Xerox WorkCentre 5016 5020 Service manual

Work Center 5016, 5020 Service Documentation

701P48365 June 2008

CAUTION Certain components in the Work Center 5016/ 5020 are susceptible to damage from electrostatic discharge. Observe all ESD procedures to avoid component damage.

While Xerox has tried to make this documentation accurate, Xerox will have no liability arising out of any inaccuracies or ommissions. Changes are periodically made to this document. Changes, technical inaccuracies, and typographical errors will be corrected in subsequent editions. 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 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 changes 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 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 customer agrees to indemnify, defend and hold Xerox harmless from any third party claims which arise directly or indirectly from such service.

Acknowledgements Prepared by Global Knowledge & Llanguage Services - North America 800 Phillips Road - Building 0218-01A Webster, New York 14580-9791 ISO9001 AND ISO27001 Certified © Copyright 2007-2008 by Xerox Corporation. All rights reserved. Xerox® and all product names and number names are trademarks of Xerox Corporation. Printed in the USA

WorkCentre 5016, 5020

Printed in the United States of America.

Service Documentation

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

WorkCentre 5016, 5020 Service Documentation PANTONE is a registered trademark of Pantone, Inc. 701P48365 Changes are periodically made to this document. Changes, technical inaccuracies, and typographic errors will be corrected in subsequent editions.

Reissue June, 2008

CAUTION

***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 personnel 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 modules, 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.

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 found to comply with the limits for a Class A computing device pursuant to subpart B of part 15 of FCC rules, which are designed to provide reasonable 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.

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 customer 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 editions. Prepared by: Xerox Corporation Global Knowledge and Language Services 800 Phillips Road, Bldg. 0218-01A Webster, New York 14580-9791 USA ©2007 - 2008 by Xerox Corporation. All rights reserved. Copyright protection claimed includes all forms and matters of copyrightable material and information now allowed by statutory judicial law or hereinafter granted, including without limitation, material generated from the software programs which are displayed on the screen such as icons, screen displays, looks, etc.

Front Matter

June, 2008 i

Reissue WorkCentre 5016, 5020

Front Matter

June, 2008 ii


Introduction How To Use This Manual................................................................................................


iii

June, 2008 i

Introduction

Introduction

June, 2008 ii


How To Use This Manual

Chain 1 Standby Power Chain 2 Mode Selection Chain 3 Machine Run Control

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

Chain 4 Start Print Power Chain 6 Imaging

Enter any comments and/or corrections regarding the WorkCentre 5016, 5020 Service Documentationl on the Publication Comment Sheet, and send it to the Technical Support Center SDEG.

Chain 7 Paper Supplying Chain 8 Paper Transportation Chain 9 Marking

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

Chain 10 Fusing and Copy Transportation

Contents of Manual

Description of Terminology and Symbols

This manual is divided into nine sections as described below.

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

WARNING

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.

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

Section 2 Status Indicator RAPs

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.

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

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

Section 3 Image Quality RAPs

Reference: Used when other explanations are given.

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

Purpose: Used to describe the purposes of adjustment and troubleshooting.

Section 4 Removal/Replacement and Adjustment Procedures REP: This section contains the removal, replacement, and adjustment procedures for components of WorkCentre 5016, 5020.

Indicates the removal/replacement procedure for reference. ADJ:

Section 5 Parts List

Indicates the adjustment procedure for reference.

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

PL:

Section 6 General Procedures/Information

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.

ASSY: Means Assembly. Safety Critical Components (SCC):

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:


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.

June, 2008 iii

Introduction

Introduction

June, 2008 iv


1 Service Call Procedures 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 ........................................................

1-3 1-4 1-4 1-5 1-5

Reissue

June, 2008 1-1


Service Call Procedures


June, 2008 1-2


1.1 Before Starting Service

1.1.2Things to Note When Handling Customer Data

1.1.1Safety

1.

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.

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.

2.

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.

3.

3.

IOT (Platen): 31.5kg (requires 3 persons)

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

2.

Disassembling

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

2 Tray Modules: 8.6kg (requires 2 persons)

Make sure to note the assembled condition of the machine before removing parts or disassembling it.

