Re: FS-534 alignment plate wearing. I also had this problem on a C754e/FS534 after 50k copies and machine was only 4 months old. I replaced the alignment plates to fix it but, 4 months and 50k copies later it was doing it again. It cuts those grooves because the way the paper lines up perfectly with those plates. So I adjusted the mechanical centering on each paper tray (including the external LCT) so the paper is closer to rear of machine until problem goes away then adjust centering in ser mode to realign image on paper. Most trays only needed 2mm but some needed 5. That was 9 months ago and I haven't heard back. I didn't need to replace the plates again.
The reason the plates shift to the front is because it's offset sorting. As 1 set is being shifted to the front, the first sheet of the next set is coming out and should be going over the top of the rear plate until it returns to the rear. One set shifts to the front, the next set doesn't get shifted. If you are only making 1 set, there is no shift. I don't think multiple copies of 1 sheet get shifted either.
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