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WC5020

Xerox WC5016, WC5020 Service Manual

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Page 1
WC5016 WC5020
Black-and-white Multifunction Printer
Service
Manual
WorkCentre 5016 5020
Multifunction Printer
Page 2
7
01P48365
J
une 2008
W
ork Center 5016, 5020
S
ervice Documentation
CAUTION
Certain components in the Work Center 5016/ 5020 are susceptible to damage from electrostatic dis­charge. Observe all ESD procedures to avoid com­ponent damage.
Page 3
June, 2008
i
WorkCentre 5016, 5020
Introduction
Reissue
Introduction
How To Use This Manual................................................................................................ iii
Page 4
June, 2008
1-1
WorkCentre 5016, 5020
Service Call Procedures
Reissue
1 Service Call Procedures
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 Replacement Parts/Consumables List........................................................ 1-5
Page 5
June 2008
WorkCentre 5016, 5020
Status Indicator RAPS
Reissue
2 Status Indicator RAPS
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
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June, 2008
3-1
WorkCentre 5016, 5020
Image Quality
Reissue
3 Image Quality
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
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June, 2008
4-1
WorkCentre 5016, 5020
Repairs and Adjustments
Reissue
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 Interface PWB (SCC)....................... ................. ................. ................... 4-64
9. Cover
REP 9.1.1 Output Tray........................................................................ ............................ 4-6 7
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 (SCC)........... ................................................................ 4-79
REP 10.6.1 Exposure Lamp............................ ................. ............................................... 4- 8 1
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 Assembly (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 Assembly (DAD F). ................................................. ............. 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 Versio n Upgr a d e............................................................ 4-131
ADJ 10.3.1 IIT Lead Edge/Side Edge Registration ......................................................... 4-132
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4-2
WorkCentre 5016, 5020
Reissue
Repairs and Adjustments
ADJ 11.1.1 Carriage Assembly Alignment (Parallelism)................................................. 4-133
ADJ 13.1.1 ADF/DADF Positional Adjustment ................................................................ 4-134
Page 9
June 2008
WorkCentre 5016, 5020
Parts Lists
Reissue
5 Parts List
Overview
Introduction ..................................................................................................................... 5-3
Subsystem Information................................................................................................... 5-4
Symbology...................................................................................................................... 5-5
Parts Lists Drive
PL 1.1 IOT Motor............................................................................................................. 5-7
Paper Transport
PL 2.1 Tray 1...................................................................................................................5-8
PL 2.2 Tray 1 Frame Accessory...................................................................................... 5-9
PL 2.3 Tray 1 Components (1 OF 2)............................................................................... 5-10
PL 2.4 Tray 1 Components ( 2 OF 2).............................................................................. 5-11
PL 2.5 Tray 1 Frame Components.................................................................................. 5-12
PL 2.6 Tray 1 Frame Components (2 OF 2) ................................................................... 5-13
PL 2.7 No Paper Sensor Housing...........................
..
...................................................... 5-14
PL 2.8 Registration.......................................................................................................... 5-15
PL 2.9 Registration Component...................................................................................... 5-16
ROS
PL 3.1 ROS..................................................................................................................... 5-17
CRU
PL 4.1 Drum Cartridge.................................................................................................... 5-18
PL 4.2 Toner Empty Sensor and Erase Lamp ................................................................ 5-19
PL 4.3 Transfer............................................................................................................... 5-20
PL 4.4 Transfer Corotron Housing Component............................................................... 5-21
Fuser
PL 5.1 Fuser....................................................................................................................5-22
Exit Transport
PL 6.1 Exit Transport ...................................................................................................... 5-23
PL 6.2 Exit Transport Component (Simplex)................................................................... 5-24
PL 6.3 Exit Transport Component (Duplex) .................................................................... 5-25
Simplex / Duplex Module and Bypass Tray
PL 7.1 Simplex Module................................................................................................... 5-26
PL 7.2 Left Hand Cover Assembly.................................................................................. 5-27
PL 7.3 Duplex Module Component (1 OF 2)................................................................... 5-28
PL 7.4 Duplex Module Component (2 OF 2)................................................................... 5-29
PL 7.5 Bypass Tray Accessory....................................................................................... 5-30
PL 7.6 Bypass Tray Component..................................................................................... 5-31
Electrical
PL 8.1 AIOC PWB, LVPS, Power Switch........................................................................ 5-32
PL 8.2 HVPS, Interlock Switch, Duplex PWB................................................................. 5-33
PL 8.3 Control Panel Accessory ..................................................................................... 5-34
PL 8.4 Control Panel Component.................................................................................... 5-35
Cover
PL 9.1 Front / Top Cover............................... ................. ................................................ . 5 -36
PL 9.2 Rear / Right Cover and NOHAD Fan................................................................... 5-37
IIT
PL 10.1 IIT Accessory............................. ................................................ ........................ 5-38
PL 10.2 IIT Component (1 OF 2)....................................................... .... .... .. .... ......... .... .. . 5-39
