Color LaserJet 5500n Jamming -- Errors 13.09.00 and 13.0A.00

[ethanlloydb]

I recently was given a Color LaserJet 5500n. It had an issue with the Magenta Laser Scanner (which gave error 51.2M). I replaced the laser scanner and the error went away. I thought all was well, however when I tried printing a test page from the printer menu, the paper would accordion jam and make it part way through the fuser. It also had the "output bin full" message when it started printing, which went away when I moved the output bin flap up and down a few times. This came back again and again, however it doesn't come back everytime I try to print something.

I suspected the issue now was the fuser, so I replaced the fuser with a known working one I purchased online. Replacing the fuser did nothing. The paper still jams in the same spot, however sometimes the paper jams in the form of either an accordion, or it just gets stuck in the middle of the fuser. There are two errors that show up after the paper gets stuck -- either 13.09.00 (top cover area jam) or 13.0A.00 (also top cover area jam). After doing more research, I was led to believe that it could be the output bin sensor, which lets the printer know whether the output bin is full or not. I went into the sensor diagnostics menu and found that the sensor seemed to be okay -- it would the value of the sensor would change when I lifted and dropped the output bin flap. 

The only other thing I can think of now is the transfer kit. The last two photos I added show that the transfer kit has a rod that seems to be loose on the right side -- I can lift and drop it and it doesn't seem to currently be attached to anything. I was thinking it could now possibly be the transfer kit, however I can't tell.

Below are also some photos of the error message as well as a photo of the fuser (placed upside down so you can see where the paper is jammed).

I read some forum posts online about it having to do something with the page bleed or narrow margins on prints, however I am using the printer's built in test prints. I have tried the demo page, menu map page, etc. but they all jam. I am using standard 8.5x11 copier paper and have double checked the tray settings to match. I also checked print toner density, as well as updated the firmware to the last available version for this printer.

Could it still be the output bin sensor that would be having an issue while it is printing causing it to jam? Or could it be the transfer kit or something else? The printer currently has a page count of only ~53,000, with a transfer kit life of ~70%, and original HP toners (black is about 95%, and CMY all have ~30%). The magenta toner does leak some toner powder, but I really doubt that would cause this jamming issue.

Any help I can get is appreciated. Thanks.

[Repairatrooper]

Cannot see from the picture but one suggestion based on the service manual is make sure that the green levers on top of the fuser are in the correct position or there will not be proper tension on paper. Current troubleshooting documents state that if a new fuser does not solve the problem and the exit sensor and fuser sensor test ok then the DC controller is likely failing.

[ethanlloydb]

Thanks for your reply.

Here are better photos of the Transfer Kit assembly area:

Transfer KitPart of transfer kit that moves freely (rod can be moved up and down, is not mounted in place in any way)

As you can see circled in red, the right side end of the rod on the transfer kit can be moved freely. It is not mounted in any way. From the original post, I am able to pick up this end of the rod and lift it up/move it freely. The left side of the same rod (seen in the first photo) is gear driven. Nothing in that area seems broken/missing, however, which leads me to believe that the transfer kit is just like that. I have not ruled it out yet, though, which is why I may consider replacing it if the DC controller/output sensor turns out to not be the problem.

As for the paper tension with the fuser, I have ensured that both turquoise levers are engaged in the proper position on both fusers. The paper jams with either fuser (one that came with the printer and the replacement unit), sometimes like an accordion and in the middle of the fuser and other times not crumpled and just stuck in the middle of the fuser. 

As for the output bin full sensor, would you think it would be worth a shot replacing it before the DC Controller? I used to get the "output bin full" message when starting up the printer, however recently that has seemed to gone away. I do feel that it may more likely be the DC Controller that is at fault since the printer seems to almost be too quiet when printing, however both the output bin full sensor and DC Controller seem like possible culprits at this point. If the output bin full sensor was to somehow engage during printing, would it cause the print to stop and jam?

How common is it for the DC Controller to fail on a printer like this? The page count seems relatively low for a printer built like this but it is also quite old now, which may explain how the electronics like the DC controller board could be on the way out. The previous owner had this printer in storage for quite a while (about 5-7 years) and originally used it to print inserts for his business but I don't know the environment the printer was stored in during the time it was not in service.