HP 4600 Paper Jams

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  • JimF
    • Jun 2025

    #1

    HP 4600 Paper Jams

    This is going to be a little long, as I am going to try to provide all of the troubleshooting steps taken so far.

    I have a HP4600 and getting Paper Tray Jams, when running multi-page documents. (Note: it has a brand new fuser.)

    If I print one page at a time, it seems to work. However, when printing multi-page documents, it seems to start jamming after 3-4 pages. At first, there will be a sheet that is just entering the fuser, with another starting to feed into the ETB (1-2 inches past the lower ETB roller.

    However, after clearing the jam and all paper in the transport, and checking the paper tray, it resumes printing and it jams again immediately as the paper is just under the roller at the ETB paper entrance. Clear and check tray, and it jams again (immediately) at the same location... again and again and again.

    I cleared the job and started over. That's when I found that I could print one page at a time. After one page clears, I can print another and so on.

    I ran a document from Tray 1 and getting the same jam, just as the 3rd page is entering the fuser.

    With Tray 2, it might jam as the 3rd or 4th page is entering the fuser.

    However, in both cases, when it resumes printing, the Paper Jam error occurs immediately, with the first page only 1-2" past the lower ETB roller. It may take numerous attempts before it can get the paper to feed through and complete the print job.

    I'll try to explain this better, in two parts, error codes and then the mechanical aspect of the paper jam.

    Error Code Events:
    I printed out the event log. Most of the errors are 13.01 (Paper Feed - Paper Late) or 13.02 (Paper Feed - Paper Stopped), with 13.02 being the majority of the two. I'm not absolutely positive, but I think the first jam may sometimes be a 13.09 or 13.0A (Top Output Bin - Paper Late/Stop) error. Then, once cleared, it appears that it gets a 13.01(Paper Feed - Paper Late), then after clearing again, it consistently jams and gives a 13.02(Paper Feed - Paper Stopped) each time, until it finally is able to get a sheet through occasionally and the print job finishes.

    [Note: out of the 50 error codes provide in the event log, there are two consecutive 54.12 (Density Sensor Out of Range) errors at one point, but I'm not sure that this may be indicative of the actual problem, but perhaps just a random error that was set, after the onset when one of the initial jam events occurred. It didn't show up on two subsequent tests.]

    Mechanical events:
    As previously mentioned, often on the first jam, there is a sheet just entering the fuser and it likely sets the Top Output error (sometimes the last sheet is barely hanging on the output of the fuser, about to drop into the output tray). However, I don't feel it is actually a jam in the fuser, as there is a sheet which is entering the ETB at the attachment roller on the bottom (it may or may not be wrinkled, as also further described below).

    This problem occurs regardless of which Tray is used, although it seems to work slightly better with Tray 2 before jamming.

    After clearing the jam, it immediately jams again as it tries to continue the document printing. All subsequent jams are at the bottom of the ETB. Sometimes the paper has already entered between the attachment roller and the ETB belt (usually without any noticeable wrinkling), however on some occasions it may not be under the roller and is wrinkled.

    I removed the 3 color cartridges and put it into "Disable Cartridge Check".

    1. Tray 1 closed - no paper
    2. 6 page Print Job sent to printer - to print from Tray 2
    3. Same results as before - "Paper Jam Tray 2" error -
    * 1 sheet just entering the fuser
    * 1 sheet approx 2" beyond the roller at the bottom of the ETB
    * Paper pick-up D-rollers in a down position
    4. Clear paper and allow to resume - immediate "Paper Jam Tray 2" error
    * 1 sheet approx 2" beyond the roller at the bottom of ETB
    5. Repeat of step #4 with same results
    6. Print job finally completed
    - - - - - - -
    Repeat test with Tray 1
    1. Tray 1 open and loaded with paper
    2. 6 page Print Job sent to printer - to print from Tray 1
    3. "Paper Jam Tray 1" error -
    * 1 sheet just entering the fuser
    * 1 sheet approx 1" to 1-1/2" beyond the roller at the bottom of the ETB
    4. Clear paper and allow to resume - immediate "Paper Jam Tray 1" error
    * 1 sheet approx 1" beyond the roller at the bottom of ETB
    5. Cleared jam - printer went to Tray 2 and completed job - not sure why it did this.

