Tray 4 Lifting Malfunction Causes a 58.4 Error

 The 58.4 error is a temporary printing error caused by Tray 4 not lifting. The most common causes for this error are:

Extra paper stored on the left side of the tray that creates a strain on the lifting mechanism.

The paper guides are set too close for the size of paper in the tray. This causes the paper to drag against the guides and stop the paper deck from lifting.

Broken bushing on the paper deck drive assembly (also known as the main drive).

The paper deck drive assembly is defective and not lifting.

Old style 2000-sheet input tray (C3763A)

New style 2000-sheet input tray (C4781A) (Has status LED on front of tray.)

Tray 4 paper cassette

RG5-2155-000CN

Tray 4 paper deck drive assembly

RG5-2164-030CN

Power cycle the printer and verify the error is still present.

Open Tray 4 and check for extra paper stored in the left side of the tray and remove if present.

Lift the paper plate a few inches by hand to verify free movement. Replace the Tray 4 cassette if there is no movement from the plate.

Remove all paper from the right side of the tray and reseat the tray guides. Make sure they are correctly seated at the top and bottom of the tray.

Power cycle the printer and verify the error is still present.

Open the Vertical Transfer Unit (VTU) and defeat the interlock (see Figures 2 and 3 below for location on both tray styles).

Open Tray 4 and put 10 to 20 sheets of paper in the tray. Close the tray and watch the plate lift through the right side of the printer by the VTU.

Open Tray 4 and check the paper to make sure it is not bent. If the paper is bent or starting to wrinkle, the tray guides are not seated correctly at the top and bottom. This will cause the paper to drag and prevent proper lifting of the plate. Reseat the guides and test again.

Pull the drawer completely open and check the bushing at the back right hand side of the tray that makes contact with the main gear drive. If the plastic is broken or threads are worn, the tray will not lift properly. (See insert in Figure 3 below.) If the bushing is damaged, replace the Tray 4 cassette.

Replace the Tray 4 paper deck drive assembly if the cassette is good and the paper plate is still not lifting or the error message does not clear.

Figure 1: Interlock switch for C4781A style input tray1 - Interlock access

Figure 2: Interlock switch for C3763A style input tray1 - Interlock access

Figure 3: Bushing on paper deck lifting gear inside Tray 4

Tray 4 cassette replacement

Figure 4: Tray 4 cassette replacement

Open the paper tray on the 2000-sheet input tray and remove any media in the tray.

Remove the Vertical Transfer Unit (VTU) from the 2000-sheet input tray. (See Figure 5 below.)

Remove the left and right covers from the unit (see Figures 6 and 7).

Remove the two (2) screws and metal retraining tabs from the sides of chassis (see Figure 4, call-out 1).

Slide the paper tray straight out of the chassis while carefully supporting the rear of the paper tray.

To reinstall

Make sure the retaining tabs are tightly secured to the unit's chassis.

After replacing the tray, print a test page. If the print is too close to the paper's edge, adjust the tray.

Removing the Vertical Transfer Unit (VTU)

Figure 5: Removing the Vertical Transfer Unit (VTU)

Open the Vertical Transfer Unit (VTU) on the 2000-sheet input tray.

Rotate the two plastic cams on the VTU hinges toward the 2000-sheet input tray to the secure position (see Figure 5, call-out 1).

WARNING: Do not release the plastic cams from the secure position while the VTU is off. The springs on the cams are very strong and may cause injury.

Locate the two cables that run from the VTU to the chassis at the right side?s upper-back corner (see Figure 5, call-out 2) and disconnect the two cables from the chassis.

Remove the two screws that secure the VTU to the chassis: one screw near each end of the VTU (see Figure 5, call-out 3).

Lift the VTU straight up to clear the metal locating tabs on the chassis.

WARNING: Release the plastic cams only after tightening the screws that secure the VTU to the chassis.

To reinstall

Before tightening the screws, make sure the metal locating tabs are in place.

Reconnect the cables that run from the VTU to the chassis at the right side's upper-back corner (see Figure 5, call-out 2).

Remove the left cover

Figure 6: Left cover

Unplug the power cord and the C-link interface cables from the 2000-sheet input tray.

Remove the two screws located at the top of the 2000-sheet input tray's left cover (see Figure 6, call-out 1).

Remove the left cover from the unit.

Pull out on the top of the left cover, then lift up on the right side to clear the retaining tabs along the left cover's bottom edge (see Figure 6, call-out 2).

Pull out on the lower left corner to release the plastic retainer tab that secures that corner of the cover to the chassis (see Figure 6, call-out 3).

To Reinstall

Replace the left side of the cover first (see Figure 6, call-out 3).

Tilt the right side down and toward the chassis to place the lower retaining tabs over the chassis rail (see Figure 6, call-out 2).

Remove the Right Cover

Figure 7: Right cover

Remove the Vertical Transfer Unit (VTU) from the tray (see Figure 5).

Remove the two (2) screws located near the middle of the 2000-sheet input tray's right cover (see Figure 7, call-out 1).

Using a flat-blade screwdriver, release the plastic retaining tab that secures the cover's upper-left corner to the chassis (see Figure 7, call-out 2.)

To remove the right cover, carefully pull out on the top of the cover while lifting it upward to clear the retaining tabs along the cover's bottom edge.

To reinstall

Place the retaining tabs along the right cover's bottom edge over the chassis rail.

Reinstall the VTU (see Figure 5).

Tray 4 paper deck drive assembly replacement

Figure 8: Paper deck drive assembly

Remove the back cover from the 2000-sheet input tray (see Figure 9 below).

Locate the cable that runs from the paper deck drive assembly on the 2000-sheet input tray to the unit?s Controller PCA. Disconnect the cable from the J206 connector on the Controller PCA (see Figure 8, call-out 1).

Release the cable from the two cable clips that hold the cable to the chassis (see Figure 8, call-out 2).

Remove the two screws that connect the paper deck drive assembly to the chassis: one screw on top of the paper deck drive assembly and one screw on the bottom (see Figure 8, call-out 3).

Pull the paper deck drive assembly away from the chassis.

Inspect the paper deck drive bushing on the paper deck drive assembly. If the bushing is damaged, it can be replaced without replacing the whole drive assembly.

To reinstall

Reroute the cable through the cable clips (see Figure 8, call-out 2) and reconnect the cable to the J206 connector on the Controller PCA (Figure 8, call-out 1)

Remove the back cover

Make sure that the power cord for the 2000-sheet input tray is unplugged from the power source.

Remove the four (4) screws that secure the back cover to the chassis (see Figure 9, call-out 1).

Pull the back cover out from the chassis.

To reinstall

Insert the tab on the lower-left corner into its alignment slot.

© 2005 Hewlett-Packard