Originally Posted by
Caffeine
I'm going to assume genuine Xerox toner. If you're using generic, that's your problem. Seriously. I'd bet a testicle on it.
So, assuming it IS the correct genuine toner, here are a couple of the more unusual reasons I've seen for fuser exit jams over the years.
1) If everything SEEMS fine, i.e. no actual jamming or accordian-ing of the paper, and it makes it part-way out the fuser into the Duplex area, you MIGHT have a bad exit sensor in the fuser. I have had this happen many times, usually towards the end of the fuser's life. Usually, however, I only experience this when running B&W speeds, though, not color. If you have a spare known-good fuser, a swap will verify if this is it or not.
2) There are some black plastic paper-path parts in the inverter which the paper travels across directly to the right of the fuser when duplexing or simplexing... I have a couple times had them get gunked up with stuff JUST enough that when printing lighter weight papers, or even heavier paper when the machine is running hot (i.e., the room is warm) and the gunk actually causes the still-hot toner on the sheet to stick, just enough to trigger the jam.
3) If you also have stopped paper part-way across the 2nd BTR, and there is some solid-black printed right in the middle of the page, sometimes the 2nd BTR exit sensor sees (or doesn't see, as the case may be) this solid black and thinks there is "no paper" there and triggers a jam. There is usually paper in the fuser at this point, too, assuming continuous printing was occurring. This is a false sensor read due to very dark/black toner on the sheet right in the middle which would be directly over the 2nd BTR exit sensor. So if this isn't the case with what you're printing, this one isn't it.
If the toner is STICKING to the fuser roller, I'd be going back to the authenticity of the toner. I've never had legitimate toner stick to the fuser roller except when there was an unrelated jam and a sheet was mid-way through the fuser and I didn't get over there and clear the jam right away and that mid-way sheet was just sitting there in the fuser the whole time.
Don't know if this will help. These all took a while to track down because they aren't immediately obvious, but all cause jams in the fuser. Although, except in the case of #1, the fuser wasn't what causes the ORIGINAL jam.
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