1. Before removing the developer assembly:

• Disconnect the A/C power cable from the back of the system.
• Press the front latch, and then rotate open the inner duplex assembly.
• Rotate open the imaging drum.
• Remove the top cover.
• Remove the toner cartridges.
• Remove the top cover frame.
• Remove the left side cover.
• Remove the HVPS.
• Remove the developer frame assembly.

2. Place the developer assembly upright on a covered work surface, taking care to avoid unnecessary toner spillage.

3. Slide the securing tabs at the ends of the developer assembly toward the top of the assembly, and then remove the developer from the frame.

WARNING: Place the developer frame assembly on a protected surface when removing the developer, to avoid toner contamination due to spillage.

4. Reverse the previous steps to replace the developer assembly.

HP LaserJet P4015 – Not Picking Up Paper

HP now recognise this as a manufacturing fault and have released a service note for it and will send you a new fuser free of charge. The description of the fault is:

When a print job is sent to the printer, the printer will display processing job on the control panel, and will continually ramp up and down attempting to print the job. After several minutes the printer will return to ready without posting any error messages. Occasionally, after several minutes the print job will print.

The fix for the fault is:

The fuser needs to be replaced and firmware needs to be upgraded to version 04.060.7 or higher.

The customer will need to download the latest firmware from hp.com, version 4.060.7 or higher. The firmware can be downloaded from hp at www.hp.com/go/support . Select Download drivers and software (and firmware) in step 1 and in step 2 type in the printer name, LJ P4014, LJ P4015 or LJ P4515

It’s probably best to update the firmware before you phone HP to report the fault, or at least tell them you have. If you do update the firmware, you will notice some extra numbers and letters on the display when the printer initialises. This is normal, it’s probably used by HP staff for diagnosis.

The fuser is a customer replaceable part, and does not require a service technician to install. If the customer requests a service technician to install the fuser the customer will be responsible for the labor. The fuser can be sent directly to the customer with instructions to upgrade their firmware.

What this means is that HP will send you a new fuser to fit yourself.

The models covered by this service note are:

HP LaserJet P4014 Printer series, HP LaserJet P4015 Printer series, HP LaserJet P4510 Printer series.

EFFECTIVE DATES
Start: 2010-01-01

Expiration: 2010-12-31

What this means, is that HP will send you a new fuser for this fault until the end of 2010, although they do sometimes extend the active time period for service notes.

Don’t forget to update the firmware to the latest version, if you haven’t already done it, to prevent the new fuser failing with the same fault.

Hewlett Packard LaserJet P4015 Fuser

CB506-67901 – Fusing Assembly – For 110 Vac

CB506-67902 – Fusing Assembly – For 220 Vac

The closest to this, with the solution is:

68.X Permanent Storage Error (Check Settings)

Explanation

An error occurred in the printer’s permanent storage and one or more printer settings has been reset to its factory default.

Recommended action

Print a configuration page and check the printer settings to determine which values have changed.

68.X Permanent Storage Full

Explanation

The printer’s permanent storage is full. Some settings might have been reset to the factory defaults.

Recommended action

1. Print a configuration page and check the printer settings to determine which values have changed.

2. Hold down CANCEL JOB while turning the printer on. This will clean up the permanent storage by removing old areas that are not being used.

Because this isn’t the precise error, it probably won’t clear the fault and you would end up replacing the formatter board.

Instead, this is what you need to do.

Firstly, try cleaning up the NVRAM as suggested on the HP website by turning the printer on while holding down the CANCEL JOB button until it says CLEANUP NVRAM on the display and then release the CANCEL JOB button.

If you still get the error, press GO to continue and then print out the configuration settings and menu settings. You then need to do a NVRAM Initialization. Before you do the NVRAM Initialization, remove any network cards, accessories, and DIMMs from the formatter that did not come with the printer.

Next, turn on the printer while holding down the SELECT and CANCEL JOB buttons until all the LEDs stay on. Release the two buttons and then press and release the CANCEL JOB button and then the SELECT button. You should then see NVRAM INIT on the display.

If you still get the error after doing the NVRAM INIT, do the NVRAM cleanup once more as described previously, that did it for me.

You will then need to enter your menu settings and then go into service mode to enter the page counts, default paper size, and any other settings that have changed.

SERVICE MODE

1 While turning on the printer, hold down SELECT snd CANCEL JOB until all of the lights on the control panel are lit.

2 Press the right side of MENU, and then press SELECT. The message SERVICE MODE temporarily appears and will reappear when the printer completes the initialization process.

3 To ext Service mode, press GO.

Note if READY appears on the control panel, the buttons might have been released too soon, or the wrong buttons were pressed.

If you look at the left hand side of the toner cartridge, you should see a metal shaft about 10mm in diameter and 5mm long. As you push the toner cartridge into the printer, this metal shaft slides under a spring loaded metal contact.

The earth contact is L shaped and measures about 40mm x 20mm with a kink in it’s short side. If this contact is resting against the white plastic block on the side frame, it has come out of place.

To replace the contact, use a metal hook, or something similar, and pull it away from the white plastic block. Swing it upwards so that it is upright and fit it into the slot. It should then slide down the slot until it reaches the end. When in it’s correct position, it sits at an angle of about 45 degrees.

