KM-4050 Jam after pickup from tray 2 with code J018

[kathyde]

First trip out I found that the Feed Guide B was broken. I ordered and replaced. Seemed to resolve the issue. Then got a call that the unit was having a problem again. Replaced the fuser (damaged) and then removed a paper jam in the registration area (appeared someone tore paper there). Then, during testing, started jamming again right after it picks up from tray 2. It gets to the rollers on the lower right door (right after pickup) and then crimps the paper and throws a jam code. i swapped cassette, pickup assembly, rollers on door and springs to hold door closed. When I say swapped springs and rollers, front to rear on springs and top with bottom on rollers so I could see if it made a difference. Nope. I then went into service and tested clutches, motors and solenoids. Slight difference in sound on one motor test for feed 2, but that was about it. I've seen some references to conveyance switches being an issue, but only for EU.

So, the door appears to be a little off kilter (if I really split hairs) but when I hold it in place, it still jams. The motor really doesn't seem to be an issue - one time a little noisy. I'm thinking the switches. Any help would be appreciated. Starting to go a little crazy on this one...or is it just because it's winter?

[blackcat4866]

I've got a record for you:

Misfeeds (Jam J18) from trays #1, #2, and #3. Misfeeds (Jam J14) from MPT. Jams every time from all sources. Harness wire broken to pre-registration clutch FCL1. It's hard to explain the occurrence at 507K prints & six years service. Repair/solder broken wire in harness inside the middle feed unit.

=^..^=

[copydocinc]

I would double check to see if one of the paper path sensor actuator arms is now broken off(with all this jamming and removing jams, it's easy to brake them and not notice that they are now missing)
If not, you will probably have a fun time removing the vertical feed assy to get to the clutches and gears that are on the back side of the vertical feed assy and in front of the rear frame of the machine.
but they are attached to the vertical feed assy. A lot of stuff to take off of the machine to get it out. (front left covers, both left side doors, rear cover, drive motors, big metal bar that holds the 2 left doors, the little left side door too)
Hope its just a broken actuator.

[kathyde]

I've got a record for you:

Misfeeds (Jam J18) from trays #1, #2, and #3. Misfeeds (Jam J14) from MPT. Jams every time from all sources. Harness wire broken to pre-registration clutch FCL1. It's hard to explain the occurrence at 507K prints & six years service. Repair/solder broken wire in harness inside the middle feed unit.

=^..^=

The strange thing is that it doesn't jam every time and it doesn't jam at all if I use tray 3, which right now is set to legal size. It's only with tray 2. Sometimes I can clear the paper, close the door, replace the finisher and it will pickup/feed/etc. just fine for 2-3 copies before it throws a jam.

[kathyde]

I would double check to see if one of the paper path sensor actuator arms is now broken off(with all this jamming and removing jams, it's easy to brake them and not notice that they are now missing)
If not, you will probably have a fun time removing the vertical feed assy to get to the clutches and gears that are on the back side of the vertical feed assy and in front of the rear frame of the machine.
but they are attached to the vertical feed assy. A lot of stuff to take off of the machine to get it out. (front left covers, both left side doors, rear cover, drive motors, big metal bar that holds the 2 left doors, the little left side door too)
Hope its just a broken actuator.

No luck there - those were one of the first things I checked. I also tested the conveyance switches. The only hint of something was a very slight delay on releasing the #2 switch.

[Tonerkiller]

Replace the vert. transport clutches. I have delt with this issue before and found this to be the solution.

[Reed]

I had a similar problem on an old KM 3035. It ended up being those black mylar pieces on the inner door were messed up causing jams out of tray 2. Other than that I would go with the vertical transport clutches.. and good luck with that

[genesistech]

I had a similar issue that resulted in great disappointment. After spending hours replacing clutches and sensors, found that putting my knee on the side door for the paper feed assembly applied enough pressure for the machine to stop jamming. I'm not saying it's a fix, but it's definitely worth checking before spending countless hours with replacing parts that are difficult to get to. (And our fix was adding a shim underneath the springs so that it applied the pressure without us holding it.)

[kathyde]

Replace the vert. transport clutches. I have delt with this issue before and found this to be the solution.

Thanks! Since I have never swapped these before and you said "clutches" - should I replace just the clutch associated with tray 2 or all? Another response said good luck...are these difficult to get to? How long would you say it would take - on average - to replace them?

[copydocinc]

Thanks! Since I have never swapped these before and you said "clutches" - should I replace just the clutch associated with tray 2 or all? Another response said good luck...are these difficult to get to? How long would you say it would take - on average - to replace them?

I gave you the readers digest version of getting to the vertical clutches by removing the vertical feed assy, in my previous reply.
If you've never done it before, plan on a couple of hours at least.
BUT
Since you said it never jams out of drawer 3, the vertical clutches might be ok and you just need to focus on drawer 2 clutch or feed assy, which is not the same area.