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  1. #1
    Master Of The Obvious 10,000+ Posts
    Zeus is kicking my ass again.

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    Zeus is kicking my ass again.

    It's a KM-8000i that started out with J4913 jams. When it first started it would jam once or twice, then print several thousand. I seems to be getting worser and worser. It will no longer pass any paper.

    Early on (3.5M prints), I had changed the conveying rollers, paper feed flags & springs, and decurl roller. Today I changed all the photointerrupters in the bridge. When I arrived there was a J4914 jam that would not clear. After changing the sensors I got C1410 and J0132 jams (de-curl rotation error). If I go into U031, BRSW2 will randomly appear blocked or unblocked. Just to be sure, I installed 3 more photointerrupters with the same result.

    So I've got all three sensors in the bridge randomly changing state. It's possible, of course, that the engine board is bad but I'm leaning towards the bridge controller as the culprit. It's the randomness that bothers me. Has anyone seen something like this?

    Zeus.jpg

    =^..^=
    Last edited by blackcat4866; 12-04-2015 at 01:21 AM.
    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 =^..^=

  2. #2
    Senior Tech 100+ Posts
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    Re: Zeus is kicking my ass again.

    All of our high volume 8000i's have already been replaced and none of them exceeded 4M. I haven't seen issues as systemic as you've described but I have witnessed some inexplicable bridge sensor behavior.

    In one case with a persistent blocked sensor I disassembled the bridge, found nothing, and the problem seemed to disappear. No recurrence though and it's unlikely that it was caused by either PWB. In your case though, your hunch (BRMPWB) seems the next best step!

  3. #3
    Senior Tech 250+ Posts
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    Re: Zeus is kicking my ass again.

    We don't have any of those over 2 mil yet, so the headaches are bearable. Looking at those C1410 and J0132 jams you have, there's a bulletin on it, where you replace actuator + stopper as set:

    stopper.jpg

    PARTS ACTUATOR PRESS SET SP (302LF94520)

  4. #4
    Master Of The Obvious 10,000+ Posts
    Zeus is kicking my ass again.

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    Re: Zeus is kicking my ass again.

    Quote Originally Posted by Kyo fan View Post
    We don't have any of those over 2 mil yet, so the headaches are bearable. Looking at those C1410 and J0132 jams you have, there's a bulletin on it, where you replace actuator + stopper as set:

    stopper.jpg

    PARTS ACTUATOR PRESS SET SP (302LF94520)
    Thanks for the information Kyo fan, but I'm not that worried about that actuator coming off. Sure it currently does not have a clip, but it's behind the copier's exit section frame, and it would take dynamite to blast it past the exit section. It can't really escape. I've had that drive unit out four times Thursday, so I am intimately familiar with it.

    I'm really getting irritated with this machine. Still waiting on the bridge unit controller PWB. =^..^=
    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 =^..^=

  5. #5
    Not a service manager 2,500+ Posts Iowatech's Avatar
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    Re: Zeus is kicking my ass again.

    Does the bridge unit has interlocks on it? There were a few on Ricohs that the actuators for those interlocks were not quite long enough, they caused random jams until I built them up with double sided tape.
    Sorry if that was a waste of time.

  6. #6
    Master Of The Obvious 10,000+ Posts
    Zeus is kicking my ass again.

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    Re: Zeus is kicking my ass again.

    Quote Originally Posted by Iowatech View Post
    Does the bridge unit has interlocks on it? There were a few on Ricohs that the actuators for those interlocks were not quite long enough, they caused random jams until I built them up with double sided tape.
    Sorry if that was a waste of time.
    I did give it some thought, but it's not a particularly easy theory to test out. I think I have a picture:

    Zeus J4913-1.JPG

    Do you see the ground spring on the front of the drive unit? About 39mm to the right of that you can see the plunger of the bridge interlock switch. It does change state from infinite to 0 ohms. This particular switch does not appear in the U031 sensor diagnostics. It is directly behind the bridge unit, so you cannot see it at all with the bridge closed. Additionally, the only place you could pin out the switch is on the bridge unit controller, trapped between the back wall of the copier and the back of the bridge unit, completely inaccessible. I can be fairly certain that the interlock is being made though. When the MFP is in one of it's moods, BRSW2 shows blocked any time the bridge unit is inserted (and the interlock made).

    Zeus J4913-3.JPG

    I think I've got that one covered. Thanks for the ideas. =^..^=
    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 =^..^=

  7. #7
    Master Of The Obvious 10,000+ Posts
    Zeus is kicking my ass again.

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    Re: Zeus is kicking my ass again.

    The bridge unit controller + (3) new photointerrupters seems to have done the trick. It ran 1000 duplex without a hitch. I'm going to cross my fingers and wait. =^..^=
    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 =^..^=

  8. #8
    Master Of The Obvious 10,000+ Posts
    Zeus is kicking my ass again.

    blackcat4866's Avatar
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    Re: Zeus is kicking my ass again.

    Back again today. It was better though. (6) jams in 24 hours. I thought since I had pretty much exhausted the bridge unit investigation, maybe I'd look at the exit assembly. Here is the exit sensor flag:

    J4913-1.JPGJ4913-2.JPG

    With the right door off, I could see that the exit sensor just barely moves because the flag is so worn. I don't have a new flag to install, but a fairly simple MacGuyver seems to help. The original flag is sandwiched between two layers of plastic, glued, trimmed, shaped, and smoothed. A little additional trimming was required to get the return spring installed.

    J4913-3.JPGJ4913-4.JPG

    I printed a couple thousand without a jam ... just like the earlier visits. Time will tell if it makes any difference =^..^=
    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 =^..^=

  9. #9
    Senior Tech. 2,500+ Posts NeoMatrix's Avatar
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    Re: Zeus is kicking my ass again.

    The MacGuyer flag repair looks like a winner. You could be onto the problem.
    Is the exit ass'y warped or out of plumb ? Check it on a flat surface or platen glass.
    What if we could count the stars... , what number would you stop at...?"
    [Exchange manual acquisitions, PM's CTN members only. ]
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  10. #10
    Master Of The Obvious 10,000+ Posts
    Zeus is kicking my ass again.

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    Re: Zeus is kicking my ass again.

    Quote Originally Posted by NeoMatrix View Post
    The MacGuyer flag repair looks like a winner. You could be onto the problem.
    Is the exit ass'y warped or out of plumb ? Check it on a flat surface or platen glass.
    It looked surprisingly good. I've seem plenty of Sharp and Kyocera delivery units that warp and crumble from the unrelenting exposure to fuser heat. =^..^=
    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 =^..^=

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