ir8500 toner fade / E020 / streaking

[tabstogo]

okay folks, here is a puzzler for you...but first some details:

ir8500 - count @ 3.7mil
Drum @ 1mil
Developer Unit @ 500k
All corona units less than @ 100k
NEW DC Controller PCB
NEW Toner Feeder Unit
22 service tech calls for this issue....

Machine has had persistent problem with E020 code, 85% of errors were this code. In conjunction with code, just prior, the image would begin to fade out but the code wouldn't always come up. We could shut off machine for 30 minutes or even just let it idle for a bit and then start up and start copying again. Sometimes for 10, 20, even 30k clicks. Then it would fade again or error out.

All of the new parts (except the PCB) had not prevented the E020 code from coming back. The tech finally tried clearing/flashing the RAM and I've now run 177k without the error. BUT the image has begun to fade out again. I was able to limp along for about 30k clicks running 500 sheets at a time (the job had to be batched like that) and it worked without fading. Now, I can't even do that.

In printing a test sheet (#6) the image is ugly. Pretty faded at one end and streaky. My first thought now is developer unit, but knowing that it has a low count it doesn't make sense to me. (NOTE: this is actually one of two new developer units that have been switched in this machine in an attempt to correct the fading issue and error issue, each has about 500k)

The images that I print are numbers and letters, along the 11" edge of 90# index card stock to make index tabs from. VERY little toner is used on each sheet and I imagine that would equate to similar impact on drum/developer/corona deterioration vs. someone printing thesis all day long.

The DC Controller PCB was replaced once the fading issue returned about 50k ago. Everything was reset/flashed and the new values for the board entered. One value won't 'stick' however. Every time I enter it and I then go back to check, it has changed back to +14 instead of +12, this is the HV-TR > D-PRE-TR value.

Let's see, what else....

New toner has been tried as well as removing all toner from the Developer Hopper. Doesn't seem to make a difference.

Doesn't matter if imaging via copier or printer function.

I look forward to your suggestions. Thanks!

[alex@wocltd.com]

increase black band in service mode to '3' will use more toner but will proabley fix what it.

the machine are so fast ie tweaked 605 that the toner feed doesn't keep up also adjust bias throw plate to maximum

[welshman]

check that the hopper is feeding toner correctly as well had these fail

to check open side cover take off fuser plate
cheat door switch and look at rear of developer you will see the drive gear running
have had the drive gear stick there is a drive assembly at rear of machine with clutch inside this can fail
will let you get about 150 copies 30 copies or hardly any other than that check that the bias conector not hanging on by a thread on the conector

hope this helps

[narenkrs]

Ir8500 toner fade

1.Developing assembly. Is there toner inside the developing assembly?

YES: Check the toner feedscrew inside the developing assembly for rotation;

if normal, replace the toner sensor (TS3).

2.Make the following selections in service mode:
COPIER>FUNCTION>PART-CHK; then, check the operation of

the hopper drive clutch (CL1). Does the clutch operate normally?

Hopper drive clutch (CL1)
3) Check the operation of the Hopper motor (M18) in reference to

NO: Check the connection; if normal, replace the motor.
YES: Check the following:

toner clogging

[narenkrs]

1.Developing assembly. Is there toner inside the developing assembly?

YES: Check the toner feedscrew inside the developing assembly for rotation;

if normal, replace the toner sensor (TS3).

2.Make the following selections in service mode: *2& 8
COPIER>FUNCTION>PART-CHK; then, check the operation of

the hopper drive clutch (CL1). Does the clutch operate normally?

Hopper drive clutch (CL1)

NO: Check the connection; if normal, replace the clutch.

3) Check the operation of the Hopper motor (M18) in reference to

NO: Check the connection; if normal, replace the motor.
YES: Check the following:

toner clogging

[tabstogo]

thanks. I'll give that a try in the morning and report back.

alex@wocltd.com
Trusted Tech
50+ Posts

Join Date: Nov 2007

Posts: 75
Rep Power: 2


increase black band in service mode to '3' will use more toner but will proabley fix what it.

the machine are so fast ie tweaked 605 that the toner feed doesn't keep up also adjust bias throw plate to maximum

[tabstogo]

1.Developing assembly. Is there toner inside the developing assembly?

YES: Check the toner feedscrew inside the developing assembly for rotation;

if normal, replace the toner sensor (TS3).

2.Make the following selections in service mode: *2& 8
COPIER>FUNCTION>PART-CHK; then, check the operation of

the hopper drive clutch (CL1). Does the clutch operate normally?

Hopper drive clutch (CL1)

NO: Check the connection; if normal, replace the clutch.

3) Check the operation of the Hopper motor (M18) in reference to

NO: Check the connection; if normal, replace the motor.
YES: Check the following:

toner clogging

LOTS of toner in the developing unit (both units)

TS3 Sensor was replaced when problem first cropped up, did not remedy situation.