Take extra care of your working posture to prevent backache. Safety Devices

3.

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.

7.

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 the packaging materials, are taken back to the Service Center.

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.

Other things to note when handling customer data.

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:

4.

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.

Drive Area Never inspect, clear or lubricate the drive components, such as chain belts, chain wheels or gears, when the machine is in operation.

Handling of copied/printed customer data.

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.

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

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

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 available.

5.

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).


June, 2008 1-3

If you have replaced the following consumables, affix the "U-TAG" so that the recyclable parts will be handled appropriately. a.

Drum Cartridge

b.

Toner Cartridge

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

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


1.1

1.2 Service Call Procedure

1.3 Service Call Details

1.2.1 Initial Actions

1.3.1 Initial Actions

1.

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

1.

2.

Record the billing meter readings.

•

Frequency and location of recent paper jams

3.

Inspect any faulty copies, then check the machine.

•

Copy quality

4.

Check the Service Log.

2.

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

Record the billing meter readings.

1.2.2 Actions to Take During UM (Unscheduled Maintenance)

3.

Inspect any faulty copies, then check the machine.

1.

Perform the service flow in Section 2 Status Indicator RAPs.

4.

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

2.

Perform the applicable RAP in Section 2 Status Indicator RAPs.

1.3.2 Checking Reproducibility of Problem

If there are no applicable RAPs, troubleshoot by referring to the BSD in Section 7 Wiring Data.

1.

Perform the service flow in Section 2 Status Indicator RAPs.

2.

Perform the applicable RAP in Section 2 Status Indicator RAPs.

Check the copy quality.

3.

If there are no applicable RAPs, troubleshoot by referring to the BSD in Section 7 Wiring Data.

3.

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.

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.

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

•

When the last error code is displayed, press the [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.

1.3.4 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 necessary. If replaced, always clear the counters of the corresponding items in the Chain Function.

1.2.3 Actions to Take During SM (Scheduled Maintenance) 1.

Check the copy quality.

2.

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

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

3.

•

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

•

When the last error code is displayed, press the [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.

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.


1.2, 1.3

June, 2008 1-4


1.4 TRIM Checklist

1.5 Periodic Replacement Parts/Consumables List

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

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 (refer to Diagnostic Mode in Section 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).

B: Always check and clean. *: Always replace at the specified interval. Table 1

CAUTION

Every time Service Details

No.

Service Items

1.1

Check before servicing A (check machine operation)

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

Turn on the machine, and make sure that there are no abnormal sounds.

Table 1 Parts/Consumables Name/PL No.

Replacement Interval (copies) Counters Check

1.2

Check before Servicing (copy the Test Pattern)

A

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

2

Clean the interior of the machine (paper transport system)

A

Clean the paper dust and toner residue in the paper path and on the jam sensor.

1

Tray 1 Feed Roll/ Retard Pad

50,000

[29/34] [29/24] [29/14] [29/4] Count up 1 for every feed. Replace both at the same time.

3

Clean the IIT

A

•

Clean the Platen Glass surface and the Platen Cushion with the optical cleaning cloth.

2

Tray 2 Feed Roll/ Retard Roll

100,000

•

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

[29/25] [29/15] [29/5] Count up 1 for every feed. Replace both at the same time.

3

MSI Feed Roll/ Retard Pad

50,000

[29/39] [29/29] [29/19] [29/9] Count up 1 for every feed. Replace both at the same time.

4

Fuser Unit

100,000

[21/39] [21/29] [21/19] [21/9] Count up 1 for every feed.

5

Toner Cartridge

6,000

6

Drum Cartridge

36,000

5

Safety Precautions

B

•

Make sure that the power cord is plugged in 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.

6.1

Check after servicing (copy quality check)

6.2

Check after servicing A (check machine operation)

•

Check the paper feed.

•

Make sure that there are no abnormal sounds.

Check after servicing (check the meter)

Create the Service Log and Service Report.

6.3

A

No

A

31,000 (Warning) 36,000 (Machine Stops)

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

CAUTION Do not touch the Drum of the Drum Cartridge.