If it’s fitted correctly, the metal shaft on the toner cartridge should slide under it. The print quality should now be normal.

UPDATE

This service note has been extended by two years and now expires 1st July 2013.

The service note for this fault ends 1st July 2011 not 7th January 2011 as I previously stated. This is because someone at HP’s call centre misinterpreted the expiration date 2011-07-01.

You can find details on how to do the repair in this post: HP LaserJet P3005 – Noisy, Grinding, Clicking, Rumbling

The symptoms are a loud clicking or ratchet type noise when the printer is running. Remove the fuser and inspect the green plastic bush on the gear end of the fuser.

Push upwards on the gear on the end of the pressure roller. Pushing against the pressure of the spring, there should be no, or very little movement. Movement shows that this bush is worn.

Contact HP and go through the warranty process. They will ask you the model number and serial number. They will probably tell you the printer is out of warranty. Insist that the printer has a known fault that is covered by a HP service note.

As part of the diagnosis procedure, they will ask you if the printer still makes the noise with the rear door open. The answer is “yes”. HP will then send an engineer out with a fuser kit (fuser and 20 tooth gear) and fit it free of charge.

Hewlett Packard P3005 Fuser

If you have to do the repair yourself, you will need a fuser:RM1-3740-030CN – Fusing assembly – For 110-127 VACRM1-3741-030CN – Fusing assembly – For 220 VAC to 240 VAC

RU5-0957-000CN

You will also need:RU5-0957-000CN – Gear – 20-tooth – Goes on the fuser drive assembly

BSH-P3005-PL

BSH-P3005-PR

You can save some money if you are able to dismantle the fuser and replace the two bushes, assuming the rest of the fuser is ok.BSH-P3005-PL Bushing Pressure Roller LeftBSH-P3005-PR Bushing Pressure Roller Right

RM1-3740-FM3

The only other thing you might need if you are reparing the fuser is the fuser film sleeve. These sometimes get torn.RM1-3740-FM3 – Fuser Film Sleeve

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 – Rotary motor assembly

The noise is not really like a grinding noise, it is just a louder than normal engine noise. If you print a black only page, the noise will become louder and higher pitched because the engine turns faster.

The cause of this problem is the black developer becoming stiff which then wears the gear on the developer drive assembly that drives the black developer.

To remove the developer unit:

1. Remove the image drum assembly
2. Remove the toner cartridge cover
3. Remove the four toner cartridges, being careful not to drop toner into the toner hoppers causing contamination to the different colours
4. Remove two screws at the front and release two clips at the back and remove the top cover
5. You can now fit the toner cartridges back in place if you want to seal the hoppers and prevent any stray toner getting into them
6. Remove the two side covers by removing the screw at the back and releasing the clip at the front of each cover
7. Pull out the two hinge pins and remove the imaging drum cover
8. Remove the high voltage power supply board by removing five screws and releasing the plastic clips on the right hand side. Disconnect the two cables at the top of the board. As you pull the board toward you, disconnect the cable plug on the other side of it. When you fit the board back in to the printer, don’t forget to reconnect this plug. Also, make sure the plastic clips are clipped over the board
9. Disconnect the four tubes from the back of the developer units by pressing the latches in and pulling them out. These tubes have sealing mechanisms on them but it’s probably a good idea to try and tape them, facing up, to the top of the printer because they will drop toner
10. Disconnect one connector at the top of the developer frame and then grab the handle and pull it up and out of the printer. You will need to keep the developer frame level or toner will drop out of the back of the developer units

Once the developer frame is on the bench, you can remove the black developer unit by pulling the two white plastic clips up and the developer can be pulled out. If you tilt the developer up, toner will pour out of the back of it.

Grasp the gear on the right hand side of the developer and see how much force is required to turn it. Compare it to the other developers. You might find it is tighter.

To remove the developer drive assembly:

1. Remove the four cable clamps and remove the cables from the cable guide
2. Remove two screws and remove the cable guide from the printer
3. Disconnect the one connector on the developer drive motor
4. Remove three screws and pull the developer drive assembly out of the printer. As you remove it, note the position of the door switch at the top which will probably drop out

With the developer drive assembly on the bench, find the gear that turns the black developer. Run your finger nail up it and you will probably feel a ridge where the teeth are worn. You might also see some white dust from the gear on both sides of the main frame where the drive unit mounts to.

Now would be a good time to remove all the loose toner that’s lying in the printer using a laser vac.

The part number for the black developer is M6091. I’ve had some new (?/refurbished/second user/second hand) developer units that are completely empty and after numerous developer cleaning cycles and printing many pages either won’t put any toner on the paper or dump toner all over the paper.

A genuine developer unit from Dell will already have some toner in it and will have two sealing plugs in the back of it. Remove these two plugs before you fit it. You will find that these work first time without any problems.

Dell 5100cn 5110cn Developer Drive Assembly

The part number for the developer drive assembly is: Dell 5100cn H6702. Dell 5110cn YD415.

After reassembling the printer with the new parts, the printer should be a lot quieter and the black will be printint normally again.