Got a weird one,
3232E that likes to pack the magenta waste toner into the toner container, causing the machine gun sound. Usage is mainly B&W, with occasional 2-3% magenta coverage according to the report. The waste gears are all in good shape on the front box, any advice??

I'm battling with one of these, but I'm not blaming the toner cartridge. I'm more focused on the guide B1 with the waste toner drive through it.

At first I noticed the broken latches, which was fixed easily enough. The next problem I noticed was that gear 19 on the guide B1 skips against gear 28 on the hopper assemble. They just do not engage deeply enough. I tried turning gear 28 on the hopper manually, and there is not an excessive load from the toner cartridges. I replaced both gears, but no improvement. I also tried the whole guide B1 assembly, which actually worked worse than the original one. I took some dimensions off the guide assy's, and could not find any major discrepancies. I tried shimming the guide from the MP tray upward to raise the whole guide B1 assembly. Still no success.

I did get it to stop skipping, but some of the measures I took were pretty desperate.
1) With a pencil torch I heated the plastic portion of the guide B1 assembly near it's swivel/hinge, and reformed the plastic guide to increase the distance from the centerpoint of gear 19 to the pin on the guide from 46mm to 48mm.
2) Again with the pencil torch I heated the "C" shaped receiver for the same pin to tighten up the hole.
3) Removed gear 19 and it's bushing from the shaft through guide B1. I cut a 5mm wide strip of 32 lb paper, fed it through the hole where the bushing goes, oriented it away from the final position of gear 28, then worked the bushing into the frame. The paper shim took up some of the slop in the hole in the steel frame, moving the shaft closer to gear 28.

One thing that I have not tried is to replace the black guide from the MP tray, that the guide B1 swivels from. Or maybe better, replace main hopper frame that supports gear 28. The frustrating thing here is that all these plastic parts flex and warp, yet have to fit together closely to work. I don't envy the engineer that has to design these plastic moldings.

I'll create a photo album with some of my pix: http://dnet-km.com/eve/forums?...3985957&f=9321059411
I hope that this helps some. =^..^=

This message has been edited. Last edited by: blackcat4866,

Funnily enough, Cat, the rear latch was missing on the B1 on this machine, it has been reinstalled, but I doubt that the rear one could have been causing this. I have left the magenta toner out and cheated the front door to see if everything turns properly, and it does. I actually have 2 of these doing the same thing, on one I tried to order the whole front toner box assy, but the boss said it was too expensive, so I have the drive gears back order right now.
That one had actually pushed the waste drive shaft to the left, so I replaced the plastic clip with a metal one, and added a zip tie to the shaft to make sure it stays centered.
I used to like these models as you knew what the majority of the problems were, but these two machines,(both in schools), are really testing me.

The more I look at the pix, and think about it, the more I think it's the black plastic part of the hopper assy.

I hate plastic structural elements. And I agree that the VoyagerE may have it's problems, but they are known problems. The devil you know is better than the devil you don't, and all that. =^..^=

Blackcat--Have had two Voyageurs where the plastic tabs on the parts guide Fd R assy (302FZ93430) have sheared half the tab off and the drive gear jumps teeth when running. The green latch that you show in your pic should latch onto the black tab, but sometimes only 1/2 the tab is left and it releases easily. Your green latch guide assy comes out easily, but the Fd R assy is a juggling act as the lower plastic unit below it has to come out almost simultaneously. I did notice as well that even with the new Fd R assy in, I still had a noise from the drive. I found that the black felts on the end of the drum cleaning auger were getting crumpled up and blocking the used toner ejection into the bottom of the toner cartridge. The black plastic sleeve that slides back and forth on the drum cleaning tube couldn't engage properly. Once I removed the felt, it stopped skipping the drive. The waste toner drive you describe drives all four drum waste tank assy's at once. I didn't tear the toner cartridge apart but there seems to be a relationship

I'll have to take a closer look at the sleeve you're talking about.

I also removed a toner cartridge and the skipping stopped, but it didn't matter which cartridge. Any combination of three, no skipping. I even tried four new cartridges, just to see if empty waste containers made any difference (no).

I have had that vertical guide out on a couple of machines. The difficulty is getting the contact assembly out of the way through the front frame. The latching surfaces on my machine are intact. I've keyed the door and watched it cycle without the door installed. It latches completely and firmly, just doesn't make adequate contact with gear 28. I believe that the molded plastic holding gear 28 is warped. =^..^=