greased
properly. See the latest User Guide.
Inform your regional manager if the press is not properly
maintained.
Config save 9Perform Config save to update the customer diskette.
Ink unit 9
9
9
Calibrate the density sensors.
Calibrate the ink conductivity sensors.
Calibrate the ink flow rate.
ITM drum 9
9
9
9
9
9
9
9
Clean ITM slip ring (the bias contacts path) using IPA.
Clean the ITM thermostat slip ring.
Verify the temperature sensor reading, and calibrate, if required.
Make sure that the surface facing the IR sensor is clean.
Inspect and thoroughly clean the ITM hood wire mesh filter on
the rear wall using IPA soaked cloth. Caution: Shut down the
press before removing the mesh.
Check the bias carbon brush on the rear wall, and replace, if
required.
Check the ITM overheat thermal fuse carbon brushes on the
front wall, and replace, if required.
Make sure that the housing did not come loose from the press
wall.
Note: See Conditional replacement on page 12.
PIP drum 9
9
Check the grounding brush, and replace, if required.
Check the condition of the SofSub (PIP underlayer).
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 9 of 18
IMP drum 9
9
9
9
9
9
9
Inspect grippers area, and pay special attention to cleanliness.
Check the stop stations for freedom of movement.
Make sure that the gripper cam followers are secured to the
drum.
Make sure that the dummy cam followers move freely, and
inspect the springs.
Oil the dummy cam follower arms and gripper arms.
Replace the gripper clamps.
Check the grippers magnet gap, and adjust as required.
Perfector 9Replace suction cups (x8).
Scorotrons 9
9
9
9
Perform a general inspection.
Inspect the inside housing sides for the formation of insulating
layer. Clean with IPA soaked cloth. Use an abrasive cleaning
pad, if required.
Inspect each corona unit for loose or broken grid rails. Glue or
replace, if necessary.
If 1 million impressions have been reached, replace the four
carbon filters.
PTE - air knife 9
9
9
Perform a general inspection, and check for paper chips.
Clean the PTE shield.
Clean and check the LED operation.
Cleaning station 9
9
9
9
9
If 1 million impressions have been reached, clean the wetting
roller.
If 1 million impressions have been reached, replace the sponge
roller.
Check the imaging oil flow rate; run imaging oil for 1 minute
before calibration.
Replace the sponge roller.
Check the drive belt tension.
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 10 of 18
Paper transport 9
9
9
9
9
9
9
9
9
9
9
9
9
9
Clean all rollers and sensors.
Clean paper path.
Clean Feeder elastic bridge conveyor belts with IPA.
Clean Feeder drawer tray.
Clean paper transport sensors.
Replace exit roller and springs.
Clean the lower feed roller and pinch rollers with IPA.
Check the duplex conveyor-impression drum gap, and adjust, if
necessary.
Replace perfector suction cups.
Clean Stacker paper path with IPA.
Check Stacker flipping wheels.
Check that the paper buckle is correct. Adjust if necessary.
Perform the suction cup margin adjustment wizard.
Perform the full placement adjustment wizard.
Utility cabinet 9
9
9
9
9
9
Perform general inspection.
Externally clean the heat exchanger, if necessary.
Drain water separator - open service valve for 30 seconds.
Check oil level in solid air compressor.
Clean vacuum pump filters. See "Appendix B - Vacuum pump
maintenance" on page 14.
Drain water separator - open service valve for 30 seconds.
Chiller unit 9
9
Check water level.
Clean the water filter, and replace, if needed. See chiller manual.
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 11 of 18
Inline densitometer 9
9
Print a new reference densitometer full calibration strip, if one is
not available, and perform the validation procedure. See the HP
Indigo service instruction for the Inline Densitometer.
Instruct the operator to store the strip in a dark, clean place.
Lubrication 9
9
Make sure that all lubrication points have been oiled and greased
properly. See "Appendix C - Grease and oil types" on page 17.
Make sure that all lubrication points have been oiled and greased
properly, including the exit elevator gears and chains. See
"Appendix C - Grease and oil types" on page 17. For a complete
list, check the User Guide, or view the press On-line
documentation videos (OPD).
BID engage 9Verify that the BID fans are working properly.
Ventilation system
9
9
9
9
Make sure that all the Amateks are working properly:
Scorotron (suction and blower).
ITM input fan.
Air knife (suction and blower).
Bottom cooling.
Print quality
9
9
9
9
9
Perform the following:
Print Fine_Tune job, adjust if necessary.
Print a gray_20 job, and verify the quality of the print.
Check writing head deskew, and adjust, if necessary. Use the
gray_20 job to observe banding of ~3.5 mm along the format that
appears due to an incorrect deskew adjustment.
Print the CATP job. Check the press performance according to
the table of specifications attached to the job.
Send 2 copies of each job, marked with the press serial number
and the date, to your service center.
