We had one of these at work and the optos were always mis aligned, causing all kinds of eerie behavior. My batman forever had a similar issue on the batwing cannon. Swipe a q-tip over the opto receiver and transmitter anywhere there is one. I think that is in the balltrough and one in each cannon. Thats a place to start if you have checked connections and fuses.

(opto is an optical switch that is activated by the beam being interrupted by the ball.)

Was my previous post invisible??

the problems you're having sound like the machine doesn't always know where the ball is. Clean and align those optos and I bet you'll see a difference.

you can put the machine in the "clear ball trough" mode in the menu and it will show you how many balls it thinks are there. then move them in and out of position and see if things act as they should.

So hard to diagnose from a distance. Good Luck. It's a great machine!

Check the alignment on that cannon opto. They can be sensitive. If it thinks the ball is there then the beam is interrupted.

Sounds like you are making good progress!

You can carefully unwrap and then re wrap. Before doing that, make sure its not just pulling the boards and warping the optos out of alignment. Make sure there in enough slack for things to move without tension.

All this is why i prefer mechanical switches