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I had the same thing happen on a 520i and the problem was the foam rubber on the inside of the main door wasn't thick enough to hold the duplex unit in. there was a bulliten... replaced the foam rubber problem went away.. go figure
UPDATE...I haven't solved this issue yet, but noticed yesterday that if I change paper output to tray A only this strange symptom doesn't occur...Keep in mind, this symptom occurs only once per day.. First copy in morning coming out of sleep mode..Rest of the day, no problem.
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