June, 2008 1-5


1.4, 1.5


1.4, 1.5

June, 2008 1-6


2 Status Indicator RAPS Error Codes Fault Repair Overview and List of Error Codes...............................................................

2-3

RAPs 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 Platen 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 Inverted Document Jam ......................................................................... 005-198 Short Scan Jam ................................................................................................ 005-199 Long Scan Jam ................................................................................................. 005-305 Feeder Top Cover Open ................................................................................... 005-920 Static Jam .........................................................................................................


2-25 2-25 2-26 2-26 2-27 2-27 2-28 2-28 2-29 2-29 2-30 2-30 2-31 2-31 2-32 2-32 2-33 2-33 2-34 2-34 2-35 2-35 2-36 2-36 2-37 2-38 2-39 2-40 2-40 2-41 2-41

June, 2008 2-1

Status Indicator RAPS


June, 2008 2-2


Fault Repair Overview 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

Diagnostic Mode Operating Principles Wiring Data

Perform RAP

Reference Information Check if the fault is repaired

Completed

Figure 1 Troubleshooting Procedure


June, 2008 2-3


Check the Status of Installation

•

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 reference 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.

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 Diagnostics 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.

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

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 necessary.


June, 2008 2-4


Ask the operator about the problem Did the operator operate the machine correctly? No

Yes

Explain how to operate the machine

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)?

No

Procedure is complete

Yes

Refer to the Error Code List and perform the relevant troubleshooting

Yes

Does the Control Panel display an Error Code?

Figure 2 RAP Flow


June, 2008 2-5


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

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

Record in Error Log

RAP

BSD

O

-

CH8.1 Figure 1

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 C1-1

•

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

–


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.


June, 2008 2-6


Error Code

Record in Error Log


RAP

BSD

-

CH8.1 Figure 1 CH8.4 Figure 4

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

C1-2

•

Tray1 Feed Sensor dirty and Sensor Actuator deformed 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).

•

O

–


–


–


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.


June, 2008 2-7


Error Code


Record in Error Log

RAP

BSD

O

-

CH8.2 Figure 2

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 C2-1

•

STM Feed Sensor dirty and Sensor Actuator deformed 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.


June, 2008 2-8


Error Code


Record in Error Log

RAP

BSD

O

-


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


C2-2

•

STM Feed Sensor dirty and Sensor Actuator deformed 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

–


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

–


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.


June, 2008 2-9


Error Code

Record in Error Log


RAP

BSD

O

-


X

-

CH7.1 Figure 1

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


C2-3

•

IOT Registration 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 IOT Registration Sensor (PL 2.9). –


–


–


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 C5-0

Check Items • 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).


June, 2008 2-10


Error Code


Record in Error Log

RAP

BSD

X

-

-

X

-

CH7.2 Figure 2

X

-

-

X

-

-

Error Name Tray1 Paper Size Mismatch

C5-1

Explanation • 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.


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 C6-0


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

C6-1


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.


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

Error Name MSI Paper Size Mismatch

C7-1


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.


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


June, 2008 2-11


Error Code


Record in Error Log

RAP

BSD

X

-

CH3.2 Figure 2

-


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 Tray 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.


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

C9-3

•

IOT Registration Sensor dirty and Sensor Actuator deformed or damaged

•


•


O

•


•

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). –


–


–


•

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).

•



June, 2008 2-12


Error Code


Record in Error Log

RAP

BSD

O

-

CH8.1 Figure 1

O

-

CH8.2 Figure 2

O

-

-

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 C8-1

Check Items • Tray1 Feed Sensor dirty and Sensor Actuator deformed or damaged •


•


•

–

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

–


–



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 C8-2

Check Items • STM Feed 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 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)

–


–


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.


June, 2008 2-13


Error Code


Record in Error Log

RAP

BSD

O

-

CH8.4 Figure 4

O

-

CH10.2 Figure 2

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 E1-6

Check Items • Sensor dirty •


•

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).

