5000 SP Web premature yield for cleaning web

[stephend]

This is a remake of a previous thread with updated information.
This specific unit shows in SP 1902-01 28% consumed web but physically is 100% depleted. Followed all TSB including TSB 010. Actually after all this was worst. Initially 1902-01 was 36% when my web was physically 100% depleted. After upgrading the firmware to he latest version Engine v1.05:0, Printer v1.10, System v1.10 the best "score" in 1902-01 is 28%.
Printed SMC reports before and after the firmware update...and surprise. The new firmware modifies the values for 1902-009, 1902-010 and 1902-011 to 0...and still no improvement.
Did you experienced something similar with my situation??

Forgot to mention but this machine is used over the rated monthly volume so it's entitled to behave weird.

[imaginemoko]

Sir i suggest to print the smc back up nvram data... engine clear then load again the firmware stated on the tsb... maybe it could help..

[dckm]

Is the one wire that goes to the web motor pinched? If it is, the motor runs constantly. Just a thought.

[stephend]

Thx for your answers. Both make sense.
If the wire is pinched the motor will run continuously...and it's from the factory because nobody opened the back cover. The problem is that this issue started at 70K when because of the light image I replaced the dev and the "TD init failed" msg showed up. To solve this problem I upgraded the firmware and this problem started. Another big issue is the customer...they won't accept any downtime...All the repairs must be done in a max 30 min timeframe...and no chance for a loaner. Yup it's fun to work for the manufacturer . We spoil our customers with fast response time and min downtime.
I will wait couple of weeks to see what this new firmware does.