PO6-250

Docutech System printer fault

                             By Raymond Cote

Several self maintainers and a few independent service techs have expressed concerns about intermittent PO6-250 / 251 system faults. For the most part the RAP’s will usually lead you to a conclusion, but then there are the persistent or intermittent PO6-250 / 251 faults that seem to defy gravity and will not be resolved no matter what you do.  This fault code indicates that the end of scan signal was not detected by the EOS PWB.  For the most part the PWB (PL4-G3) 2K27600 is quite sound and is usually not the problem. But peace of mind will result when you swap the boards to try and isolate the problem. Check the MIN NVM locations 152 = 60, and 153 = 86.  Check the Video cables for proper connections. Don’t be afraid to use a good commercial electrical contact cleaner before reconnecting the plug / jacks. Electrical noise could also contribute to the intermittent problem as well.  The funny thing about electrical noise is that it could come from almost anything. In one isolated incident the noise was being generated from a plug / jack that actually lives over the developer drive motor behind the ROS assembly.  Due to mechanical vibration the pins were vibrating and actually arcing out (from the vibrations) and eventually we had to replace the entire plug / jack device along with all the pins both male and female. Dicorotrons have been known to emit a noise that will have an effect on the ROS assembly as well. Finding a bad Dicorotron when there are no fault codes could border on the impossible.  If there is another Docutech at the account you could swap all the dicors to test your theory.  If the problem goes away, you know what has to be done.

Keep in mind that as the fleet of Docutech’s age (gracefully), we will become more aware of pins that are damaged from machine vibrations. The most visible connector is the one on the AC distribution panel (PL5-A13).Yes, the panel that drops down in the rear of the machine.  A retrofit was introduced to the field that includes gold tipped pins that will replace the existing ones. Order Kit number 605K11850. Fretting corrosion is the result of vibrations that are caused by motors, drives and compressor motors.

Once you are reasonably sure that there are no plugs / jacks causing the noise problem we can examine all the motors in the vicinity of the ROS assembly. Motors have been known to emit noise while doing their job.

Next we will want to closely examine the ROS assembly. Power off the Docutech and remove the ROS assembly and place it on a work surface so that the rear cover (PL4-G5) 2K17401 can be removed. With the ROS on your work bench remove the rear cover to expose the mirrors and components in the ROS.  Use a soft cotton cloth that is slightly damp and clean all components including the polygon motor (PL4-G3) 127E7090. The polygon motor may require a ‘Q’ tip applicator to clean the mirror. Do not use any commercial glass cleaner on the first surface mirrors or lenses because the chemicals may damage them. I have found that using plain water on a slightly moist cotton cloth was most effective in cleaning all components inside the ROS.

Check the laser tube (PL4-G3) 122E341 to make sure that it is properly seated in the ROS assembly housing. If the laser tube is not seated properly it will cause random PO6-250 / 251 system faults as well. 

As you re-assemble the ROS assembly, don’t forget to clean all Jacks and plugs with a good quality contact cleaner. Power up the Docutech when you have everything in place and test the system.

PO6-251

Tom from New England writes: I am getting a lot of PO6-251 system fault shut downs when I start the Docutech up in the morning.  It seems as if when the weather gets cold the PO6-251’s seem to get worse. It was something that started this fall. Oddly, it did not happen during the summer. I was wondering if the machine can sense the cold.

Tom: I’m not sure if the Docutech really cares whether it’s summer or winter. To me it sounds like you may need a new laser tube (PL4-G3) 122E341. Check the date on the laser you have in your Docutech. Is it more than 5 or 6 years old?  The laser loses its gas over time. It is advisable to open the ROS assembly and clean the optics inside. When you re-assemble the ROS, do the base line adjustment set up. If you need the procedure contact me at VillageCopiereNY@AOL.COM, and I will e-mail you the procedure.

C15-201 system faults

C15 tells us that it is a system communications fault.  More specifically, 201 indicates that the controller is unable to communicate with the scanner. Replacing the ‘D’ PWB may not resolve the problem. If the Rap does not resolve the issue, check all connectors in the scanner assembly. Use a good quality contact cleaner on all plugs / jacks. Seat and unseat all plugs / jacks several times to clean the contacts. Make sure that when you seat the plugs / jacks, they are in the proper position and are not tilted or cocked and are squarely mated.  All too often when we remove a plug / jack we sometimes do not watch what we are doing and accidentally leave it slightly cocked to one side. Double check all your handy work.

09-213 system fault

Danny writes: I have a 5390 that is unforgiving and will not let me fix the 09-213 system faults. So far I have replaced every component in the RAP, including the photoreceptor belt. What else can I do?

Danny, there are several things we can look at that will probably have an effect on the 09-213 system fault in your Xerox 5390 copier.  For starters, replace the ground brush and replace it with a new one (PL4-B1) 115E2200. Close the Photoreceptor belt and (kneel down) visually check that the brush is actually in contact with the ground strip on the Photoreceptor belt itself.  It only happened once where it was assumed the brush was in contact with the photoreceptor belt and it drove us crazy until someone actually discovered that the brush was not anywhere in contact with the ground strip on the PR belt. 

Check the height adjustment on Charge one and two Dicorotrons. Make sure the slope is within specifications. The adjustment should be made with the yellow (Chopped) dicorotrons. Double check the ozak connectors and the ESV height. Swap out the AC / and DC PWB’s one at a time with another machine that you know is in good working order.

09-201 system faults

Arcing Dicorotrons are sometimes hard to pin point when they are intermittent.  Use the Rap’s and follows the “initial Actions” very closely.  Replacing the Dicorotron wire (48K56790) may not always fix this problem. The Dicorotron housing must be clean and the black surface inside the dicorotron housing must not be disturbed. If there is any evidence of the black paint being worn or otherwise damaged, replace the entire housing with a new one.  Also check the HVAC output power supply white connector for signs of arcing or discoloration inside the jack. Carefully examine the High Voltage Leads for signs of damage or contamination. And check the OZAC connectors for signs of discoloration and cleanliness. In the past I have used a baby’s nipple brush to clean out the inside of the connectors. It can be purchased at any baby store. The brush has soft bristles that will not scratch the inside of the connectors while cleaning out the inside.

Interlock problems?

Danny offers this for switch maintenance:  Interlock switches are, for the most part, very reliable. The interlock switch 110K3530 is comprised of two internal switches.  One side has a small optical switch which never seems to fail, but the other switch will fail. Replace the mechanical switch with an 110E1910 micro switch and the unit will be good for another million copies.  It certainly is a much less expensive way to go.

If you do not have access to an adjustment manual, let me know and I will e-mail you the procedure.  I can be reached at VillageCopierNY@AOL.COM for additional information. u

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