PL 10.3 IIT Component (2 OF 2)....................................................... .... .... .. .... ......... .... .. . 5-40
PL 10.4 IIT Upper Cover Cover Component ................................................................... 5-41
PL 10.5 IIT Under Cover Component.......................................................... .. ......... .... .... . 5-42
PL 10.6 IIT Carriage Component .................................................................................... 5-43
PL 10.7 Center Plate Component ................................................................................... 5-44
Single Tray Module
PL 11.1 Single Tray Module ............................................................................................ 5-45
PL 11.2 Tray 2 Component (1 OF 3)............................................................................... 5-46
PL 11.3 Tray 2 Component (2 OF 3)............................................................................... 5-47
PL 11.4 Tray 2 Component (3 OF 3)............................................................................... 5-48
PL 11.5 Single Tray Frame Component (1 OF 2) ........................................................... 5-49
PL 11.6 Single Tray Frame Component (2 OF 2) ........................................................... 5-50
PL 11.7 STM No Paper Sensor............... ........................................................................ 5-51
Stand
PL 12.1 Stand Component.............................................................................................. 5-52
ADF/DADF
PL 13.1 ADF/DADF Accessory ....................................................................................... 5-53
PL 13.2 Component, Cover............................................................................................. 5-54
PL 13.3 Base Cover Component.... ................. ................. ............................................... 5-55
PL 13.4 Feeder Component............................................................................................ 5-56
PL 13.5 Lower Feeder Component ................................................................................. 5-57
PL 13.6 Retard Roll Component ..................................................................................... 5-58
PL 13.7 Lower Feeder Assembly .................................................................................... 5-59
PL 13.8 Retard Roll Assembly ........................................................................................ 5-60
PL 13.9 Upper Feeder Assembly .................................................................................... 5-61
PL 13.10 Document Tray............. ................. ................. ................................................ . 5-62
Common Hardware
Common Hardware......................................................................................................... 5-63
Part Number Index.......................................................................................................... 5-64
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June, 2008
5-1
WorkCentre 5016, 5020
Parts Lists
Reissue
Overview
Introduction ..................................................................................................................... 5-3
Subsystem Information................................................................................................... 5-4
Symbology...................................................................................................................... 5-5
Parts Lists Drive
PL 1.1 IOT Motor............................................................................................................. 5-7
Paper Transport
PL 2.1 Tray 1...................................................................................................................5-8
PL 2.2 Tray 1 Frame Accessory...................................................................................... 5-9
PL 2.3 Tray 1 Components (1 OF 2)............................................................................... 5-10
PL 2.4 Tray 1 Components ( 2 OF 2).............................................................................. 5-11
PL 2.5 Tray 1 Frame Components.................................................................................. 5-12
PL 2.6 Tray 1 Frame Components (2 OF 2) ................................................................... 5-13
PL 2.7 No Paper Sensor Housing...........................
.
....................................................... 5-14
PL 2.8 Registration.......................................................................................................... 5-15
PL 2.9 Registration Component...................................................................................... 5-16
ROS
PL 3.1 ROS..................................................................................................................... 5-17
CRU
PL 4.1 Drum Cartridge.................................................................................................... 5-18
PL 4.2 Toner Empty Sensor and Erase Lamp ................................................................ 5-19
PL 4.3 Transfer............................................................................................................... 5-20
PL 4.4 Transfer Corotron Housing Component............................................................... 5-21
Fuser
PL 5.1 Fuser....................................................................................................................5-22
Exit Transport
PL 6.1 Exit Transport ...................................................................................................... 5-23
PL 6.2 Exit Transport Component (Simplex)................................................................... 5-24
PL 6.3 Exit Transport Component (Duplex) .................................................................... 5-25
Simplex / Duplex Module and Bypass Tray
PL 7.1 Simplex Module................................................................................................... 5-26
PL 7.2 Left Hand Cover Assembly.................................................................................. 5-27
PL 7.3 Duplex Module Component (1 OF 2)................................................................... 5-28
PL 7.4 Duplex Module Component (2 OF 2)................................................................... 5-29
PL 7.5 Bypass Tray Accessory....................................................................................... 5-30
PL 7.6 Bypass Tray Component..................................................................................... 5-31
Electrical
PL 8.1 AIOC PWB, LVPS, Power Switch........................................................................ 5-32
PL 8.2 HVPS, Interlock Switch, Duplex PWB................................................................. 5-33
PL 8.3 Control Panel Accessory ..................................................................................... 5-34
PL 8.4 Control Panel Component ................................................................................... 5-35
Cover
