09-213 System Faults
By Raymond Cote

   
Probably the most annoying fault code you’ll ever deal with is the xerographic fault code 09-213. Many technicians and customers have contacted me looking for additional troubleshooting tips for their Xerox 5090, 5390, 5690, 4135, 4635, 6100, 6135, and 6180 as well as Docutech printers. The complaint is always the same: “I fix the problem only to have it reoccur again at a later time.” This particular fault code is dependent on a lot of factors, and as the fleet of copiers and printers age, we’ll start to see some of these relentless, stubborn problems become more of a pain in the neck.

If you check some of the back issues of ENX magazine, you might find an article or two that dealt with this fault code. After the articles were published, a number of technicians contributed tips and suggestions on resolving the system fault.

First off, I can’t emphasize enough the importance of using the Xerox service manual specifically designed for your particular copier/printer. If you log on to www.Xerox.com, you can purchase the service documentation for your particular copier or printer. Or if you have the patience to shop around on e-Bay, you may get lucky and find a complete, used, service manual at a bargain price. If all else fails, contact me at WWW.VillageCopierNY@AOL.COM with the exact fault code and specify which copier or printer, and I’ll e-mail you some additional information. Use the documentation in the RAP for 09-213, and pay particular attention to the Initial Actions and Table 1 of dc 131 MIN locations.       

When your copier was manufactured in Rochester N.Y., it was brand new and squeaking clean. Over the years, wear and tear occurs and dirt accumulates (everywhere). If you can remember the day it was first installed, it ran like a powerhouse day and night. That was because the system was brand new, and it was just breaking in. Now, after 15 to 20 years of service, the unit is quite worn and dirt from toner and paper lint is everywhere. Dirt can, and will, have an effect on your copiers operation. If this is a reoccurring system fault (09-213) and you’re fairly sure you’ve gone through all the steps in the RAP and have run out of things to do, then it’s time to take a serious look at the following components one at a time.           

From Table 9: Subsystems           

Remove all Dicorotron shields and examine them for damage and cleanliness. A technician from New England suggested using a 12-gauge shot gun cotton cleaning pad to ensure the inside of the shield was clean. Examine the black paint to make sure it hasn’t been washed away by previous technicians and has no pit marks from arcing. Sometimes, techs use a wet rag to wipe the shield clean and, thereby, remove some of the protective paint. When the protective paint exposes the shield, you’ll experience several 09-xxx fault codes. Inspect the housings as well (802K19830) for contamination of the Dicorotron housing. If you even think it’s contaminated, replace it with a fresh 125K1080 or 124K1450. I’ve discovered that the plastic housing will retain ozone contamination causing deletion problems on a photoreceptor belt. The complete assembly is inexpensive, so replace it if you suspect that it’s bad.          

From Table 10: Subsystems         

Take a close look at the developer zone roller (PL4-A9) and the cleaner zone roller (PL4-A6) 22K7893. Remove the zone rollers, and examine them for any damage. Make sure they’re clean and the bearings haven’t seized or in any way caused a problem in the xerographic process. Use your ohm meter to make sure there’s zero resistance between the zone roller (22K7893) surface and the end bearing. While you’re in the belt module, examine the photoreceptor belt module latching device and make sure the cleaner zone roller is doing what it’s supposed to do, that is, go up and down when the latch is engaged and disengaged. Check all the cables to this mechanism and watch it operate.          

Examine the ID lamp (PL4-B10) 122K351; make sure all the segments are lit when the copier is in print.  Examine the multipurpose lamp assembly as well to ensure all segments are functioning. Look at the pretransfer lamp (PL4-A7) and precharge erase lamp (PL4-A9) 122K391, and make sure all segment lamps are functioning. Clean the belt hole sensor (PL4-B1) 130K49300 and belt hole LED 130K29910.  Take a close look at the DSS assembly, and make sure it’s clean and the hose connecting it to the power supply is free of dirt. You might have to disconnect it and blow air through it to make sure there’s no blockage. While you’re in the belt module, look at the POP sensor assembly. I’ve never had a problem directly related to the POP sensor assembly, but you never know … Also, look at the waste bottle full sensor assembly. Make sure it’s working properly with the DC-330 screen.          

Check the photoreceptor ground brush assembly (PL4-B1) 115E2200. Gently tug on the strands. Do they come out easily? Replace the ground brush. Use your ohm meter and make sure the ground brush actually grounds the PR belt. Next, open the fuser assembly and remove the metering assembly (PL3-E1) 48K27280. Check if the metering roller ground strap is in physical contact with the bearing of the metering roller. All too often, we overlook this ground wire thinking it’s not important at all.           

From Table 11: Subsystems          

Examine the document glass assembly. Is the glass displaying any streaks that are the results of abrasion from the document handler belts (PL6-D7) 600K15180? Before going any further, check the height adjustment and make sure the adjustment is within specifications according to the adjustment procedure in the adjustment section of the service manual. When the platen glass is abraded it will cause stray light to interfere with the xerographics and cause 09-213 problems as well. The next thing you might want to look at is the lens itself. Is it clean--the top and bottom? Remove the cavity bottom panel (PL4-F6) 600K36550 to access the lens assembly. Clean it with a soft cotton cloth slightly dampened with water. Use a clean cotton swab to dry the lens.         

