Xerox 5020, 5016 Service Manual

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7 J

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ork Center 5016, 5020

ervice Documentation

CAUTION

Certain components in the Work Center 5016/ 5020 are susceptible to damage from electrostatic dis-

01P48365 une 2008

charge. Observe all ESD procedures to avoid component damage.

P 8 W

While Xerox has tried to make this documentation accurate, Xerox will have

no liability arising out of any inaccuracies or ommissions. Changes are pe

rio-

odically made to this document. Changes, technical inaccuracies, and typ graphical errors will be corrected in subsequent editions.

All service documentation is supplied to Xerox external customers for info mational purposes only. Xerox service documentation is intended for use b certified product trained service personal only. Xerox does not warrant or represent that such documentation is complete, nor does Xerox represent or warrant that it will notify or provide to such customer any future change to this documentation. Customer performed service of equipment, or modules, components or parts of such equipment may affect the warranty offered by Xerox with respect to such equipment. You should consult the applicable warranty for its terms regarding customer or third party provide service. If the customer services such equipment, modules, components o parts thereof, the customer releases Xerox from any and all liability for the customer actions, and the customer agrees to indemnify, defend and hold Xerox harmless from any third party claims which arise directly or indirectl from such servic e.

cknowledgements

repared by Global Knowledge & Llanguage Services - North America

00 Phillips Road - Building 0218-01A

ebster, New York 14580-9791

SO9001 AND ISO27001 Certified

re trademarks of Xerox Corporation.

rinted in the USA

WorkCentre 5016, 5020

Printed in the United States of America.

Service Documentation

WorkCentre 5016, 5020 Service Documentation

701P48365

Reissue

June, 2008

***Xerox Private Data***

All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by certified, product-trained service per sonnel only. Xerox does not warrant or represent that it will notify or provide to such customer any future change to this documentation. Customer performed service of equipment, or m od ules, components, or parts of such equipment may affect whether Xerox is responsible to fix machine defects under the warranty offered by Xerox with respect to such equipment. You should consult the applicable warranty for its terms regarding customer or third-party provided service.

If the customer services such equipment, modules, components or parts thereof, the customer releases Xerox from any and all liability for the customer actions, and the custom er agrees to indemnify, defend and hold xerox harmless from any third party claims which arise directly or indirectly for such service.

While Xerox has tried to make the documentation accurate, Xerox will have no liability arising out of any inaccuracies or omissions. Changes are periodically made to this document. Changes, technical inaccuracies, and typographical errors will be corrected in subsequent edi tions.

XEROX® and all Xerox product names mentioned in this publication are trademarks of XEROX CORPORATION. Other company trademarks are also acknowledged.

PANTONE is a registered trademark of Pantone, Inc.

Changes are periodically made to this document. Changes, technical inacc uracies, and typographic errors will be corrected in subsequent editions.

CAUTION

This equipment generates, uses and can radiate radio frequency energy, and if not installed and used in accordance with the instructions documentation, may cause interference to radio communications. It has been tested and f ound to comply with t he limits for a Clas s A comput ing device pursuant to subpart B of part 15 of FCC rules, which are designed to provide rea-

sonable protection against such interference when operated in a commercial environment. Operation of this equipment in a residential area is likely to cause interference in which case

the user, at his own expense, will be required to correct the interference.

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Front Matter

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Front Matter

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How To Use This Manual................................................................................................ iii

Introduction

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Introduction

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How To Use This Manual

This manual is used as the standard service manual for the WorkCentre 5016, 5020.

Enter any comments and/or corrections regarding the WorkCentre 5 016, 5020 Service Documentationl on the Publication Comment Sheet, and send it to the Technical Support Center SDEG.

This manual describes the standard procedures for servicing the WorkCentre 5016, 5020. Refer to Section 1 Service Call Procedure f or efficient and effective servicing during mainte nance calls.

Chain 1 Standby Power Chain 2 Mode Selection Chain 3 Machine Run Control Chain 4 Start Print Power Chain 6 Imaging Chain 7 Paper Supplying Chain 8 Paper Transportation Chain 9 Marking

Chain 10 Fusing and Copy Transportation

Contents of Manual

This manual is divided into nine sections as described below.

Section 1 Service Call Procedures

This section describes the structured process for determining the type and sequence of actions that are performed during a service call.

Section 2 Status Indicator RAPs

This section contains the Repair Analysis Pr ocedures (RAPs) necessary to repair all faults other than image quality faults.

Section 3 Image Quality RAPs

This section contains the Repair Analysis Procedures (RAPs) that are used to diagnose image quality defect problems.

Section 4 Removal/Replacement and Adjustment Procedures

This section contains the removal, replacement, and adjustment procedures for components of WorkCentre 5016, 5020.

Section 5 Parts List

This section contains a list of spare parts list for the WorkCentre 5016, 5020.

Section 6 General Procedures/Information

Description of Terminology and Symbols

The terminology and symbols used throughout this service manual are described as follows:

WARNING

A Warning statement indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in personal injury or loss of life.

CAUTION

A Caution statement indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in damage to, or destruction of, equipment.

NOTE: A Note statement indicates an operating or maintenance procedure, practice, or condition that is necessary to accomplish a task efficiently.

Reference:

Used when other explanations are given.

Purpose:

Used to describe the purposes of adjustment and troubleshooting.

REP:

Indicates the removal/replacement procedure for reference.

ADJ:

Indicates the adjustment procedure for reference.

PL:

Indicates the parts list for reference.

This section contains frequently used procedures that relate to the diagnosis, setup, or operation of the machine. It also contains pertinent information that will not be found in any other part of the service documentation.

Section 7 Wiring Data

This section contains the wiring information for the WorkCentre 5016, 5020. It contains a connector list/locator, wirenet diagrams, and Block Schematic Diagrams (BSDs) for the following chains:

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ASSY:

Means Assembly.

Safety Critical Components (SCC):

These are components, such as electrostatic-sensitive IC chips, which could be damaged if not handled properly. Follow the regulations regarding Safety Critical Components set by XEROX Corp.

Introduction

iii

Introduction

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1.1 Before Starting Service............................................................................................. 1-3

1.2 Service Call Procedure . ............................................................................................ 1-4

1.3 Service Call Details................................................................................................... 1-4

1.4 TRIM Checklist.......................................................................................................... 1-5

1.5 Periodic Replaceme n t Pa rts/Consumables List................................................. ....... 1-5

1 Service Call Proced ur es

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Service Call Procedures

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1.1 Before Starting Service

1.1.1Safety

To prevent any accident that may occur during maintenance service, any warning or any caution regarding the service must be strictly observed. Do not perform any hazardous operation.

1. Power Supply To prevent electrical shocks, burns, or injury, etc., be sure to switch OFF the machine and

disconnect the plug before starting the maintenance service. If the machine has to be switched ON, such as when measuring a voltage, take extra care to avoid an electrical shock.

2. Drive Area Never inspect, clear or lubricate the drive components, such as chain belts, chain wheels

or gears, when the machine is in operation.

3. Heavy Parts When removing or installing heavy parts, keep your back straight and lift with your legs.

Some parts should not be lifted by one person:

IOT (Platen): 31.5kg (requires 3 persons) 2 Tray Modules: 8.6kg (requires 2 persons)

Take extra care of your working posture to prevent backache.

4. Safety Devices See that safety devices for preventing accidents, such as fuses, circuit breakers, interlock

switches, etc., and those for protecting customers from injury, such as panels and covers, function properly. Modifications that hinder the function of any safety devices are strictly prohibited.

5. Installing and Removing Parts The edges of parts and covers may be sharp, so take care not to touch them. Be careful

not to touch those parts, and wipe off any oil that may have adhered to your fingers or hands before servicing. When pulling out parts, cables, etc., do it gently. Do not use excessive force.

6. Specified Tools Follow the instructions when a particular tool is specified.

7. Cleaning Up Toner Spills Since toner can be explosive, sweep or brush any spilled toner into a container to collect

it. To clean away the remaining toner using a vacuum cleaner, always use an FX standard vacuum cleaner that is toner-tolerant. Never use the customer's vacuum cleaner.

8. Earthquake Preparedness Measures If the customer requests earthquake proofing, an earthquake preparedness kit is avail-

able. Check the Service Guide for more information on the earthquake preparedness kit.

9. Modifications to the Machine Before altering the machine, submit an irregular use license application.

10. Other Safety Precautions Follow the recommendations in WORKING PRACTICES FOR ENGINEERS issued by

FXAP EH&S (Environmental Health and Safety).

1.1.2Things to Note When Handling Customer Data

1. Handling of copied/printed customer data. Before you bring back any sample for the purpose of investigation/analysis, always obtain

permission from the customer. Make sure you assure them that the data will not be used for any other purpose.

2. Security-related NVM values that were changed during diagnostics. If any security-related NVM values, such as polling, were set for test purposes, make sure

you restore them to their original values after the test.

3. Other things to note when handling customer data. Follow the safety guidelines established within the OpCo and ensure that customer data

do not get compromised during service.

1.1.3 Other Precautions

To avoid performing wrong or unnecessary service, observe the following:

1. Reference Materials Read all relevant service documentation, so that you can take a systematic approach.

2. Disassembling Make sure to note the assembled condition of the machine before removing parts or dis-

assembling it.

3. Installation and Adjustment After the installation or adjustment is complete, check that no parts or tools are left inside

the machine.

4. Handling of replaced parts and consumables Make sure that any replaced parts or consumables, as well as t he packaging materials,

are taken back to the Service Center.

WARNING

Never discard the Drum/Toner Cartridges into a fire. Always keep them away from open flames to prevent them from igniting and causing a fire.

NOTE: For separation and processing methods for replaced parts or consumables, refer to Common Technical Information No. 2-138 for all machines.

• If you have replaced the following consumables, affix the "U-TAG" so that the recy-

clable parts will be handled appropriately. a. Drum Cartridge b. Toner Cartridge

• For recyclable parts, fill in the necessary items on the "U-TAG."

5. General Precautions

• Take care not to disturb the customer's daily work.

• Place any service-related trash into a trash bag and bring it to the service office.

• Clearly record the following information in the Machine Service Log:

– Details of the service call – Parts and consumables replaced

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1-3

Service Call Procedures

1.1

1.2 Service Call Procedure

1.2.1 Initial Actions

1. Ask the operator(s) about the machine’s condition.

2. Record the billing meter readings.

3. Inspect any faulty copies, then check the machine.

4. Check the Service Log.

1.2.2 Actions to Take During UM (Unscheduled Maintenance)

1. Perform the service flow in Section 2 Status Indicator RAPs.

2. Perform the applicable RAP in Section 2 Status Indicator RAPs. If there are no applicable RAPs, troubleshoot by referring to the BSD in Section 7 Wiring

Data.

3. Check the copy quality. Make several copies using the Test Pattern (499T247), then check the quality.

4. Look at the last 20 error codes in order to understand the machine status.

• Enter Diagnostic Mode. Enter [40-01] (Display Error History How to Enter the Diag -

nostic Mode).

• When the last error code is displayed, press t he [Start] key to return to the Function

input screen.

• Pressing the [Stop] key during the display will stop it and return you to the Function

input screen.

5. Repair all the secondary problems.

6. Perform TRIM servicing.

1.2.3 Actions to Take During SM (Scheduled Maintenance)

1. Check the copy quality. Make several copies using the Test Pattern (499T247), then check the quality.

2. Look at the last 20 error codes in order to understand the machine status.

• Enter Diagnostic Mode. Enter [40-01] (Display Error History How to Enter the Diag -

nostic Mode).

• When the last error code is displayed, press t he [Start] key to return to the Function

input screen.

• Pressing the [Stop] key during the display will stop it and return you to the Function

input screen.

3. Perform TRIM servicing.

1.2.4 Final Actions

1. Check overall machine operation/features.

2. Check the machine exterior and consumables.

3. Train the operator as required.

4. Complete the Service Log and Service Report.

5. Keep the copy samples with the Service Log.

1.3 Service Call Details

1.3.1 Initial Actions

1. Ask the operator(s) about the machine’s condition.

• Frequency and location of recent paper jams

• Copy quality

2. Record the billing meter readings.

3. Inspect any faulty copies, then check the machine.

4. Check the copy sample and the Service Log from the last call.

1.3.2 Checking Reproducibility of Problem

1. Perform the service flow in Section 2 Status Indicator RAPs.

2. Perform the applicable RAP in Section 2 Status Indicator RAPs.

3. If there are no applicable RAPs, troubleshoot by referring to the B SD in Se ction 7 Wiring Data.

1.3.3 Checking Copy Quality

1. Make several copies using the Test Pattern (499T247), then check the quality.

2. If there is a problem in copy quality, perform the applicable RAP in Section 3 Image Quality.

1.3.4 TRIM Servicing

Perform TRIM servicing during the maintenance call.

1. Perform the necessary TRIM items using the TRIM Checklist.

2. Check for parts that require periodic cleaning/replacement by referring to the TRIM Checklist and the Periodic Replacement Parts/Consumables List. Clean them if neces sary. If replaced, always clear the counters of the corresponding items in the Chain Function.

Service Call Procedures

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1.4 TRIM Checklist

A: Check. Clean, replace, or replenish if necessary.

B: Always check and clean.

*: Always replace at the specified interval.

Table 1

Every

No. Service Items

1.1 Check before servicing (check machine operation)

1.2 Check before Servicing (copy the Test Pattern)

2 Clean the interior of the

machine (paper transport system)

3 Clean the IIT A • Clean the Platen Glass surface and the Platen

5 Safety Precautions B • Make sure that the power cord is plugged in

6.1 Check after servicing (copy quality check)

6.2 Check after servicing (check machine operation)

time

Service Details

A Turn on the machine, and make sure that there are

no abnormal sounds.

A Make several copies using the Test Pattern

(499T247), then check the image quality.

A Clean the paper dust and toner residue in the paper

path and on the jam sensor.

Cushion with the optical cleaning cloth.

• Clean the Reflector, back of the Platen Glass, mirrors and lens with the optical cleaning cloth.

properly.

• Make sure that there are no cracks in the power plug and no holes or cuts in the power cord insulation.

• If an extension cord or power strip is used, make sure it is of sufficient capacity to handle the power requirements of the machine.

• Make sure that no more than one power plug is connected to a single socket.

A Make several copies using the Test Pattern

(499T247), then check the image quality.

A • Check the paper feed.

• Make sure that there are no abnormal sounds.

1.5 Periodic Replacement Parts/Consumables List

When servicing the machine, check the number of copies and the replacement interval for the consumables and parts that require periodical cleaning/replacement. Clean or replace them if necessary. The IOT history can be checked at Chain-Function > NVRAM R/W, while the IIT history can be checked in the Counters (r efer to Diagnost ic M ode in S ect ion 2 Status Indicator RAPs). For items that cannot be checked in the Diagnostic Mode, clean or replace them according to the replacement intervals (standard PV).

CAUTION

Do not keep toner and drum cartridges in your car for long periods of time.

Table 1

Parts/Consumables Name/PL No.

1 Tray 1 Feed Roll/

Retard Pad

2 Tray 2 Feed Roll/

Retard Roll

3 MSI Feed Roll/

Retard Pad

4 Fuser Unit 100,000 [21/39] [21/29] [21/19] [21/9]

5 Toner Cartridge 6,000 6 Drum Cartridge 36,000 31,000 (Warning)

Replacement Interval (copies)

50,000 [29/34] [29/24] [29/14] [29/4]

100,000 [29/25] [29/15] [29/5]

50,000 [29/39] [29/29] [29/19] [29/9]

Counters Check

Count up 1 for every feed. Replace both at the same time .

Count up 1 for every feed. Replace both at the same time.

Count up 1 for every feed.

36,000 (Machine Stops)

6.3 Check after servicing (check the meter)

Do not touch the Drum of the Drum Cartridge.

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A Create the Service Log and Service Report.

