How to Fix an Epson Printer That Will Not Pick Up Paper from Cassette 2

When an Epson printer refuses to load paper from cassette number two, the problem can feel confusing at first. The printer may act like it wants to feed paper, but nothing moves. In some cases, the paper stays untouched in the lower tray. In other cases, the machine may attempt to print, pause, and then report a paper feed issue or paper-out condition.

One common cause is a problem with the pickup arm assembly. More specifically, the pickup feed gear, often shortened to PFG, may have broken or missing teeth. When this happens, the pickup rollers on the arm cannot rotate correctly, so the printer cannot grab paper from the cassette.

This guide explains how the cassette 2 pickup system works, how to inspect the pickup arm, how to identify a broken pickup feed gear, and how to replace the damaged gear. At BCH Technologies, we work with many Epson paper feed problems, and this type of mechanical failure is a good example of why careful inspection matters before replacing major parts.

We also have a video below to show how it's done, so you can follow the repair visually while using this article as a written reference.

Understanding the Cassette 2 Paper Feed Problem

Cassette 2 is the lower paper tray on many Epson printers. When the printer needs paper from that tray, it uses a pickup arm with rubber rollers to touch the top sheet of paper, rotate, and feed the sheet into the paper path. If any part of that movement fails, the printer cannot load paper.

A cassette 2 feeding problem may appear in several ways. The printer may say that paper is out even though the tray is full. It may make a short movement and then stop. It may try to print but never pull paper into the machine. Sometimes the rear feed or upper tray still works, which can make the issue seem more mysterious.

However, this symptom often points to the pickup system for the lower cassette. The pickup arm must drop down at the correct time, touch the paper, and rotate its rollers. If the pickup arm does not drop, the tray lever system may be stuck. If the arm drops but the black rollers do not turn, the pickup feed gears may be damaged.

Therefore, the first step is not to guess. Instead, you should observe the pickup arm while the printer attempts to feed paper.

Removing the Duplexer to Inspect the Pickup Arm

To inspect the pickup arm, first allow the printer to begin a print job that uses cassette 2. Then remove the duplexer from the back of the printer. The duplexer is the rear unit that helps with two-sided printing and paper path control. Once you remove it, you can see deeper into the rear area of the printer.

With the duplexer removed, look for the pickup arm. This arm holds two black pickup rollers. These rollers are responsible for contacting the paper and moving it forward from the cassette.

Next, watch the rollers while the printer tries to pick up paper. If the pickup system is healthy, the arm should lower and the two black rollers should rotate. If the rollers turn but the paper does not move, the rollers may be dirty, worn, glazed, or not making enough contact with the paper. However, if the rollers do not turn at all, the problem is more likely inside the pickup arm gear system.

In the situation shown in the video, the rollers do not rotate. That is an important clue. The printer is trying to feed paper, but the pickup rollers cannot turn because the gear drive inside the arm has failed.

Accessing the Pickup Arm from Under the Printer

After confirming that the pickup rollers are not turning, move underneath the printer to access the pickup arm assembly. Remove the paper tray first. If the white tray or guide is still installed, slide it all the way to the right and pull it out.

This area includes two important levers. One is a white lever, and the other is a black lever. These levers control how the pickup arm moves depending on which tray or guide is installed.

The black lever is usually easier to remove first. Hold the black lever and pull it straight out. Once you remove the black lever, you will have better access to the white lever and pickup arm.

Then turn the rod so the white lever moves to its highest point. This position gives the pickup arm enough clearance to flip out. After the white lever reaches the correct position, flip the pickup arm down or out so you can inspect it more closely.

At this stage, handle the assembly carefully. Many printer mechanisms use small plastic tabs, springs, and gears. Forcing the arm can break tabs or cause gears to fall out. Take your time and observe how each piece sits before removing anything.

Identifying a Broken Pickup Feed Gear

Once the pickup arm is exposed, inspect the gears. The pickup feed gear, or PFG, transfers motion from the printer's drive system to the pickup rollers. When the PFG has missing teeth, the gear can no longer transfer rotation consistently. As a result, the pickup rollers may stop turning completely or turn only part of the time.

A damaged PFG is usually easy to identify once you can see it. Look for teeth that are missing, worn flat, cracked, or uneven. In the video example, the PFG is missing several teeth. This prevents the pickup rollers from rotating when the printer tries to feed paper from cassette 2.

There are typically two large PFGs and two small PFGs on the pickup arm. You do not need to replace every gear on the arm. Instead, replace only the damaged gear. This saves time, reduces the chance of disturbing good parts, and keeps the repair focused.

Before ordering a replacement, make sure you identify whether the broken gear is a large PFG or a small PFG. The large and small gears are not interchangeable. If the damaged gear is one of the larger gears, you need the large replacement PFG. If it is one of the smaller gears, you need the small replacement PFG.

BCH Technologies offers replacement parts for many Epson repair situations, and choosing the correct size is important for a successful repair.

Removing the Pickup Arm Cover

After identifying the broken gear, remove the two screws on the side of the pickup arm. These are typically Phillips number two screws. Use a proper Phillips screwdriver so you do not strip the screw heads.

Once the screws are removed, slowly pull the pickup arm apart. Do not force the housing open. Inside the arm, several gears may be seated together. If you separate the parts too aggressively, gears can fall out or shift position, making reassembly harder.

As you open the arm, pay attention to how the gears are arranged. Taking a picture before removing the broken gear can help if you need a reference later. Even if the mechanism looks simple, a quick photo can save time during reassembly.

Remove the broken PFG and compare it with the replacement gear. Confirm that the size, shape, and tooth pattern match. If the replacement does not match, stop before installing it. Installing the wrong gear can cause binding, poor rotation, or additional damage.

