I know this is a super old thread, but it ranks at the top in Google when I search for HP Laserjet 8100 Tray 3 Empty. I decided to revive this thread so that others can benefit from what I found with my HP Laserjet 8100 printer.
I acquired an HP Laserjet 8100 from a company that used it for decades. It's an awesome workhorse, but they didn't need it anymore. It only has one problem: Tray 3 doesn't work. There is always a message that Tray 3 is empty even when it's full. And, Tray 3 Doesn't Lift when I look inside. I did some searching and found that the Paper Input Unit (PIU) is broken. However, Paper Input Units for these printers are now very hard to find. I only found one online, and the company wanted almost $500 for it. That's more than the printer is worth. It think it would be great to have a solution that allows people to continue using their current PIU.
Here is what I found with my super simple solution to the problem.
In the PIU, there is a spring that holds up a metal clip. The metal clip looks a little like a heavy paper clip that was bent. The metal clip moves a plastic bar. The plastic bar engages the tray lifting mechanism when the paper tray is inserted, or releases the mechanism when the paper tray is removed. The metal clip goes through the middle of a plastic pin and the spring is wrapped around the plastic pin. When the plastic pin breaks it slips down on the metal clip. Because the plastic pin has slipped down on the metal clip, the plastic lever that engages the lifting mechanism now hits the plastic pin and can't move.
There is a YouTube video that shows the spring that breaks when this happens. The video is only a few seconds long, and this image is all that's really needed. You can see that the spring is at a 45 degree angle to everything else because the plastic pin is broken. You can easily see if the plastic pin holding your spring is broken by removing the trays and looking inside with a flashlight.
laserjet 8100 broken spring.jpg
I disassembled my printer and discovered that the plastic pin for tray 3 could simply be removed. The metal clip and the spring still work perfectly without the plastic pin in place. I don't know if this works for tray 2, but it has worked perfectly for tray 3 on my printer.
Here are the steps I took to remove the broken plastic pin. Details about each step are outlined in the service manual, which is easy to find online. It is very important to consult the service manual for more detailed instructions.
1- I opened all doors and opened the top cover.
2- I removed both paper trays
3- I removed the toner just to keep it safe.
4- I removed the back cover
5- Removed the front cover
6- Removed the tray 1 door
7- Removed the tray 1 pickup unit
8- Removed the door and panel covering tray 2-3 paper pickup unit.
9- Removed the tray 2-3 Paper Pickup Unit.
Now, using a pair of needle nose pliers, I simply removed the metal clip. The plastic pin and spring came out with it. I removed the plastic pin from the metal clip and reinserted the metal clip and spring without the plastic pin. Everything is now working perfectly. It was an easy job and didn't take very long at all.
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