CAUTION

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Service Call Procedures

1.4, 1.5

Service Call Procedures

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Error Codes

Fault Repair Overview and List of Error Codes............................................................... 2-3

RAPs

U0-1 Main Motor Stop Error............................................................................................ 2-25

U1-1 Main Motor Rotation Error...................................................................................... 2-25

U2-1 Carriage Module Fail.............................................................................................. 2-26

U3-5 Laser Power Or ROS Motor Fail.............. ................... ................................... ....... 2-26

U4-1 Fuser On Time Fail............................ ................... ................... .............................. 2-27

U4-2 Over Heat Temp Fail............................................................................................. 2-27

U4-3 FS1 Thermistor Defect.......................................................................................... 2-28

U4-9 Fuser Fan Defect........................... ................... ..................................................... 2-28

U6-2 RAM Read/Write Check Error ............................................................................... 2-29

U6-3 NVM Data Defect .................................................................................................. 2-29

U6-4 NVM Read/Write Cannot Be Executed ................................................................. 2-30

U6-5 CPU Power To Access NVM Is Not Enough......................................................... 2-30

U7-0 UI Communication TimeOut....................... ...................................................... ..... 2-31

U7-1 UI Communication Error................................. ................... ................... ................. 2-31

U8-1 Billing Counter Defect............................................................................................ 2-32

U9-0 HVPS Fail........................................ .................................... ................... ............... 2-32

062-300 Platen Interlock Open ....................................................................................... 2-33

062-345 IISS EEPROM Failure....................................................................................... 2-33

062-360 Carriage Position Fail........................................................................................ 2-34

062-371 Lamp Illumination Fail....................................................................................... 2-34

062-380 AGC Failure ...................................................................................................... 2-35

062-386 AOC Failure ...................................................................................................... 2-35

062-392 IPS PWB Memory Fail ...................................................................................... 2-36

062-393 IPS PWB Fail .................................................................................................... 2-36

005-170 DADF Feed Failure........................................................................................... 2-37

005-171 DADF Regi / Exit Failure.................................................................................. 2-38

005-172 DADF Inverted Document Jam......................................................................... 2-39

005-198 Short Scan Jam ................................................................................................ 2-40

005-199 Long Scan Jam................................................................................................. 2-40

005-305 Feeder Top Cover Open................................................................................... 2-41

005-920 Static Jam......................................................................................................... 2-41

2 Status Indicator RAPS

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Status Indicator RAPS

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Fault Repair Overvie w and List of Error Codes

Fault Repair Overview

The fault repair operation proceeds in the following flow. After performing the pre-check, verify the symptoms and refer to the Error Code List and Section 7 Wiring Data to effectively repair the fault:

Check the status of Installation

Check the problem status

Perform RAP

Diagnostic Mode Operating Principles Wiring Data

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Check if the fault is repaired

Completed

Figure 1 Tr oubleshooting Procedure

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Reference Information

Status Indicator RAPS

Check the Status of Installation

Before starting to troubleshoot, always check the following items:

• The voltage of the power supply (measure the voltage at the power outlet to see if it is within specification).

• The power cord for damage, short circuits, open circuits, and wrong internal connections.

• The machine for proper grounding.

• The machine is not installed in a place with high temperature, high humidity, low temperature, low humidity, or a place with drastic changes in temperature.

• The machine is not installed near a water outlet, humidifier, heater or fire source, dusty areas, or under the direct draft of an air conditioner.

• The machine is not installed in a place where volatile or flammable gas is generated.

• The machine is not installed in a place exposed to direct sunlight.

• The machine is installed in a well-ventilated place.

• The machine is installed on a stable level surface.

• The paper is within specification (standard paper is recommended).

• The machine for any improper handling.

• The Periodic Replacement Parts are replaced at the proper intervals.

Safety Considerations

• Before servicing, always unplug the power cord unless required otherwise. When the power is turned ON, never touch a current-carrying part unless required otherwise. Also, since current is carried in the LVPS power switch/inlet even when the power is turned OFF, never touch this area.

• When turning the power ON to perform a check while the Interlock Switch or Security Switch is also turned ON and the covers are removed, always disconnect the connector ( P/J140) that is connected to the ROS, unless required otherwise, because a laser beam might be emitted from the ROS.

• When connecting the connector ( P/J520) on the HVPS according to the instructions in the RAP, never touch the HVPS and high-voltage output parts.

• When performing a high voltage output check using the Input Diagnostics or Output Diagnostics in Diagnostic Mode, make sure that all covers are installed unless specified otherwise. Also, never touch any high voltage output section when performing the high voltage output check.

• When operating the Drive Section using the Input Diagnostics or Output D iagnostics in Diagnostic Mode, make sure that all covers are installed unless specified otherwise. Also, never touch the Drive Section while operating it.

• Be careful not to burn yourself when touching parts that can get very hot.

• When servicing, use a grounded wrist band to remove static electricity from your body.

Things to Note When Using RAPs

• When troubleshooting using RAPs, prepare normally working parts such as the AIOC PWB, LVPS, HVPS and Fuser in advance because they might be required to identify a failure. In addition, if the fault cannot be repaired, replace the "parts considered to be the cause" and related parts in sequence and check the operation.

• When servicing, always disconnect the power cord unless required otherwise. When the power cord is connected, never touch any current-carrying part unless absolutely neces sary.

• Descriptions related to connectors are expressed as follows: “P/J12" -> The connector (P/ J12) is in the connected state. "P12" -> The plug side when the connector (P/J12) is in the disconnected state (except when it is directly connected to a board). "J12" -> The jack side when the connector (P/J12) is in the disconnected state (except when it is directly connected to a board).

• In a RAP, "P/J1 <=> P/J2" means that all the opposing pins between "P/J1" and "P/J12" (refer to Section 7, Wiring Data) should be measured.

• The voltages on small connectors are measured using a special tool. Handle the tool carefully because it has a sharp tip.

• The numerical values described in the RAPs are for re ference only. Approximate values are considered to be the same.

• Note that for the checks specified in the RAP, you must check the references for the parts that must be removed and their procedures.

• "Replacement" in the RAPs indicates the parts that are considered to be the cause of the problem. Check by replacing the parts and, if necessary, the assembly that contains those parts.

• In the RAPs, the highest level paper supply is called "Tray 1," and the one below it is called "Tray 2."

• In the RAPs, some procedures are described separately for each specification. Follow the instructions for your model to repair the faults.

RAP Flow

RAPs are a good place to start in diagnosing a failure. RAPs guide you through the troubleshooting process by checking for th e presence of error codes and other types of problematic symptoms. To troubleshoot problems related to image quality, refer to Section 3 Image Qu ality Troubleshooting.

Status Indicator RAPS

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Ask the operator about the problem Did the operator operate the machine correctly?

Yes

Turn the Power Switch OFF then ON

Does the error recur when operating the machine in the same way as before (when the problem originally occurred)?

Yes

Does the Control Panel display an Error Code?

Yes

Figure 2 RAP Flow

Explain how to operate the machine

Procedure is complete

Refer to the Error Code List and perform the relevant troubleshooting

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Status Indicator RAPS

Error Code List

NOTE: In the “Record in Error Log” column, “O” = yes and “X” = no.

Error Code

C1-1

Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name

Tray1 F/O#1 SNR on JAM

Explanation

Timeout between Tray1 Feed Clutch ON and Tray1 Feed Sensor ON.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

• [08-07] Tray1 Feed Sensor

• [08-12] Tray1 Feed Clutch

Check Items

• Feed Roll or Retard Pad dirty, contaminated with paper dust, worn, or faulty

• Tray1 Feed Sensor dirty and Sensor Actuator deformed or damaged

• Paper damaged, not within specification, or not loaded correctly

• Foreign matter, burrs, or paper in the paper path

• Drive gear worn or damaged

• Tray1 Feed Clutch faulty

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Tray 1 Feed Sensor (PL 2.5)(REP 2.5.1).

– Wire between Tray 1 Feed Sensor J158-3 ( P/J158) and LVPS J501-6 ( P/J501) – Wire between Tray 1 Feed Sensor J158-2 and LVPS J501-7 – Wire between Tray 1 Feed Sensor J158-1 and LVPS J501-8

• Replace the Tray1 Feed Clutch (PL 2 . 2) (REP 2.2.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

Record in Error Log

O -

RAP BSD

CH8.1

Figure 1

Status Indicator RAPS

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Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

Tray1 Regi SNR on JAM

Explanation

Timeout between Tray1 Feed Sensor ON and IOT Registration Sensor ON.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

• [08-07] Tray1 Feed Sensor

• [08-05] IOT Registration Sensor

• [08-10] IOT Registration Clutch

Check Items

• Take Away Roll 1 dirty, contaminated with paper dust, worn, or faulty

• Tray1 Feed Sensor dirty and Sensor Actuator deformed or damaged

• Paper damaged, not within specification, or not loaded correctly

• Foreign matter, burrs, or paper in the paper path

C1-2

• Drive gear worn or damaged

• IOT Registration Clutch faulty

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Tray 1 Feed Sensor (PL 2.5) (REP 2.5.1).

– Wire between Tray 1 Feed Sensor J158-3 ( P/J158) and LVPS J501-6 ( P/J501) – Wire between Tray 1 Feed Sensor J158-2 and LVPS J501-7 – Wire between Tray 1 Feed Sensor J158-1 and LVPS J501-8

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the IOT Registration Sensor (PL 2.9).

- Wire between IOT Registration Sensor J156-3 ( P/J156) and LVPS J503-1 ( P/J503)

- Wire between IOT Registration Sensor J156-2 and LVPS J503-2

- Wire between IOT Registration Sensor J156-1 and LVPS J503-3

• Replace the IOT Registration Clutch (PL 2.9) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

Record in Error Log RAP BSD

CH8.1

O -

Figure 1

CH8.4

Figure 4

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Status Indicator RAPS

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

STM F/O#2 SNR on JAM

Explanation

Timeout between STM Feed Motor ON and STM Feed Sensor ON.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

• [08-06] STM Feed Sensor

• [08-11] STM Feed Clutch

• [08-13] STM Feed Motor

Check Items

• Tray2 Feed Roll or Tray2 Retard Roll dirty, contaminated with paper dust, worn, or faulty

• STM Feed Sensor dirty and Sensor Actuator deformed or damaged

C2-1

• Paper damaged, not within specification, or not loaded correctly

• Foreign matter, burrs, or paper in the paper path

• Drive gear worn or damaged

• STM Feed Clutch faulty

• STM Feed Motor faulty

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the STM Feed Sensor (PL

11.5) (REP 11.5.1 ).

– - Wire between STM Feed Sensor J172-3 ( P/J172) and STM PWB J542-6 ( P/J542) – - Wire between STM Feed Sensor J172-2 and STM PWB J542-7 – - Wire between STM Feed Sensor J172-1 and STM PWB J542-8

• Replace the STM Feed Clutch (PL 11.6) (REP 11.6.1), the STM Feed Motor (PL 11.6) (REP 11.6.2), and the STM PWB (PL 11.5) (REP

11.5.2 ) in that order.

Record in Error Log RAP BSD

O -

CH8.2

Figure 2

Status Indicator RAPS

June, 2008

2-8

Reissue

WorkCentre 5016, 5020

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

Tray1 F/O#1 SNR on JAM from STM feed

Explanation

Timeout between STM Feed Out Sensor ON and Tray 1 Feed Out Sensor ON.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

• [08-06] STM Feed Sensor

• [08-07] Tray1 Feed Sensor

• [08-11] STM Feed Clutch

• [08-13] STM Feed Motor

Check Items

• Take Away Roll 2 dirty, contaminated with paper dust, worn, or faulty

• STM Feed Sensor dirty and Sensor Actuator deformed or damaged

• Paper damaged, not within specification, or not loaded correctly

• Foreign matter, burrs, or paper in the paper path

C2-2

• Drive gear worn or damaged

• STM Feed Clutch faulty

• STM Feed Motor faulty

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the STM Feed Sensor (PL

11.5) (REP 11.5.1).

– Wire between STM Feed Sensor J172-3 ( P/J172) and STM PWB J542-6 ( P/J542) – Wire between STM Feed Sensor J172-2 and STM PWB J542-7 – Wire between STM Feed Sensor J172-1 and STM PWB J542-8

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Tray 1 Feed Sensor (PL 2.5) (REP 2.5.1).

– Wire between Tray 1 Feed Sensor J158-3 ( P/J158) and STM PWB J501-6 ( P/J501) – Wire between Tray 1 Feed Sensor J158-2 and STM PWB J501-7 – Wire between Tray 1 Feed Sensor J158-1 and STM PWB J501-8

• Replace the STM Feed Clutch (PL 11.6) (REP 11.6.1), the STM Feed Motor (PL 11.6) (REP 11.6.2), and the STM PWB (PL 11.5) (REP

11.5.2) in that order.

Record in Error Log RAP BSD

CH8.1

O -

Figure 1

CH8.2

Figure 2

Reissue WorkCentre 5016, 5020

June, 2008

2-9

Status Indicator RAPS

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

STM Regi SNR on JAM

Explanation

• When feeding paper from the STM, timeout between Tray1 Feed Sensor ON and IOT Registration Sensor ON.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

• [08-05] IOT Registration Sensor

• [08-10] IOT Registration Clutch

Check Items

• Take Away Roll 1 dirty, contaminated with paper dust, worn, or faulty

• IOT Registration Sensor dirty and Sensor Actuator deformed or damaged

• Paper damaged, not within specification, or not loaded correctly

• Foreign matter, burrs, or paper in the paper path

C2-3

• Drive gear worn or damaged

• IOT Registration Clutch faulty

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Tray 1 Feed Sensor (PL 2.5) (REP 2.5.1).

– Wire between Tray 1 Feed Sensor J158-3 ( P/J158) and LVPS J501-6 ( P/J502) – Wire between Tray 1 Feed Sensor J158-2 and LVPS J501-7 – Wire between Tray 1 Feed Sensor J158-1 and LVPS J501-8

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the IOT Registration Sensor (PL 2.9).

– Wire between Tray 1 Feed Sensor J156-3 ( P/J156) and LVPS J503-1 ( P/J503) – Wire between Tray 1 Feed Sensor J156-2 and LVPS J503-2 – Wire between Tray 1 Feed Sensor J156-1 and LVPS J503-3

• Replace the IOT Registration Clutch (PL 2.9) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

Error Name

No paper in the selected paper tray (Tray1)

Explanation

• No paper is detected in Tray1 when ATS function is disabled and Tray1 is selected during a copy job.

• No paper is detected in Tray1 when Tray1 is selected during a print job (the paper size setting matches the one specified for the job).

I/O Diagnostic Codes

[07-07] Tray1 No Paper Sensor

Check Items

C5-0

• Press the [Stop] button on the Control Panel.

• Check the tray to see if it is empty; if it is, add paper specified by the job.

• Tray1 No Paper Sensor dirty and Sensor Actuator deformed or damaged

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Tray 1 No Paper Sensor (PL 2.7) (REP 2.7.1).

– Wire between Tray1 No Paper Sensor J157-3 ( P/J157) and LVPS J501-3 ( P/J501) – Wire between Tray1 No Paper Sensor J157-2 and LVPS J501-4 – Wire between Tray1 No Paper Sensor J157-1 and LVPS J501-5

• Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Record in Error Log RAP BSD

CH8.1

O -

Figure 1

CH8.4

Figure 4

X -

CH7.1

Figure 1

Status Indicator RAPS

June, 2008

2-10

Reissue

WorkCentre 5016, 5020

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

Tray1 Paper Size Mismatch

Explanation

C5-1

• Paper that is different from the one in the Tray Settings is detected when feeding.

• Or, paper size setting in Tray1 is different from the paper size specification of the job when Tray1 is selected during a print job.

Check Items

• Press the [Stop] button on the Control Panel.

• Change the paper size of Tray 1 to the one specified by the job.

Error Name

No paper in the selected paper tray (Tray2)

Explanation

• No paper is detected in the STM when ATS function is disabled and STM is selected during a copy job.

• No paper is detected in the STM when STM is selected during a print job (the paper size setting matches the one specified for the job).

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

[07-08] STM No Paper Sensor

Check Items

C6-0

• Press the [Stop] button on the Control Panel.

• Load the correct paper into the STM.

• STM No Paper Sensor dirty and Sensor Actuator deformed or damaged.

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the STM No Paper Sensor (PL 11.7) (REP 11.7.1).

– Wire between STM No Paper Sensor J171-3 ( P/J171) and STM PWB J542-3 ( P/J542) – Wire between STM No Paper Sensor J171-2 and STM PWB J542-4 – Wire between STM No Paper Sensor J171-1 and STM PWB J542-5

• Replace the STM PWB (PL 11.5) (REP 11.5.2) and the AIOC PWB (PL 8.1) (REP 8.1.1).

Error Name

Tray2 Paper Size Mismatch

Explanation

C6-1

• Paper that is different from the one in the Tray Settings is detected when feeding.

• Or, paper size setting in the STM is different from the paper size specification of the job when STM is selected during a print job.

Check Items

• Press the [Stop] button on the Control Panel.

