HP Color LaserJet 8500 and 8550 Series Printers - Troubleshooting 54.2 Carousel Errors


Introduction
The HP Color LaserJet 8500 and 8550 series printer control panel error, 54.2 CAROUSEL ERROR CYCLE POWER , informs the user that an event has occurred that prevents the carousel from rotating. The carousel is the internal assembly that holds the color print cartridges. This error may happen at any time during the initial setup of the printer, the installation of a new cartridge, or in the middle of a print job. Any of the following factors may cause the error:
  • A print cartridge was not locked properly.
  • A print cartridge has a damaged shutter.
  • A foreign object is jamming the carousel.
In most cases, previous damage to a print cartridge or incorrectly installing a print cartridge are the most common causes of 54.2 errors. For example, if the blue locking lever for a print cartridge is not latched correctly, the cartridge shutter will not be secured and it will rub up against the carousel housing or become hung up when the carousel rotates. This prevents the carousel from rotating correctly. In this case, if you repair or replace the damaged shutter or cartridge component, this will resolve the 54.2 error and return the printer to its normal operation.
You must clear the 54.2 error by first removing all of the color print cartridges. If a print cartridge is the source of the error, this will help you identify which cartridge is causing it.
How to remove print cartridges
Perform the following steps to remove the print cartridges.
NOTE: The carousel that holds the print cartridges must be in a position that allows you to easily remove the cartridges (see Figure 1). If the carousel is not in the correct position (see Figure 2), the cartridge will be difficult to remove or may be damaged. The section of this document entitled "If the print cartridge is correctly aligned " shows you how to remove a print cartridge when it is in the correct position. The section of this document entitled "If the print cartridge is not correctly aligned " shows you how to remove a print cartridge when it is not in the correct position.
CAUTION: As a general guideline, prior to removing a print cartridge, the label on the cartridge should be right side up and as close to level as possible.
If the print cartridge is correctly aligned (see Figure 1)
  1. Leave the printer on (powered up).
  2. Open the front door of the printer to gain access to its interior components.
  3. Open the clear plastic door that covers the print cartridge access area (above the blue button and the small, colorful CMY diagram).
  4. If the blue locking lever to the right of the cartridge is accessible, rotate it to the right to release the cartridge. Pull out the print cartridge.
  5. If the blue lever is not accessible, go to the "If the print cartridge is not correctly aligned " section of this document to correctly align the print cartridge so that it is accessible.
  6. Close the clear plastic door.
  7. Press the blue button under the clear plastic door to rotate the carousel to the next cartridge. If necessary, rotate the carousel manually by turning it counter-clockwise.
  8. Remove the remaining cartridges.
  9. If the carousel will not rotate to access the remainder of the cartridges, go to the section of this document entitled "If the carousel will not rotate and one print cartridge was removed ."
  10. Go to the section below entitled “How to test print cartridges .�?
Figure 1: The cartridge in the correct position for removal
1 - The label is level
If the print cartridge is not correctly aligned (see Figure 2)
  1. Press down on the print cartridge to rotate the carousel counterclockwise.
  2. If the carousel will not rotate counterclockwise, rotate it clockwise.
  3. If the carousel will not rotate in any direction, go to Step 4.
  4. Rotate the carousel until a print cartridge is in a position to be removed (see Figure 1).
  5. Rotate the blue lever to the right and pull out the print cartridge.
  6. Repeat 1-5 for the remainder of the cartridges.
  7. If the carousel will not rotate to access the remainder of the cartridges, go to the section of this document entitled "If the carousel will not rotate and one print cartridge was removed ."
  8. Go to the section below entitled “How to test print cartridges .�?
Figure 2: The cartridge is not in the correct position for removal
1 - Label is not level
If the carousel will not rotate and one print cartridge was removed
  1. Identify the grill underneath the blue carousel rotation button.
  2. With a flat-head screwdriver, a key or similar device, press the grill locks toward the center of the grill and lift it out.
  3. Remove the toner collection tray. Depending on weather the printer has had a PEP kit installed access to the tray will look different, see Figure 3. With the PEP kit tray just pull it out of the printer.
    NOTE: The PEP kit program has been discontinued as of September 30, 2003.
    Figure 3: Toner overflow tray
    1 - PEP kit toner overflow tray
    2 - Toner overflow tray without PEP kit
  4. Remove any obstructions in the toner collection chambers.
  5. Verify that the carousel moves correctly.
  6. If the carousel does not move, lift up the carousel release lever located at the very back of the print cartridge chamber (see Figure 4).
    Figure 4: Carousel release lever in the back of the cartridge chamber
    1 - Carousel release lever
  7. Rotate the carousel until a print cartridge is in a position to be removed.
  8. Rotate the cartridge’s blue lever to the right and pull out the print cartridge.
  9. Repeat 7-8 for the remainder of the cartridges.
  10. Go to the section below entitled “How to test print cartridges .�?
If the carousel will not rotate and no print cartridges were removed
CAUTION: Attempt this step only if an experienced technician or if comfortable with handling the internal assemblies of the printer. Otherwise, if unable to remove the print cartridges and rotate the carousel, refer to the User’s Guide to obtain contact information for HP Service and Support, for an experienced HP certified technician's assistance.
