iR5570 jam code 0102

[angelntx]

Morning. I'm assisting a fellow tech with a strange issue on an iR5570. The problem he is having is a jam code of 0102, delay jam at pre registration(PS28). He has replaced the Duplex verticle feed assembly, pre registration motor, ps 24 & 28 and the DC Controller. We even added an extra wrap to the springs on the sensor flags. In service mode under parts check>motor he can watch the motor turn and in I/O mode you can see that the sensors are working. In copying mode it is a different story. The bypass tray is the only source of feeding paper at the moment. Any other drawer will jam even with using different sizes of paper. We thought that the side door was warped and tried applying pressure to the door as it copied-no change in the out come.
Any other suggestions that we may have missed?

angentx

[charm5496]

Check this out:

When jam code 0102 is occurring intermittently, inspect PS24, the Vertical Path #1 sensor and PS28, the Laser Write Start sensor.

Make sure both sensors are clean - check for stray toner or paper dust contaminating the sensors.

Inspect the operation of both sensor flags. Make sure the flags are not sticking or hanging up. Try putting an extra wrap on the sensor flag springs.

Check for wear and tear on the sensor flags. If the sensor flags have paper cuts on them or the point of the flag is worn down, replace the sensor flags. Part number for PS24 sensor flag is FF5-9842-000. Part number for PS28 sensor flag is FF5-3002-030.

Inspect wiring for PS24 and PS28. Try removing tie wraps from the wiring.

[costd]

Other than what you have tried, e-support has:

Check the condition of the Vertical Path Swing Guides. If the fins on the guides are nicked or even if the fins are worn down too much, (usually on high copy count machines) may result in improper pressure from the right side door. This may lead to the 0102 jam.

[Canuck]

I have seen paper cuts on the right door guides cause jams on these machines.

[victor_v]

I faced such problem when the WORN OUT rollers badly moved a paper. As a result the sheet was late during giving.

[c0846]

1 side copy or 2 side copy ?
duplex unit roller

[angelntx]

Update:
I asked the tech to get the sensor flags and wire harness. The wire harness for PS24 and 28 looked suspect. We went to the account last week and all is goiong well.
Thank You for the help everyone and Happy Holidays.

angel