• Change the paper size of STM to the one specified by the job.

Error Name

MSI Paper Size Mismatch

Explanation

C7-1

• Paper that is different from the one in the Tray Settings is detected when feeding.

• Or, paper size setting in the MSI is different from the paper size specification of the job when MSI is selected during a print job.

Check Items

• Press the [Stop] button on the Control Panel.

• Change the paper size of Bypass to the one specified by the job.

Record in Error Log RAP BSD

X - -

X -

CH7.2

Figure 2

X - -

Reissue WorkCentre 5016, 5020

June, 2008

2-11

Status Indicator RAPS

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

APS NG Unselected

Explanation

• Either Tray 1 or STM is in one of the "paper settings is of a size that causes missing image" states when APS is selected during a copy job.

C0-1

• Or, either T r ay 1 or STM is "set with paper size that is different from the one specified for the job" when Auto Tray is selected during a print job.

Check Items

• Press the [Stop] button on the Control Panel.

• Change the paper size of Tray 1 or STM to the one specified by the job.

Error Name

MSI Regi SNR on JAM

Explanation

Timeout between Bypass Solenoid ON and IOT Registration Sensor ON.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

• [08-05] IOT Registration Sensor

• [08-17] Bypass Solenoid

Check Items

• Bypass Feed Roll, Retard Pad, or Bypass Take Away Roll dirty , contaminated with paper dust, worn, or faulty

• IOT Registration Sensor dirty and Sensor Actuator deformed or damaged

• Paper damaged, not within specification, or not loaded correctly

C9-3

• Foreign matter, burrs, or paper in the paper path

• Drive gear worn or damaged

• Bypass Solenoid faulty

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the IOT Registration Sensor (PL 2.9).

– Wire between Tray 1 Feed Sensor J156-3 ( P/J156) and LVPS J503-1 ( P/J503) – Wire between Tray 1 Feed Sensor J156-2 and LVPS J503-2 – Wire between Tray 1 Feed Sensor J156-1 and LVPS J503-3

• Check that the Bypass Solenoid and the LVPS J502-1/3 ( P/J502) pins are connected securely with good electrical contact. If there is no problem, replace the Bypass Solenoid (PL 7.5).

• Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Record in Error Log RAP BSD

X -

CH3.2

Figure 2

CH8.3

O -

Figure 3

CH8.4

Figure 4

Status Indicator RAPS

June, 2008

2-12

Reissue

WorkCentre 5016, 5020

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

F/O#1 SNR Static JAM

Explanation

Tray1 Feed Sensor ON is detected during standby.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

[08-07] Tray1 Feed Sensor

Check Items

C8-1

• Tray1 Feed Sensor dirty and Sensor Actuator deformed or damaged

• Foreign matter, burrs, or paper in the paper path

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Tray 1 Feed Sensor (PL 2.5) (REP 2.5.1).

• Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Error Name

F/O#2 SNR Static JAM

Explanation

STM Feed Sensor ON is detected during standby.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

[08-06] STM Feed Sensor

Check Items

C8-2

• STM Feed Sensor dirty and Sensor Actuator deformed or damaged

• Foreign matter, burrs, or paper in the paper path

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the STM Feed Sensor (PL

11.5) (REP 11.5.1).

– Wire between STM Feed Sensor J172-3 ( P/J172) and STM PWB J542-6 ( P/J542) – Wire between STM Feed Sensor J172-2 and STM PWB J542-7 – Wire between STM Feed Sensor J172-1 and STM PWB J542-8

• Replace the STM PWB (PL 11.5) (REP 11.5.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

Error Name

CPM Image Lost

E0-1

Explanation

During a copy job in CMP Priority Mode, it is detected that the paper containing an image cannot be output after the image is deleted.

Check Items

Press the [Stop] button on the Control Panel.

Record in Error Log RAP BSD

O -

CH8.1

Figure 1

CH8.2

Figure 2

O - -

Reissue WorkCentre 5016, 5020

June, 2008

2-13

Status Indicator RAPS

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

Regi SNR Static JAM

Explanation

IOT Registration Sensor ON is detected during standby .

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

[08-05] IOT Registration Sensor

Check Items

E1-6

• Sensor dirty

• Foreign matter, burrs, or paper in the paper path

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the IOT Registration Sensor (PL 2.9).

– Wire between Tray 1 Feed Sensor J156-3 ( P/J156) and LVPS J503-1 ( P/J503) – Wire between Tray 1 Feed Sensor J156-2 and LVPS J503-2 – Wire between Tray 1 Feed Sensor J156-1 and LVPS J503-3

• Replace the AIOC PWB (PL 8.1)(REP 8.1.1).

Error Name

Exit SNR JAM

Explanation

Fuser Exit Sensor ON is detected during standby.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

[10-23] Fuser Exit Sensor

Check Items

E3-6

• Fuser Exit Sensor dirty and Sensor Actuator deformed or damaged

• Foreign matter, burrs, or paper in the paper path

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Fuser Exit Sensor (PL

6.2).

– Wire between Fuser Exit Sensor J153-3 ( P/J153) and LVPS J505-1 ( P/J505) – Wire between Fuser Exit Sensor J153-2 and LVPS J505-2 – Wire between Fuser Exit Sensor J153-1 and LVPS J505-3

• Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Record in Error Log RAP BSD

O -

CH8.4

Figure 4

CH10.2

Figure 2

Status Indicator RAPS

June, 2008

2-14

Reissue

WorkCentre 5016, 5020

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

IOT L/H Cover open

Explanation

The Left Hand Cover is open.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

[01-01] LH Cover Interlock Switch

E5-1

Check Items

• Check that the Left Hand Cover closes correctly.

• Check that the LH Cover Interlock Switch is correctly installed and that the electrical connection is good.

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the LH Cover Interlock Switch (PL 8.2).

– Wire between LH Cover Interlock Switch FS151 ( FS151) and LVPS J506-4 ( P/J506) – Wire between LH Cover Interlock Switch FS152 ( FS152) and LVPS J506-3

• Replace the LVPS (PL 8.1) (REP 8.1.2) and the AIOC PWB (PL 8.1 ) (REP 8.1.1) in that order.

Error Name

IOT Front Cover open

Explanation

The Front Cover is open.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

[01-12] Front Cover Interlock Switch

E5-2

Check Items

• Check that the Front Cover closes correctly.

• Check that the Front Cover Interlock Switch is correctly installed and that the electrical connection is good.

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Front Cover Interlock Switch (PL 8.2).

– Wire between Front Cover Interlock Switch FS153 ( FS153) and LVPS J506-2 ( P/J506) – Wire between Front Cover Interlock Switch FS154 ( FS154) and LVPS J506-1

• Replace the LVPS (PL 8.1) (REP 8.1.2) and the AIOC PWB (PL 8.1 ) (REP 8.1.1) in that order.

Error Name

L/H Low Cover open

Explanation

Access Cover 1 is open.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

[01-11] Tray1 Interlock Switch

E6-1

Check Items

• Check that Access Cover 1 closes correctly.

• Check that the Tray 1 Interlock Switch is correctly installed and that the electrical connection is good.

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Tray 1 Interlock Switch (PL 2.5).

– Wire between Tray 1 Interlock Switch J161-2 ( P/J161) and LVPS J501-9 ( P/J501) – Wire between Tray 1 Interlock Switch J161-1 and LVPS J501-10

• Replace the LVPS (PL 8.1) (REP 8.1.2) and the AIOC PWB (PL 8.1 ) (REP 8.1.1) in that order.

Record in Error Log RAP BSD

X -

CH1.2

Figure 2

CH1.2

Figure 2

CH7.1

Figure 1

Reissue WorkCentre 5016, 5020

June, 2008

2-15

Status Indicator RAPS

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

STM L/H Cover open

Explanation

Access Cover 2 is open.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

[01-10] STM Interlock Switch

E6-2

Check Items

• Check that Access Cover 2 closes correctly.

• Check that the STM Interlock Switch is correctly installed and that the electrical connection is good.

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the STM Inte r lo ck Sw it ch (PL 11.5).

– Wire between STM Interlock Switch J173-2 ( P/J173) and STM PWB J542-9 ( P/J542) – Wire between STM Interlock Switch J173-1 and STM PWB J542-10

• Replace the STM PWB (PL 11.5) (REP 11.5.2), the LVPS (PL 8.1) (REP 8.1.2), and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

Error Name

Nup NG Out Of Range

Explanation

The magnification is not within the range of 50 to 200% during Nup.

E8-1

Check Items

• Press the [Stop] button on the Control Panel.

• Press the [Paper Supply] button on the Control Panel.

• Press the [Special Copy] button on the Control Panel.

• Press the [Original Size Input] button on the Control Panel.

• Press the [Clear All] button on the Control Panel.

Error Name

Nup Paper direction mismatch

Explanation

The paper orientation of the document and the tray are not aligned during Nup.

E8-2

Check Items

• Press the [Stop] button on the Control Panel.

• Press the [Paper Supply] button on the Control Panel.

• Press the [Special Copy] button on the Control Panel.

• Press the [Original Size Input] button on the Control Panel.

• Press the [Clear All] button on the Control Panel.

Record in Error Log RAP BSD

X -

CH7.2

Figure 2

CH3.2

Figure 2

CH3.2

Figure 2

Status Indicator RAPS

June, 2008

2-16

Reissue

WorkCentre 5016, 5020

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

Exit SNR on JAM

Explanation

Timeout between IOT Registration Clutch ON and Fuser Exit Sensor ON.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

• [08-10] IOT Registration Clutch

• [10-23] Fuser Exit Sensor

Check Items

• Registration Roll dirty, contaminated with paper dust, worn, or faulty

• Fuser Exit Sensor dirty and Sensor Actuator deformed or damaged

• Paper damaged or not within specification

E1-2

• Foreign matter, burrs, or paper in the paper path

• Drive gear worn or damaged

• IOT Registration Clutch faulty

• Check that the IOT Registration Clutch and the LVPS J503-4/5 ( P/J503) pins are connected securely with good electrical contact. If there is no problem, replace the IOT Registration Clutch (PL 2.9).

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Fuser Exit Sensor (PL

6.2).

– Wire between Fuser Exit Sensor J153-3 ( P/J153) and LVPS J505-1 ( P/J505) – Wire between Fuser Exit Sensor J153-2 and LVPS J505-2 – Wire between Fuser Exit Sensor J153-1 and LVPS J505-3

• Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Error Name

Exit SNR off JAM

Explanation

Timeout between Fuser Exit Sensor ON and Fuser Exit Sensor OFF.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

[10-23] Fuser Exit Sensor

Check Items

• Fuser Exit Sensor dirty and Sensor Actuator deformed or damaged

E3-1

• Paper damaged or not within specification

• Foreign matter, burrs, or paper in the paper path

• Drive gear worn or damaged

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Fuser Exit Sensor (PL

6.2).

– Wire between Fuser Exit Sensor J153-3 ( P/J153) and LVPS J505-1 ( P/J505) – Wire between Fuser Exit Sensor J153-2 and LVPS J505-2 – Wire between Fuser Exit Sensor J153-1 and LVPS J505-3

• Replace the LVPS (PL 8.1) (REP 8.1.2) and the AIOC PWB (PL 8.1 ) (REP 8.1.1) in that order.

Record in Error Log RAP BSD

O -

CH10.2

Figure 2

CH10.2

Figure 2

Reissue WorkCentre 5016, 5020

June, 2008

2-17

Status Indicator RAPS

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

• MCU-STM comm. error

Explanation

H9-7

A communication failure has occurred between the MCU and the Tray Module.

Check Items

• Turn the power OFF then ON.

• Check for any open circuit or short circuit between the STM connectors.

• Replace the STM PWB (PL 11.5) (REP 11.5.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

Error Name

Copy Counter Full

L9-0

Explanation

The user that is logged in has reached the allotted copy limit in the Account Mode.

Check Items

Press the [Stop] button on the Control Panel.

Error Name

Toner Cartridge was PRENEAR empty

Explanation

The toner cartridge is low.

J1-0

Check Items

• Refill the toner.

• Foreign matter on the sensor.

• Check that the T oner Empty Sensor and the L VPS J509-1-4 ( P/J509) pins are connected securely with good electrical contact. If there is no problem, replace the Toner Empty Sensor (PL 4.2).

• Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Error Name

Toner Empty

Explanation

The Toner Cartridge is empty.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

J1-2

[09-07] Toner Empty Sensor

Check Items

• Refill the toner.

• Foreign matter on the sensor.

• Check that the Toner Empty Sensor and the LVPS J509 ( P/J509) 1-4 pins are connected securely with good electrical contact. If there is no problem, replace the Toner Empty Sensor (PL 4.2).

• Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Record in Error Log RAP BSD

O -

X -

CH3.1

Figure 1

CH3.2

Figure 2

X - -

O -

CH9.2

Figure 2

Status Indicator RAPS

June, 2008

2-18

Reissue

WorkCentre 5016, 5020

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

No Drum Cartridge

Explanation

Unable to detect the Drum Cartridge.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

[09-02] Drum Cartridge

Check Items

• Turn the power OFF then ON.

J3-1

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Drum Cartridge (PL

4.1) (REP 4.1.1).

– Wire between Drum Cartridge P610-7 ( P610) and AIOC PWB J402-1 ( P/J402) – Wire between Drum Cartridge P610-3 and AIOC PWB J402-4 – Wire between Drum Cartridge P610-2 and AIOC PWB J402-5 – Wire between Drum Cartridge P610-5 and AIOC PWB J402-2 – Wire between Drum Cartridge P610-4 and AIOC PWB J402-3 – Wire between Drum Cartridge P610-1 and AIOC PWB J402-6

• Replace the Drum Cartridge (PL 4.1) (REP 4.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

Error Name

Drum near end of life

J6-0

Explanation

The Drum Cartridge is near the end of its life.

Check Items

Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).

Error Name

Drum cartridge life end

J6-1

Explanation

The Drum Cartridge has reached the end of its life.

Check Items

Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).

Record in Error Log RAP BSD

O -

CH9.2

Figure 2

X - -

O - -

Reissue WorkCentre 5016, 5020

June, 2008

2-19

Status Indicator RAPS

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

Drum CRUM comm. Error

Explanation

The AIOC PWB is unable to communicate with the Drum Cartridge.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)

• [09-02] Drum Cartridge

Check Items

• Turn the power OFF then ON.

J7-1

• Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Drum Cartridge (PL

4.1) (REP 4.1.1).

• Replace the Drum Cartridge (PL 4.1) (REP 4.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

Error Name

Drum CRUM Market Identity Mismatch

Explanation

J7-2

The AIOC PWB has detected that the Drum CRUM destination does not match.

Check Items

• Turn the power OFF then ON.

• Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).

Error Name

Drum CRUM ID error

Explanation

J7-3

• The AIOC PWB has detected that the Drum CRUM ID is incorrect.

Check Items

• Turn the power OFF then ON.

• Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).

Error Name

EPC Memory F ull

Explanation

N1-1

• During a copy job in Collate Mode, the EPC memory is full.

• Or, the machine has reached a state where it is unable to scan in any more documents.

Check Items

Press the [Stop] button on the Control Panel.

Record in Error Log RAP BSD

O -

CH9.2

Figure 2

CH9.2

Figure 2

CH9.2

Figure 2

O - -

Status Indicator RAPS

June, 2008

2-20

Reissue

WorkCentre 5016, 5020

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

No Response from USB-Host

Explanation

N4-0

• Either "USB disconnected" or "Communication timed-out" is detected during a print job.

• Or, either "USB disconnected" or "Communication timed-out" is detected during a scan job.

Check Items

• Cancel the print job.

• Reconnect the USB cable correctly.

Error Name

HBPL or XPJL Syntax Error

Explanation

N4-1

An abnormal command that cannot be ignored is received from the USB-Host during a print job.

Check Items

• Cancel the print job.

• Reconnect the USB cable correctly.

Error Name

Download File Error

N4-2

Explanation

There is an abnormal Product ID or there is a checksum error in the download file.

Check Items

Press the [Stop] button on the Control Panel.

Error Name

Download Flash Write Error

N4-3

Explanation

Unable to write the downloaded file into flash memory.

Check Items

Press the [Stop] button on the Control Panel.

Error Name

CPM Image Lost

E0-1

Explanation

During a copy job in CPM Priority Mode, the paper containing an image cannot be output after the image is deleted.

Check Items

Press the [Stop] button on the Control Panel.

Error Name

Push Scan TimeOut

Explanation

N5-0

• Push scan notification failed during a scan job.

