20-21 PC-416 intermittent

[4Toon]

We have several relatively new MFPs, with print counts ranging from 40,000 to 200,000 over the past four months, experiencing intermittent 20-21 misfeed errors originating from the PC-416 paper feed unit (affecting both 0i and newer 1i models). The only consistent solution so far has been to orient the paper with the curl facing downward. The issue occurs sporadically, and the paper fails to exit the feed section. We’ve confirmed the lift plate is level and replaced the feed tires, one-way clutches, and torque limiter, yet the problem persists, with curl-down orientation being the only effective fix or mitigation.

Could the mylar in Tray 3 be the issue? When the paper curl faces upward, might the mylar be pushing the stack too high, causing the paper to collide with the feed roller? Has anyone else encountered this and found a solution? Should I try adjusting the mylar downward by 1–2 mm to test this theory?

[copyman]

We have several relatively new MFPs, with print counts ranging from 40,000 to 200,000 over the past four months, experiencing intermittent 20-21 misfeed errors originating from the PC-416 paper feed unit (affecting both 0i and newer 1i models). The only consistent solution so far has been to orient the paper with the curl facing downward. The issue occurs sporadically, and the paper fails to exit the feed section. We’ve confirmed the lift plate is level and replaced the feed tires, one-way clutches, and torque limiter, yet the problem persists, with curl-down orientation being the only effective fix or mitigation.

Could the mylar in Tray 3 be the issue? When the paper curl faces upward, might the mylar be pushing the stack too high, causing the paper to collide with the feed roller? Has anyone else encountered this and found a solution? Should I try adjusting the mylar downward by 1–2 mm to test this theory?

I remember a bulletin for the 8 series addressing a mylar. Will try and find it. Maybe it will help with the "i" series. Also if the stack of paper slams down when drawer is open the rear lift cable can jump off pulley causing paper skew and jamming. There is a small part called "damper" that makes the elevator tray drop slowly. Probably not your issue but something to keep in mind.

[and]

If you have old cluch try

AAV5R71400

Clutch ASSY

work for me.

Purpose of Change and Where Changed

In order to improve the performance of kick spring clutch, the following changes have been implemented. - The single item supply of "Gear", "Spring", "Guide" and "Washer" have been discontinued, "Clutch ASSY", which is an assembly of "Gear", "Spring" and "Guide", has been added. [Figure 1]

[4Toon]

This jam changed to a 30-03 jam. It seems related to a warped registration unit, dirty clutches, and, in one recent case, a severely bound-up registration unit in a C450i that wouldn’t move. These MFPs are less than two years old, with approximately 500,000 prints, depending on their location in the school.

Has anyone else encountered this issue? If so, is the only solution to order a new registration unit for the warped plastic? This problem is occurring at one school where all MFPs were ordered simultaneously, so I’m wondering if the registration units might be from a defective batch.

We replaced the clutch and adjusted the registration unit to match the spacing between the plastic and the transfer belt found in a functioning unit. Additionally, the worst-affected MFP had burrs forming on the plastic housing around the registration unit, and you could see paper nicking those burrs on the edges. We replaced the plastic guard, and for a few days, no issues have been reported.

[SAR]

KM put a bulletin out claiming the warped registration units are caused by a wiring harness binding in the reg unit. I have tried loosening up the harness like they recommend, with no luck.
I think they don't want to admit their reg units are defective, so they come up with this lame excuse. I put a post on here a few years ago about some warped registration units we got. I'll see if I can find it and post it and the bulletin about the wiring harness.

[SAR]

Here's the bulletin:
Harness Binding.pdf

[4Toon]

Here's the bulletin:
[ATTACH]n1613308[/ATTACH]

Yeah, I saw that bulletin too and looked at the reg unit and thought the same thing as you, that it was BS.