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When Lexmark Paper Trays Will Not Install

21 Apr, 2004 By: Bill Voelker imageSource

When Lexmark Paper Trays Will Not Install

Writing articles gives me great pleasure because I am passing on the knowledge
to help technicians solve printer problems. In the process of looking for new
printer problems that other technicians would like to know about, I sometimes
will run across an old problem that continues to resurface. After calling our
technical support department, and then looking into my notes for ongoing
problems, a common theme emerged with the Lexmark business class of printers. It
seems that after the customer fills the paper tray, they can’t get the tray back
in. This is applicable to Lexmark Optra S, and all “T” printers. The complaint
is actually a simple fix, both temporarily and permanently. This fix is so
simple though, that a lot of customers choose not to have it repaired even
though it is necessary. Customers need to be aware that, if not corrected, this
can cause problems later on. The reasons for this will be explained later in
this article.


src="index_files/image001.gif" align=left v:shapes="_x0000_s1025">The
reason the tray won’t close is because the integrated paper tray pickup arm, or
paper level compensator, is hanging down instead of retracting up like it is
supposed to when the tray is removed (Figure 1). It is hanging down because the
tension spring on the right side (Yellow Arrow Figure 2) is either missing or
not connected. In very rare cases, it can be reinstalled with no problem. In
most cases however, the spring lug on the bell crank (Red Arrow Figure 2) is
broken and the bel

src="index_files/image002.gif" align=left v:shapes="_x0000_s1026">l crank (part number 56P1228) has to be replaced. If the
spring is missing, it too will have to be replaced. As proper tension is key for
paper pickup

in each drawer, there are four different springs available depending on the
model. These are for the integrated 250-sheet drawer (model number 99A1927), the
integrated 500-sheet drawer (model number 99A1930), the optional 250-sheet
drawer (model number 99A1929), and the optional 500-sheet drawer (model number

is also a very small chance that the spring lug is broken on the

src="index_files/image003.gif" align=left v:shapes="_x0000_s1030">base of the
printer (Figure 3). If this has happened, you are in trouble because this lug is
molded into the side frame of the printer. This would then turn this simple
repair into a major repair that requires replacement of the side frame. As I
mentioned earlier, this problem is applicable to all Optra S, Optra T and
Lexmark T printers.

check the bell crank, place the printer on its back to access the paper pickup
arm. On the right side, where the pickup arm pivot shaft attaches, there should
be a spring attached to the bell crank. If the spring is missing, it will have
to be replaced and reconnected to the bell crank. If the bell crank lug is
broken, the bell crank will have to be replaced. This problem can be temporarily
overcome by lifting the arm from the rear of the printer until the tray is
inserted past the arm. However, the bell crank should be replaced as the missing
or disconnected spring will become a nuisance to the user. There is also the
possibility that the user, or someone not knowledgeable of the problem, forces
the tray and breaks the arm assembly and maybe even the tray itself.

Step by Step

To change the bell crank for the integrated tray (250 or 500), the paper pickup
arm assembly will have to be partially

src="index_files/image004.gif" align=right v:shapes="_x0000_s1032">
removed. To remove the arm assembly, follow these steps:

  1. Gently rest the
    printer on its back to access the lower portion of the printer.

  2. Using a small
    screwdriver, remove the “e-clip” on the right side of the pickup arm pivot
    shaft (Figure 4, Arrow 1). Use caution not to lose this “e-clip.”

  3. Remove one screw
    (Figure 4, Arrow 2).

    src="index_files/image005.gif" align=right v:shapes="_x0000_s1037">

  4. Slide the whole arm
    assembly to the right in order to clear the left side and the motor mount clip
    (Figure 4,
    Circle 3).

  5. There is no need to
    disconnect cables unless replacement of the arm assembly is necessary.

  6. At this point, the
    bell crank can be pulled off of the end of the shaft (Figure 5). It is a tight
    fit, so pull hard. You must overcome two detents.

  7. Install the new
    bell crank and reinstall the arm assembly into the printer by inserting the
    right side of the shaft first. Then move the entire assembly left to engage
    the motor mount clip and the left side of the shaft.

  8. Reinstall the “e
    clip” onto the shaft and hook the spring into the lugs.

  9. At this point, the
    arm should be retracted and the tray can be reinstalled.

change the bell crank on the
arm in the optional feeder assemblies, follow these steps:

src="index_files/image006.gif" align=right v:shapes="_x0000_s1039">

  1. Remove the printer
    from the optional feeder assembly. Take note of the paper sensor flag
    mentioned in Figure 5.

  2. Remove three screws
    and two cables (Figure 6) and lift the arm assembly out of the base. Use
    caution to prevent breaking the paper quantity sensor flag that you noted in
    Step One.

  3. After the arm
    assembly is removed, turn the assembly over and remove the bell crank by
    pulling hard (Figure 7).

  4. Reinstall the bell
    crank on the shaft.

  5. Reinstall the arm
    assembly into the base.

    src="index_files/image007.gif" align=right v:shapes="_x0000_s1040">

though Lexmark relates this breakage to a “temporary manufacturing problem,” we
continue to see this problem even with the T63x series. It is speculated that
this lug breakage is due to rough tray handling. The actual cause is unknown.





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