• Or, there is no scan job request from the PC after a push scan notification.

Check Items

The error will clear itself after a set amount of time has passed.

Record in Error Log RAP BSD

O -

CH3.2

Figure 2

CH3.2

Figure 2

O - -

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June, 2008

2-21

Status Indicator RAPS

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

Controller Logic fail

N9-0

Explanation

A software defect that cannot be ignored is found in the Controller software.

Check Items

Turn the power OFF then ON.

Error Name

IOT Communication Error

N9-1

Explanation

The AIOC PWB has detected a Type-Di communication error.

Check Items

Turn the power OFF then ON.

Error Name

U0-1

Main Motor stop error

Explanation

The motor runs for over 120 seconds without any paper being fed.

Error Name

U1-1

Main Motor rotation error

Explanation

500ms after the IOT has started, the Main Motor Lock signal is "Low."

Error Name

U2-1

Carriage Module Fail

Explanation

An abnormality was detected in the Carriage Module.

Error Name

Laser Power or ROS Motor Fail

U3-5

Explanation

• The ROS Motor is unable to rotate.

• Or, the laser output is not normal.

Error Name

Fuser On Time Fai l

U4-1

Explanation

• The lamp did not turn OFF within the specified time after turning ON.

• Or, Warm Up was not completed within the specified time after power ON.

Error Name

U4-2

Over Heat Temp Fail

Explanation

A temperature above 250°C is continuously detected for 480ms .

Error Name

U4-3

FS1 thermistor defect

Explanation

FS1 cannot be monitored any more.

Record in Error Log RAP BSD

O -

O U0-1

O U1-1

O U2-1

O U3-5

O U4-1

O U4-2

O U4-3

CH3.2

Figure 2

CH3.2

Figure 2

CH4.1

Figure 1

CH4.1

Figure 1

CH6.2

Figure 2

CH6.3

Figure 3

CH10.1

Figure 1

CH10.1

Figure 1

CH10.1

Figure 1

Status Indicator RAPS

June, 2008

2-22

Reissue

WorkCentre 5016, 5020

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Error Name

U4-9

Fuser Fan defect

Explanation

After the start of Fan Fail Signal monitoring, the signal level was Low not more than 30 times.

Error Name

U6-2

RAM read/write check error

Explanation

When the MCU runs the overall Read/Write check for RAM during startup, the Read Data and Write Data do not match.

Error Name

NVM data defect

U6-3

Explanation

• The NVM Header data ERROR and NVM 3 page data do not match.

• Or, unable to find the NVM Write & Read area.

• The NVM or Counter areas are full.

Error Name

NVM read/write cannot be executed

U6-4

Explanation

• An NVM Ack NG is detected during NVM Read.

• An NVM Write Error is detected 5 times during NVM Recovery.

Error Name

U6-5

CPU Power to access NVM is not enough

Explanation

NVM queue full is detected during NVM Write.

Error Name

U7-0

UI Communication TimeOut

Explanation

At the Power On Sequence, the AIOC PWB did not communicate with the User Interface PWB.

Error Name

U7-1

UI Communication Error

Explanation

The User Interface PWB has detected a communication failure.

Error Name

Billing Counter Defect

U8-1

Explanation

• It is detected that the Billing Counter Value is incorrect.

• Or, the AOIC PWB has failed to read the Billing Counter.

Error Name

U9-0

HVPS fail

Explanation

A 500 msec cycle of the signal HVPS#ERR=High was detected twice in a row.

Record in Error Log RAP BSD

O U4-9

O U6-2

O U6-3

O U6-4

O U6-5

X U7-0

X U7-1

O U8-1

O U9-0

CH10.3

Figure 3

CH3.2

Figure 2

CH3.2

Figure 2

CH3.2

Figure 2

CH3.2

Figure 2

CH2.1

Figure 1

CH2.1

Figure 1

CH3.2

Figure 2

CH9.1

Figure 1

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June, 2008

2-23

Status Indicator RAPS

Display Priority in Case of Multiple Errors

When multiple errors occur simultaneously, they will be shown on the Control Panel display in the following priority order. Always begin troubleshooting with the highest-priority error.

Priority Order

1 (Highest)

2 U7-1 UI Communication Error 3 H9-7 MCU-STM comm. error 4 N9-1 IOT Communication Error 5 N9-0 Controller Logic fail 6 U0-1 Main Motor stop error 7 U1-1 Main Motor rota t ion error 8 U2-1 Carriage Module Fail 9 U3-5 Laser Power or ROS Motor Fail 10 U4-1 Fuser On Time Fail 11 U4-2 Over Heat Temp Fail 12 U4-3 FS1 thermistor defect 13 U4-9 Fuser Fan defect 14 U6-2 RAM read/write check error 15 U6-3 NVM data defect 16 U6-4 NVM read/write cannot be executed 17 U6-5 RAM read/write check error 18 U8-1 Billing Counter Defect 19 U9-0 HVPS fail 20 E9-1 AMS NG Out Of Range 21 E9-2 Paper direction mismatch 22 E8-1 Nup NG Out Of Range 23 E8-2 Nup Paper direction mismatch 24 L9-0 Copy Counter Full 25 N4-0 No Response from USB-Host 26 N4-1 HBPL or XPJL Syntax Error 27 N4-2 Download File Error 27 N4-3 Download Flash Write Error 29 N5-0 Push Scan TimeOut 30 A5-1 Platen Cover Open Document Cover

32 E5-1 IOT L/H Cover open 33 E5-2 IOT Front Cover open 34 E6-1 L/H Low Cover open 35 E6-2 STM L/H Cover open

Error Code

U7-0 UI Communication TimeOut

Error Name Error Characteristic

Unable to control the

display at the Control

ler

Fatal Error

Dynamic Error

(Job Cancel)

Open

Paper Cover Open

Priority Order

36 A1-1 Doc Misfeed Jam 37 A2-2 No Supported Doc Size 38 A4-1 Short Length Detect 39 A4-2 Long Length Detect 40 C1-1 Tray1 F/O#1 SNR on JAM 41 C1-2 Tray1 Regi SNR on JAM 42 C2-1 STM F/O#2 SNR on JAM 43 C2-2 Tray1 F/O#1 SNR on JAM from STM feed 44 C2-3 STM Regi SNR on JAM

46 C9-3 MSI Regi SNR on JAM 47 E1-2 Exit SNR on JAM 48 E3-1 Exit SNR off JAM 49 C8-1 F/O#1 SNR Static JAM 50 C8-2 F/O#2 SNR Static JAM 51 E1-6 Regi SNR Static JAM 52 E3-6 Exit SNR JAM 53 E0-1 CPM Image Lost 54 C0-1 APS NG Unselected

56 C5-1 Tray1 Paper Size Mismatch 57 C6-1 Tray2 Paper Size Mismatch 58 C7-1 MSI Paper Size Mismatch 59 C5-0 No paper in the select paper tray (Tray1) 60 C6-0 No paper in the select paper tray (Tray2) 61 J1-2 Toner Empty 62 J3-1 No Drum cartridge 63 J6-1 Drum cartridge life end 64 J7-1 Drum CRUM comm. Error 65 J7-2 Drum CRUM Market Identity Mismatch 66 J7-3 Drum CRUM ID error 67 N1-1 EPC Memory Full An error that only

Error Code Error Name Error Characteristic

Document Jam

Paper Jam

Tray-related errors

Resolvable by replac-

ing parts

stops scanning

Status Indicator RAPS

June, 2008

2-24

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WorkCentre 5016, 5020

U0-1 Main Motor Stop Error

BSD-Reference: CH4.1 (Figure 1)

U1-1 Main Motor Rotation Error

BSD-Reference: CH4.1 (Figure 1)

Explanation

The motor runs for over 120 seconds without any paper being fed.

Procedure

The problem can be solved according to RAP U1- 1 Main Motor Rotation Error (U1-1). YN

Execute diagnostics [29-49] (How to Enter the Diagnostic Mode) to check the ROM ve rsion. The ROM is the latest version.

Upgrade the ROM to the latest version.

Replace the IOT Motor (PL 1.1) (REP 1.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

Completed

Explanation

500 ms after the IOT Motor starts, the IOT Motor Lock signal is Low.

Procedure

Close the Left Hand Cover and the Front Cover. Execute diagnostics [04--01 Main Motor On]. (How to Enter the Diagnostic Mode)

Check P/J504 and P/J201. Both P/J504 and P/J201 are connected securely. YN

Connect P/J504 and P/J201 securely.

Measure the voltage between LVPS PWB P504-1 ( P/J504) (+) and GND (-). The volt-

age is approximately +24VDC. YN

Replace the LVPS (PL 8.1) (REP 8.1.2).

Check the wire between J504-3 ( P/J504) and J201-3 ( P/J201). The wire is not

shorted or o pe n . YN

Repair the wire.

Replace the IOT Motor (PL 1.1) (REP 1.1.1) a nd the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

Check the installation of the IOT Motor (PL 1.1 ) (REP 1.1.1). The IOT Motor is installed

properly. YN

Install the IOT Motor (PL 1.1 ) (REP 1.1.1) properly.

The IOT Motor can be heard rotating.

Reissue WorkCentre 5016, 5020

Turn the rotor of the IOT Motor (PL 1.1 ) counterclockwise by hand. It rotates smoothly, without any abnormal loa d. YN

Check for any foreign substances that obstruct the drive and for any incorrectly installed

There are foreign substances or incorrectly installed parts.

parts.

Replace the IOT Motor (PL 1.1) (REP 1.1.1).

Remove any foreign substances and fix any installation errors.

Check the wire between J504-3 ( P/J504) and J201-3 ( P/J201). The wire is not shorted

or open. YN

Repair the wire.

Replace the IOT Motor (PL 1.1) (REP 1.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

June, 2008

2-25

Status Indicator RAPS

U0-1, U1-1

U2-1 Carriage Module Fail

BSD-Reference: CH6.2 (Figure 2)

U3-5 Laser Power Or ROS Motor Fail

BSD-Reference: CH6.3 (Figure 3)

Explanation

A carriage fault was detected.

Procedure

Execute diagnostics [05-22 Move scanner to home position] and [05-23 Move scanner to maintenance position]. (How to Enter the Diagnostic Mode) The carriage moves.

Check each IIT Carriage connector. Each connector is connected securely. YN

Connect each connector securely.

Check for foreign substances and deformed parts in the carriage. None is found.

Remove the foreign substances and repair the deformed parts.

Replace the IIT Carriage (PL 10.3)(REP 10.3.1).

Execute diagnostics [05-23 Move scanner to maintenance position]. When the IIT Carriage has moved to the leftmost position, press the [Stop] button to put the Carriage Sensor into the blocked state.

Check each IIT Carriage and Carriage Sensor connector. Each connector is connected securely. YN

Replace the Carriage Sensor (PL 10.6) and the IIT Carriage (PL 10.3) (REP 10.3.1) in that order.

Check the Carriage Sensor (PL 10.6 ). The Carriage Sensor is installed properly.

Install the Carriage Sensor (PL 10.6) properly.

Replace the IIT Carriage (PL 10.3) (REP 10.3.1).

Execute diagnostics [5-11 Home Sensor], and "H" is displayed.

Connect each connector securely.

Explanation

The ROS Motor does not turn, or the laser output is not normal.

Procedure

Execute diagnostics [6-15 ROS Motor ON]. (How to Enter the Diagnostic Mode) The ROS Motor can be heard rotating. YN

Measure the voltage between the AIOC PWB P403-7 ( P/J403) (+) and GND (-). The voltage is approximately +24VDC. YN

Replace the AIOC PWB (PL 8.1) (REP 8.1.1) and the LVPS (PL 8.1) (REP 8.1.2) in that order.

Replace the ROS (PL 3.1) (REP 3.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

Measure the voltage between the AIOC PWB P403-1 ( P/J403) (+) and GND (-). The volt-

age is approximately +5VDC. YN

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Check the AIOC PWB P/J403 ( P/J403), LD PWB P/J140 ( P/J140), and P/J130 ( P/J130) connectors. The P/J403, P/J140, and P/J130 connectors are connected securely.

Connect the AIOC PWB P/J403 ( P/J403), LD PWB P/J140 ( P/J140), and P/J130 ( P/

J130) connectors securely.

Check the wires between J403 ( P/J403) and J140 ( P/J140) and between J403 and J130 ( P/

The wires are not shorted or ope n.

J130)

Repair the wire(s).

Replace the ROS (PL 3.1) (REP 3.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

Status Indicator RAPS

U2-1, U3-5

June, 2008

2-26

Reissue

WorkCentre 5016, 5020

U4-1 Fuser On Time Fail

BSD-Reference: CH10.1 (Figure 1)

U4-2 Over Heat Temp Fail

BSD-Reference: CH10.1 (Figure 1)

Explanation

• The lamp did not turn OFF within the specified time after turning ON.

• Or, Warm Up was not completed within the specified time after power ON.

Procedure

When U4-1 occurs, [NVM 50-20 FSR Reset FuserOverTemp] becomes "3." Run [NVM 50-20 FSR Reset FuserOverTemp] using "0" to reset it. (How to Enter the Diagnostic Mode) Check to see if there is paper in the Fuser.

Remove the paper.

Check the condition of the Fuser. The Fuser is installed pr ope r ly.

Install the Fuser properly.

Remove the Fuser. Check the conductivity between the Thermostat contacts. The contacts

are conductive. YN

Replace the Fuser (PL 5.1) (REP 5.1.1).

Check the Heater Rod for an open circuit. There is no open circuit between J600-1 ( P/

J600) and J600-2.

Replace the Fuser (PL 5.1) (REP 5.1.1).

Check the resistance of the Thermistor. There is no open circuit between J601-1 ( P/J601)

and J601-2, and the resistance is a minimum of 228k ohms (cold). YN

Replace the Fuser (PL 5.1) (REP 5.1.1).

The Fuser is normal and there is no paper in it.

Explanation

A temperature of 250°C or higher was detected continuously for 480 ms.

Procedure

When U4-2 occurs, [NVM 50-20 FSR Reset FuserOverTemp] becomes "1." Run [NVM 50-20 FSR Reset FuserOverTemp] using "0" to reset it. (How to Enter the Diagnostic Mode) Check the resistance of the Thermistor.

J601-2, and the resistance is a minimum of 228k ohms (cold). YN

Replace the Fuser (PL 5.1) (REP 5.1.1).

Check the wire between J408 ( P/J408) and P601 ( P/J601). The wire between J408 and

P601 is not shorted or open. YN

Repair the wire.

Replace the Fuser (PL 5.1) (REP 5.1.1), the LVPS (PL 8.1) (REP 8.1.2), and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

There is no open circuit between J601-1 ( P/J601) and

Immediately after Main Switch ON, the voltage between J3-3 ( P/J3) (ACH) and J3-1 (ACN) is approximately 200VAC. YN

Replace the LVPS (PL 8.1) (REP 8.1.2).

Check the wire between J408 ( P/J408) and P601 ( P/J601). The wire between J408 and

P601 is not shorted or open. YN

Repair the wire.

Check the wire between J3 ( P/J3) and P600 ( P/J600). The wire between J3 and P600 is

not shorte d or o pe n. YN

Repair the wire.

Replace the Fuser (PL 5.1) (REP 5.1.1), the LVPS (PL 8.1) (REP 8.1.2), and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

Reissue WorkCentre 5016, 5020

June, 2008

2-27

Status Indicator RAPS

U4-1, U4-2

U4-3 FS1 Thermistor Defect

BSD-Reference: CH10.1 (Figure 1)

U4-9 Fuser Fan Defect

BSD-Reference: CH10.3 (Figure 3)

Explanation

Thermistor FS1 cannot be monitored any more.

Procedure

Check the condition of the Fuser. The Fuser is installed pr ope r ly. YN

Install the Fuser properly.

Check the resistance of the Thermistor. There is no open circuit between J601-1 ( P/J601)

and J601-2, and the resistance is a minimum of 228k ohms (cold). YN

Replace the Fuser (PL 5.1) (REP 5.1.1).

Check the wire between J408 ( P/J408) and P601 ( P/J601). The wire is not shorted or

open. YN

Repair the wire.

Replace the Fuser (PL 5.1) (REP 5.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

Explanation

After the start of Fan Fail Signal monitoring, the signal level was Low not more than 30 times.