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 12 of 18
Special tools and jigs
Density sensor cleaning paper MJX-0221-51
Monthly routine parts
Checklist/BOM (CA290-00960)
Upon reaching 1 million impressions
Part number Description Quantity
MFL-0013-01 Carbon filter 4
MPT-1078-51 Gray sponge roller 1
MKT-1060-01 Suction cups kit 1
2 million imp. routine parts
Mandatory replacement
Part number Description Quantity
MFL-0013-01 Carbon filter 4
CA244-11150 Gripper clamp 6
MPT-1078-51 Gray sponge roller 1
CA245-04160 Exit roller 1
MPT-4737-01 Exit roller springs 2
Conditional replacement
Part number Description Quantity
EZO-2111-02
EZO-2113-01
CA244-09380
Carbon brush (rear ITM & PIP)
Thermal carbon brush (front ITM)
Carbon brush (new type for ITM)
2
2
1
MPT-8383-51 Wetting roller assembly 1
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 13 of 18
Appendix A - Imaging oil pump maintenance
Figure 1 Imaging oil system
Printing engine
frame
Ink cabinet
Imaging oil refill
funnel assembly
Heat exchanger
Imaging agent refill
funnel assembly
C
leaning station
Imaging oil
filter assembly
Imaging oil
tank
Imaging oil
tank gauge
Tank level tube
Imaging oil pump
Figure 2 Oiling points for the imaging oil pump
Oiling points
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 14 of 18
Appendix B - Vacuum pump maintenance
To perform vacuum pump maintenance, do the following:
1. Remove the water and process oily waste bottles from their positions behind the lower service
door at the press rear. See Figure 3.
Figure 3 Press rear
1
2
3
1
2
3
1 - Waste bottles 2 - Vacuum pump 3 - Removable door
2. Lift up the lower door and remove it. See Figure 3.
3. Disconnect the fast-on tube. See Figure 4.
Figure 4 Vacuum pump location
1
3
2
1
3
2
1 - Fast-on tube 2 - Vacuum pump filters 3 - Muffler filter
4. Remove the vacuum pump filters. See Figure 4.
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 15 of 18
Figure 5 Vacuum pump assembly
(8-10) - Vacuum pump filters 6 - Muffler box 11 - Muffler filter
2 - Vane 4 - End plate 5 - Gasket
7 - Vacuum pump filter O-ring
5. Remove the muffler box with its five retaining screws. See Figure 5.
For 2 million preventive maintenance
1. Clean the vacuum pump filters using pressurized air. See Figure 5.
2. Clean the muffler box with a clean, dry cloth. See Figure 5.
3. Clean the muffler filter. See Figure 5.
For 8 million preventive maintenance
1. Remove the end plate with its five retaining screws. See Figure 5.
2. Remove the four old vanes. See Figure 5 and Figure 6.
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 16 of 18
Figure 6 Vacuum pump vanes
11
3. Clean the inside of the pump. See Figure 6.
4. Install new vanes. See Figure 6.
5. Reinstall the end plate and its five retaining screws with a new gasket from the maintenance
kit.
6. Install new O-rings and clean filters. See Figure 5.
7. Reinstall muffler box.
8. Reconnect the fast-on tube.
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 17 of 18
Appendix C - Grease and oil types
Item Type Supplier
Grease, mechanic:
General greasing points
NLGI #1
Shell Alvania 1 EP or R1
Mobilux EP1
Or equivalent
Purchase locally
Gear oil sep 32:
General oiling points
ISO VG100
Sell GC SE100
Mobil DTE Heavy
Esso Spartan EP-100
Or equivalent
Purchase locally
Grease BG-87 Molykote:
For main drum (PIP, ITM,
and impression) gear
lubrication only.
Molykote BG-87
Or equivalent
Purchase locally
Oil, compressor:
ISO VG32 or VG46
Shell Tellus 32 or 46
Mobil DTE 24 or 46
Or equivalent
Purchase locally
Note:
For further information, contact your local Customer Center.
2 Million Imp - Preventive Maintenance Guide - HP Indigo press 5000
CA294-00570 rev 01 page 18 of 18
Revision history
Revision Description
00 Initial document
01 Updated part numbers
Responsible engineer Michael Selinger
Group manager Neev Elbaz
R&D engineer Michal Lavi
Engineering Ami Kellner
Documentation manager Ronit Shugal
Written by John Burket/William Easley/Isaac Diwan
Confidentiality Notice
This document contains valuable trade secrets and confidential information of Hewlett-Packard Company. Nothing herein may
be copied, reproduced or distributed in any form or medium, or disclosed to any third party in any manner, without prior written
authorization of Hewlett-Packard Company. The copyright notice, which appears in this document, is purely precautionary and
shall not be deemed to constitute publication or intent to publish, in whole or in part.
©Copyright Hewlett-Packard Company, 2005. All rights reserved.
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