PL 9.1 Front / Top Cover................................................................................................. 5-36
PL 9.2 Rear / Right Cover and NOHAD Fan................................................................... 5-37
IIT
PL 10.1 IIT Accessory............................. ................................................ ........................ 5-38
PL 10.2 IIT Component (1 OF 2)....................................................... .... .... .. .... ......... .... .. . 5-39
PL 10.3 IIT Component (2 OF 2)....................................................... .... .... .. .... ......... .... .. . 5-40
PL 10.4 IIT Upper Cover Cover Component ................................................................... 5-41
PL 10.5 IIT Under Cover Component.......................................................... .. ......... .... .... . 5-42
PL 10.6 IIT Carriage Component .................................................................................... 5-43
PL 10.7 Center Plate Component ................................................................................... 5-44
Single Tray Module
PL 11.1 Single Tray Module ............................................................................................ 5 -45
PL 11.2 Tray 2 Component (1 OF 3)............................................................................... 5-46
PL 11.3 Tray 2 Component (2 OF 3)............................................................................... 5-47
PL 11.4 Tray 2 Component (3 OF 3)............................................................................... 5-48
PL 11.5 Single Tray Frame Component (1 OF 2) ........................................................... 5-49
PL 11.6 Single Tray Frame Component (2 OF 2) ........................................................... 5-50
PL 11.7 STM No Paper Sensor............... ........................................................................ 5-51
Stand
PL 12.1 Stand Component.............................................................................................. 5-52
ADF/DADF
PL 13.1 ADF/DADF Accessory ....................................................................................... 5-53
PL 13.2 Component, Cover............................................................................................. 5-54
PL 13.3 Base Cover Component.... ................. ................. ............................................... 5-55
PL 13.4 Feeder Component............................................................................................ 5-56
PL 13.5 Lower Feeder Component ................................................................................. 5-57
PL 13.6 Retard Roll Component ..................................................................................... 5-58
PL 13.7 Lower Feeder Assembly .................................................................................... 5-59
PL 13.8 Retard Roll Assembly ........................................................................................ 5-60
PL 13.9 Upper Feeder Assembly .................................................................................... 5-61
PL 13.10 Document Tray............. ................. ................. ................................................ . 5-62
Common Hardware
Common Hardware......................................................................................................... 5-63
Part Number Index.......................................................................................................... 5-64
Page 11
June, 2008
5-3
WorkCentre 5016, 5020
PL 1.1
Parts Lists
Reissue
PL 1.1 IOT Motor
Item Part Description
1 007K94880 IOT Motor (REP 1.1.1) 2 120E22470 Push Tie 3 – Gear Pulley (Not Spared) 4 – Cover (Not Spared) 5 – Belt (Not Spared) 6 – Traceability Label (Not Spared)
Page 12
June, 2008
6-1
WorkCentre 5016, 5020
General Procedures
Reissue
6 General Procedures
Diagnostics
Diagnostic Mode ............................................................................................................. 6-3
Basic Operations of the Diagnostic Mode....................................................................... 6-4
IOT Diagnostics............................................................................................................... 6-7
General Procedures
GP1 Serial Number Locations......................................................................................... 6-43
GP 2 Viewing the Six Digit Error Code............................................................................ 6-43
General Information
Specifications..................................................................................................................6-45
Tools ...............................................................................................................................
6-52
Consumables.................................................................................................................. 6-52
Glossary of Terms................................................................... ........................................ 6-53
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June, 2008
7-1
WorkCentre 5016, 5020
Wiring Data
Reissue
7 Wiring Data
BSDs
Chain 1 Standby Power.................................................. ............................................... 7-3
Chain 2 Mode Selection................................................................................................. 7-5
Chain 3 Machine Run Control............................................ ................ ............................ 7-6
Chain 4 Start Power............................. ................. ......................................................... 7-8
Chain 5 ADF/DADF........................ ................................................................................ 7-9
Chain 6 Imaging.............................................. ................ ............................................... 7-18
Chain 7 Paper Supplying ............................................................................................... 7-21
Chain 8 Paper Transportation........................................................................................ 7-23
Chain 9 Marking...... ................. ................ ...................................................................... 7-28
Chain 10 Fusing and Copy Transportation .................................................................... 7-31
Wirenets
Wirenets.......................................................................................................................... 7-35
P/J Locations
7.1 P/J Locations........... ................. ................. ................................................ ............... 7-45
Page 14
Xerox WorkCentre 5016, WorkCentre 5020 service manual
Xerox WorkCentre 5016, WorkCentre 5020 service manual
Xerox WorkCentre 5016, WorkCentre 5020 service manual
Xerox WorkCentre 5016, WorkCentre 5020 service manual
Xerox WorkCentre 5016, WorkCentre 5020 service manual
Xerox WorkCentre 5016, WorkCentre 5020 service manual
Xerox WorkCentre 5016, WorkCentre 5020 service manual
Xerox WorkCentre 5016, WorkCentre 5020 service manual
Xerox WorkCentre 5016, WorkCentre 5020 service manual
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