Procedure

Turn the power ON. Visually check the NOHAD Fan (PL 9.2 ). The NOHAD Fan is rotating. YN

Measure the voltage between the AIOC PWB P405-3 ( P/J405) (+) and GND (-). The voltage is approximately +24VDC. YN

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Replace the NOHAD Fan (PL 9.2) and the AIOC PWB (PL 8.1 ) (REP 8.1.1) in that order.

Measure the voltage between the AIOC PWB P405-2 P/J405 (+) and GND (-). The voltage

is 0. YN

Replace the NOHAD Fan (PL 9.2) and the AIOC PWB (PL 8.1 ) (REP 8.1.1) in that order.

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Status Indicator RAPS

U4-3, U4-9

June, 2008

2-28

Reissue

WorkCentre 5016, 5020

U6-2 RAM Read/Write Check Error

BSD-Reference: CH3.2 (Figure 2)

U6-3 NVM Data Defect

BSD-Reference: CH3.2 (Figure 2)

Explanation

When the AIOC PWB checked RAM read/write at activation, a mismatch of read and write data was detected.

Procedure

Check each AIOC PWB connector. Each connector is connected securely YN

Connect each connector securely.

Turn the power OFF and ON. U6-2 recurs.

Completed

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Explanation

• NVM Header data and NVM 3 page data are mismatched.

• Or, the NVM Write & Read area is not found.

• Or, the NVM or Counter area is full.

Procedure

Check each AIOC PWB connector. Each connector is connected securely. YN

Connect each connector securely.

Turn the power OFF and ON. U6-3 recurs.

Completed

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Reissue WorkCentre 5016, 5020

June, 2008

2-29

Status Indicator RAPS

U6-2, U6-3

U6-4 NVM Read/Write Cannot Be Executed

BSD-Reference: CH3.2 (Figure 2)

U6-5 CPU Power To Access NVM Is Not Enough

BSD-Reference: CH3.2 (Figure 2)

Explanation

• During NVM read/write, the NVM Ack NG state was detected.

• Or, during NVM repairs, an NVM write error was detected five times.

Procedure

Check each AIOC PWB connector. Each connector is connected securely. YN

Connect each connector securely.

Turn the power OFF and ON. U6-4 recurs.

Completed

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Explanation

At NVM write, the NVM queue full state was detected.

Procedure

Execute diagnostics [29-49] to check the ROM version. (How to Enter the Diagnostic

Mode) The ROM is the latest version.

Upgrade the ROM to the latest version.

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Status Indicator RAPS

U6-4, U6-5

June, 2008

2-30

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WorkCentre 5016, 5020

U7-0 UI Communication TimeOut

BSD-Reference: CH2.1 (Figure 1)

U7-1 UI Communication Error

BSD-Reference: CH2.1 (Figure 1)

Explanation

At Power ON, the AIOC PWB does not communicate with the User Interface PWB.

Procedure

Measure each voltage between AIOC PWB J401-1 ( P/J401) (+), J401-2 (+), and GND (-).

The voltages are approximately +5VDC. YN

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Check the wire between J401 ( P/J401) and J710 ( P/J710). The wire is neither shorted nor

open. YN

Repair the wire.

Replace the User Interface PWB (PL 8.4) (REP 8.4.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

Explanation

The User Interface PWB detected a communication failure.

Procedure

Check each User Inferface PWB connector. Each connector is connected securely. YN

Connect each connector securely.

Turn the power OFF and ON. U7-1 recurs.

Completed

Replace the User Interface PWB (PL 8.4) (REP 8.4.1).

Reissue WorkCentre 5016, 5020

June, 2008

2-31

Status Indicator RAPS

U7-0, U7-1

U8-1 Billing Counter Defect

BSD-Reference: CH3.2 (Figure 2)

U9-0 HVPS Fail

BSD-Reference: CH9.1 (Figure 1)

Explanation

• An illegal Billing Counter value was detected.

• Or, the AIOC PWB failed to read the Billing Counter.

Procedure

TBD

Explanation

A 500 ms cycle of HVPS#ERR=High was detected twice in a row.

Procedure

Close the Left Hand Cover and the Front Cover. Make sure that the Drum Cartridge and the Transfer Corotron are properly seated. Measure the voltages between P406-2 ( P/J406) (+)/ P406-4(+)/P406-5(+) on the AIOC PWB and ground (-).

+5VDC. YN

Replace the AIOC PWB (PL 8.1) (REP 8.1.1) and the HVPS (PL 8.2) (REP 8.2.1) in that order.

Execute diagnostics [09-04 HVPS ON (Low Voltage)]. (How to Enter the Diagnostic Mo de)

The voltages at P406-2 ( P/J406) (+)/P406-4 (+)/P406-5 (+) become 0. YN

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Replace the HVPS (PL 8.2) (REP 8.2.1). The problem is solved.

Measure the voltage between P406-1 ( P/J406) (+) on the AIOC PWB and ground (-).

The voltage is approximately +5VDC. YN

Check between J520-1 ( P/J520) and J406-1 ( P/J406) on the HVPS PWB for a short circuit. If there is no short, replace the HVPS (PL 8.2) (REP 8.2.1).

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Completed

The voltages are approximately

Status Indicator RAPS

U8-1, U9-0

June, 2008

2-32

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WorkCentre 5016, 5020

062-300 Plat en Interlock Open

BSD-Reference: CH 5.6

062-345 IISS EEPROM Failure

BSD-Reference: CH 3.1

Explanation

Detected the opened Platen Interlock.

Procedure

Ensure that the DADF can be closed normally. The DADF can be closed normally. YN

Remove obstructions or repair the DADF Counter Balances. (REP 13.3.2, REP 13.3.3)

Check that the Platen Interlock is functioning properly. The Platen Interlock is functioning

properly. YN

Replace the Platen Interlock Sensor.

Replace the SLCC PWB (AIOC/Network PWB). (REP 8.1.3) (PL 8.1)

Explanation

Error in writing on or communicatiing with the EEPROM.

Procedure

Switch off the machine power then switch on the power. The problem is solved. YN

Replace the SLCC PWB (AIOC/Network PWB). (REP 8.1.3) (PL 8.1)

Problem is resolved.

Reissue WorkCentre 5016, 5020

June, 2008

2-33

Status Indicator RAPS

062-300, 062-345

062-360 Carriage Position Fail

BSD-Reference: CH 6.2

062-371 Lamp Illumination Fail

BSD-Reference: CH 6.1

Explanation

Detected no input of Regi Sensor when carriage was working or detected the failure of the Regi Sensor position, or detected the failure of the IIT Regi Sensor level.

Procedure

Check that the Lamp Carriage can move freely and has no loose cables. The Lamp Carriage and cables are good. YN

Repair the Lamp Carriage. (REP 10.3.1)

Enter the Diagnostic Mode. Enter Component Control Code [62-212]. Check the operation of the IIT Regi Sensor.

Reseat the Regi Sensor connector. Check the wiring for proper operation and repair if necessary. Replace the Regi Sensor. (PL 10.6)

Enter the Diagnostic Mode. Enter Component Control Code [05-22]. The Carriage moves in

the scan direction. YN

Check the connector of the Carriage Moto r and repair if necess ary. Replace the Carriage Motor. (PL 10.6)

Replace the SLCC PWB (AIOC/Network PWB). (PL 8.1) (REP 8.1.3)

The Regi Sensor is good.

Explanation

Detected incufficient light provided from the Lamp to the CCD.

Procedure

Check for any obstructions in the optical path between the lamp, the lens or the mirror. The optical path is clear of any obstructions. YN

Remove the obstuctions.

Check that the White Color Correction Plate (Reflector) is in place and not deterioarated. (PL

The White Color Correction Tape is good.

10.6)

Clean or replace the White Color Correction Plate. (PL 10.6)

Enter the Diagnostic Mode. Enter Component Control Code [62-02]. The Illumination Lamp

is good. YN

Check that the Lamp harness is properly connected and repair if necessary. Replace the Illumination Lamp. (REP 10.6.1)

Replace the SLCC PWB (AIOC/Network PWB). (PL 8.1) (REP 8.1.3)

Status Indicator RAPS

062-360, 062-371

June, 2008

2-34

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WorkCentre 5016, 5020

062-380 AGC Failure

BSD-Reference: CH 6.2

062-386 AOC Failure

BSD-Reference: CH 6.1

Explanation

Control logic has detected insufficient light from the Illumination Lamp during AGC (Automatic Gain Congrol) of the auto IIT Calibration at Start.

Procedure

Check for any obstructions in the optical path. Clean the Mirror, lens and the white balance strip. Switch off the power then switch it on again.

Enter the Diagnostic Mode. Enter Component Control Code [62-02]. The lamp is good. YN

Check that the Lamp harness is properly connected and repair if necessary. Replace the Illumination Lamp. (REP 10.6.1)

Replace the SLCC PWB and (3) EEPROMS (AIOC/Network PWB). (PL 8.1) (REP 8.1.3)

POPO the machine and retry.

The problem has been resolved.

Explanation

Control logi c has detec ted an out put defect o f the CCD at AO C (Automa tic Offset Co ntrol) of the auto IIT Calibration at Start.

Procedure

Check the connector P/J410 for proper connection. The problem has been resolved. YN

Replace the SLCC PWB and (3) EEPROMS (AIOC/Network PWB). (PL 8.1) (REP 8.1.3)

POPO the machine and retry.

Reissue WorkCentre 5016, 5020

June, 2008

2-35

Status Indicator RAPS

062-380, 062-386

062-392 IPS PWB Memory Fail

BSD-Reference: CH 3.1

062-393 IPS PWB Fail

BSD-Reference: CH 3.1

Explanation

Control logic has detected RAM malfunction of IISS PWB.

Procedure

Switch off the power then switch it on again. If the problem is not solved, replace the SLCC PWB (AIOC/Network) and the 3 EEPROMs. (REP 8.1.3)

Explanation

Control logic has detected a test error or a writing error to the SLCC EEPROMs.

Procedure

Switch off the power then switch it on again. If the problem is not solved, replace the SLCC PWB (AIOC/Network) and the 3 EEPROMs. (REP 8.1.3)

Status Indicator RAPS

062-392, 062-393

June, 2008

2-36

Reissue

WorkCentre 5016, 5020

005-170 DADF Feed Failure

BSD-Reference: CH 5.2

Replace the Document Feed Clutch (PL 13.9)

Replace the Pick Up Roller and Feed Roller. (REP 13.9.1)

Explanation

The control logic has detected the failure of paper to reach the Document Feed Sensor a fter the Feed Clutch has energized.

Procedure

Check for obstructions in the Document Tray. Clean the Feed Roll. Confirm that a document is feeding into the document handler.

dler. YN

The Document Drive Motor operates. YN

Enter the Diagnostic Mode. Enter Component Control Code [05-01]. The Document Drive Motor operates. YN

There is +24 VDC at connector CN2 pin 1 and pin 4 on the DADF PWB. YN

Check the following in order:

1. Check the connectors CN1 and CN2 on the DADF PWB for proper connections

2. Check the connector J414 on the SLCC PWB (AIOC) for proper connection.

3. Check the harness from the DADF PWB to the SLCC PWB for an open circuit.

If the harness and the connectors are good, replace the DADF PWB (REP

13.2.4)

Replace the Document Drive Motor (PL 13.5)

The Feed Roller feeds paper into the document han-

Replace the Document Feed Sensor (PL 13.9).

The Feed Roller rotates. YN

Enter the Diagnostic Mode. Enter Component Control Code [05-62]. The Document Feed Clutch operates. YN

Check the connector of the Document Feed Clutch (PL 13.9) If the connector is good, replace the Document Feed Clutch (PL 13.9).

Replace the Document Feed Clutch (PL 13.9)

Replace the Pick Up Roller and Feed Roller. (REP 13.9.1)

The Feed Roller rotates. YN

Enter the Diagnostic Mode. Enter Component Control Code [05-62]. The Document Feed Clutch operates. YN

Check the connector of the Document Feed Clutch (PL 13.9) If the connector is good, replace the Document Feed Clutch (PL 13.9).

AABBC

Reissue WorkCentre 5016, 5020

June, 2008

2-37

Status Indicator RAPS

005-170

005-171 DADF Regi / Exit Failure

BSD-Reference: CH 5.8

Replace the Document Feed Clutch (PL 13.9)

Replace the Pick Up Roller and Feed Roller. (REP 13.9.1)

Explanation

Control logic has detected no paper at the Registration Sensor after turning on the Registration Clutch or detected no paper at the Exit/Invert Sensor after turning on the Registration Clutch.

Procedure

Check for obstructions in the Document Tray. Clean the Feed Roll. Confirm that a document is feeding into the document handler.

dler. YN

The Document Drive Motor operates. YN

Enter the Diagnostic Mode. Enter Component Control Code [05-01]. The Document Drive Motor operates. YN

There is +24 VDC at connector CN2 pin 1 and pin 4 on the DADF PWB. YN

Check the following in order:

1. Check the connectors CN1 and CN2 on the DADF PWB for proper connections

2. Check the connector J414 on the SLCC PWB (AIOC) for proper connection.

3. Check the harness from the DADF PWB to the SLCC PWB for an open circuit.

If the harness and the connectors are good, replace the DADF PWB (REP

13.2.4)

Replace the Document Drive Motor (PL 13.5)

The Feed Roller feeds paper into the document han-

Enter the Diagnostic Mode. Enter Component Control Code [05-206]. Actuate the Document Registration Sensor acutator.

Replace the Document Registration Sensor. (PL 13.7)

Enter the Diagnostic Mode. Enter Component Control Code [05-205]. Actuate the Exit/Invert Sensor actuator.

Replace the Exit/Invert Sensor. (PL 13.7)

Replace the DADF PWB (REP 13.2.4), or replace the SLCC PWB (AIOC/Network) (REP 8.1.3)

The display changes from High to Low.

The Feed Roller rotates. YN

Enter the Diagnostic Mode. Enter Component Control Code [05-62]. The Document Feed Clutch operates. YN

Check the connector of the Document Feed Clutch (PL 13.9) If the connector is good, replace the Document Feed Clutch (PL 13.9).

Replace the Document Feed Clutch (PL 13.9)

Replace the Pick Up Roller and Feed Roller. (REP 13.9.1)

The Feed Roller rotates. YN

Enter the Diagnostic Mode. Enter Component Control Code [05-62]. The Document Feed Clutch operates. YN

Check the connector of the Document Feed Clutch (PL 13.9) If the connector is good, replace the Document Feed Clutch (PL 13.9).

AABBC

Status Indicator RAPS

005-171

June, 2008

2-38

Reissue

WorkCentre 5016, 5020

005-172 DADF Inve rted Document Jam

BSD-Reference: CH 5.8

Check the connector of the Document Feed Clutch (PL 13.9) If the connector is good, replace the Document Feed Clutch (PL 13.9).

Explanation

When inverting documents, the control logic detected a failure of a document at the Feed Sensor after turning off the Feedout Forward or document f ailure at the Exit/Invert Sensor after turning on the Document Registration Sensor.

Procedure

Check for obstructions in the Document Tray. Clean the Feed Roll. Confirm that a document is feeding into the document handler.

dler. YN

The Document Drive Motor operates. YN

Enter the Diagnostic Mode. Enter Component Control Code [05-01]. The Document Drive Motor operates. YN

There is +24 VDC at connector CN2 pin 1 and pin 4 on the DADF PWB. YN

Check the following in order:

1. Check the connectors CN1 and CN2 on the DADF PWB for proper connections

2. Check the connector J414 on the SLCC PWB (AIOC) for proper connection.

3. Check the harness from the DADF PWB to the SLCC PWB for an open circuit.

If the harness and the connectors are good, replace the DADF PWB (REP

13.2.4)

Replace the Document Drive Motor (PL 13.5)

The Feed Roller feeds paper into the document han-

Replace the Document Feed Clutch (PL 13.9)

Replace the Pick Up Roller and Feed Roller. (REP 13.9.1)

Enter the Diagnostic Mode. Enter Component Control Code [05-204]. Actuate the Document Feed Sensor acutator.

Replace the Document Feed Sensor. (PL 13.9)

Enter the Diagnostic Mode. Enter Component Control Code [05-205]. Actuate the Exit/Invert Sensor actuator.

Replace the Exit/Invert Sensor. (PL 13.7)

Replace the DADF PWB (REP 13.2.4), or replace the SLCC PWB (AIOC/Network) (REP 8.1.3)

The display changes from High to Low.

The Feed Roller rotates. YN

Enter the Diagnostic Mode. Enter Component Control Code [05-62]. The Document Feed Clutch operates. YN

Check the connector of the Document Feed Clutch (PL 13.9) If the connector is good, replace the Document Feed Clutch (PL 13.9).