•

–


–


–


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 E3-6

Check Items • Fuser Exit 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 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

–




June, 2008 2-14


Error Code


Record in Error Log

RAP

BSD

X

-

CH1.2 Figure 2

X

-

CH1.2 Figure 2

X

-

CH7.1 Figure 1

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


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



June, 2008 2-15


Error Code


Record in Error Log

RAP

BSD

X

-

CH7.2 Figure 2

X

-

CH3.2 Figure 2

X

-

CH3.2 Figure 2

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 Interlock Switch (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


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


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.


June, 2008 2-16


Error Code


Record in Error Log

RAP

BSD

O

-

CH10.2 Figure 2

O

-

CH10.2 Figure 2

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 • E1-2

Fuser Exit Sensor dirty and Sensor Actuator deformed or damaged

•

Paper damaged or not within specification

•


•


•


•

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).

•


•

–


–


–



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

•


•


•


•

–


–


–




June, 2008 2-17


Error Code


Record in Error Log

RAP

BSD

O

-

CH3.1 Figure 1

X

-

CH3.2 Figure 2

X

-

-

O

-

CH9.2 Figure 2

Error Name • MCU-STM comm. error

H9-7

Explanation 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 Toner Empty Sensor and the LVPS 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).

•


Error Name Toner Empty Explanation The Toner Cartridge is empty.

J1-2

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

•



June, 2008 2-18


Error Code


Record in Error Log

RAP

BSD

O

-

CH9.2 Figure 2

X

-

-

O

-

-

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

–


–


–


–


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).


June, 2008 2-19


Error Code


Record in Error Log

RAP

BSD

O

-

CH9.2 Figure 2

O

-

CH9.2 Figure 2

O

-

CH9.2 Figure 2

O

-

-

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). –

Wire between Drum Cartridge P610-7 ( P610) and AIOC PWB J402-1 ( P/J402)

–


–


–


–


–


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 J7-2

Explanation 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 J7-3

Explanation • The AIOC PWB has detected that the Drum CRUM ID is incorrect. Check Items • Turn the power OFF then ON. •


Error Name EPC Memory Full N1-1

Explanation • 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.


June, 2008 2-20


Error Code


Record in Error Log

RAP

BSD

O

-

CH3.2 Figure 2

O

-

CH3.2 Figure 2

Error Name No Response from USB-Host

N4-0

Explanation • 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 N4-1

Explanation 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.

O

-

-

O

-

-

Check Items Press the [Stop] button on the Control Panel. Error Name Push Scan TimeOut N5-0

Explanation • 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.


June, 2008 2-21


Error Code


Record in Error Log

RAP

BSD

O

-

CH3.2 Figure 2

O

-

CH3.2 Figure 2

O

U0-1

CH4.1 Figure 1

O

U1-1

CH4.1 Figure 1

O

U2-1

CH6.2 Figure 2

O

U3-5

CH6.3 Figure 3

O

U4-1

CH10.1 Figure 1

O

U4-2

CH10.1 Figure 1

O

U4-3

CH10.1 Figure 1

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.

U0-1

U1-1

U2-1

Error Name Main Motor stop error Explanation The motor runs for over 120 seconds without any paper being fed. Error Name Main Motor rotation error Explanation 500ms after the IOT has started, the Main Motor Lock signal is "Low." Error Name 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 Fail U4-1

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

U4-2

U4-3

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

Error Name Over Heat Temp Fail Explanation A temperature above 250°C is continuously detected for 480ms. Error Name FS1 thermistor defect Explanation FS1 cannot be monitored any more.


June, 2008 2-22


Error Code

U4-9

U6-2

Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name Fuser Fan defect Explanation After the start of Fan Fail Signal monitoring, the signal level was Low not more than 30 times. Error Name 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.

