FS-4200DN strange jams

[Kyo fan]

This is a new one to me, and so far i haven't heard of anyone with the same issue.

Had two of these today with the same problem. Paper randomly stops and tears a bit just when it's about to be pulled from cassette. The printer only shows "Paper jam cassette 1" and event log is showing J0501 (the last 16 occurrences). There is nothing broken, bent on deformed in any way on the paper cassette, and the 3 pulleys aren't worn out yet (both printers have about 100k on them). First i tried with pulley and paper dust cleaning, adjusting cassette margins, checking paper settings, upgrading firmware etc. After all that i ended up replacing the retard roller with brand new one, and after that replaced entire paper cassette.
Unfortunately none of those mentioned helped, still it randomly starts to jam and paper stops like every 4-5 pages.

I provides pics so you can see how it looks. Thx for any input.

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[HenryT2]

What kind of paper are they using ?
Is the pan in the cassette lifting correctly ?
Is the Paper Empty actuator seated properly and functioning correctly ?

This could happen if the rear cursor is not set correctly, but, you did say you
checked this, and even changed cassettes .

[blackcat4866]

The situation you describe is usually by a flat spot on the separation roller. At 100k I'd replace rollers for a jamming problem. =^..^=

[Kyo fan]

I replaced 3 rollers and so far so good. Why do i have a feeling that somehow pulleys aren't what they used to be on older machines, they used to last much longer.

[leroyal]

I replaced 3 rollers and so far so good. Why do i have a feeling that somehow pulleys aren't what they used to be on older machines, they used to last much longer.

I had this problem today....the very tip of the fuser exit switch was broken off, paper was riding over the top of it. Super glued a piece of plastic to the actuator and all was good.

[blackcat4866]

I replaced 3 rollers and so far so good. Why do i have a feeling that somehow pulleys aren't what they used to be on older machines, they used to last much longer.

I don't know how far you go back Kyo fan, but back in the analog days PF rollers were 35mm or more in diameter. Gradually they've gotten smaller and smaller. Some of the Ricoh rollers are less than 16mm, which is too small to be useful, in my humble opinion. I'm sure that the roller materials have improved over the years, but for longevity I'd like to see some larger feed rollers. There's more surface contact with the paper. =^..^=

[Kyo fan]

One was fixed with pulleys, but this second one has something else. The first paper stops just when it exits fuser unit, as you can see in pics. The second one is pulled like half below, and second half is hanging in the cassette. Event log says J0501 (The registration sensor 2 (RS2) does not turn on during paper feed from cassette 1). leroyal mentioned sensor actuators, but in my case the are all fine. I'm thinking this might be paper quality issues couse this client uses some of the lowest quality paper i have ever seen. You don't fully realize how rock solid FS-3920/4020DN (have many that reached 1 mil with just 1 maintenance kit) were until you start messing with these.

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@blackcat Yep, it's like with cars these days.

[DWise]

One was fixed with pulleys, but this second one has something else. The first paper stops just when it exits fuser unit, as you can see in pics. The second one is pulled like half below, and second half is hanging in the cassette. Event log says J0501 (The registration sensor 2 (RS2) does not turn on during paper feed from cassette 1). leroyal mentioned sensor actuators, but in my case the are all fine. I'm thinking this might be paper quality issues couse this client uses some of the lowest quality paper i have ever seen. You don't fully realize how rock solid FS-3920/4020DN (have many that reached 1 mil with just 1 maintenance kit) were until you start messing with these.

3.jpg4.jpg

@blackcat Yep, it's like with cars these days.

Could this be something as simple as incorrect paper size selected? Are the prints delayed any on the page (registration)?

[Kyo fan]

It was something simple indeed that i couldn't see right away. If you get something like this, pay attention if client likes to fix things on his own and not tell you about it. The spring under the paper feed assy was missing...

spring.jpg

[blackcat4866]

Good catch. Kyo fan!

Thanks for sharing. =^..^=