Replace the Document Feed Clutch (PL 13.9)

Replace the Pick Up Roller and Feed Roller. (REP 13.9.1)

The Feed Roller rotates. YN

Enter the Diagnostic Mode. Enter Component Control Code [05-62]. The Document Feed Clutch operates.

AAB

Reissue WorkCentre 5016, 5020

June, 2008

2-39

Status Indicator RAPS

005-172

005-198 Short Sca n Jam

BSD-Reference: CH 6.2

005-199 Long Scan Jam

BSD-Reference: CH 6.2

Explanation

The control logic has found that the length of slow scan is less than 80mm.

Procedure

Choose a document size equal to or larger than A4 paper or 208mm SEF or larger, in the Document Tray. The problem is solved.

Replace the Document Registration Sensor. (PL 13.7)

Inform the customer of the minimum size limitation of documents used in the DADF Document Tray.

Explanation

The control logic has detected that the length of slow scan is 450mm or more.

Procedure

Choose a document size equal to or less than A3 paper or 294mm SEF or less in the Document Tray. The problem is solved.

Replace the Document Registration Sensor. (PL 13.7)

Inform the customer of the maximum size limitation of documents used in the DADF Document Tray.

Status Indicator RAPS

005-198, 005-199

June, 2008

2-40

Reissue

WorkCentre 5016, 5020

005-305 Feeder Top Cover Open

BSD-Reference: CH 5.6

005-920 Static Jam

BSD-Reference: CH 5.6

Explanation

The control logic has detected that the Feeder Top Cover is open.

Procedure

Close the Feeder Top Cover. The problem continues. YN

Adjust or repair the Feeder Top Cover latch. (REP 13.4.1)

Replave the Feeder Top Cover Switch. (PL 13.9)

Explanation

At power on, the control logic detected either the Platen Interlock is close when the Feeder Cover is open or the Feeder Cover Interlock is close when the Platen Interlock is open.

Procedure

If this occurs frequently, confirm if there is any interferance with the Feed Sensor (PL 13.9), the Document Registration Sensor (PL 13.7) or the Exit/Invert Sensor (PL 13.7). Check the sensor connectors for prober connection. Replace one sensor at a time until the problem is solved.

Reissue WorkCentre 5016, 5020

June, 2008

2-41

Status Indicator RAPS

005-305, 005-920

Status Indicator RAPS

005-305, 005-920

June, 2008

2-42

Reissue

WorkCentre 5016, 5020

Image Quality RAPs

IQ1 IOT Image Quality Entry RAP .................................................................................. 3-3

IQ2 IIT Image Quality Entry RAP.................................................................................... 3-3

IQ3 Low Image Density RAP................................. ................... .................................... .. 3-4

IQ4 Wrinkled Image RAP............ ................................... ................... .............................. 3-4

IQ5 Residual Image (Ghosting) RAP ........................................................... .... .... .... ....... 3-5

IQ6 Background RAP...................................................................................................... 3-5

IQ7 Deletion RAP............................................................................................................ 3-6

IQ8 Skew/Misregistration RAP........................................................................................ 3-6

IQ9 Process Direction Bands, Streaks, and Smears RAP.............................................. 3-7

IQ10 Unfused Copy/Toner Offset RAP ........................................................................... 3-7

IQ11 Repeating Bands, Streaks, Spots, and Smears RAP............................................. 3-8

IQ12 Mottle RAP............................................................................................................. 3-8

IQ13 Spots RAP.............................................................................................................. 3-9

IQ14 Black Prints RAP...................... .................................... ................... ....................... 3-9

IQ15 Blank Image RAP................................................................................................... 3-10

Copy Quality Specification.............................................................................................. 3-10

Samples of Image Quality Defects.................................................................................. 3-16

3 Image Quality

Reissue WorkCentre 5016, 5020

June, 2008

3-1

Image Quality

June, 2008

3-2

Reissue

WorkCentre 5016, 5020

IQ1 IOT Image Quality Entry RAP

Initial Actions

Determine whether the image quality problem occurs in Copy Mode or Print Mode. If the pr oblem occurs in Copy Mode, go to IQ2.

Procedure

Determine the image quality problem and go to the relevant RAP.

IQ2 IIT Image Quality Entry RAP

Initial Actions

Clean the IIT Upper Cover (PL 10.2) (REP 10.2.1).

Clean the mirrors and lens with a lint-free cloth.

Determine the image quality problem and go to the relevant RAP.

Table 1 IOT Image Quality Problems

Image Quality Problem Symptom RAP

Low image density Overall low density of images. IQ3 Wrinkled images The printed paper is creased, folded or torn. IQ4 Ghost images Ghost images appear on the paper. Parts of the

Background contamination The whole page or part of the page is contami-

Deletion Part of the image is missing. IQ7 Skew/Misregistration Printed images are not parallel to the edges of

Black lines, blank areas, or smears in the process direction

Improper fusing, offset Printed images are not properly fused onto the

Black lines, blank areas, or smears at right angles to the process direction.

Mottle Uneven printed image density. IQ12 Spotted blanks Toner spots and blank areas are spread irregu-

Solid black copy The output is completely black. IQ14 Blank copy The output is completely white. IQ15

previous page or current page appear as ghost images on the paper.

nated by toner. The contamination appears as a very light grayish color.

the paper. Black lines or white streaks running parallel to

the direction of paper transport.

paper. When rubbed, the image comes off easily.

Black lines or white streaks running at right angles to the direction of paper transport.

larly over the whole page.

IQ5

IQ6

IQ8

IQ9

IQ10

IQ11

IQ13

T able 1 IIT Image Quality Problems

Image Quality Problem Symptom RAP

Low image density Overall low density of images. IQ3 Background contamination The whole page or part of the page is contami-

Black lines, blank areas, or smears in the process direction.

Black lines, blank areas, or smears at right angles to the process direction.

Spotted blanks Toner spots and blank areas are spread irregu-

Solid black copy The output is completely black. IQ14

nated by toner. The contamination appears as a very light grayish color.

Black lines or white streaks running parallel to the direction of paper transport.

Black lines or white streaks running at right angles to the direction of paper transport.

larly over the whole page.

IQ6

IQ9

IQ11

IQ13

Reissue WorkCentre 5016, 5020

June, 2008

3-3

Image Quality

IQ1, IQ2

IQ3 Low Image Density RAP

Overall low density of images.

IQ4 Wrinkled Image RAP

The output is creased, folded or torn.

Procedure

Check for dirt on the Platen Glass. The Platen Glass is clean. YN

Clean any dirt on the Platen. If unable to clean the dirt, replace the IIT Upper Cover (PL 10.2) (REP 10.2.1).

Check the drum ground contact. The drum ground contact is clean and not damage d.

Clean the drum ground contact. If necessary, restore it to its proper shape.

Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF then ON and make a print.

Completed

Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a

The problem recurs.

print.

Completed

Print a page that is entirely black. During the print cycle, turn OFF the power after you hear the paper feed (to force a stop during image transfer). Check the surface of the Drum.

considerable amount of toner left on the surface of the Drum. YN

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Replace the Transfer Corotron (PL 4.3) (REP 4.3.1), followed by the HVPS (PL 8.2) (REP

8.2.1), and finally the AIOC PWB (PL 8.1) (REP 8.1.1).

The problem recurs.

There is a

Procedure

Check the paper type. The paper used is within specifications. YN

Use paper that is within specifications.

Use paper from a freshly opened packet. The problem recurs.

Completed

Remove the Fuser (PL 5.1) (REP 5.1.1) and reinstall it properly. Turn the power OFF then ON and make a print.

Completed

Check for foreign substances and damaged components in the paper transport path. No for-

eign substances or damaged components are found in the paper transport path. YN

Remove the foreign substances. Reshape or replace any damaged components.

Replace the Fuser (PL 5.1) (REP 5.1.1).

The problem recurs.

Image Quality

IQ3, IQ4

June, 2008

3-4

Reissue

WorkCentre 5016, 5020

IQ5 Residual Image (Ghosting) RAP

Ghost images appear on the paper. Part s of the previous page or current p age appear as ghost images on the paper.

IQ6 Background RAP

The whole page or part of the page is contaminated by toner. The contamination appears as a very light grayish color.

Procedure

Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF then ON and make a print.

Completed

Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a

The problem recurs.

print.

Completed

Remove the Fuser (PL 5.1) (REP 5.1.1), lower the green levers on both sides , turn the Drive Gear of the Heat Roll and check the Heat Roll surface for dirt and/or contamination.

face of the Heat Roll is clean. YN

Remove any dirt and/or contamination. If you can’t clean the surface of the Heat Roller, replace the Fuser (PL 5.1) (REP 5.1.1).

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

The problem recurs.

The sur-

Procedure

Check for dirt on the Platen Glass. Th e Platen Glass is clean. YN

Remove any dirt from the Platen Glass. If you cannot clean the Platen Glass, replace the IIT Upper Cover (PL 10.2) (REP 10.2.1).

Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF then ON and make a print.

Completed

Install a new Drum Cartridge (PL 4.1) (REP 4.1.1) and install it properly. Turn the power OFF then ON and make a print. The problem recurs.

Completed

Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron (PL 4.3) (REP

4.3.1) is clean and not damaged.

Clean the Transfer Corotron (PL 4.3) (REP 4.3.1). If it is damaged, replace it.

Remove the HVPS (PL 8.2) (REP 8.2.1) and reinstall it properly. Turn the power OFF then ON and make a print. The problem recurs.

Completed

Replace the AIOC PWB (PL 8.1) (REP 8.1.1), followed by the HVPS (PL 8.2) (REP 8.2.1).

The problem recurs.

Reissue WorkCentre 5016, 5020

June, 2008

3-5

Image Quality

IQ5, IQ6

IQ7 Deletion RAP

Part of the image is missing.

IQ8 Skew/Misregistration RAP

Printed images are not parallel to the edges of the paper.

Procedure

Check the paper type. The paper used is within specifications. YN

Use paper that is within specifications.

Use paper from a freshly opened packet. The problem recurs.

Completed

Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF then ON and make a print.

Completed

Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a print.

The problem recurs.

Completed

Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Tra ns fer Corotron is not damaged.

Replace the Transfer Corotron (PL 4.3) (REP 4.3.1).

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

The problem recurs.

Procedure

Check the location where the machine is installed. The machine is installed on a stable, level surface. YN

Install the machine on a stable, level surface.

Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF then ON and make a print.

Completed

Check the Paper Cassette. The Paper Cassette is installed properly.

Install it properly.

Check the paper transport path. There are no obstructions or damaged parts in the paper

transport path. YN

Remove any obstructions. Reshape or replace any damaged parts.

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

The problem recurs.

Image Quality

IQ7, IQ8

June, 2008

3-6

Reissue

WorkCentre 5016, 5020

IQ9 Process Direction B ands, Streaks, and Smears RAP

Black lines or white streaks running parallel to the direction of paper transport.

Procedure

Check the IIT Carriage Mirrors. The mirrors are not dirty, scratched, or damaged. YN

Clean the mirrors. If the mirrors can’t be cleaned, have scratches, or are damaged, replace the IIT Carriage (PL 10.3) (REP 10.3.1).

IQ10 Unfused Copy/Toner Offset RAP

Printed images are not properly fused onto the paper . When rubbed, the image comes off easily.

Procedure

Check the paper type. The paper used is within specifications. YN

Use paper that is within specifications.

Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF then ON and make a print.

Completed

Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a print.

The problem recurs.

Completed

Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron is clean and not

damaged. YN

Clean the Transfer Corotron (PL 4.3) (REP 4.3.1). If it is damaged, replace it.

Check for dirt in the paper transport path. The paper transport path is clean.

Clean away the dirt.

Check the IIT Carriage Mirror. The mirror is clean and not damaged.

Clean the IIT Carriage Mirror (PL 10.3) (REP 10.3.1). If it is damaged, replace it.

Remove the F user (PL 5.1) (REP 5.1.1), and check the Heat Roll. The surface of the Heat

Roll is clean. YN

Remove any dirt. If you can’t clean the surface of the H eat Roll, replace the Fuser (PL

5.1) (REP 5.1.1).

Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron is clean and not

damaged. YN

Clean the Transfer Corotron (PL 4.3) (REP 4.3.1). If it is damaged, replace it.

The problem recurs.

Use paper stored under room conditions. The problem recur s . YN

Completed

Check the power supply voltages. The voltages are within the specified range.

Connect a power supply with voltages within the specified range.

Remove the Fuser (PL 5.1) (REP 5.1.1) and reinstall it properly. Turn the power OFF then ON and make a print.

Completed

Check the fusing temperature using the Diagnostics. A normal fusing temperature is set.

Set a normal fusing temperature using the Diagnostics.

Replace the Fuser (PL 5.1) (REP 5.1.1).

The problem recurs.

Check the ROS (PL 3.1) (REP 3.1.1). The ROS is clean and not scratched. YN

Clean the ROS (PL 3.1) (REP 3.1.1). If it is scratched, replace it.

Replace the ROS (PL 3.1) (REP 3.1.1), followed by the AIOC PWB (PL 8.1) (REP 8.1.1).

Reissue WorkCentre 5016, 5020

June, 2008

3-7

Image Quality

IQ9, IQ10

IQ11 Repeating Bands, Streaks, Spots, and Smears RAP

Black lines or white streaks running at right angles to the direction of paper transport.

Procedure

Check the IIT Carriage. The carriage has no foreign substances or damaged parts. YN

Remove any foreign substances. If any parts of the IIT Carriage (Capstan Pulley, Capstan Shaft, Carriage Cable, etc.) are damaged, replace them.

Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF then ON and make a print.

Completed

Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a print.

The problem recurs.

Completed

Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron is clean and not

damaged. YN

Clean the Transfer Corotron (PL 4.3) (REP 4.3.1). If it is damaged, replace it.

Check the pitch of the black lines or white streaks. The pitch of the black lines is approxi-

mately 78mm (circumference of the Heat Roll ). YN

Clean the surface of the Heat Roll. If you can’t, replace the Fuser (PL 5.1) (REP 5.1.1).

Replace the ROS (PL 3.1) (REP 3.1.1), followed by the AIOC PWB (PL 8.1) (REP 8.1.1).

The problem recurs.

IQ12 Mottle RAP

Procedure

Check the paper type. The paper used is within specifications. YN

Use paper that is within specifications.

Use paper from a freshly opened packet. The problem recurs.

Completed

Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF then ON and make a print.

Completed

Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a

The problem recurs.

print.

Completed

Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron is clean and not

damaged. YN

Clean the Transfer Corotron (PL 4.3) (REP 4.3.1). If it is damaged, replace it.

Remove the HVPS (PL 8.2) (REP 8.2.1) and reinstall it properly. Turn the power OFF then ON and make a print.

Completed

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

The problem recurs.

Image Quality

IQ11, IQ12

June, 2008

3-8

Reissue

WorkCentre 5016, 5020

IQ13 Spots RAP

Toner spots and blank areas are spread irregularly over the whole page.

IQ14 Black Prints RAP

The paper is printed completely black.

Procedure

Check for dirt on the Platen Glass. The Platen Glass is clean. YN

Remove any dirt on the Platen. If you can’t remove the dirt, replace the IIT Upper Cov er (PL 10.2) (REP 10.2.1).

Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF then ON and make a print.

Completed

Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a print.

The problem recurs.

Completed

Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron is clean and not

damaged. YN

Clean the Transfer Corotron (PL 4.3) (REP 4.3.1). If it is damaged, replace it.

Check for dirt in the paper transport path. The paper transport path is clean.

Clean away the dirt.

Remove the F user (PL 5.1) (REP 5.1.1) and check the surface of the Heat Roll. The surface

of the Heat Roll is clean. YN

Clean away the dirt. If you can’t remove the dirt, replace the Fuser (PL 5.1) (REP 5.1.1).

Check the paper type. The paper used is within specifications.

Use paper that is within specifications.

Use paper from a freshly opened packet. The problem recurs.

Completed

The problem recurs.

Procedure

Check the IIT Carriage for foreign substances and damaged parts. The carriage has no foreign substances or damaged parts. YN

Remove any foreign substances. If any parts of the IIT Carriage Assembly (cable, capstan, etc.) (PL 10.3) are damaged, replace them.

Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF then ON and make a print.

Completed

Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a

The problem recurs.

print.

Completed

Remove the HVPS (PL 8.2) (REP 8.2.1) and reinstall it properly. Turn the power OFF then ON and make a print.

