Xerox DCP excessive toner usage, waste toner from drums blocks auger

[Detonation]

I have a customer with a DCP700 who has had a lot of waste toner auger problems: constant toner leaks in the machine, contaminating prints and een leading to belt positioning faults. I have replaced the auger pipe, vertical funnel and leveller box with new ones. The machine is performing a lot better, bit still after 40.000 prints or so the auger pipe 'overflows' in the machine, and I'm back to vacuum cleaning it all.

When inspecting the auger pipe, I noticed the 'pipes' removing waste from the developer units looked perfectly fine, while the pipes removing waste from the (color) drums were filled to the brim. Which makes me suspect there is insufficient toner transfer from the color drums to the ITB. The drums themselves are ok, the 1st BTR's have around 600K prints on them.

Theoretically I should suspect the 1st BTRs, but in real life I have so rarely noticed a big effect from the 1st BTRs that I'm not sure that would solve it. What else is there to suspect? The 1st BTR power supply I guess? Any insights would be greatly appreciated. Customer is at quite some distance, so these service calls are really time consuming.

[adriansto]

Re: Xerox DCP excessive toner usage, waste toner from drums blocks auger

Remove belt from IBT assy. Then clean everything inside it. Belt edge learn after put the belt and IBT assy back into machine. MAX Setup all procedures from adj9.1 to adj9.13 even adj9.14.
Print on A3 size paper each CMYK 80% density and panic stop the machine for every colour sheet you print.
Examine what toner remain after transfer on drums and on belt to verify your theory.

[Detonation]

Re: Xerox DCP excessive toner usage, waste toner from drums blocks auger

Thanks Adrian. Will try next time I am at the customer. But looking ahead: if there would be a good amount of toner left on the drums, what would be your next move? I'd like to take all parts with me to make it one service call, as it take me pretty much a full day since the customer is quite far away.

[xcopytech]

Re: Xerox DCP excessive toner usage, waste toner from drums blocks auger

You will always have more waste toner then waste developer.
Any problem with first btr will produce CQ issue.
First btr do not have anything with toner covers on drum.
You can check developer blade nip for toner on drum.
You should clean or replace adc sensor if you have problem with overtoning.
Check value in max setup

[adriansto]

Re: Xerox DCP excessive toner usage, waste toner from drums blocks auger

Thanks Adrian. Will try next time I am at the customer. But looking ahead: if there would be a good amount of toner left on the drums, what would be your next move? I'd like to take all parts with me to make it one service call, as it take me pretty much a full day since the customer is quite far away.

How old are developer units, which is the bias voltage of developer. HVPS sources. How good is the ground contact at the drums. How good is the exposure - ROS units.There are a lot. For this after you will do a good cleanning of the machine, including also the filters, and run MAXSetup you can see if there is a problem.

[Detonation]

Re: Xerox DCP excessive toner usage, waste toner from drums blocks auger

The machine has had the problem for a while. Developers and drums have been replaced meanwhile, so have the entire toner waste system (auger pipe, funnel, leveller box) and belt cleaner. 2nd BTR has around 200K clicks and is 6 months or so old.

Today I came back to the machine. Waste auger pipe had again overflowed, so I cleaned the machine, giving extra care to ROS, erase lamps and ADC sensor. Ran all of MAXSetup and passed all tests well within margins. Print quality is really good as well. The customer thinks the machine is using more toner than usually (both running out of toner faster, as well as waste cartridge filling up faster). No special paper either, mainly 80 and 160 grams plain paper.

[adriansto]

Re: Xerox DCP excessive toner usage, waste toner from drums blocks auger

Presuming toners and drums are OEM. May be some incorrect nvms. It use Fiery for printing , he use the machine for copying, what is the version of machine system software, printer filters was changed ?
More information will help.