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.

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RG5-6958-000CN

RG5-6958-000CN - Rotary motor assembly

Dell 5100cn 5110cn - Noisy And Not Printing Black Or Faint Black

If you have a Dell 5100cn or 5110cn colour laser printer that is noisy when printing and prints faint black or no black at all, check the black developer and the developer drive 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.

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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 printing normally again.

8 thoughts on “Dell 5100cn 5110cn – Noisy And Not Printing Black Or Faint Black”

 Anthony A

We have a Dell 5110CN printer that was being used at our switzerland office (different voltage.) We have since shipped the printer to our Canadian office but it will not power up. I was told that we have to switch over the voltage setting on the power supply but i cannot locate it. Do you know where this switch is on the printer?

admin

This printer doesn’t have a voltage select switch. It is sold as a 110 volt version or a 220 volt version. To convert the printer from one version to the other, you would have to replace both the power supply and the fuser. At least it just didn’t power up. If you had moved the printer in the opposite direction, it would probably have gone bang and/or tripped out the whole office.

J.B. Allen

OK…I managed to get the side panels off. Now, to remove the high voltage power supply I must remove 5 screws. Which 5? There are dozens of screws and I don’t know what any of them attach. Is there any way to send me a step by step guide with photos on how to replace the black developer and black developer drive assembly?

admin

I’ve put the following pages up explaining how to remove the high voltage board, developer drive assy, developer frame, and developer assy:
http://printers-repair.blogspot.com/2014/02/dell-5100-5110-high-voltage-power-supply.html
http://printers-repair.blogspot.com/2014/02/dell-5100-5110-developer-drive-assembly.html
http://printers-repair.blogspot.com/2014/02/dell-5100-5110-developer-frame.html
http://printers-repair.blogspot.com/2014/02/dell-5100-5110-developer-assembly.html
Hope this helps.

Shane

I have a grinding noise that is keeping me from printing anything from the Cyan toner. Could this be the same case?

admin

It’s possible, although I’ve only had it happen with black. It could be that the cyan toner cartridge is faulty, it might be stiff.

Shane

Replaced the cartridge, same issue with grinding. Don’t know what to do because its 6 years old, and no real repair places. I might tear it apart and look at it. Thanks.

admin

It could be the cyan developer has gone stiff. This might have worn the gear on the developer drive assembly or it might have just taken the teeth off the cyan developer. You will have to strip it apart and check it.