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Identifying and Correcting Lift Errors

12 Feb, 2004 By: Stephanie Hinz imageSource

Identifying and Correcting Lift Errors

assimilation of new features into familiar and reliable products is something we
have grown to expect in any industry. Changing and improving products is a
necessity—from toothpaste to cars and, of course, laser printers.

we have seen over the past couple of years, Hewlett-Packard’s laser printers
have undergone a number of changes, including a more aerodynamic look and
redesigned control panel, in its quest to become more user-friendly. The latest
line of monochrome printers by HP for medium to large workgroups incorporate
this new look along with a few upgrades in engine design. While similar to the
4100, the HP 4200/4300, introduced in the fall of 2002, has a tray lifting
mechanism that, while designed to ensure consistent pickup and feed operation,
is the source of three separate issues. While all three problems can occur in
any cassette tray, this article will focus on errors from Tray 2.

Motor Mount

First, technicians are reporting obnoxious clicking, thumping and/or grinding
noises, followed by a 60.x tray lift motor error. This problem is related to the
lift motor mount which is a small piece of metal on the right hand side below
the lift motor (see
Figure 1
). A white plastic bracket is attached to the lift motor and
secures to the mount with one screw (see
Figure 2
). There is also a tension spring at the top that allows the
motor to swing back and forth when the tray is absent from the machine (see
Figure 3

normal operation, the tray lift motor rotates and raises the tray until the
paper stack surface sensor detects media. If the sensor isn’t triggered in
eight seconds, the machine will report a 60.x error code (the prefix in the
error code corresponds with the affected tray). If the mount isn’t seated at a
90 degree angle, the lift motor and tray gears do not engage properly to lift
the tray into proper position.

indicates the symptom(s) of a bent lifter motor mount to include:

  • A
    clicking noise from the engine after the tray is inserted

  • The
    lift motor spins but the paper indicator at the front left hand side of the
    tray does not move

  • If
    the mount is bent close to the 90 degree angle, the motor and tray gear may
    engage but will not have enough strength to lift a full cassette tray.

determine if the mount is bent, follow these steps. First, remove the affected
cassette tray from the printer. Locate the motor on the right side inside the
tray cavity and move the assembly from side to side (see
Figure 4
). Remember, the motor will swing—but if the motor slides at
the base or bounces up and down, the mount isn’t at the correct angle. If this
is the case, remove the right cover, locate the lift motor and remove the white
plastic bracket (one screw). Bend the mount to the correct angle and reinstall
the motor.


If the motor mount isn’t the source of the problem, the pickup assembly may be
missing an essential piece. To determine if this is the problem, tug on the feed
roller shaft to the left. If the feed roller and shaft fall out of place, the
assembly is could be missing a bushing and/or the 18-tooth gear is defective.
The printer will also report a 60.x lift error or a 13.x paper jam error (again,
the prefix in the error code corresponds to the affected tray).

fix for this problem is time consuming and a bit tricky. Before the feed roller
shaft can be accessed, the pickup gear assembly has to be removed. To accomplish
this step correctly, refer to the HP 4200/4300 service manual, part number
Q2431-90921. A brief step-by-step process is listed below.

  1. Remove
    the right cover. You must remove the top cover and formatter cover to access
    the locking tabs to release the cover from the machine.

  2. Disconnect
    the power rod switch from the pickup gear assembly.

  3. Locate
    the e-clip and remove. After this step, proceed with caution. From the right
    hand side of the printer remove the drive-gear shaft connected in the tray
    cavity. Located on the drive-gear shaft is a large gear that will slide off
    once the shaft is removed. Therefore, reassembly of the pickup gear assembly
    will require some patience to position the large gear on the drive-gear
    shaft while reinstalling the pickup gear assembly at the same time.

  4. Disconnect
    the pickup assembly solenoid from J92 on the DC controller. Note. It may be
    necessary to un-route additional cables along the harness.

  5. Locate
    four screws to remove the pickup gear assembly from the machine.

  6. The
    bushing and/or gear for the feed roller shaft will be missing or damaged (see
    Figures 5 & 6
    ). To access the feed roller bushing, remove the
    gear by lifting up on the tab while pulling the gear away from the printer.
    A replacement bushing and gear are available for this problem. These part
    numbers are not listed in the service manual. The RC1-0264-000CN is the feed
    roller bushing for Tray 2 and optional sheet feeder. The RU5-0045-000C is
    the 18-tooth gear for Tray 2 and the RU5-0088-000CN is the 18-tooth gear for
    the optional 500-sheet feeder.


Finally, the last possible cause could be the tray and HP recommends upgrading
the cassette tray (standard or 500-sheet) to a redesigned version. When the
cassette becomes too heavy, the rear of the tray lifts, which prevents the tray
and motor gear from properly engaging. An intermittent banging noise may occur
when the tray is full (400 sheets or more). HP has released a redesigned
cassette tray (standard and optional 500 – sheet) to combat this problem. The
upgraded tray has “ribs” on the back right hand side to diminish the gap
between the tray and cassette guide. The gear (14 tooth) on the front right hand
side has been heightened by 0.3mm to reinforce proper gear alignment (see
Figures 7 & 8

part number for an upgraded standard 500-sheet tray (Tray 2 and optional tray)
is RM1-0028-060CN. To determine if the 500-sheet feeder requires an upgraded
tray, locate the serial number on the feeder. Feeders with new trays are in the
following ranges: CNCX100001 and higher or CNCX20001 and higher.

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