1. A smudging pattern that repeats approximately every 1"and fades away if printing continuously.
2. False "Paper Jam"or "Paper Jam/Track"errors on the Models 1 & 3.
3. "Laser Failures"on the Models 5 and 6.
4. Broken or cracked developer drive gear assemblies.
5. Image creep and drift on the Models 1 and 3.
6. A "bulge"of toner on the magnetic roller that may spill toner onto the form.
7. Grinding or ratcheting noises when paper tries to move.
8. "Random dots"on OPC drum and print out.

The symptoms listed above could be caused by either a "High Torque"developer unit or excessive layers of toner on the developer's magnetic toner roller. These conditions exist in the developer because of:

• Misalignment of the developer's internal doctor blade, which affects "pile height"of the toner on the magnetic roller.
• Toner that has settled or packed into the mixing chamber of the developer, can cause "High Torque", this occurs after installing new toner, or too much toner, or defective toner from improper storage.
  

SOLUTION/PROCEDURE:

SHORT TERM SOLUTION FOR A "HIGH TORQUE" DEVELOPER:

A short term solution may be to remove the developer. Hold it over a trash can at an angle that makes the toner compartment lower than the magnetic roller (the exposed roller with toner on it), keep the magnetic roller horizontal. Alternately shake the unit, tap the side of the unit, and rotate the top of the white gear on the right side away from you. It is sometimes helpful to "rock"the gear back and forth a bit and then forward many turns. The unit should actuate more freely after this procedure. This may correct a "high torque"problem temporarily.

Another possibility is that the developer may be worn out or defective. The rated life of the developer is approximately 92,000 feet or 100,000 letter sized pages. Check the foot count in the extended configuration menu (Model 5 and 6). The summary page will show the counts if printed from the extended configuration menu (Model 5 and 6). The foot count can be and should be cleared in the extended menu once a summary page has been printed and a new developer has been installed (Model 5 and 6). This is done to keep track the life of the new developer unit.

DOCTOR BLADE ALIGNMENT PROCEDURE:

This procedure can be messy and should only be performed by a qualified technician.

WARNING: OTC IS NOT RESPONSIBLE FOR DAMAGE DUE TO SPILLED TONER.

Remove the plastic cover above the magnetic roller by prying it off.

Wipe a strip of toner from the full length of the magnetic roller. Roll this bare spot back until it is under the doctor blade.

Check the gap between the roller and the doctor blade using feeler gages. A gap of .012"is too great and a gap of .011"is too small, the actual gap is .3mm.

If the gap requires adjustment, loosen all three screws. Place the .011"feeler gage under the left or right screw. Push the full length of the doctor blade down against the feeler gage and roller. Tighten the screw above the gage and slide the gage under the screw at the other end. Tighten all the screws and recheck the gap.

If the gap is erratic and won't adjust accurately, the bearings may be worn. This will require the developer to be replaced. There are other things besides the doctor blade gap that can cause developer problems, but none of them are serviceable.