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Time Saving Tips for the HP CLJ 2500

14 Oct, 2003 By: Bill Voelker imageSource

Time Saving Tips for the HP CLJ 2500

As a
printer technician, have you ever made one of the following statements when
working on a new printer? "There has got to be an easier way!" or
"I wish someone would have told me this before I started." It's
frustrating when you spend hours trying to solve a problem, only to find out
later that there was a simple solution. This article will explore quick fixes
for problems you may encounter when working on the HP CLJ 2500 or 1500.

experience began when a printer was received with an error code that wasn't
listed in the manual. The printer, an HP CLJ 2500, is different from other HP
printers in that it does not have a control panel like other printers do. It
uses eight lights to indicate status (see Figure
). These lights are broken into two groups: supply status lights and
printer status lights.

supply status lights keep track of consumables including the four color toners
and tracking the imaging drum life. Since we are talking about errors and
printer status, we won't be discussing these five lights, focusing instead on
the three printer status lights. The printer status lights indicate errors and
require technicians to refer to the service manual in order to interpret what
the various lights mean. Listed from front to back, these lights are the
"go" light, the "ready" light, and the "attention"
light (see Figure
). To indicate various errors, the lights will come on in different
configurations and must be analyzed using the service manual.

three printer status lights were on steady. Anytime a service error is
indicated, a secondary light pattern must be obtained. To obtain the secondary
pattern, hold down the "go" and "cancel" buttons. In the
case of the unknown error we were dealing with, the "ready" and
"attention" lights both remained on.

thing you can do if this ever happens is connect the printer to a computer that
has the proper driver software with toolbox. The toolbox software is located
within the driver CD and when installed (usually when drivers are installed),
gives the operator the ability to communicate with the printer. The toolbox will
contain items including a control panel, various troubleshooting tools and a
tools that will help an operator determine when there is a problem.

In this
case, the toolbox revealed what this error is a T2 clutch error. However the
manual doesn't show a T2 clutch. Now what? T2 means secondary transfer. The T2
is the same as CL2 which engages the secondary transfer roller cam that lifts
and lowers the secondary transfer roller.

that we know what the error is, it should be an easy fix. Replace the clutch,
right? Instead of shot-gunning parts, a quick ohm check of the clutch can show
if it has continuity. A good clutch is usually 150? to 200?. Our clutch was in
this range, so it was good. Replacing the clutch isn't the answer in this case.

next thing was to check for voltage at the DC controller. While looking up the
connector in the wiring diagram to get a voltage reading, I discovered this
wasn't the proper connector. It was obvious to me that someone had been
attempting to fix this printer and got the wires crossed. There are two cables
that can be interchanged, J114 (CL2) and J112 (SL 92-MP tray pickup solenoid)
(see red arrows on Figure
). Both of these connectors have two pins. Could this be the problem?
Perhaps, so I reconnected them properly, expecting to see a normal indication.

I was
really shocked when the error reappeared. At this point, I was sure the DC
controller was bad. After a known working DC controller was installed and the
error again reappeared, I was really frustrated. What else could cause this
error? After brainstorming with a co-worker, I decided to check for a sensor
that would monitor the lifting of the secondary transfer roller, and guess what?
Not only is there a sensor, but after checking the wiring diagram again, it was
discovered that this sensor, the roller engagement sensor, was plugged into the
wrong connector on the DC controller.

further examination, the waste toner detection sensor was connected to the
roller engagement sensor connector-more crisscrossed cables. So, the J108 (waste
toner sensor) and J115 (roller engaging sensor), both of which have three pins,
were also misconnected. After properly plugging in these connectors, the printer
worked fine (see Figure
, yellow arrows).

to be sure that all the connections are in place and working properly can save a
lot of time and energy when working on any machine. Sometimes, like this one,
what appears to be completely confusing, can be easily fixed if you know where
to look.

access the DC controller of the printer: Remove the right side panel by removing
one screw (see figure
). Remove the right rear cover by pressing on one tab at the top (see figure
). Remove the formatter by removing five black screws (see figure
) and two cables. This will expose the DC controller. If you ever have to
remove or replace a DC controller on a HP CLJ 1500 2500, keep in mind these
connections can be mixed up. Or, if you get an error code that is not in the
manual, remember to use the toolbox in the printer software.

- - -

Voelker is a printer trainer for Parts Now!! LLC. PARTS NOW!! is a major printer
parts wholesaler for HP, Canon, Lexmark and Okidata. To contact PARTS NOW! call
800/886-6688 or visit www.partsnowinc.com.

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