Record in Error Log

RAP

BSD

O

U4-9

CH10.3 Figure 3

O

U6-2

CH3.2 Figure 2

O

U6-3

CH3.2 Figure 2

O

U6-4

CH3.2 Figure 2

O

U6-5

CH3.2 Figure 2

X

U7-0

CH2.1 Figure 1

X

U7-1

CH2.1 Figure 1

O

U8-1

CH3.2 Figure 2

O

U9-0

CH9.1 Figure 1

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. •

U6-5

U7-0

U7-1

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

Error Name CPU Power to access NVM is not enough Explanation NVM queue full is detected during NVM Write. Error Name UI Communication TimeOut Explanation At the Power On Sequence, the AIOC PWB did not communicate with the User Interface PWB. Error Name 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. •

U9-0

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

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


June, 2008 2-23


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

Error Code

Error Name

Error Characteristic

1 (Highest)

U7-0

UI Communication TimeOut

2

U7-1

UI Communication Error

Unable to control the display at the Controller

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 rotation 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

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


Fatal Error

Dynamic Error (Job Cancel)

Priority Order

Error Code

Error Name

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

Error Characteristic

Document Jam

Paper Jam

Tray-related errors

Resolvable by replacing parts

An error that only stops scanning

Document Cover Open

Paper Cover Open

June, 2008 2-24


U0-1 Main Motor Stop Error

U1-1 Main Motor Rotation Error

BSD-Reference:

BSD-Reference:

CH4.1 (Figure 1)

CH4.1 (Figure 1)

Explanation

Explanation

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

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

Procedure

Procedure

The problem can be solved according to RAP U1- 1 Main Motor Rotation Error (U1-1). Y N Execute diagnostics [29-49] (How to Enter the Diagnostic Mode) to check the ROM version. The ROM is the latest version. Y N Upgrade the ROM to the latest version.

Close the Left Hand Cover and the Front Cover. Execute diagnostics [04--01 Main Motor On]. (How to Enter the Diagnostic Mode) The IOT Motor can be heard rotating. Y N Check P/J504 and P/J201. Both P/J504 and P/J201 are connected securely. Y N Connect P/J504 and P/J201 securely.

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.

Measure the voltage between LVPS PWB P504-1 ( P/J504) (+) and GND (-). The age is approximately +24VDC. Y N Replace the LVPS (PL 8.1) (REP 8.1.2).

Completed

Check the wire between J504-3 ( P/J504) and J201-3 shorted or open. Y N Repair the wire.

volt-

( P/J201). The wire is not

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. Check the installation of the IOT Motor (PL 1.1 ) (REP 1.1.1). The IOT Motor is installed properly. Y N Install the IOT Motor (PL 1.1 ) (REP 1.1.1) properly. Turn the rotor of the IOT Motor (PL 1.1 ) counterclockwise by hand. It rotates smoothly, without any abnormal load. Y N Check for any foreign substances that obstruct the drive and for any incorrectly installed parts. There are foreign substances or incorrectly installed parts. Y N 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). or open. Y N Repair the wire.

The wire is not shorted

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


U0-1, U1-1

U2-1 Carriage Module Fail

U3-5 Laser Power Or ROS Motor Fail

BSD-Reference:

BSD-Reference:

CH6.2 (Figure 2)

CH6.3 (Figure 3)

Explanation

Explanation

A carriage fault was detected.

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

Procedure

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. Y N Check each IIT Carriage connector. Each connector is connected securely. Y N Connect each connector securely.

Execute diagnostics [6-15 ROS Motor ON]. (How to Enter the Diagnostic Mode) The ROS Motor can be heard rotating. Y N Measure the voltage between the AIOC PWB P403-7 ( P/J403) (+) and GND (-). The voltage is approximately +24VDC. Y N Replace the AIOC PWB (PL 8.1) (REP 8.1.1) and the LVPS (PL 8.1) (REP 8.1.2) in that order.

Check for foreign substances and deformed parts in the carriage. None is found. Y N Remove the foreign substances and repair the deformed parts.

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

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. Execute diagnostics [5-11 Home Sensor], and "H" is displayed. Y N Check each IIT Carriage and Carriage Sensor connector. Each connector is connected securely. Y N Connect each connector securely. 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. Y N Install the Carriage Sensor (PL 10.6) properly.

Measure the voltage between the AIOC PWB P403-1 ( P/J403) (+) and GND (-). age is approximately +5VDC. Y N Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

The

volt-

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. Y N 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/ J130) The wires are not shorted or open. Y N 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.