Completed

Check the connectors of the HVPS (P/J520) and AIOC PWB (P/J406). The connectors are

connected securely. YN

Connect the connectors securely.

Check the wire between J460-4 and J520-2. The wire between J460-4 and J520-2 is not

shorted or o pe n . YN

Repair the wire.

Check the wires between the ROS (PL 3.1) (REP 3.1.1 ) and the AIOC PWB (PL 8.1) (REP

8.1.1).

The wires between J140 (ROS) and J403 (AIOC P WB), as well as between J130 (ROS) and J403 (AIOC PCB), are not shorted or open. YN

Repair the wire(s).

The problem recurs.

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Reissue WorkCentre 5016, 5020

Replace the ROS (PL 3.1) (REP 3.1.1), followed by the HVPS (PL 8.2) (REP 8.2.1), and finally the AIOC PWB (PL 8.1) (REP 8.1.1).

June, 2008

3-9

Image Quality

IQ13, IQ14

IQ15 Blank Image RAP

The paper is printed completely white.

Procedure

Check the ROS (PL 3.1) (REP 3.1.1). The ROS is installed correctly. YN

Install the ROS (PL 3.1) (REP 3.1.1) correctly.

Check the drum ground contact. The drum ground contact is clean and not damaged.

Clean the drum ground contact. If it is damaged, reshape or replace it.

Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF then ON and make a print.

Completed

Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a print.

The problem recurs.

Completed

Print a page that is entirely black. During the print cycle, turn OFF the power after you hear the paper feed (to force a stop during the image transfer) and check the surface of the Drum.

There is a considerable amount of toner left on the surface of the Drum. YN

Check the P/J140, P/J406, J403, and J140 connectors. The connectors are connected securely. YN

Connect the connectors securely.

Check the ROS (PL 3.1) (REP 3.1.1). The ROS is installed correctly.

Install the ROS (PL 3.1) (REP 3.1.1) correctly.

The problem recurs.

Copy Quality Specification

1. Copy Alignment

How to measure

Make a copy of the Test Pattern STP3600 (A3) (Figure 1) and measure.

Table 1 Copy Alignment: Measurement

Item How to measure (Refer to Figure 1)

Lead Edge Registration (mm) (P1~P2) – Standard Value *1 Side Edge Registration (mm) (P7~P19) – Standard Value *1: A3S Lead Skew (mm) (P5~P6) – (P3~P4) Vertical Ratio (%) ((P2~P14) - 200) / 200 x 100: A3S Horizontal Ratio (%) ((P8~P13) - 280) / 280 x 100 Perpendicularity (mm) Difference between the perpendicular line of the intersection

point between the line that connects P4 and P6, and P14.

Linearity (Vertical) (mm) 400mm

Linearity (Horizontal) (mm) 280mm

Linearity (Skew) (mm) 280mm Maximum difference between the [Intersection point of the

Parallelism (mm) (P10~P12) – (P15~P16)

*1: Measure the length of the position of FX STP#3600 and use it as the Standard Value in the table.

Maximum difference between the [Intersection point of the vertical line A and each vertical line] and the line that con nects P2 and P14.

Maximum difference between the [Intersection point of the horizontal line C and each horizontal line] and the line that connects P10 and P15.

skew line D and each line] and the line that connects P17 and P13. Or Maximum difference between the [Intersection point of the skew line E and each line] and the line that connects P8 and P18.

Measure the voltage between pin 1 and pin 2 of connector P403 on the AIO C PWB (PL

8.1) (REP 8.1.1).

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Check the wire between J140 and J403. The wire between J140 and J403 is not

shorted or o pe n . YN

Repair the wire.

Replace the ROS (PL 3.1) (REP 3.1.1), followed by the AIOC PWB (PL 8.1) (REP 8.1.1).

Replace the Transfer Corotron (PL 4.3) (REP 4.3.1), followed by the HVPS (PL 8.2) (REP

8.2.1), and finally the AIOC PWB (PL 8.1) (REP 8.1.1).

Image Quality

The voltage is +5VDC.

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Specification

[System] IOT + IIT

Table 2 Copy Alignment: Specification

Specification

Item

SYSTEM

Application

Lead Edge Registration (mm) +/- 2.90 Side Edge Registration (mm) +/- 3.40 Lead Skew (mm) +/- 2.30 280 mm Vertical Ratio (%) 100% +/- 1.40 400 mm Horizontal Ratio (%) 100% +/- 1.40 280 mm Perpendicularity (mm) +/- 3.40 400 mm Linearity (Vertical) (mm) +/- 2.00 400 mm Linearity (Horizontal) (mm) +/- 1.40 280 mm Linearity (Skew) (mm) +/- 1.42 280 mm Parallelism +/- 3.70 400 mm

[DC] IOT + IIT

Table 3 Copy Alignment: Specification

Item Specification Measurement Length

Simplex MSI Skew H +/-1.9 +/-2.2 200mm Perpendicularity +/-2.8 +/-3.0 400mm Linearity: V 1.4 -- 400mm Linearity: H 1.4 -- 280mm Linearity: D 1.4 -- 283mm Registration: Lead +/-2.4 +/-3.1 Registration: Side +/-3.0 +/-3.2 Magnification: V (%) +/-0.95 (100%)

-- 400mm +/-1.16 (50%-99%) +/-1.47 (101%-200%)

Magnification: H (%) +/-0.95 (100%)

-- 280mm +/-1.16 (50%-99%) +/-1.47 (101%-200%)

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Image Quality

Figure 1 Copy Alignment Measurement Positions (Test Pattern STP3600)

2. Image Quality

How to measure

Image Quality

Make a copy of the Test Pattern 499T247 (A3) and measure. See Table 5 for specifications.

Table 4

Item How to measure (Refer to Fi gure 2)

Text/Image Density (100%/Normal mode only)

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Measure the 0.7G line image (10) at 3 locations. Determine the maximum and minimum mean value measured (within the same copy).

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Table 4

Item How to measure (Refer to Figure 2)

Low Contrast (100% only)

Normal mode: Check that the 0.2G line image 13 can be read. Darker mode: Measure the 0.2G line image 13 at 3 locations. Determine the maximum and minimum mean value measured (within the same copy).

Reproducibility of the blue color density (100% only)

Normal mode: Check that the 0.2B line image 14 can be read. Darker mode: Measure the 0.2B line image 14 at 3 locations. Determine the maximum and minimum mean value measured (within the same copy).

Solid Density Reproducibility (100%/Normal mode only)

Measure the 1.0G solid 16 at 3 locations. Determine the maximum and minimum mean value measured

(within the same copy). Background Meas ure the margin. Resolution 70.7, 100%: Measure the resolution target 17 at 3 locations.

141.4%: Measure the resolution target 17 at 2 locations.

Skip and Smear 100%: Check that the 2.5lp/mm ladder 18 is resolving across the

entire page.

70.7~99%: Check that the 1.8lp/mm ladder 19 is resolving across

the entire page.

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Image Quality

Image Quality Specification

Total System

Figure 2 Image Quality Measurement Positions (Test Pattern 499T247)

Image Quality

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T able 5

Item

Reduce/ Enlarge (%)

INPUT

OUTPUT (Density Settings Button) Lighter 3

OUTPUT (Density Settings Button) Normal

OUTPUT (Density Settings Button) Darker 3

OUTPUT (Density Settings Button) Auto

Text/Image Density 100 0.7 Gray - >=1.08 - >=1.08 Text/Image Density Evenness 100 0.7 Gray - =<0.2 - =<0.2 Low Contrast Reproducibility 100 0.2 Gray - >=0.17 >=0.46 >=0.22 Low Contrast Evenness 100 0.2 Gray - - =<0.4 Low Contrast Reproducibility 100 0.1 Gray Does not

- - -

reproduce

Reproducibility of the blue color den-

100 0.2 Blue - >=0.17 >=0.57 >=0.22

sity Blue Color Density Evenness 100 0.2 Blue - - 0.4 (Max) Reproducibility of the blue color den-

sity

100 0.1 Blue Does not

reproduce

- - -

Solid Density Reproducibility 100 1.0 Solid - >=1.0 - >=1.0 Solid Density Evenness 100 1.0 Solid - =<0.3 - =<0.3 Background (SIR#302) 100 - - =<1.2 - =<1.2 Resolution

(Excluding Skip/Smear) Resolution

100 NBS Target - - - 4.3 Lo/mm

(Min)

70 NBS T arget - - - 2.5 Lo/mm

(Min)

141 NBS Target - - - 3.5 Lo/mm

(Min)

200 NBS Target - - - 3.5 Lo/mm

(Excluding Skip/Smear) Depth of Focus 100 NBS Target - - - 3 Lo/mm

(Min)*1

Skip/Smear 100 Ladder A3 Entire

Page

Skip/Smear 70 Ladder A3 Entire

Page

Skip/Smear 141 Ladder A3 Entire

Page

Skip/Smear 200 Ladder A3 Entire

Page

- - - 2.5 Lo/mm (Min)*1

- - - 1.8 Lo/mm (Min)

- - - 2.5 Lo/mm (Min)

- - - 2.5 Lo/mm (Min)*1

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Image Quality

Samples of Image Quality Defects

IOT Image Quality Defects

These are samples of image quality defects due to IOT problems and their corresponding solutions.

• Auger Marks (Figure 1)

• Strobing (28mm or 14mm Pitch Density) (Figure 2)

• White Streaks (Process Direction) (Figure 3)

• Black Bands (Figure 4)

• Toner Contamination (Figure 5)

• Toner Splattering (Figure 6)

• White Spots (Irregular) (Figure 7)

• Regular Blanks in the Process Direction (Spots, Streaks, Bands etc.) (Figure 8)

• Regular Toner Contamination in the Process Direction (Spots, Streaks, Bands etc.) (Fig-

ure 9)

IIT Image Quality Defects

These are samples of image quality defects due to IIT problems and their corresponding solutions.

• Moire Due to Interference with Copy Original

• Fluctuation in Background Suppression Values for Copies of Originals

• Defects Related to Scan Print

• Light Background Due to Background Suppression in Copies o f Originals with Frames (Figure 10)

Image Quality

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Auger Marks

Cause

1. Magnetic field failure in the Developer Magnetic Roll.

2. There was a drop in the level of developer material.

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Figure 1 Auger Marks

Action

1. Replace the Drum Cartridge (PL 4.1) (REP 4.1.1). The problem may occur immediately after you install a new Drum Cartridge. This can be corrected by feeding a few sheets of paper.

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Image Quality

Strobing (28mm or 14mm Pitch Density)

Cause

1. Developer Magnetic Roll bias.

Action

1. Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).

Image Quality

Figure 2 Strobing (28m m or 14 mm Pitch Density)

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White Streaks (Process Direction)

Figure 3 White Streaks (Process Direction)

Cause

1. Foreign substances are blocking the ROS Laser.

2. Developer material clogging on the Developer Magnetic Roll due to foreign substances.

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Action

1. Clean the optical path between the ROS (PL 3.1) (REP 3.1.1) and the Drum Cartridge (PL

4.1) (REP 4.1.1), and clean the seal glass.

2. Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).

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Image Quality

Black Bands

Cause

1. The developer material is not well mixed.

Action

1. Mix the developer material by processing blank paper.

Image Quality

Figure 4 Black Bands

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Toner Contamination

Cause

1. Cloud of toner falling from the Drum Cartridge (PL 4.1) (REP 4.1.1).

Action

1. Mix the developer material by processing blank paper.

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Figure 5 Toner Contamination

2. Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).

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Image Quality

Toner Splattering

Cause

1. Paper size mismatch (tray settings and paper size are different).

2. Increased paper resistance due to dry conditions.

Image Quality

Figure 6 Toner Splattering

Action

1. Check the tray settings.

2. Use paper from a freshly opened packet.

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White Spots (Irregular)

Cause

1. Increased paper resistance due to dry conditions.

Action

1. Use paper from a freshly opened packet.

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Figure 7 White Spots

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Image Quality

Regular Deletions in the Process Direction (Spots, Streaks, Bands, etc.)

Figure 8 Regular Deletions in the Process Direction (Spots, Streaks, Bands, etc.)

Cause

1. 94mm Pitch (Drum): Scratches or foreign substances.

2. 57mm Pitch (Developer Roll): Developer material clogging on the Magnetic Roll.

3. 44mm Pitch (Charger): Scratches or foreign substances.

Image Quality

4. 80mm Pitch (Fuser Heat Roll): Scratches or foreign substances.

Action

1. 1,4: Clean or replace the Drum Cartridge (PL 4.1) (REP 4.1.1)/Fuser (PL 5.1) (REP

5.1.1).

2. 2,3: Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).

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Regular Toner Contamination In the Process Direction (Spots, Streaks, Bands, etc.)

Figure 9 Regular Toner Contamination In the Process Direction (Spots, Streaks, Bands, etc.)

Cause

1. 94mm Pitch (Drum): Scratches or foreign substances.

2. 57mm Pitch (Magnetic Roll): Developer material clogging on the Magnetic Roll.

3. 44mm Pitch (Charger): Scratches or foreign substances.

4. 80mm Pitch (Heat Roll): Scratches or foreign substances.

5. 19mm Pitch (Fuser Roll-Exit): Dirt.

6. 44mm Pitch (Registration): Dirt.

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Action

1. 1,4,5,6: Clean or replace the Drum Cartridge (PL 4. 1) (REP 4.1.1)/Fuser (PL 5.1) (REP

5.1.1).

2. 2,3: Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).

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Image Quality

Moire Due to Interference with Copy Original

Cause

Copying originals with certain line patterns may cause moire (wavy lines) on the copy. Combinations of certain angles of screen ruling near 150dpi and certain Reduce/Enlarge ratios m ay also cause moire.

Action

1. Reduce sharpness. Secondary defect: Text is blurred.

2. Make copies at a different Reduce/Enlarge ratio.

3. Change the orientation of the original.

Fluctuation in Background Suppression V alues for Copies o f Originals of Medium Density

When [Auto] is selected for originals with a background of medium density (0.5G), the effectiveness of Automatic Exposure fluctuates for each job.

Cause

Since medium density (0.5G) is near the upper limit value for background detection, the Background Suppression value fluctuates according to the result of background detection, which responds to variations in the original density and how the original is positioned.

Action

Select [Off] for [Auto].

Defects Related to Scan Print

Moire may occur when scanned images are printed.

Cause

This could be due to the resolution c onversion process between the original and the printer driver.

Action

Reduce sharpness.

Secondary defect: Text is blurred.

Image Quality

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Light Background in Copies of Originals with Frames

When [Auto] is selected for originals with dark frames along the Lea d Registration Edge, the background suppression value is set so large that areas of m edium density appear extrem ely light.

Figure 10 Light Background in Copies of Originals with Frames

Cause

[Auto] performs background detection of images at a distance of up to 10mm from the Lead Registration Edge. If there are dark frames along the Lead Registration Edge, Automatic Expo sure cannot detect the original background density. Therefore, Background Suppression is calculated based on the density of the frames.

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June, 2008

Action

Select [Off] for [Au t o ].