    Summary:
    Color Cartridges removed
    Paper Tray Jams from either Tray
    Leading edge of paper is usually found 1-2 inches beyond the lower ETB roller when jam occurs.

    So it seems that the problem may be related to parts that effect paper path from both Trays.

    I don't have parts available to just swap out, so I'm hoping someone might be better acquainted with this printer and the likely problem.
  • blackcat4866
    Master Of The Obvious

    Site Contributor
    10,000+ Posts
    • Jul 2007
    • 22997

    #2
    Are the correct paper sizes programmed for the trays? =^..^=
    If you'd like a serious answer to your request:
    1) demonstrate that you've read the manual
    2) demonstrate that you made some attempt to fix it.
    3) if you're going to ask about jams include the jam code.
    4) if you're going to ask about an error code include the error code.
    5) You are the person onsite. Only you can make observations.

    blackcat: Master Of The Obvious =^..^=

    Comment

    • JimF

      #3
      HP 4600 Paper Jams

      Originally posted by blackcat4866
      Are the correct paper sizes programmed for the trays? =^..^=
      If you are referring to the program settings through the control panel:
      Tray1 is set to "any" and Tray2 is set to "letter".
      So, yes, they are properly set for the correct paper size being used by either tray.

      Comment

      • JimF

        #4
        I'm guessing that the problem may lie with one of the follow assemblies:
        ETB
        Paper Pickup Assy
        Paper Tray

        I have visually inspected these items, but can not find anything that appears to be significantly worn or damaged. Of course, I could be missing something.

        While it may still be a physical problem that I'm overlooking, I would suspect that it could also be attributed to an intermittent sensor or perhaps a sticky solenoid or other similar problem, that shows up after a few pages have run and then becomes chronic on subsequent attempts to feed the paper.

        I'm hoping someone with a bit of experience with this printer, may be able to offer some additional troubleshooting tips, other things to look for that may not be so obvious, or perhaps the most likely culprit associated with the above symptoms that I provided in my own troubleshooting efforts.

        Thanks

        Comment

        • LaserSharp
          Technician

          50+ Posts
          • Sep 2007
          • 94

          #5
          Hi Jim,

          I've worked on quite a few of these and the only time I've seen the ETB cause issues is when there is actual damage visible to the belt i.e. Holes...tear etc.

          That said I've seen quite a few cases where the pickup assembly is damaged. There is a diverter plate that in on the underside that can crack or be broken when frustrated users pull open the tray after a paper jam.
          However- you said that the issue happens from the MP (tray 1) as well, and would be bypassing the above problem.

          My bet without actually looking at the machine would be on the fuser, specifically the exit sensor.

          Your 54.xx errors are density sensor errors, and will only be thrown when the machine does a calibration cycle, normally if OEM cartridges are being used then the sensor just needs to be cleaned, but with aftermarket cartridges all bets are off with this machine.

          You said you don't have parts to swap to test with this machine, but if the supplies page indicates the ETB is near the end of it's life you might be abel to get your customer to replace it a bit ahead of time just to eliminate that as part of the problem.

          Good luck - less us know how it turns out.

          BTW if you still have the old fuser that was just replaced you might try it in the printer just for trouble shooting.

          Comment

          • JimF

            #6
            Thanks for the input.
            The old fuser is long gone, as it had a tear in the drum and was originally causing a lot more problems, as I couldn't get it to run more than one page without a wrinkled up jam in the fuser.

            I installed a brand new fuser and on the first run (10-15 page documents), it ran fine and then started jamming again. However, the paper is only at the fuser on the first jam (but not wrinkled, just stopped) of a multiple page document (single page print jobs don't ever seem to jam). After clearing everything, the paper never gets to the fuser and it sets the paper feed error over and over, until it finally gets a page through, after continuing to clear the paper and letting it try again (or until I just cancel the print job).

