canon IR5880c problem

[cetverooki]

Friend asked for help so here goes.

Machine worked with few problems for last year, but lately developed few strange problems. First problem was with halftone printouts where print was missing color in streaks. That problem is now less important.
Main problem is that machine is displaying error E004-002 which points to thermistors. All thermistors were replaced but error persisted. Clear error has been performed too.
Next parts to be replaced are AC driver pcb and DC controller pcb.

Did someone encounter this problem and how it was solved? Ordering pcb's is problematic because of lead time so simpler solution is most welcome.

[Herrmann]

The Harness and the Connectors in the Fusing Unit of this Beast are known to get bad, so before you begin ordering expensive Spare Parts, be sure, that you have controlled them over and over.

Second: make sure, that the Fuser Rollers are perfectly round shape, they tend to get bumps, throwing a lot of strange fuser errors

[Fer]

It's the connector in the machines rear plate that doesn;t make propper connection with the fuser unit. Canon has a plate to mount the connector deeper inside the the machine. It makes better conntection this way.

[charm5496]

The 80 series machine should have those mods already installed and like herrman suggested the fusers on these things get flat spots like crazy and cause all kinds of errors. Wouldn't be surprised at all if the machine needed a fuser rebuild.

[Canuck]

You replaced the thermistors...what about the thermal overheats...probably popped. Check if they are open(resistance). If they are take them out and stick them in the freezer for 10 minutes then give them a smack with a screwdriver handle. This should reset them. Re-meter their resistance. If not open now,re-install,clear the error.

[cetverooki]

I heave replaced the whole deal, thermistors and thermal overheats with same resoult, in addition fixing roller was replaced few weeks ago (problem with thumping noise).
speaking of overheating that seams to be a trouble. After trying to figure out what is wrong with this copier, i heave opened drawer with fusing assy and paper transport and railing were hot on left side of drawer.

[Fer]

... i heave opened drawer with fusing assy and paper transport and railing were hot on left side of drawer.

That;s not right, all metal parts around the fuser should be finger burning, untouchable, cover melting hot. The result of making an IR5000 fuser fuse color.

But seriously, E004 can be an connector(resistance) problem very often. Take out the fuser and inspect the connectors and also the connectors in the back of the machine.

[Canuck]

Check all the heater lamp connectors also for poor contact or shorts. You said the UFR was replaced earlier for flat spots....errors appear shortly after that? As stated carefully inspect inside the connectors on the rear of the fuser and inside machine. AC to SSR? AC output from AC driver PCB?Get the meter out to isolate it

[cetverooki]

Hi to all.

finally after digging in fusing assy i heave found error. sub heater lamp was bad (had a broken heating wire inside of glass barely visible).

thx for all help and info

[charm5496]

nice find and thanks for posting the solution to your issue!

[Fer]

Good to hear, i thought E000 was for broken lamps and E004 for thermistors/wiring. But good u found the problem instead of ordering expensive boards.

Did u also fix the color/streaks? Ussually it's just the Primary charging corona going bad, if so replace the whole assy, because the grid wears just as fast as the wire most of the time.