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HP Color LaserJet 2500 - Error 54.07 All Lights On

This error occurred on a long print run after 100-200 pages. The printer stopped mid print with the  Attention light, Ready light, and Go lights all on indicating a service error.

If the printer has a service error (Attention light, Ready light, and Go light are on), press and hold (GO) and (CANCEL JOB) simultaneously to see the secondary error message.

Doing this, the Attention and Ready lights were on. This secondary fault code wasn’t in the service manual. Although the Hewlett Packard Color LaserJet 2550 sevice manual lists this as a carousel error.

Turning the printer off and back on resulted in it trying to initialise with a lot of clunking noises coming from the carousel and the error coming up again. With the top off and the lid switch defeated, the carousel was seen to judder forwards and backwards.

After the printer was left switched off for a while, it was possible to print a config page by pressing the Go and Cancel buttons. The error log on the config page showed a 54.07.00 error. Again, this error isn’t listed in the service manual.

This fault was caused by the rotary motor assembly, part number RG5-6958-000CN. This is the motor on the rotary drive assembly that turns the carousel around.

To remove the rotary drive assembly:

  1. Remove the left and right side covers by removing one screw at the bottom of each, pulling the bottom out, and lifting off at the top and front.
  2. Release two tabs on the interface cover on the back and remove.
  3. Release two tabs on the rear cover and remove.
  4. Open the top door, remove the gear on the right hand side, and remove the top door rack. Refit the gear.
  5. Remove three screws and lift the top cover off.
  6. Lift off the top output bin cover.
  7. Remove five screws from the formatter assembly and lift it up and off. Disconnect two cables as you lift it away from the printer.
  8. Disconnect the three cables from the rotary drive assembly at the DC controller.
  9. Disconnect the flat ribbon cable from the laser scanner assembly to the DC controller.
  10. Remove four screws from the top of the rotary drive assembly.
  11. Looking from the side of the printer, remove the left hand screw from the left hand motor on the rotary drive assembly.
  12. Lift the rotary drive assembly out of the printer.

The motor you need to replace is the longer one towards the rear of the rotary drive assembly. Remove the two screws, and the motor can be pulled out.

Reassembly is the reverse of this procedure. Take note of the following:

  • Fit the the back of the rotary drive assembly into place first.
  • Make sure the formatter assembly is hooked into place at the top. If it’s sticking out at the top, the surface mount LEDs and resistors at the top of the formatter board can get knocked off when the right side cover is fitted.
  • When you fit the top output bin cover, make sure the two plastic flaps fit over it and are not trapped behind it.
  • Make sure the top cover is located properly in the top output bin cover.
  • When fitting the side covers, hook them in at the front and top, and then push the bottom in.
  • When you fit the right side cover, it might be best to remove the control panel first. When you fit the control panel into the cover, ease the top of the cover away from the printer. This can prevent damaging the surface mount LEDs and resistors at the top of the formatter board.
RG5-6958-000CN

RG5-6958-000CN

RG5-6958-000CN – Rotary motor assembly

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October 29th, 2009 | Tags: , , , , , , , , , , , | Category: Color LaserJet 2500 | Leave a comment

HP Color LaserJet 2500 - Attention Light Flashes After Every Page

If your Hewlett Packard Color LaserJet 2500 Attention light flashes after every page and you have to press the Go button to continue, you need to check the size of the paper in the paper tray and the size of the paper set in the printer properties.

If these are the same, print out a config page by pressing the Go and Cancel buttons together. Look for the Default Paper Size in the bottom right of the first page.

What you might find is that the paper in the paper tray is A4 and the software is set for A4, but the printer has defaulted to Letter size.

In normal use, this won’t happen or you probably won’t notice it. You’re more likely to come across this in a workshop enviroment while repairing and testing the printer. You will see it when you print a test page or config page.

Two possible causes of this are:

  1. You’ve replaced the formatter board and the paper size is set to the factory default Letter.
  2. You’ve performed an NVRAM INIT on the printer which has set the paper size to the factory default Letter.

There’s two ways to fix this. If you’ve got the original CD that’s shipped with the printer, there’s a utility on it to set the default paper size.

If you’ve not got this CD, you need to send a file to the printer to set the default paper size. This is the contents of the file with comments to explain what each line does:

←%-12345X@PJL    Start PJL job
@PJL SET SERVICEMODE=HPBOISEID    Enter Service mode
@PJL SET CRPAPER=A4    Set cold reset page size [=Letter/A4]
@PJL SET SERVICEMODE=EXIT Exit Service mode
@PJL RESET    Perform PJL Reset
←%-12345X    Exit PJL mode

The left arrow ← at the start of the first and last lines represents the Escape character. If you create this file using MS-DOS Edit, you enter the Escape character by holding down CTRL-P and pressing Esc. This will look like a left facing arrow, ←, on the screen.

There’s a good chance you’re not running a Windows 98 / MS-DOS machine with MS-DOS Edit. Whatever operating system you’re using, you will need to create a plain text file. You will also have to consult the documentation for the editor you’re using to see how to insert the Escape character.

Once you’ve created the text file, save it with any name you like but give it the pjl extension, e.g. A4.PJL. You then send this file to the printer. If you can go to an MS-DOS command line, the following will work if you are connected to the parallel port of the printer:

type a4.pjl > prn

The green light will flash for a few seconds and then the printer should go into the ready state. Print out a config page and check that the default paper size is now set to A4.

For your convenience, I’ve created A4.PJL for you which you can download by right-clicking and selecting save on the following link:

A4.PJL

The escape characters will look like squares if you open this file in Windows XP Notepad.
Pinnaclemicro 3 Million Computer Products

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September 27th, 2009 | Tags: , , , , , , , , | Category: Color LaserJet 2500 | Leave a comment