Let’s look at some other areas that will have an impact on this system fault code. Take out all six Ozak hose connectors to the Dicorotrons, 0, 1, and 2 (PL4-B4) 114K281; and while we’re in this section, let’s visibly check the preclean connector (PL4-B3) 114K271 and the transfer and detack connector (PL4-B3) 114K261. What we’re looking for is any sign of contamination, arcing, or any yellowing of the connectors in any way. Check the metal connectors for any signs of contamination, dirt, dust, any foreign material, or anything that might suggest interference with the device. A service technician from the Midwest suggested using a baby bottle brush to clean the connectors. And our technician from New England sticks by his 12-gauge shot gun cotton cleaning pads to clean the inside of the connectors. Hey, whatever works!          

The next thing you might want to look at is the actual Ozak hose connector assembly itself, (PL4-B4) 600K24340. The logic here is there’s high voltage going through the Ozak hose connection wire, and this can radiate energy. When the Ozak hose becomes contaminated with toner, the high voltage AC power supply (HVAC) has to work harder in order to satisfy the AC slope target. Actually, what happens is the HVAC power supply will set the ACV to 245, the maximum. I recommend changing the Ozak hose assembly pronto.           

Ok, let’s review what we’ve accomplished so far: We replaced the platen glass assembly because it was abraded from the document handler belts and that contributes to all sorts of 09-xxx faults. We adjusted the document handler height according to the service manual so that the new platen glass wouldn’t get abraded too early in its life. An abraded platen glass will give you problems with copy quality and will deliver xerographic faults. We replaced the Ozak hose and all the connectors, and we replaced all the Dicorotron shields. If the problem remains, we should consider installing new Dicorotron housings. Why? The housings can and will be contaminated from toner and Ozak gases. Replace them all, and don’t use any Dicorotron housings that were found behind the machine.

Now, we know for sure we have new Dicorotron housings and new Dicorotron wires (48K56790) installed. Let’s look at the photoreceptor belt (1R88). If the edges are starting to curl up, they’ll touch the Dicorotron housings and cause a short. When it comes to the photoreceptor belts, accept no substitutes--use only the real McCoy, Xerox brand (1R88). In my experience, the cheap, knock-off photoreceptors last about 200,000 impressions before they fail. The genuine Xerox brand (1R88) will last a lot longer. If the price for the cheap knock-offs was about $50, I would recommend them. But for the amount of aggravation they generate, I say, forget them. Besides, what’s more important, a satisfied customer or a cheap belt that doesn’t work?          

Let’s look at the optics cavity. It’s my belief and experience that when the optics tub becomes dull and dirty, the paint will not reflect the brilliance of the flash lamps (PL4-F3) 122E275, and that will generate numerous 09-xxx faults. Use an excellent-quality exterior latex white paint that’s extremely resistant to heat. There are several paint makers out there that have what you need. Xerox offers great optic cavity paint, but the cost is way out of range (overpriced, in my opinion). You can do better in Home Depot or Lowe’s for about $20 per quart. Paint the cavity, replace the flash lamps, and then adjust the cavity sensor assembly to about 160 (bits). Look in the adjustment section of the service manual for the particular adjustment or e-mail me and I’ll send you the adjustment procedure.         

Now, we have a new photoreceptor belt, 1R88, new Ozak hose and connectors, and new Dicorotron housings and wires. On the Xerox 5090 family of copiers, we have a newly painted optics cavity, and the cavity sensor is adjusted to 160 (bits). Select DC-131, select MIN 169, and reset it to 100 (bits). Run a DC-951 preflash setup. After the completing the DC-951 preflash, select DC-951 and select Xerographic Default. When Xerographic Default is selected, it will reset most MIN locations to the nominal setting. But be aware, they also set the default settings for the printers that have the two charge Dicorotron configuration in the 6100 family. In that case, use the DC-131 MIN location 223 and reset the information to 95; and in DC-131 MIN location 224, reset the information to 0. This tells the Docutech (family) that it only has the two Dicorotrons in charge one and two.          

There were a few things I failed to mention. Initially, I hope you double-checked your Dicorotron height (yellow) of charge one and two. It should be a snug fitting of 2.55mm. If the height is too high, the AC slope will be so low that it might not register. If it’s too low, the AC slope will be too high and cause other problems. Follow the adjustment procedures in the service manual. A few techs have mentioned that the trimmer bar inside the developer housing contributed to some xerographic faults, and when the trimmer bar was replaced the fault codes went away. While you’re in the developer housing, check the three bearings on the ends of the magnetic rolls.  If you even think the bearings are starting to fail, replace them.           

Next month, we’ll explore communication faults in all the Xerox copiers and printers. If you have information that you’d like to contribute to the article, please send it to me. I’ll share your thoughts and solutions with the field. Meanwhile, remain brand-conscious and use Xerox-brand photoreceptor belts whenever possible. I can be reached at the following address: VillageCopierNY@AOL.COM.

NOTE:

To all independent service organizations (ISOs) and independent service providers, we’re taking a survey of independents that might be interested in forming an association that will link all independents in some way from Maine to Hawaii. I think it’s about time we tried to organize ourselves to get some political power in the United States. If you’re remotely interested, please let me know. At this stage, we’re only brainstorming, and any suggestions are welcomed. Our goal is to create a nationally recognized service company that will do business pretty much the same from Maine to California and beyond. Our focus will also be directed to sales of re-furbished copiers and, of course, the service end as well. We can be contacted at the following e-mail address if you would like more information about the association: CopierServiceNY@AOL.COM. If you’re interested only from an investment perspective, there’s unlimited earnings potential.