Xerox Docutech Copy Transports and Fusing Problems

Copy transports and fusing problems seem to account for the bulk of the concerns I get from the field. While troubleshooting a fuser problem as a technician, it was sometimes very difficult for me to see what was happening inside the machine because of the speed of the paper or maybe covers and doors blocking the view. In some instances, it was almost impossible to actually see what was happening as the paper was going through transports and other devices even with doors open. When the fuser assembly is in place and the machine is in print, it is almost impossible to see its internal workings. Sure, you can see the fuser roller cam in as the paper tries to enter and exit the fuser module. The question that keeps nagging at us is what the heck is happening, or not happening, when the heat roller cams down?

The first clue should always be the fault code the machine generates, and that should be your starting point. All too often I have seen technicians jump right into the problem and ignore the system fault code. As a businessman you should consider the time factor in troubleshooting. One technician from eastern Long Island (NY) started off trying all the little tricks he knew because he was trying to avoid the service manual and had seen the exact same problem last month at The Copy Shop. The service manual will almost always bring you to a logical conclusion, but if it doesn’t, you have to rely on other technicians’ experience with similar problems or use your saved technical notes. Not many of us actually save our notes and we usually forget the problem in a week or two.

Thanks to the technicians that are out there in the field who have contributed tips and home remedies for common fuser problems in the Docutech and 5090 family of copiers. The most important tool at our disposal is the visual inspection of various components before jumping into the repair process. When I was first hired as a technical representative, I was assigned to work with another experienced technician and just observe what he did. So here I was, a fresh graduate from the Garden City training facility in Long Island and reduced to the status of an observer. What the original complaint was from the customer that generated the service call is not important, but what he did initially was far more important.

And that was to question the key operator to discover all the information about the problem they were having. No matter what the problem was, discarded copies were always examined and analyzed. Step two would be to duplicate the customer’s problem before opening his / her tool bag. Step three would be to visually check the module in question for any signs of unusual wear, broken components or any sign of something not being kosher in Denmark. If you are at a customer’s site that has two of the same machines in service, don’t pass up the opportunity to compare one module with the same module on the other machine.

Enter diagnostics and look at the HSFI screen for the module in question. Do you notice any red flags? Or do you notice any HSFI counters that are near the end of their service life? Needless to say, about 85 to 90% of the repairs I have done were resolved by replacing the HSFI components that were due (or overdue). The Docutech will tell you what to replace and when it should be replaced. For example, if you are not sure what a P10-101 is, open the service book and find out what the fault code is trying to tell you. P10-101 RAP indicates that a copy did not actuate the Prefuser Jam Sensor, Q1009 after the sheet passed the Registration Sensor. Hey, at least you know where to start troubleshooting rather than guessing.

If you have one, always use your service manual as your first tool in troubleshooting any Chain 10 (P-10-xxx) problem. If the book does not bring you to a logical conclusion, then use the crib sheets that I have collected from my personal experiences and the experiences of fellow technicians in the field.

PRESSURE ROLL FAILURES:

Copy Transports / Fusing

Problem: Split, cracked or separated laminate; delaminated or peeling; twisted, wavy, or bumpy appearance; any type of physical damage

Cause: Excessive pressure on contact arc, high fuser roll temperature, vacuum manifold gap (distance from the roller), worn stripper fingers

Solution: (1) Use dC701 and adjust the pressure roll contact arc to 15mm after four (4) fuser reps. (2) Check and adjust the fuser roller temperature to 395 degrees. Never go above 400 degrees. I have found that the ideal setting is 390 degrees on the engines that are 135 copies per minute or below. Check and adjust the vacuum manifold assembly and ensure it is seated squarely on the pressure roller assembly. Check and replace the stripper fingers if they are worn or twisted in some way. Do not try to fix the spring supports that the stripper fingers are attached to; it never works. Just replace them. There is a Blue Chalk Bag Tool to measure the contact arc— (P/N) 99P3211. Order one and use it.

AIR & MOISTURE FILTER(s):

Copy Transports / Fusing

PROBLEM: Replacing the processor air and moisture filter; 53K1710; the fittings might not match.

CAUSE: Processor might not have TAG P-175. The purpose of this kit is to replace the processor air filter assembly with quick disconnect fittings.