Doesn't it seem odd that two different Developer Units can be used and yet the problem persists? Seems like there has got to be something else there.

Could something like the RAM chip be bad and keep self-corrupting and causing problems?

Oh, one other thing, the HV packs were changed out also without improvement.

I'll try the things suggested and report back to you all. Keep thinking of things though as the techs (on any one of their 22 visits) have done these things as well.

[tabstogo]

increase black band in service mode to '3' will use more toner but will proabley fix what it.

the machine are so fast ie tweaked 605 that the toner feed doesn't keep up also adjust bias throw plate to maximum

this did not change anything. Ran 50 copies with lid up to see if toner field across the sheet improved and it did not. :-(

[kwazimoto]

couple of questions have you turned off potential control to see how the copies look??? and the other sound like it maybe a transfer problem how is the block and springs for the transfer corona block?? i know you replaced it but the DC controller will cause light copies he had one doing that.. might be good idea to try another one...

[kwazimoto]

what is your vaules of VL1M sould be 50- 90
and VDM value if rom 360-420 under copier/ display/ dpot

[narenkrs]

Ir8500 toner fade

Did you enter the settings of the following from the service mode, Replacing the DC Controller PCB. Execute the following service mode to initialize RAM- COPIER>FUNCTION>CLEAR>DC-CON And do again these settings)

COPIER>ADJUST>LASER (all items)
COPIER>ADJUST>DEVELOP (all items) (.
COPIER>ADJUST>DENS (all items)
COPIER>ADJUST>BLANK (all items)
COPIER>ADJUST>V-CONT (all items)
COPIER>ADJUST>HV-PRI (all items)
COPIER>ADJUST>HV-TR (all items)
COPIER>ADJUST>HV-SP (all items)
COPIER>ADJUST>FEED-ADJ (all items)
COPIER>ADJUST>CST-ADJ (all items)
COPIER>ADJUST>EXP-LED (all items)

Enter the settings of the following from the service mode after Replacing the High-Voltage
DC PCB

COPIER>ADJUST>DEVELOP>HVT-DE
COPIER>ADJUST>HV-SP>HVT-SP
COPIER>ADJUST>HV-TR>HVT-TR
COPIER>ADJUST>HV-TR>H-PRE-TR

[tabstogo]

Did you enter the settings of the following from the service mode, Replacing the DC Controller PCB. Execute the following service mode to initialize RAM- COPIER>FUNCTION>CLEAR>DC-CON And do again these settings)

COPIER>ADJUST>LASER (all items)
COPIER>ADJUST>DEVELOP (all items) (.
COPIER>ADJUST>DENS (all items)
COPIER>ADJUST>BLANK (all items)
COPIER>ADJUST>V-CONT (all items)
COPIER>ADJUST>HV-PRI (all items)
COPIER>ADJUST>HV-TR (all items)
COPIER>ADJUST>HV-SP (all items)
COPIER>ADJUST>FEED-ADJ (all items)
COPIER>ADJUST>CST-ADJ (all items)
COPIER>ADJUST>EXP-LED (all items)

Enter the settings of the following from the service mode after Replacing the High-Voltage
DC PCB

COPIER>ADJUST>DEVELOP>HVT-DE
COPIER>ADJUST>HV-SP>HVT-SP
COPIER>ADJUST>HV-TR>HVT-TR
COPIER>ADJUST>HV-TR>H-PRE-TR

yup, entered in all the data from the sticker on the new board, followed all the procedures on that.

comparing test copies made with 'old' board vs. 'new' board I can see no difference.

[tabstogo]

what is your vaules of vl1m sould be 50- 90
and vdm value if rom 360-420 under copier/ display/ dpot

vlim = 65

vdm = 367

[narenkrs]

Ir8500 toner fade

Minor problem grate challenge.
The ends of the drum warm. Drum heater controller PCB is O.K ?
Set the meter range to 12 VDC. Connect the meter probes to J505-
A7 (+) and -A8 (−) on the DC controller PCB. Is the voltage between
the terminals 5 V in standby?

Remove the drum. Set the meter range to Ωx1, and connect the meter probes across the terminals of the heater. Does the index of the meter swing?

NO: Replace the drum heater.
YES: Replace the drum heater controller PCB.

[tabstogo]

couple of questions have you turned off potential control to see how the copies look??? and the other sound like it maybe a transfer problem how is the block and springs for the transfer corona block?? i know you replaced it but the DC controller will cause light copies he had one doing that.. might be good idea to try another one...

Turning of the potential control didn't make a difference. Tried that a while back, at first it seemed to improve things but then it actually seemed worse after 50 or so copies.

The block and springs all seem okay.