Installing the Replacement PFG

To install the replacement pickup feed gear, place it onto the rod and press it down into position. The gear and rod are shaped so they fit together in a specific orientation. In the video, the wheel has a triangular style with two small arms. These correspond to two matching arms on the rod.

Because of this shape, the gear has a direction. You cannot simply place it in any position and expect it to work correctly. Set the gear onto the rod, rotate it gently, and feel how it fits. Once it lines up with the matching shape, press it down fully.

After placing the new gear, align the other side of the pickup arm and close the housing. Reinstall the two Phillips screws. Tighten them securely, but do not overtighten them. Plastic housings can crack if too much force is applied.

Next, rotate the gear system by hand a few times. This step is important. The gears should rotate smoothly without binding, skipping, or popping out of position. If the movement feels rough, open the arm again and check gear alignment before reinstalling the arm into the printer.

A smooth hand test gives you confidence that the replacement gear is seated correctly.

Reinstalling the Pickup Arm Correctly

The pickup arm has two small hand-like tabs. One tab is larger than the other. The smaller tab goes to the smooth side of the rod, while the larger tab goes to the rough side of the rod. This orientation matters because the arm must pivot and lock correctly.

Before reinstalling the arm, lift the white tab as high as possible. Then flip the pickup arm into position so the white tab fits into its slot. Once it lines up, press the arm down.

Next, reinstall the black lever. One side of the black lever has a tab that fits into a hole on the pickup arm. Insert that tab first, then press down firmly until the lever clicks into place. There are two tabs, so make sure both tabs lock securely.

If only one tab locks, the lever may sit crooked or fail to control the pickup arm correctly. That can cause the same feeding problem to continue even after replacing the gear. Therefore, always confirm that the black lever is fully seated.

After the arm and lever are installed, move the mechanism by hand where possible. The pickup arm should move smoothly between its lowered and retracted positions.

How the Cassette and CT Tray Levers Work

Understanding the lever system helps explain why the pickup arm behaves differently depending on which tray is installed.

When cassette number two is installed, the tray presses the white lever. The white lever releases the pickup arm, allowing the arm to lower and touch the paper. Once the arm touches the paper, the pickup rollers can rotate and feed the sheet into the printer.

However, when the CT tray is installed, there may not be paper in the same position for the pickup arm to grab. In that case, the CT tray presses the black lever. The black lever retracts the pickup arm so it does not stay lowered unnecessarily.

This lever system is simple but very important. If either lever is missing, stuck, misaligned, or not fully clicked into place, the pickup arm may not lower or retract correctly. That can cause paper feed errors even if the gears are good.

Therefore, after replacing the PFG, always check the lever action. Cassette 2 should release the arm so it can touch the paper. The CT tray should retract the arm. If the movement does not match that behavior, inspect the white and black levers again.

Testing the Repair After Reassembly

After replacing the broken PFG and reinstalling the pickup arm, reinstall the paper tray and duplexer. Load paper into cassette 2 and run a test print that specifically uses the lower cassette.

Listen to the printer as it starts feeding. The pickup arm should lower, the rollers should turn, and the paper should begin moving into the paper path. If the printer loads the paper normally, the repair is successful.

If the printer still does not pick up paper, remove the duplexer again and observe the pickup rollers. If the rollers now turn, but paper still does not feed, the rollers may need cleaning or replacement. Dust, paper coating, and ink mist can reduce roller grip over time. Clean the rollers with an appropriate rubber roller cleaner or a lightly dampened lint-free cloth, depending on your repair process.

If the rollers still do not turn, recheck the replacement gear installation. Make sure the gear is the correct size and that it is seated in the proper direction. Also inspect the surrounding gears for additional missing teeth. Sometimes one broken gear is obvious, but another damaged gear may be nearby.

If the pickup arm does not lower, inspect the white lever, black lever, cassette position, and tray engagement points. The tray must be fully inserted to activate the lever system.

Common Mistakes to Avoid During This Repair

One common mistake is replacing the wrong gear. Since the pickup arm contains both large and small PFGs, always compare the broken gear with the replacement before installation. A large gear must be replaced with a large gear, and a small gear must be replaced with a small gear.

Another mistake is forcing the pickup arm apart. The arm contains small gears that can shift or fall out. Open the housing slowly and keep the assembly flat when possible.

A third mistake is reinstalling the black lever without locking both tabs. The lever may look installed even when one tab is not fully seated. Press it down until it clicks and visually confirm that both tabs are locked.

Also, avoid testing the printer without fully reinstalling the tray system. The cassette and levers must interact correctly for the pickup arm to move as designed. A partially installed tray can create a false failure during testing.

Finally, do not assume every cassette 2 problem is a broken PFG. The PFG is a common failure point, but worn rollers, dirty rollers, damaged tray parts, misaligned levers, or paper path obstructions can create similar symptoms. Always inspect the movement first, then repair the part that actually failed.

Final Notes for a Reliable Cassette 2 Feed Repair

A printer that cannot load paper from cassette 2 often has a mechanical issue in the pickup system. When the pickup rollers do not turn, a broken pickup feed gear is one of the most likely causes. By removing the duplexer, watching the pickup arm, accessing the mechanism from underneath the printer, and inspecting the PFG teeth, you can identify the problem accurately.

Replacing only the damaged gear keeps the repair efficient. However, proper alignment matters. The replacement PFG must match the original gear size, fit the rod in the correct direction, and rotate smoothly before the arm goes back into the printer.

At BCH Technologies, we encourage careful troubleshooting before replacing expensive assemblies. A small gear failure can create a major paper feed symptom, but with the right inspection and repair approach, you can restore cassette 2 feeding without replacing the entire printer.

We have a video below to show how it's done, including how to remove the levers, expose the pickup arm, replace the broken PFG, and test the mechanism.