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dljorg
01-06-2016, 02:29 AM
Machine is a C6501 with RU-504 and FS-521 Finisher. If the RU and Finisher are removed the machine runs perfectly all day. With the RU and Finisher in place it will run 10 to 20 cycles and then the main body stops with the motors in the finisher still running and will stay there forever if you let it. Op Panel message stays at "Copying in Progress." When you open the finisher and RU doors the op panel changes to show either a J-3201 or J-7540. There is paper in the RU but it is undamaged, just stopped in transport. Does this with all paper sizes from all five drawers.

Both these jam types are about timing between the main body exit sensor PS13 and the RU entrance sensor PS1. Both sensors test good in IO check but have been replaced anyway. PS13 actuator replaced. Machine exit assembly with PS13 has been rebuilt, one way gears and all rollers. RU main board replaced. Main body printer control board replaced. Did not replace the exit assembly motor and AC drive board as it runs fine without the finisher attached.

There seems to be some magic here but I am out of ideas as to its source. Anyone seen something like this? Suggestions welcome.

dljorg
Connecticut USA

dljorg
01-07-2016, 02:30 AM
Update on what we tried today...
Replaced wiring between exit assembly and printer control board
Replaced exit assembly complete
Figuring paper may be slow thru machine replaced ADU clutches, registration roller and registration motor
Figuring some kind of electronic noise from HV supply replaced HV2 transfer supply
Careful observation of fuser motor and transmission shows normal fuser operation.

Machine symptoms unchanged in any way - still shuts down after 20 to 30 cycles with "Copying in Progress" on screen and FS521 motors running, undamaged sheet of paper in Relay Unit and a 7540 or 3201 jam code after the doors are opened. This happens with all paper trays and sizes and will do the same if you run copy face up or face down.

If you run single sheets or groups of 2 or 3 all is well and there are no jams or stoppages.

Puzzling for sure.

allan
01-07-2016, 05:36 AM
So you loose the current job if that happens?
Could be a firmware related issue?
So the issue is between the main body and the RU.
How many prints on the machine.

Worn down transport rollers could cause this. I have seen this on other models too the machine jams and the finisher just keeps on running.

dljorg
03-30-2016, 03:40 PM
Finally figured this out but it took a while. Replaced the entire fuser and the problem went away but that is really not the answer.

Fuser Exit sensor PS17 is mounted on a bracket that got bent but not very much. Careful comparison of problem fuser to a new one showed it was bent just a bit out toward the machine exit. The bent bracket altered the timing of the sensor just enough to create magic. Quick pry with a screwdriver and the thing has worked fine since.

Definitely strange.

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