enx magazine

When you think of what repairs will fix a specific problem, most techs will usually rely on past experiences. This isn’t a bad thing if it works. However in real life when we run into a situation where the problem will not simply go away, what do we do? Drop back 10 yards and punt! That usually works in football but I’m not sure if that will be true in real life. For the small independent service techs, the only other option is a neighboring tech or maybe a business associate that is still connected to a large organization. But for the most part, we are pretty much on our own.

Most of the e-mail I receive is for the same machine problems and the people trying to repair these malfunctions are self-maintainers and/or technicians that have been recently separated from their employers. In most cases, a lack of technical data is usually responsible for a host of unresolved issues. And with some techs that are trained on everything from pencil sharpeners to twenty-six different brands of copiers and printers, it becomes a little confusing. There is no way that someone that is so cross-trained on “everything” can be efficient in some of today’s monster printers. Product specialization is not a luxury but a necessity in the successful world of service.

I would like to focus on several problems that seem to be popular faults in the field with the Xerox 5090 and Docutech family of copiers and printers. P12-140 finisher shutdowns in the Docutech family are the same as the 12-140 finisher shutdowns in the 5090 family. What the machine is trying to tell us is that when the Set Transport assembly gets the signal to remove the set from bin A from the bindexer, there is nothing to unload. The way that the logic sees it is as follows: The bins exit sensor assembly (Q-1222) doesn’t see the set being removed. And then the machine thinks that there is a problem and displays a fault on the screen. One energetic technician in Eugene, Oregon had this experience and told me that he even swapped the transport assembly with two other machines he had (as spare parts machines). The results were always the same, 12-140 shut down. By the time he contacted me, he was totally frustrated and understandably so. The best approach to troubleshooting, I have discovered, is to watch and see what happens when the machine is operating. Sometimes it’s really difficult to see things happen when the machine is delivering 135 copies per minute. In my experience, I have to watch it several times because I am not the sharpest tool in the shed and it usually happens so quickly. It’s always a good idea to start from scratch and go back to the basics. First off, check to see if the vacuum transport blower (127P2347) is functioning properly (PL7-E1) and the vacuum transport belts (600K21490) are not worn. Check that the gap between the vertical transport and the bindexer is within ½ inch and is evenly spaced from top to bottom. Check the Bins gate (PL7-E5) 600K32480. NOTE: On bin A (the lowest bin) the gate is fixed and is not supposed to move. It should be open and inside the channel in the vertical transport assembly. Watch the paper entering the gate on bin A. Is the paper moving smoothly and is it being stacked against the registration gate (PL7-D9) 50K3341 in a neat pile? If the set is not being stacked neatly, replace the Scuffer roll kit (PL7-D9) 600K11472.

Next step is to restore the machine to its original parts. Replace the set transport to the one that was originally installed and continue the observations while the machine is running. Remove the bindexer door assembly (PL7-D9) 50K3341 and install the clear plastic cover so that you can observe the bindexer while the machine is running. Program the copier for three sets of ten pages to be collated and press start. Sit on the floor with your trusty handy little flashlight and observe what happens in the bindexer (bin A). Is paper stacked neatly against the gate? When the set transport (PL7-F9) moves in to grab the set (in bin A) does the lower clamp bracket (PL7-F11) open fully quickly before it arrives at the bin A position? You may have to watch this several times because it is really fast. One giveaway that it is opening late is when the lower clamp bracket touches or bumps the set of paper in bin A. If it does touch or bump the paper (backwards) in the tray, it will move slightly back from the registration gate and the lower clamp bracket will close on nothing. Then the set transport will try to move the phantom set out of the bin A and the Q-1222 sensor will not be blocked and the logic (on board) will think that there is something wrong. Wow, what a smart machine. Put two aspirins in the metering assembly and when you come back in the morning, everything will be the same. Before you replace any components in the set transport assembly, find, borrow, or steal an adjustment guide and in section 4, ADJ 12.19, you will find a critical adjustment “Vertical Clamp Position”. Perform this adjustment first and then proceed to the next adjustment ADJ 12.20 “Stacker Shock Absorber” (Set transport home position). And last but not least, ADJ 12.21 Home and Position Sensor (Q1224 & Q1225). It is always a good idea to check the following adjustments: ADJ 12.22 bins and stacker clamp, and set the position cylinder alignment ADJ 12.23.

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