Accufast XL Troubleshooting

Common Problems and solutions for the Accufast XL labeler / Stamp Affixer
(We will update this page as needed. If you have a problem or a solution to contribute send us an email.)

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Problem: Inconsistent Label Placement
Possible Solutions:

  • Too much or too little roll tension. Adjust the tensioner/pressure plate -there should be slack in the roll when running. The backing paper should pull freely when in thread mode.
  • The label drive idler roller is worn out and causing the backing paper to slip in the drive roller. Replace THIS PART. A temporary solution is the clean the roller.
  • The transport belts are worn and not gripping the envelope consistently. – The belts part 02-0506-00 should have some grip and should not be smooth.
  • The foam rollers part number 02-0826-00 are hard a smooth and not driving the envelope.
  • There is a worn out shaft in the internal of the machine causing the transport belts to not run smoothly. – You can visually check the running belts by taking the labeling head off the machine and then turning the XL on to see it run.

Problem: Double Stamps or Streaming Stamps
Possible Solution:

  • Clean the upper and lower label sensors. See the label sensor cleaning instructions on this page. If sensors are damaged, contact us to order new ones.
  • Make sure the run/thread knob is in the run position.
  • The label drive idler roller is worn out and causing the backing paper to slip in the drive roller. Replace THIS PART. A temporary solution is to clean the roller.

Problem: “LABEL IS MISSING” error shows on display and the machine stops.
Possible Solutions:

  • This is the error message shown when the labeler is out of labels. If it is showing the message when it is not out of labels try the following.
  • Turn off the “Missing Label” button to disable the missing label detect feature. This is a feature that makes the machine stop if there is a gap in the labels. It is only needed when applying address labels that need to be sorted by zip code.
  • Make sure the labeling head is properly seated / mounted on the machine.
  • Make sure the run/thread knob is in the run position.
  • Clean the upper and lower label sensors. See the label sensor cleaning instructions on this page.

Problem: Stamp Backing Paper Is Breaking
Possible Solutions:

  • New teflon tape is needed around the peel bar. If the tape is gone the sharp metal edges will break the backing paper.
  • Too much tension on the stamp roll. Loosen the tension so the roll can turn – There should be a little slack in the roll when running. The backing paper should pull freely when in thread mode.

Problem: Labels being delivered too late and sticking over back edge of even falling off the back of the mail piece.
Possible Solution:

  • The drive idler roller is worn out and causing the backing paper to slip in the drive roller. Replace THIS PART.

Problem: Backing Take-up Roller Is Not Turning
Possible Solutions:

  • The belt is probably old and stiff or broken. You can buy a new belt HERE. The installation instructions are in a video on this page.

Problem: Display Says “Position Label” And Does Not Apply A Stamp
Possible Solution:

  • The stamp or label is adjusted too close to the trailing edge. Adjust the label position farther to the lead edge of the mail piece. Due to the mechanical limits of the labeler it cannot place the stamp closer than about 3/8″ from the trailing edge. The measurement in the display might not be accurate and there is not a way to re-calibrate it. Just adjust the stamp position visually.

Problem: Machine Only Feeds When Holding Down the Feed Button
Possible Solution:

  • Make sure the labeling head is properly seated / mounted on the machine.

Problem: Display always says “Take Up Spool Full” after turning on the machine even with take up spool empty.
Possible Solution:

  • Make sure the labeling head is properly seated / mounted on the machine. This is the most common reason.
  • Remove the labeling head and check the sensor wiring and clean the sensors with compressed air.

Problem: Only applies 1 stamp or label then keeps feeding blank envelopes without advancing any more labels.
Possible Solution:

    • Make sure the run/thread knob is in the run position.
    • Clean the label sensors and media sensor. See the label sensor cleaning instructions on this page.
    • The drive idler roller is worn out and causing the backing paper to slip in the drive roller. Replace THIS PART. A temporary solution is the clean the roller.

More Troubleshooting ideas from the user manual here:
Accufast XL Troubleshooting PDF

How to Disassemble the Accufast XL

This is not an easy job but it can be done by someone who is careful and has basic mechanical/electronics repair ability.
This is a simple overview. To take the machine apart, take the top assemblies off including the bar with the sensor in it and the separation assembly wall that includes the 2 upper separators. Basically everything that is above the feed deck has to be removed. Then lift up and out the whole feed deck which has the feed wheels and drive components attached to the bottom of it. Before you lift it out, disconnect the 2 motors and the ground strap. If you would like to rebuild your machine and would like tech support help consider buying this:
Accufast XL Rebuild Kit

Sensor Cleaning Instructions

Label Sensor Upper and Lower

Remove the labels from the machine. Remove the silver Press Roller and open the access door. Clean the sensors with compressed air. If they are hard to clean you can use a cotton swab dipped in Isopropyl Alcohol to gently wipe the sensors. Never use any abrasive cleaner or brush on the sensors. The locations of the upper and lower sensors are shown in the following pictures:

Upper Label Sensor

Lower Label Sensor. (In pin hole)

Media Sensor Upper and Lower

The upper media sensor is mounted on a bar across the base of the machine as indicated by the picture. The lower media sensor is down in the machine visible through a hole directly under the upper sensor. Clean them by blowing compressed air on them. If they are hard to clean you can use a cotton swab dipped in Isopropyl Alcohol to gently wipe the sensors. Never use any abrasive cleaner or brush on the sensors.

Media Sensors

General XL Troubleshooting Overview Video

Replacing Backing Take-up Belt Video

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