            The ETB has over 60% life remaining. Of course, I don't see anything physically wrong with it.

            I have visually inspected everything I can possibly see and I can't find a crack or chip in anything. Although the rollers, etc. seemed OK, I went through and cleaned any moving part I could see.

            At this point, I went ahead and ordered the paper pickup assy. It should be here in a day or two, so I'll see what happens after replacing it.

            Comment

            • mo0651
              Service Manager

              1,000+ Posts
              • Apr 2009
              • 1054

              #7
              I agree with the exit sensor may be the problem. That style of printer can warp the actuator it is also easy to break that unit.

              Comment

              • JimF

                #8
                I'm not sure that I follow... are you indicating that within 10-15 pages on a new fuser, that the actuator may have warped or broken?

                Please keep in mind, there have been no wrinkling of the paper in the fuser area or other indication of an actual physical jam in the NEW fuser.

                When the machine quits and logs an error and only on the 1st time that this occurs, there may be a single sheet barely hanging on at the output of the fuser and there is a single sheet that has just started to enter the fuser and in contact with the drum. However, there has been no apparent jam, wrinkling or other indication that the problem actually is due to a jam in the fuser area.

                Since this is a brand new fuser and there has been no actually jam, wrinkling, or multiple sheets within in the fuser, I don't quite understand how anything may have been warped or otherwise potentially damaged on a new unit. A visual inspection does not reveal any damage that I can see, as well.

                Once the original jam occurs and all paper is cleared and the cassette is reset into the printer, subsequent attempts sets a Paper Tray Jam and paper never reaches the fuser. As the printer continues to try to finish the print job, it may occasionally get 1 or perhaps 2 sheets through before it sets another Paper Tray Jam error. This continues until the job finally completes or I cancel the print job.

                This is the reasoning that I indicated my assumptions for the possible areas of defect. However, I could understand a bad sensor, even on a new fuser, but it would seem that it would also cause error codes indicating problems in the fuser area, as opposed to Paper Tray Jams.

                Of course, if there is something else, such as the manner in which the firmware handles certain codes, upon subsequent errors being set, which may give false errors, then I might be more acceptable to the possibility that the problem may be a result of an area that would not otherwise make sense. In such case, I would be quite interested in the theory of operation, which would make this the likely culprit.

                Thanks

                Comment

                • mo0651
                  Service Manager

                  1,000+ Posts
                  • Apr 2009
                  • 1054

                  #9
                  I'm sorry didn't get that picture. what is the error page telling you? On your config page, if the paper tray is set to a certain size then I would doubt if it is any sensor from the tray. The paper stopped error is usually thinks it has paper left in it after clearing. the sensor is not resetting bad sensor or damaged flag, or dirty sensor.
                  Last edited by mo0651; 04-14-2009, 02:33 PM. Reason: OOPs Missed that.

                  Comment

                  • JimF

                    #10
                    HP 4600 Paper Jams

                    Update - Corrective Action:
                    Replaced Paper Pickup Assembly
                    Problem Resolved.

                    Comment

                    • prntrfxr
                      Service Manager

                      1,000+ Posts
                      • Apr 2008
                      • 1627

                      #11
                      HP 4600 Paper Jams

                      Id say about 75% of the time its the p/u asm, followed by tray, and then fuser for jamming issues. The other problems with this machine are (not jamming related) laser scanner, developer disengagement plate, color registration detector, and front door switch. These are the parts I would keep on hand if you repair a lot of these machine. Hope this helps others in future.
                      Life should NOT be a journey to the grave with the intention of arriving safely in an attractive and well-preserved body, but rather to skid in sideways - Coke in one hand - chocolate in the other - body thoroughly used up, totally worn out and screaming "WOO-HOO, what a ride!".

                      Comment

                      • JimF

                        #12
                        Thanks for the info.
                        I may look you up the next time I run into problems.

                        Comment

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