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


U2-1, U3-5

June, 2008 2-26


U4-1 Fuser On Time Fail

U4-2 Over Heat Temp Fail

BSD-Reference:

BSD-Reference:

CH10.1 (Figure 1)

CH10.1 (Figure 1)

Explanation

Explanation

•

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

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

•

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

Procedure

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. The Fuser is normal and there is no paper in it. Y N Remove the paper. Check the condition of the Fuser. The Fuser is installed properly. Y N Install the Fuser properly. Remove the Fuser. Check the conductivity between the Thermostat contacts. The are conductive. Y N Replace the Fuser (PL 5.1) (REP 5.1.1).

contacts

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 ( P/J601) and the resistance of the Thermistor. There is no open circuit between J601-1 J601-2, and the resistance is a minimum of 228k ohms (cold). Y N 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. Y N 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.

Check the Heater Rod for an open circuit. There is no open circuit between J600-1 ( P/ J600) and J600-2. Y N 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). Y N Replace the Fuser (PL 5.1) (REP 5.1.1). Immediately after Main Switch ON, the voltage between J3-3 ( P/J3) (ACH) and J3-1 (ACN) is approximately 200VAC. Y N Replace the LVPS (PL 8.1) (REP 8.1.2). Check the wire between J408 ( P/J408) and P601 ( P/J601). P601 is not shorted or open. Y N Repair the wire.

The wire between J408 and

Check the wire between J3 ( P/J3) and P600 ( P/J600). The wire between J3 and P600 is not shorted or open. Y N 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.


June, 2008 2-27


U4-1, U4-2

U4-3 FS1 Thermistor Defect

U4-9 Fuser Fan Defect

BSD-Reference:

BSD-Reference:

CH10.1 (Figure 1)

CH10.3 (Figure 3)

Explanation

Explanation

Thermistor FS1 cannot be monitored any more.

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

Procedure

Procedure

Check the condition of the Fuser. The Fuser is installed properly. Y N Install the Fuser properly.

Turn the power ON. Visually check the NOHAD Fan (PL 9.2). The NOHAD Fan is rotating. Y N Measure the voltage between the AIOC PWB P405-3 ( P/J405) (+) and GND (-). The voltage is approximately +24VDC. Y N Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

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

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

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

Measure the voltage between the AIOC PWB P405-2 P/J405 (+) and GND (-). The voltage is 0. Y N Replace the NOHAD Fan (PL 9.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

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



U4-3, U4-9

June, 2008 2-28


U6-2 RAM Read/Write Check Error

U6-3 NVM Data Defect

BSD-Reference:

BSD-Reference:

CH3.2 (Figure 2)

CH3.2 (Figure 2)

Explanation

Explanation

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

•

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 Y N Connect each connector securely. Turn the power OFF and ON. U6-2 recurs. Y N Completed Replace the AIOC PWB (PL 8.1) (REP 8.1.1).


Procedure Check each AIOC PWB connector. Each connector is connected securely. Y N Connect each connector securely. Turn the power OFF and ON. U6-3 recurs. Y N Completed Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

June, 2008 2-29


U6-2, U6-3

U6-4 NVM Read/Write Cannot Be Executed

U6-5 CPU Power To Access NVM Is Not Enough

BSD-Reference:

BSD-Reference:

CH3.2 (Figure 2)

CH3.2 (Figure 2)

Explanation

Explanation

•

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

At NVM write, the NVM queue full 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. Y N Connect each connector securely. Turn the power OFF and ON. U6-4 recurs. Y N Completed

Procedure Execute diagnostics [29-49] to check the ROM version. Mode) The ROM is the latest version. Y N Upgrade the ROM to the latest version.

(How to Enter the Diagnostic




U6-4, U6-5

June, 2008 2-30


U7-0 UI Communication TimeOut

U7-1 UI Communication Error

BSD-Reference:

BSD-Reference:

CH2.1 (Figure 1)

CH2.1 (Figure 1)

Explanation

Explanation

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

The User Interface PWB detected a communication failure.

Procedure

Procedure

Measure each voltage between AIOC PWB J401-1 ( P/J401) (+), J401-2 (+), and GND (-). The voltages are approximately +5VDC. Y N Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Check each User Inferface PWB connector. Each connector is connected securely. Y N Connect each connector securely.

