60.2, 60.3, or 60.4 Error

Loud Clunking or Thumping A Tray Lift or 60.x error displayed on the HP LaserJet 4200 or 4300 series printer is caused by a variety of issues and may display a variety of symptoms:

A loud banging noise from Tray 2; intermittent, when approximately 400 sheets of paper are loaded in the tray.
A clicking sound from the engine after the tray is inserted; the motor is spinning, but paper indicator is not moving.
A loud banging occurs in the engine after the tray is inserted; the paper indicator on the front is moving to the full position, regardless of whether the tray is full or empty.

Design tolerance symptoms

A design tolerance lift failure has been identified by the field where the rear of the cassette moves upward when the lift-up load becomes too large (most likely to occur at around 400 or more loaded pages), which may result in the gear tooth skipping. Symptoms include a 60.x control panel error and a loud "clunking" or "thumping" noise.

When there is a design tolerance issue, a loud banging noise is heard from Tray 2 or a feeder lifter motor. The loud banging noise may be heard, one or more times, is usually intermittent, and easiest to reproduce when approximately 400 sheets of paper are loaded into the tray.

Tray lift motor mounted wrong symptoms

Clicking may or may not be heard from the engine after the tray is inserted. The motor may be audibly spinning, but the paper indicator on the front does not move. This happens even when the tray is empty. The motor doesn't stop running until the engine errors out after twelve seconds of banging.

A manufacturing defect has been noted on the base of the engine chassis section that supports the lifter motor. This small metal support should normally be bent at a 90-degree angle, however in some instances, some have been observed with a less than 90-degree bend. This in turn disallows the motor gear from engaging to the tray gear, resulting in failure to lift and a 60.x error. If the angle is less than 90-degrees, but not extremely less than 90-degrees the gears may engage slightly and be able to lift small amounts of media, but not large amounts of media.

Pickup assembly not secure symptoms

Symptoms include the printer reporting a 13.x Jam or a 60.x tray lifter error, or a loud banging is heard from the engine after the tray is inserted. The customer will see the paper indicator on the front moving into the full position. This happens with the tray full or empty. The motor doesn't stop banging until it errors out (twelve seconds of banging).

Remove the suspect paper tray (cassette) from the engine/feeder.

Try to slide the lifter side to side while on the gear train.

If the motor slides, then the issue is in fact the lifter motor support angle (tray lift motor mounted wrong).

If not, tug the feed roller/feeder shaft to the left.

If the feed roller/feeder shaft falls out of place, the pick-up assembly is missing a bushing and/or gear. The Feed Shaft Bushing and the Gear 18 Tooth for Tray 2 will need to be replaced, if it was affected; If the Optional 500-sheet feeder was affected, then the Feed Shaft Bushing and Gear 18 Tooth for the 500-sheet feeder will need to be replaced.

If the feed roller/feeder shaft does not fall out of place, reinstall the paper tray (cassette) and try to recreate the issue.

NOTE: These new trays will be hard-rolled in GSO for replacement purposes. The hard roll cassette service part number has rolled from RM1-0028-000CN to RM1-0028-060CN and from Q2441-69001 to Q2441-69002.

Figure 1: Old style paper tray

Figure 2: New style paper tray

NOTE: A single digit in the 500-sheet feeder serial number indicates the countermeasure on the feeder. The counter-measured feeders are in the following ranges: CNCX100001 and higher or CNCX200001 and higher.

Counter-measure tray (500-sheet tray)
RM1-0028-060CN
Q2441-69002

Gear 18 Tooth (Tray 2)
RU5-0045-000CN

Gear 18 Tooth (Optional 500-Sheet Feeder)
RU5-0088-000CN

Bushing Feed Shaft
RC1-0264-000CN

Lift Motor (Lifter Driver Assembly)
RM1-0033-000CN*

Compression Spring
RC1-0213-000CN*

Paper Pick-up Arm (Feed Roller Plastic Housing)
RC1-0211-000CN

* Denotes optional parts

NOTE: Paper out/Tray lift sensor assembly cannot be replaced, as it requires frame separation.

Remove the suspect paper tray (cassette) from the engine/feeder.
Try to slide the lifter, side to side, while on the gear train.
If the motor slides, then the issue is in fact the lifter motor support angle (tray lift motor mounted wrong). On the base unit, the sheet metal on the engine itself needs to be bent to a 90 degree angle (see figure below). On the optional Tray 3 and Tray 4, the sheet metal will need to be bent into a 90 degree angle on the sheet feeders. Follow the instructions in the Service Manual for more information about how to access the lifter motor support mount.

Figure 3: Lifter motor support mount

If not, take the suspect paper tray (cassette) out.
Tug the feed roller/feeder shaft to the left.
If it falls out of place, the pick-up assembly is missing a bushing and/or gear. Replace the Feed Shaft Bushing, and the Gear 18 Tooth for Tray 2 if it was affected, and the Gear 18 Tooth for the Optional 500-sheet feeder if it was affected. Refer to the "Repair and replacement instructions" below for additional information.

If the feed roller/feeder shaft does not fall out, verify that none of the other trays are missing a bushing by removing the trays and tugging the feed roller/feeder shaft to the left.
If the feed roller/feeder shaft does not fall out, replace the tray with a new design tolerance failure counter measure tray, when available.

The differences in the new trays are:

Ribs have been added to the cassette main body to reduce the gap between the Cassette Main Body and the right guide.
The teeth of 14T Gear have been heightened by 0.3mm to ensure stable engagement between the cassette and the drive gears.

Repair and Replacement instructions for bushing feed shaft

Figure 4: Location of feed roller gear (small white gear in middle of picture)

1.1 Remove the Tray pick-up gear assembly and bushing.

1.2. Once the gear assembly has been removed, the feed roller gear will be exposed. Lift up the little phlange, attaching the gear to the feed roller, lift up the little phlange on the shaft, while pulling away from the chassis of the printer.

Figure 5: Closeup of gear

Figure 6: Location of bushing

1.3. Remove the bushing from the bushing feed shaft.

NOTE: The bushing may be missing and/or broken.

NOTE: Stop here to replace the gear and bushing only. If the pick-up Feed Roller Assembly (inside the tray cavity) has come apart, continue to Step 1.4.

Figure 7: Outside view of feed roller shaft with bushing and gear removed

1.4. The shaft will have to be shifted to the left to begin removal from the chassis of the printer.

Figure 8: Internal location of feed roller shaft and plastic housing

1.5. Locate the feed roller shaft from within the chassis of the printer.

Figure 9: Left side alignment of feed roller shaft, during removal

1.6. Grasp the feed roller shaft and begin guiding it to your left, into a notch in the opposite side of the chassis. This allows the right side of the shaft to clear the opening that it was previously installed in.

Three parts are now free to be removed:

Feed roller shaft and two gear assembly (these come out together)
Plastic housing for pick-up assembly
Spring

Figure 10: Chassis view with feed roller shaft, plastic housing, and spring removed

Figure 11: Inserting feed roller shaft to plastic housing

1.7. Slide the feed roller shaft into the sleeve of the plastic housing, while sliding shaft through. Ensure that the plastic cut out fits over the locator peg of the plastic housing.

Figure 12: Installing shaft, spring, and place house.

1.8. With the spring in place, slide the shaft through the plastic housing and chassis of the printer, while aligning the fin on the back side of the plastic housing with the tray lift sensor (sensor shown in Figure 10)

1.9. Install the gear and the bushing that were previously installed on the outside of the chassis.

© 2005 Hewlett-Packard