Persistent Fuser Jams and Fuser Wraps

Xerox Docutech and 135 Families

                                    By Ramond Cote

One of the most upsetting challenges is to be troubleshooting a machine jamming problem and not exactly fixing the root cause. Case in point: The customer’s complaint is Fuser Wraps and in your initial examination you duplicate the problem and in your mind you tell yourself this is a piece of cake. I’ll have it fixed in no time. 

I have been repairing this family of duplicators since their introduction in 1984 and I am still learning things about the copier all the time. Sometimes you think you know and then you learn there are things that you never ran into in the field until you became an independent service agent. In all actuality what we are seeing is problems we never saw because the copiers were never that old. One thing I have to say about the manufacturer was they were always ready, willing and able to up-grade your customer’s equipment and sales was always trying to sell the newest model to your customer. It was great for the economy and for the manufacturer because of the added income it generated. As an independent service provider most of the equipment that I service has been in the field for quite some time and as the fleet ages we start to see problems that we would never have seen while working for the manufacturer.

Generally, when you start having problems in the fuser area, check the HFSI’s and replace the components that are highlighted in the fuser HSFI screen. More times than often that’s all you have to do to fix Fuser jams. However, when you start getting recalls for fuser jams (or Fuser Wraps), that’s when the fun starts.

One thing I have learned over the years is never second guess what was done by the previous tech. All too often I have heard stories from techs telling me that the last tech replaced the components on a previous call. Sometimes, I’ll have to admit, it’s difficult to tell if the device is new or used. And that seems to be true for the Metering Roller (22K9161). If you look at the Metering Roller assembly it’s difficult to tell if the roller is new or used. Unless you have a magnifying glass in your tool bag you might not be able to tell.  In the field many techs have looked at the Metering Roller and re-set the HFSI counter because it looked ok.  If you were able to closely examine a Metering Roller, you would see there is a slight texture on the roller that carries the fuser agent up to the Donor Roller (22K27670). When the Metering Roller gets smooth (about 2 million copies) it will loose its ability to carry the fuser agent to where it’s supposed to go. The Donor Roller gets dry and then the Fuser Heat roller (22K53280) does not get coated with a thin layer of fuser agent. With a dry Fuser Roller the results will be fuser jams or fuser wraps. It’s always best not to go with looks alone. If it looks ok, but you have that sinking feeling that it’s old then replace it.

Fuser Jams First Call

A fuser trim will usually resolve most fuser related paper jams. Start off by removing the Metering assembly (PL3-D10, part number 48K27290). It’s interesting to note that some of the old timers called this assembly the RAM assembly (RAM = Release Agent Module), two names for the same item. Find a suitable flat work area and clean the metering assembly with a few soft absorbent rags. After the Metering assembly is clean, replace the following components: Metering Blade (33E1110), Fuser Wick (94K680 make sure this wick is fully saturated with fuser agent when you install it). Replace the Fuser agent filter assembly (600K20330), Donor Roller (22K27670) and Metering Roller (22K9161).

The Metering assembly should have a thin coating of fuser agent on the bottom of the tray.  If you were to measure the depth of the fuser agent in the tray, it should be about 1/16 deep.  When completed, install the Metering assembly in the processor and let the system warm up to Ready. Reset all HFSI’s that were changed, this way you will know how many copies the components have on them the next time you do a service call in the fuser area. I always make a notation in the service log as well. Sometimes it’s hard to tell when an item was replaced but when you write it down in the log, it is proof positive that it was done. Test the copier out and if it’s running smoothly, return the copier to service.

Fuser Jams Second Call

If there is a recall or the above does not resolve the problem, the next step would be to closely examine the following components: Fuser Idler Gear (7K120) and the Fuser Drive Gear (7K1700). Take notice if the gears are feathered (sharp points). If that’s the case then there will be slop in the Idler gear and fuser jams will occur. Some techs replace both Gears at the same time. Actually it will probably save you a trip doing the both of them at the same time. Next I would remove the Prefuser Transport assembly (PL3-B13) and clean the vacuum holes with a Q-tip or some soft cloths. When the holes are Metering Roller, you would see there is a slight texture on the roller that carries the fuser agent up to the Donor Roller (22K27670). When the Metering Roller gets smooth (about 2 million copies) it will loose its ability to carry the fuser agent to where it’s supposed to go. The Donor Roller gets dry and then the Fuser Heat roller (22K53280) does not get coated with a thin layer of fuser agent. With a dry Fuser Roller the results will be fuser jams or fuser wraps. It’s always best not to go with looks alone. If it looks ok, but you have that sinking feeling that it’s old then replace it.

Fuser Jams First Call

A fuser trim will usually resolve most fuser related paper jams. Start off by removing the Metering assembly (PL3-D10, part number 48K27290). It’s interesting to note that some of the old timers called this assembly the RAM assembly (RAM = Release Agent Module), two names for the same item. Find a suitable flat work area and clean the metering assembly with a few soft absorbent rags. After the Metering assembly is clean, replace the following components: Metering Blade (33E1110), Fuser Wick (94K680 make sure this wick is fully saturated with fuser agent when you install it). Replace the Fuser agent filter assembly (600K20330), Donor Roller (22K27670) and Metering Roller (22K9161).