Image Quality

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Image Quality

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4 Repairs and Adjustments

Introduction

Introduction ..................................................................................................................... 4-3

Repairs

1. Drive

REP 1.1.1 IOT Motor (SCC)............................................................................................ 4-5

2. Paper Transport

REP 2.2.1 Tray 1 Feed Clutch (SCC)............................................................................. 4-7

REP 2.3.1 Tray 1 Feed Roll (SCC)................................................................................. 4-9

REP 2.5.1 Tray 1 Feed Sensor...................................................................................... 4-10

REP 2.7.1 Tray 1 No Paper Sensor............................................................................... 4-12

REP 2.8.1 Registration (SCC)......................................................................................... 4-13

3. ROS

REP 3.1.1 ROS (SCC).................................................................................................... 4-17

4. CRU

REP 4.1.1 Drum Cartridge.................. ................... ................... .................................... .. 4-19

REP 4.2.1 Toner Empty Sensor...................................................................................... 4-20

REP 4.2.2 Erase Lamp ................................................................................................... 4-21

REP 4.3.1 Transfer Module............................................................................................. 4-23

REP 4.4.1 Corotron Wire ................................................................................................ 4-27

5. Fuser

REP 5.1.1 Fuser (SCC)................................................................................................... 4-29

REP 5.1.2 Temperature Control Sensor Assembly......................................................... 4-31

REP 5.1.3 Fuser Lamp.................................................................................................... 4-32

REP 5.1.4 Fuser Roll ...................................................................................................... 4-35

REP 5.1.5 Fuser Pressure Roll....................................................................................... 4-38

6. Exit

REP 6.1.1 Exit Transport (Simplex)................................................................................ 4-39

REP 6.1.2 Exit Transport (Duplex).................................................................................. 4-42

7. Simplex Module and Bypass Tray

REP 7.1.1 Simplex, Duplex Module................................................................................ 4-45

REP 7.5.1 Bypass Feed Roll........................................................................................... 4-47

8. Electrical

REP 8.1.1 AIOC PWB (SCC)................ ........................................................................ .. 4-49

REP 8.1.2 LVPS (SCC)................................................................................................... 4-52

REP 8.1.3 AIOC/Network PWB (DADF/Network Only)................................................... 4-55

REP 8.2.1 HVPS (SCC).................................................................................................. 4-58

REP 8.2.2 Duplex PWB (SCC) ....................................................................................... 4-61

REP 8.3.1 Control Panel (SCC)............................................................................. .... ..... 4-62

REP 8.4.1 User Interfac e PWB (SCC)..................... ....................................................... 4-64

9. Cover

REP 9.1.1 Output Tray....................................................... .................................... ......... 4-67

REP 9.1.2 Front Left Cover.................................................... ......................................... 4-68

REP 9.2.1 Rear Cover.......................................................... ................... ........................ 4-69

REP 9.2.2 Right Cover........................................ ................... ......................................... 4-70

10. IIT

REP 10.1.1 IIT Platen Cover..................................................................... ................... ... 4-71

REP 10.2.1 IIT Upper Cover (SCC) ................................................................................ 4-72

REP 10.3.1 IIT Carriage (SCC).................................................................................. .... . 4-73

REP 10.3.2 Flexible Print Cable (S CC)......... ................... ................... ................... ......... 4-79

REP 10.6.1 Exposure Lamp........................................... .................................... ............. 4-81

REP 10.7.1 Carriage Cable and Drum.................................................... .. .. .... ..... .... .. .. ... 4-82

REP 10.7.2 Inverter PWB. ................................... .................................... ........................ 4-85

11. Single Tray Module

REP 11.1.1 Tray 2............................... ................................... ................... ...................... 4-89

REP 11.1.2 Single Tray Module (Separation from IOT).................................................. 4-89

REP 11.4.1 Tray 2 Feed Roll .......................................................................................... 4-91

REP 11.4.2 Tray 2 Retard Roll........................................................................................ 4-93

REP 11.5.1 STM Feed Sensor........................................................................................ 4-96

REP 11.5.2 STM PWB (SCC).................................................. .................................... ... 4-97

REP 11.6.1 STM Feed Clutch........................................................... .. .... .. .... .. ....... .... .. ... 4-98

REP 11.6.2 STM Feed Motor.......................................................................................... 4-99

REP 11.7.1 STM No Paper Sensor........... .................................... .................................. 4-100

13. ADF

REP 13.1.1 ADF Assembly............................... ................... .................................... ....... 4-101

REP 13.1.2 ADF/DADF Platen Cushion ................... .................. ................... .................. 4-102

REP 13.2.1 Document Tray Asse mbly (ADF)................................................................. 4-104

REP 13.2.2 ADF Feeder Assembly................................................................................. 4-106

REP 13.2.3 Front Cover.................................... .................................... ................... ....... 4-109

REP 13.2.4 Rear Cover....................... .................. .......................................................... 4-110

REP 13.2.5 DADF Eject Roller Solenoid......................................................... ....... .. .. .. ... 4-111

REP 13.2.6 DADF Assembly..................... .................................... .................. ................ 4-112

REP 13.2.7 Document Tray Asse mbly (DADF)............................................................... 4-113

REP 13.2.8 DADF Feeder Assembly .............................................................................. 4-116

REP 13.3.1 ADF Control PWB..................................... ................................... ................ 4-119

REP 13.3.2 Left Counter Balance (SCC) ........................................................................ 4-121

REP 13.3.3 Right Counter Balance (SCC)...................................................................... 4-122

REP 13.3.4 DADF PWB...................... ................................... .................................... ..... 4-124

REP 13.4.1 Top Cover.................................... .................................... ................... ......... 4-125

REP 13.8.1 Retard Roll..................................... ................... ........................................... 4-126

REP 13.9.1 Pickup Roll, Feed Roll......................................................................... .. .. .. ... 4-128

Adjustments

ADJ 8.1.1 Edge Erase Adjustment............................. ................... .................................. 4-131

ADJ 8.1.2 Controller Firmware Ve rsion Upgrade...................................... ...................... 4-131

ADJ 10.3.1 IIT Lead Edge/Side Edge Registration......................................................... 4-132

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Repairs and Adjustments

ADJ 11.1.1 Carriage Assembly Alignment (Parallelism)................................................. 4-133

ADJ 13.1.1 ADF/DADF Positional Adjustment................................................................ 4-134

Repairs and Adjustments

June, 2008

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Introduction

This section contains procedures required for parts replacement and adjustment.

How to Use the Replacement and Adjustment Section

For installation procedures, only NOTEs are described here since installation procedures are the reverse of removal ones.

1. (Figure X) at the beginning of a procedure indicates that its detailed steps are shown in the illustration. Numbers in the illustration indicate the sequence of the steps.

2. (REP X.X.X) at the end of a procedure indicates the replacement procedure to be referred to.

3. Item numbers of replacement and adjustment procedures (i.e. REP/ADJ No.) correlate to the PL No. in Section 5 Parts List. Therefore, an appropriate replacement o r adjustment procedure can easily be referred to a PL No. and v ice versa. For exam ple, t he replace ment or adjustment procedure of Component PL 1.1 is REP 1.1.X or ADJ 1.1.X.

4. When replacement/adjustment procedures or title items vary by modification or model, the modification number or the model is indicated at the beginning or the end of the respective titles or procedures.

Example 1: REP X.X.X Main PWB [Models with 1V] indicates that the entire proce dure under this title applies to machines with Tag 1V.

Example 2: See Table 1.

Table 1

Symbol Description

Illustration 1: Indicates that a specific part has been modified by the tag number within the circle.

Terms and Symbols

Terms and symbols used throughout this section are explained here.

WARNING

A Warning statement indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in personal injury or loss of life.

CAUTION

A Caution statement indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in damage to, or destruction of, equipment.

NOTE: A Note statement indicates an operating or maintenance procedure, practice, or condition that is necessary to accomplish a task efficiently.

Reference: Used when other explanations are given. Purpose: Used to describe the purpose of the Adjustment.

Safety Critical Components (SCC): Safety Critical Components are components, such as static-sensitive integrated circuit chips,

that require special precautions to prevent them from being damaged. Follow the regulations regarding Safety Critical Components set by FUJI XEROX Co., Ltd.

Important Information Stored Component (ISC): This component stores all the important customer information that is input after the installation.

When replacing this component, follow the procedures in Section 4 Repairs and Adjustments. Make absolutely sure that no customer information gets revealed.

Figure 1 Illustration 1

Illustration 2: Indicates that the configuration of the part shown is the configuration before the part was modified by the number within the circle.

Figure 2 Illustration 2

5. Positions or directions are defined as follows: a. Front: Front of the machine. b. Right: Right-hand side facing the machine. c. Left: Left-hand side facing the machine. d. Rear: Rear of the machine.

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Repairs and Adjustments

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REP 1.1.1 IOT Motor (SCC)

Parts List on PL 1.1 Removal

WARNING

To avoid personal injury or electrical shock, ensure that the machine is completely off before disassembling or adjusting. Turn OFF the power and unplug the machine.

1. Remove the Drum Cartridge (REP 4.1.1).

2. Remove the Rear Cover (REP 9.2.1).

3. Disconnect the connector (Figure 1). 1 Remove the screw that secures the Ground Wires (2). 2 Disconnect P/J 504. 3 Release the wire harness of the IOT Motor from the hook. 4 Remove the wire harness of the IOT Motor from the slot in the frame.

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Figure 1

Repairs and Adjustments

REP 1.1.1

4. Remove the IOT Motor (Figure 2). 1 Remove the Tapping Screws (4). 2 Remove the IOT Motor.

Figure 2

Replacement

1. To install, do the removal steps in reverse order.

Repairs and Adjustments

REP 1.1.1

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REP 2.2.1 Tray 1 Feed Clutch (SCC)

Parts List on PL 2.2 Removal

WARNING

To avoid personal injury or electrical shock, ensure that the machine is completely off before disassembling or adjusting. Turn OFF the power and unplug the machine.

1. Remove the Rear Cover (REP 9.2.1).

2. Disconnect the connector (Figure 1). 1 Disconnect the connector. 2 Release the wire harness from the clamp.

3. Remove the screws (3) that secure the Clutch Bracket (Figure 2). 1 Remove the screws (3).

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Figure 1

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Figure 2

Repairs and Adjustments

REP 2.2.1

4. Remove the Tray 1 Feed Clutch (Figure 3). 1 Remove the Clutch Bracket. 2 Remove the bearing. 3 Remove the Tray 1 Feed Clutch. 4 Pull out the wire harness through the hole.

Replacement

1. To install, do the removal steps in reverse order.

2. When installing the Tray 1 Feed Clutch, place the tab of Clutch Bracket in the notch of Tray 1 Feed Clutch (Figure 4).

Repairs and Adjustments

REP 2.2.1

Figure 3

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Figure 4

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REP 2.3.1 Tray 1 Feed Roll (SCC)

Parts List on PL 2.3 Removal

WARNING

To avoid personal injury or electrical shock, ensure that the machine is completely off before disassembling or adjusting. Turn OFF the power and unplug the machine.

1. Remove all paper from Tray 1.

2. Remove Tray 1.

3. Remove the Feed Shaft (Figure 1). 1 Lower the Bottom Plate. 2 Release the Feed Shaft from the bearing by pressing down on the white tab. 3 Remove the Feed Shaft by pulling it in the direction of the arrow.

4. Remove the Tray 1 Feed Roll (Figure 2). 1 Gently lift up the tab to remove the Tray 1 Feed Roll.

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Figure 1

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4-35

Figure 2

Repairs and Adjustments

REP 2.3.1

Replacement

1. To install, do the removal steps in reverse order.

2. When installing the Tray 1 Feed Roll, align the pin of the Feed Shaft with the slot in the Tray 1 Feed Roll (Figure 3).

REP 2.5.1 Tray 1 Feed Sensor

Parts List on PL 2.5 Removal

WARNING

To avoid personal injury or electrical shock, ensure that the machine is completely off before disassembling or adjusting. Turn OFF the power and unplug the machine.

1. Remove Tray 1.

2. Remove Tray 2 (REP 11.1.1).

3. Remove the Sensor Housing of the Tray 1 No Paper Sensor (REP 2.7.1).

4. Open the Tray 1 Access Cover on the left side of the machine.

Repairs and Adjustments

REP 2.3.1, REP 2.5.1

Figure 3

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WorkCentre 5016, 5020

5. Remove the Tray 1 Feed Sensor (Figure 1). 1 Remove the Tapping Screw. 2 Remove the cable bands (2). 3 Release the wire harness from the clamps (2). 4 Move the wire harness toward you and disconnect the connector. 5 Remove the Tray 1 Feed Sensor.

Replacement

1. To install, do the removal steps in reverse order.

2. Insert the Connector Housing of the Tray 1 Interlock Switch into the square hole of the frame (Figure 2).

A Square hole

Reissue WorkCentre 5016, 5020

Figure 1

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Figure 2

Repairs and Adjustments

REP 2.5.1

REP 2.7.1 Tray 1 No Paper Sensor

Parts List on PL 2.7 Removal

WARNING

To avoid personal injury or electrical shock, ensure that the machine is completely off before disassembling or adjusting. Turn OFF the power and unplug the machine.

1. Remove Tray 1.

2. Remove Tray 2 (REP 11.1.1).

3. Remove the Sensor Housing (Figure 1). 1 Disconnect the connector. 2 Release the tabs (2) to remove the Sensor Housing.

4. Remove the Tray 1 No Paper Sensor (Figure 2). 1 Remove the Actuator. 2 Release the tabs to remove the Tray 1 No Paper Sensor.

Repairs and Adjustments

REP 2.7.1

Figure 1

Replacement

1. To install, do the removal steps in reverse order.

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Figure 2

Reissue

WorkCentre 5016, 5020

REP 2.8.1 Registration (SCC)

Parts List on PL 2.8 Removal

WARNING

To avoid personal injury or electrical shock, ensure that the machine is completely off before disassembling or adjusting. Turn OFF the power and unplug the machine.

1. Remove the Drum Cartridge (REP 4.1.1).

2. Remove the Rear Cover (REP 9.2.1).

3. Remove the Transfer Corotron Housing (REP 4.3.1).

4. Disconnect the connector (Figure 1). 1 Remove the screw to remove the Ground Wire. 2 Remove the screw to remove the Ground Wires (2). 3 Disconnect P/J 503. 4 Remove the wire harness from the hooks (2). 5 Remove the wire harness from the slots (2) in the frame. 6 Remove the wire harness from the guides (3).

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Figure 1

Repairs and Adjustments

REP 2.8.1

5. Remove the Connector Housing (Figure 2). 1 Remove the wire harness from the guide. 2 Slide the Connector Housing through the hole.

6. Remove the Front Stopper (Figure 3). 1 Remove the Front Stopper.

Repairs and Adjustments

REP 2.8.1

Figure 2

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Figure 3

Reissue

WorkCentre 5016, 5020

7. Remove the Registration (Figure 4). 1 Press the tab in the direction of the arrow to remove the boss of the Registration from the frame.

Figure 4

Replacement

1. To install, do the removal steps in reverse order.

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Repairs and Adjustments

REP 2.8.1

Repairs and Adjustments

REP 2.8.1

June, 2008

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WorkCentre 5016, 5020

Xerox 5020, 5016 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

How To Use This Manual

1 Service Call Proced ur es

1.1 Before Starting Service

1.2 Service Call Procedure

1.3 Service Call Details

1.4 TRIM Checklist

1.5 Periodic Replacement Parts/Consumables List

2 Status Indicator RAPS

Fault Repair Overvie w and List of Error Codes

Fault Repair Overview

U0-1 Main Motor Stop Error

U1-1 Main Motor Rotation Error

U2-1 Carriage Module Fail

U3-5 Laser Power Or ROS Motor Fail

U4-1 Fuser On Time Fail

U4-2 Over Heat Temp Fail

U4-3 FS1 Thermistor Defect

U4-9 Fuser Fan Defect

U6-2 RAM Read/Write Check Error

U6-3 NVM Data Defect

U6-4 NVM Read/Write Cannot Be Executed

U6-5 CPU Power To Access NVM Is Not Enough

U7-0 UI Communication TimeOut

U7-1 UI Communication Error

U8-1 Billing Counter Defect

U9-0 HVPS Fail

062-300 Plat en Interlock Open

062-345 IISS EEPROM Failure

062-360 Carriage Position Fail

062-371 Lamp Illumination Fail

062-380 AGC Failure

062-386 AOC Failure

062-392 IPS PWB Memory Fail

062-393 IPS PWB Fail

005-170 DADF Feed Failure

005-171 DADF Regi / Exit Failure

005-172 DADF Inve rted Document Jam

005-198 Short Sca n Jam

005-199 Long Scan Jam

005-305 Feeder Top Cover Open

005-920 Static Jam

3 Image Quality

IQ1 IOT Image Quality Entry RAP

IQ2 IIT Image Quality Entry RAP

IQ3 Low Image Density RAP

IQ4 Wrinkled Image RAP

IQ5 Residual Image (Ghosting) RAP

IQ6 Background RAP

IQ7 Deletion RAP

IQ8 Skew/Misregistration RAP

IQ9 Process Direction B ands, Streaks, and Smears RAP

IQ10 Unfused Copy/Toner Offset RAP

IQ11 Repeating Bands, Streaks, Spots, and Smears RAP

IQ12 Mottle RAP

IQ13 Spots RAP

IQ14 Black Prints RAP

IQ15 Blank Image RAP

Copy Quality Specification

Samples of Image Quality Defects

Introduction

REP 1.1.1 IOT Motor (SCC)

REP 2.2.1 Tray 1 Feed Clutch (SCC)

REP 2.3.1 Tray 1 Feed Roll (SCC)

REP 2.5.1 Tray 1 Feed Sensor

REP 2.7.1 Tray 1 No Paper Sensor

REP 2.8.1 Registration (SCC)