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[Federalgraphics Ben]

I've got a customer with a Kip 860 that is dumping cyan toner. The lead edge of every print (color or black) has cyan on it as if it ran through toner just before entering the fuser. Initially the call was for an error E0410 and when I arrived the Cyan dev unit seemed to be over filled with toner. the dev motor couldn't turn at all. Cyan toner was dumped everywhere inside the machine. I emptied about half of the toner from the dev and the dev motor turns normally now and the machine has no errors but it is still dumping. The cyan image on the prints seems to be a bit light. I feel like I might have an issue with the dev Bias but I'm not sure how to confirm or correct it.
Any Ideas?

[dlee]

Did you completely vacuum out the paper path? I had an issue where the printer was dumping toner and I kept getting lots of toner smudges on the LE, even after I thought I cleaned up everything already. Basically, I found tons of leftover toner sitting in the Discharge Needles section. If you have the SM, look up page 5-189 Replacement of Secondary Transfer Roller. On page 5-190, you'll see pics of the Discharge Needles. And even in the SM, the Discharge Needles have toner all over the place, and I'm guessing this is from a properly running machine. If there was a toner dump, this area would be loaded with toner.

[Federalgraphics Ben]

Thanks for the reply dlee. The discharge has been cleaned. I went as far as to remove the fuser and clean everything from the back. It gets dirty again after just a few prints.

[Federalgraphics Ben]

I rebuilt the developer using the rebuild kit, cleaned toner from the machine for an hour until it was spotless, installed the dev and ran a test print. TONER DUMPED EVERYWHERE!

I noticed something else, If you trip the side door and look between the imaging units you can see a small white gear. Using the service software I can activate the dev motors one at a time. When it kicks on, that white gear turns counter clockwise on all of the units except cyan. The cyan dev unit is ROTATING BACKWARDS (clockwise) and dumping everywhere.

I am ordering a main board, if that does'nt work I'm calling a priest!

[dlee]

I see that you already ordered it and it'll probably end up being the main board but did you try swapping the motors to see if the issue moves with the motor?

[Federalgraphics Ben]

I did swap motors pretty early in the process and the problem stayed with the cyan.
The board fixed the issue of cyan dev turning backwards but brought a bunch of new issues. I was getting a 'Toner K Missing' message. The counters were cleared and I lost my serial number (which made keycodes invalid).
Firmware update fixed the error, I used the serial number reset tool from the website to set the serial number and I'm just going to deal with the counter for now.

Now there are a few more new issues.

1. A magenta vertical line down the far right side of 36 inch prints. It does not go all the way to the edge (inside print area) and seems to be a very straight and pretty clear line about 1/8 inch wide. It doesn't look like lines made by dirty wires.

2. Even after updating the windows driver to match the updated firmware and System K software (1.6a), the windows driver is not working right. When you send a job as grayscale or black only it jams in mid transport every time. If it's color it prints fine (except the magenta line). Anything sent through the service software feeds fine as well.

[ssbmi]

I'm having the same problem, the gear is spinning backwards. Did the (MAIN CONTROL PCB ASSY) take care of this problem?
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thank you.