SOLUTION: Order processor kit (TAG- P-175) 600K22600. This kit comes with all fittings plus a new air & moisture filter to convert to the latest configuration. NOTE: If your processor already has TAG –175, order the moisture & filter only, 53K1710. To check for the TAG level, open the left processor door and check the white plastic card in the holder. If the TAG has been installed, it will be marked in some way or perhaps someone used a hole puncher to obliterate the actual number on the card.

P10-101 / 102 (or P03-2XX / 3XX):

Copy Transports / Fusing

PROBLEM: P10-101 / 102 or P03-2xx / 3xx

CAUSE: Open static ground in the fuser metering roll assembly, or very high resistance between the end bearings on the metering roller and the metering roller itself. Static electricity is not going to the machine ground.

SOLUTION: Check the resistance with your handy dandy OHM meter. If you have high resistance, replace the metering roller and make sure the ground wire is intact and properly grounded. When checking the resistance on a new metering roller, the resistance should be below 10 Ohms and should be measured between the end bearing assembly and the body of the metering roller assembly. Replace the ground wire with 117K11010. In a pinch, use a 18 gauge naked wire, making sure it is in solid contact with the metering roller assembly bearing and ground on the fuser metering assembly. (Some technicians refer to the metering assembly as the RAM assembly).

P10-102 WITH 9 INCH (wide) PAPER:

Copy Transports / Fusing

PROBLEM: P10-102 jams when using 9” wide paper during duplexing.

CAUSE: The software thinks it is 8 ½ inch wide paper and the duplex feed is actually early because the paper is ½ inch wider. There is a timing problem with the PWB 140K2739. Check for the new EPROM #537E26030 in location U-11.

SOLUTION: Replace Registration Servo PWB EPROM KIT 600K32780 and install PWB 140K7401, or Kit # 600K24741. EPROM and all instructions are available in the kit 600K32780.

NOTE: Kit Number 600K24741 will have the Registration Servo PWB 140K45640 W/TAG P-184 and TAG P-221.

P10-102:

Copy Transports / Fusing

PROBLEM: P10-102

CAUSE: The air filter inside the bowl of the MIN moisture trap / air filter assembly becomes clogged with foreign material that will cause a blockage of air to the stripper air assembly. (MIN moisture trap PL3-E7 part number 53K1910)

SOLUTION: Check for a clogged internal air filter by disconnecting the air line connection to the fuser air stripper solenoid (PL3-D11 part number 121K5500). In diagnostic mode, actuate the MIN compressor assembly and look at the air gauge. If the air pressure is above 8 PSI, replace the internal air filter element or the entire MIN moisture trap / air filter assembly. Replace the internal air filters with kit 600K31070. If the customer needs the machine and you can’t wait for the new part, go to a local auto supply store and purchase a small bottle of carburetor cleaning fluid. Use a glass bowl and soak the filter in the carburetor solution, and it will clean the filter. Use compressed air (if available) and dry out the filter, re-install the filter and return the copier to service.

NOTE: Do not use kit 600K31070 in the finisher air system because it is a different air filter. Never run the copier without the moisture air filter unless you want moisture to get into everything and cause even more aggravation.

P10-102:

Copy Transports / Fusing

PROBLEM: P10-102

CAUSE: Problem only occurs when the top output tray is selected and the MIN air pressure reads 5 PSI. However when the finisher is selected, MIN pressure appears to be normal, 19 to 22 PSI. Incorrect air line and/or check valve at wrong location. Check TAG F- 80 (round accumulator tank).

SOLUTION: Use the service manual and consult RAP P12-758 and P12-757 for the correct air line configuration.

NOTE: With TAG 80, make sure the check valve is not missing or cheated in some way. The finisher check valve is attached to the “T” fitting that goes from the moisture filter to the solenoid and the compressor assembly. It is easier to replace the “T” fitting than to attempt replacing the check valve. Order part 118K822 and call it a day. The check valve is a cute little device that should always be replaced and never fixed when it malfunctions. Some clever techs have tried crazy glue, duct tape, ty-wraps, you name it to repair or just temporarily fix these check valves. It never works and the device must be replaced unless you are a glutton for punishment and want to clear jam after jam.

Next month we will explore additional helpful hints in the Copy Transport and Fusing chain in the Xerox Docutech and 5090 families of copiers. Meanwhile if you have any concerns, e-mail me and I will assist where I can. I can be reached at VillageCopierNY@AOL.COM . I encourage all technicians and self maintainers to contribute any information that they feel will assist fellow techs and self maintainers in the field and I will gladly pass the information along.