HP cp6015dn paperlift noise

[northerntech]

i have an cp6015dn that makes a clunk sound when lifting tray 2 loaded with 24lbs letter. it has just started doing this and it comes and goes but getting more often. will not do it if cassete is half full. gears look good tray lifts smoothly by hand. any suggestions?

[prntrfxr]

First of all, I'm not that familiar with this machine. I have seen a similar problem with the 4200/4300 series printers, however. This may help you or may not. HP redesigned the trays when they created the 4250/4350 series printers. Usually the problem is accompanied by 60.x Errors. This is the service note I wrote for these problems to help my techs. You may find it useful to at least give you a direction to go in when troubleshooting (remember the info below including part numbers are for 4200/4300 printers):

Symptom: (Use these symptoms to troubleshoot problem)
60.X Error (X indicating which tray – 2, 3, or 4.) – Indicates tray lift error followed by one of the following symptoms -

• A loud clunking or banging noise – from offending tray area. Usually when significant quantity of paper is loaded (more than 400).
• Clicking noise after tray installation – motor spins, but paper level indicator is not moving. Banging will continue for 12 seconds, then it will display the error. The symptom is usually intermittent and may not occur with only small amount of paper loaded and will produce 60.X Error
• Loud banging sound occurs when tray is installed, followed by the paper indicator moving to the full position regardless of amount of paper in the tray. Accompanied by 13.X or 60.X Error.
• Lift motor does not rotate; no lift occurs followed by 60.X Error.

Problem:
Tray Design Problem
Occurs with more than 400-sheets of paper loaded in paper tray, and tray lifts up in the rear (due to load becoming to large for tray to lift). It causes skipping of gears, thumping or clunking noise, and 60.X Error.

Pick-up Assembly Loose
The pick-up assembly is missing the bushing, gear, or both, which causes the assembly to be loose.

Tray Lift Motor Mount Defect
The motor gear does not engage the tray gear, preventing tray from lifting and causing subsequent 60.X Error. This is caused by a bent metal mount that attaches the plastic part that secures the tray lift motor to the chassis. Sometimes this metal is bent (it should be 90° from frame). It will be worse when there is a lot of paper in the tray, and may work fine with small amounts of paper.

Bad Lift Motor
Lift motor failure causing no lift of paper in the tray.

Resolution:
(Listed by symptom – not by most likely repair or cheapest expense)
Ø Symptom #1 – Replace paper tray with new type. There are ribs that have been added to the tray on the right side guide to decrease tray motion (reduces tray motion when 400 pages or more have been loaded). In addition the 14T Gear has been raised to improve contact between the tray and the lift drive gears (raised by about .3mm).
- RM1-1088 – 500-sheet tray 4200/4250/4300/4350

Ø Symptom #2 - Remove paper tray and try to move the lift drive assembly side to side, while still in the printer. If it slides back and forth check the motor mount. It should be at a 90° angle and may need to be bent to be corrected. Lift drive assembly will have to be removed to perform this repair.

Ø Symptom #3 – Pull tray feed shaft to the left. If it falls out of place there is a missing/broken bushing and/or gear on the paper pickup-drive assembly. In addition, the feed shaft bushing and 18-T gear will need to be replaced. If the shaft does not fall out of position, then proceed to next step. See part numbers below.
- RU5-0045 - Tray 2, 18T Gear
- RU5-0088 - Tray 3, 4 Opt feeder, 18T Gear
- RC1-0264 - Bushing, Feed Shaft
- RC1-0211 – Paper Pick-up Arm (as needed)

Ø Symptom #4 – Lift Drive Asm Failure. Replace assembly.
- RM1-0033 – Lifter Drive Assembly, Tray 2, Opt Feeder – 4200/4300

[prntrfxr]

This is just an added note. Service manual states maximum capacity of tray 2 is 500 sheets with 20lb paper. Maybe its less when using heavier paper. Try 450 sheets and see if it produces the same problem. I dont know what others do, but my personal opinion (do what you wish), NEVER put 500 sheets in a paper tray. I've always put a bit less, because I believe service manuals exaggerate. I've advised my customers to do the same and have had less problems. If it does it when you have like 200 or 250 pages, then there is definately a problem that must be resolved, but if it works with 450 or 475 then have them put 450 or 475.