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Thanks Guys. Increased Heap Stack and it resolved my 991 &bunch of HDD errors. (Note-HDD was replaced a day ago for not being able to recover)

Service mode- Peripheral - Extras - Increase Staple and Fold capacity by 30 if I remember. Used it for a slightly larger job with a higher gsm with 0 issues.

What happens when you do a input output test on effected parts?