  1. Turn the printer off.
  2. With the front printer door still open, press the white button on the large, green locking lever and turn it all the way to the right.
  3. Rotate the large blue lever (to the right of the black print cartridge) all the way right and upward.
  4. Remove the imaging drum by pulling on the small, blue handle to the lower right of the large blue handle.
  5. Remove the black print cartridge.
  6. Open the right printer door and remove the transfer drum by grasping and pulling on the two large, green handles.
    CAUTION: Protect the imaging drum from exposure by covering it with the gray plastic drum cover that shipped with the printer. If the cover is not available, put the drum in a safe and dark location. The drum is light sensitive and can be permanently damaged in just a few minutes of light exposure out of the printer if it is not covered.
  7. Locate and release the carousel release lever by reaching behind and to the right of the carousel.
    1. Carousel release lever will not be visible.
    2. Carousel release can be released by reaching over the top of the carousel to the very back of the printer.
      NOTE: The release lever cannot be seen by looking in the printer. It can only be located with prior experience of observing the lever when a print cartridge is removed (see Figures 4 and 5).
      Figure 5: Reaching over the top of the carousel to release the carousel break
  8. After releasing the carousel, rotate it until the first print cartridge is in a position to be removed.
  9. Use the information in the section of this document entitled "How to remove print cartridges " to remove the print cartridges.
  10. If still unable to get the carousel to move, refer to the User’s Guide to obtain contact information for HP Service and Support for an experienced HP certified technician's assistance.
How to test print cartridges
After removing the print cartridges from the printer, inspect them carefully for full functionality by doing the following:
  1. Check each cartridge for missing or broken parts.
  2. Rotate the print cartridge until the left end of the cartridge is in view. (This end does not have the colored label.)
  3. Press the spring-loaded button on the end of the cartridge (this is the end that goes into the printer; see Figure 6).
  4. Verify that the shutter opens.
  5. Inspect the shutter and shutter arm for damage (see Figure 6).
    Figure 6: Spring-loaded button and shutter arm
    1 - Shutter arm
    2 - Spring-loaded button
    NOTE: While the shutter is in the open position, note a black or black and white plastic shutter retaining arm on the right side of the shutter (near the CAUTION warning). (See Figure 7.) This may have become disengaged from the pin on the shutter. If it is possible, reconnect any disconnected parts. Any cartridge that cannot be restored to an operating condition will need to be replaced.
  6. While holding the shutter open, inspect the right-rear corner of the cartridge. Locate the black shutter lock lever. (See Figure 7.) When this lever is slid to the left (in the direction of the arrow on the shutter) with the shutter open, the shutter should shift forward another 0.0625 of an inch. If the shutter will not move after repeated attempts, the cartridge may be damaged. Contact a local reseller to replace the cartridge.
    Figure 7: Retaining arm and shutter lock lever
    1 - Shutter retaining arm
    2 - Shutter lock lever
  7. Test the remaining print cartridges.
How to reinstall print cartridges
After inspecting the print cartridges and the carousel assembly, reinstall the print cartridges by doing the following:
  1. Power cycle the printer with all the cartridges removed.
  2. Insert the appropriate color print cartridge into the carousel.
  3. Press the cartridge firmly against the back of the carousel.
  4. Move the Blue Latch into the closed position.
  5. A "double-click" should be heard and felt if the cartridge is installed correctly. Figure 8 shows a properly locked down cartridge and Figure 9 is an example of an incorrectly locked down cartridge.
    Figure 8: Correctly locked lever
    1 - No gap between the blue lever and the metal stop
    Figure 9: Incorrectly locked lever
    1 - Gap between the blue lever and metal stop
    NOTE: If any of these three latches are not completely in the locked position they may release and allow the print cartridges to shift during printer operations.
  6. Close the clear plastic door and push the blue carousel rotation button. The carousel will rotate to the next vacant cartridge slot.
  7. Repeat 2-5 for the remaining cartridges.
  8. After installing all of the print cartridges, close the front printer door.
  9. Go to the section entitled, “How to test the printer for normal functionality .�?
How to test the printer for normal functionality
  1. Print a demo page or a configuration page to test for normal printer functionality.
  2. Power cycle the printer one more time to verify that the printer control panel does not display the 54.2 error and is in the Ready state.
Contact HP?
If the issue is unresolved, click here to contact HP support for further assistance. Document number bpl06541 used for troubleshooting and a brief description to assist HP support in resolving the issue.
  • Is the 54.2 error condition still unresolved after performing the troubleshooting in this document?
  • Did the 54.2 errors occur after changing a print cartridge? If so, which one?
  • Is there a cartridge that is stuck in the printer? If so which one?
  • Did a cartridge get damaged during installation? If so which one?
  • Is the printer making any unusual noises after replacing a print cartridge?
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