The Metering assembly should have a thin coating of fuser agent on the bottom of the tray.  If you were to measure the depth of the fuser agent in the tray, it should be about 1/16 deep.  When completed, install the Metering assembly in the processor and let the system warm up to Ready. Reset all HFSI’s that were changed, this way you will know how many copies the components have on them the next time you do a service call in the fuser area. I always make a notation in the service log as well. Sometimes it’s hard to tell when an item was replaced but when you write it down in the log, it is proof positive that it was done. Test the copier out and if it’s running smoothly, return the copier to service.

Fuser Jams Second Call

If there is a recall or the above does not resolve the problem, the next step would be to closely examine the following components: Fuser Idler Gear (7K120) and the Fuser Drive Gear (7K1700). Take notice if the gears are feathered (sharp points). If that’s the case then there will be slop in the Idler gear and fuser jams will occur. Some techs replace both Gears at the same time. Actually it will probably save you a trip doing the both of them at the same time. Next I would remove the Prefuser Transport assembly (PL3-B13) and clean the vacuum holes with a Q-tip or some soft cloths. When the holes are clogged the Prefuser transport will not advance the paper into the fuser module at the correct speed and might be late in getting to the puffer manifold. Replace the Prefuser Transport belts (600K8320) as well. The belts may appear to be in decent condition but if they feel smooth (no texture) then it’s way past the time to replace them. Re-install the Prefuser Transport and enter DC-330 (10) and activate the Prefuser Transport blower. You should be able to hear the blower (I wiggle my hand behind the blower to feel the air stream). This way I know for sure that the Blower is working properly.  Re-assemble the copier and test it by running a long job. Return the copier to service and remain on location for at least a half hour to see that the machine is working properly.

Fuser Jams Third Call

Still having Fuser Jams? Next I would check the Fuser Air Knife manifold Clearance Adjustment (ADJ 10.12).  Open tray 3 and use 8 sheets of 14 inch, 20 pound paper for the check. Place the 14 inch paper on the Heat Roller and close the Air Knife assembly.  Loosen 4 screws on the manifold and gently press down on the manifold until it rests on the 14 inch paper (inboard and outboard). Tighten the screws and remove the paper.  Next check the Pressure roller Contact Arc, ADJ 10.8. And while you are in the Adjustment mode check the Donor Roll Contact Arc, ADJ 10.9. With the proper Donor Roll contact arc we will insure that the fuser Heat roller gets the proper coating of fuser agent.  A number of techs have devised shims (cut from Chip boards) to raise the Donor Roller slightly so that the Metering roller coats the Heat Roller properly.  That’s extra work and sometimes it helps.

It would be interesting to note if there is fuser agent in the Metering assembly. If there appears to be fuser agent in the tray then we know the Fuser agent Pump is working properly. And the adjustments will fix the jamming problem. It would be a good idea to check the Fuser Agent Pump by entering DC-330 (10). Cheat the interlock bypass and open the fuser drawer. In the chain 10 screen select Fuser Agent Pump (PL3-E3) and press the start button to observe the pumps action. The fuser agent should just about ooze out of the opening. We are not looking for volume but rather a tiny but steady supply of Fuser Agent. If you notice the Metering Tray is bone dry then you may want to replace the Fuser Agent Pump Assembly (94K2030). Some techs have tried to repair Fuser Agent Pumps with some success. But for peace of mind replace the pump.

The next thing I would look at is the Heat roller itself. It’s really hard to tell if the Heat roller is at fault and that’s especially true when the Heat Roller looks like it’s in decent shape. Whenever possible I try swapping out the Heat Roller with another running machine. If the Fuser Wraps and Fuser Jams seem to disappear then you know you’re on the right track. If the Fuser Jams and Fuser Wraps only occur with solids on the paper, then it is almost certain that the heat Roller is at fault. 

There are a few companies out there that re-coat the Heat Rollers and sell them cheap. Not saying that ‘cheap’ Heat Rollers are bad, but most of the time when a Heat Roller does go bad it’s (almost) always the competition that supplied the heat roller. You pay for what you get, and you get what you pay for. 

If the account is yours, then it would be advisable to make careful notations in the log book about any parts that are used in the copier. The more detail you write in the log book the better it is for you in the long run. For example, entering just the part number is fine if they are genuine parts from the manufacturer. However if “Badda Bing” Parts are used in the machine it would be advisable to make that notation in the log book. And it will be an excellent way of keeping track of the service life of the component in question.  All too often I have seen cheap parts replaced prematurely due to failure. You think that you’re saving a few bucks, but in the long run you are probably paying twice what the manufacturer charges for similar parts and supplies.

In the next issue of ENX we will be exploring a number of other contributing factors for Fuser Wraps in the Xerox 135 copiers. Hopefully the information I have provided today will help you in repairing Fuser problems you see in the field. If you have any ideas, information or thoughts about this topic please contact me at VillageCopierNY@AOL.COM and I will gladly include it in future articles. As it is now there are a number of techs that have supplied information to this article and I would like to thank them all for a super job.  I don’t know about the vast majority of Technicians out in the field, but sometimes I get the feeling that I am out here all alone. It’s probably a silly notion but I miss the comradely that we had when I worked for the manufacturer. When we had problems in the field we would call our territory neighbor and hook up at the account to jointly troubleshoot an annoying problem. More times than often we would resolve the issue because there were two heads working on the problem. Two sets of eyes to observe and some one to talk to about the impending situation. u

Raymond Cote can be contacted at Village Copier Service, 718-931-2830 • e-mail: VillageCopierNY@AOL.COM.