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

Turn the power OFF and ON. U7-1 recurs. Y N Completed Replace the User Interface PWB (PL 8.4) (REP 8.4.1).

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.


June, 2008 2-31


U7-0, U7-1

U8-1 Billing Counter Defect

U9-0 HVPS Fail

BSD-Reference:

BSD-Reference:

CH3.2 (Figure 2)

CH9.1 (Figure 1)

Explanation

Explanation

•

An illegal Billing Counter value was detected.

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

•

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

Procedure TBD

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 (-). The voltages are approximately +5VDC. Y N 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 Mode) The voltages at P406-2 ( P/J406) (+)/P406-4 (+)/P406-5 (+) become 0. Y N 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. Y N Measure the voltage between P406-1 ( P/J406) (+) on the AIOC PWB and ground (-). The voltage is approximately +5VDC. Y N 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


U8-1, U9-0

June, 2008 2-32


062-300 Platen Interlock Open

062-345 IISS EEPROM Failure

BSD-Reference:

BSD-Reference:

CH 5.6

CH 3.1

Explanation

Explanation

Detected the opened Platen Interlock.

Error in writing on or communicatiing with the EEPROM.

Procedure

Procedure

Ensure that the DADF can be closed normally. The DADF can be closed normally. Y N Remove obstructions or repair the DADF Counter Balances. (REP 13.3.2, REP 13.3.3)

Switch off the machine power then switch on the power. The problem is solved. Y N Replace the SLCC PWB (AIOC/Network PWB). (REP 8.1.3) (PL 8.1)

Check that the Platen Interlock is functioning properly. The Platen Interlock is functioning properly. Y N Replace the Platen Interlock Sensor.

Problem is resolved.

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


June, 2008 2-33


062-300, 062-345

062-360 Carriage Position Fail

062-371 Lamp Illumination Fail

BSD-Reference:

BSD-Reference:

CH 6.2

CH 6.1

Explanation

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.

Detected incufficient light provided from the Lamp to the CCD.

Procedure Procedure Check that the Lamp Carriage can move freely and has no loose cables. The Lamp Carriage and cables are good. Y N 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. The Regi Sensor is good. Y N 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. Y N Check the connector of the Carriage Motor and repair if necessary. Replace the Carriage Motor. (PL 10.6)

Check for any obstructions in the optical path between the lamp, the lens or the mirror. The optical path is clear of any obstructions. Y N Remove the obstuctions. Check that the White Color Correction Plate (Reflector) is in place and not deterioarated. (PL 10.6) The White Color Correction Tape is good. Y N 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. Y N 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)

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


062-360, 062-371

June, 2008 2-34


062-380 AGC Failure

062-386 AOC Failure

BSD-Reference:

BSD-Reference:

CH 6.2

CH 6.1

Explanation

Explanation

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

Control logic has detected an output defect of the CCD at AOC (Automatic Offset Control) of the auto IIT Calibration at Start.

Procedure

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. The problem has been resolved. Y N Enter the Diagnostic Mode. Enter Component Control Code [62-02]. The lamp is good. Y N Check that the Lamp harness is properly connected and repair if necessary. Replace the Illumination Lamp. (REP 10.6.1)

Check the connector P/J410 for proper connection. The problem has been resolved. Y N Replace the SLCC PWB and (3) EEPROMS (AIOC/Network PWB). (PL 8.1) (REP 8.1.3) POPO the machine and retry.

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


June, 2008 2-35


062-380, 062-386

062-392 IPS PWB Memory Fail

062-393 IPS PWB Fail

BSD-Reference:

BSD-Reference:

CH 3.1

CH 3.1

Explanation

Explanation

Control logic has detected RAM malfunction of IISS PWB.

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

Procedure

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)

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)


062-392, 062-393

June, 2008 2-36


A

005-170 DADF Feed Failure BSD-Reference:

CH 5.2

B

C Replace the Document Feed Clutch (PL 13.9)

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

Explanation

Replace the Document Feed Sensor (PL 13.9).

The control logic has detected the failure of paper to reach the Document Feed Sensor after 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. The Feed Roller feeds paper into the document handler. Y N The Document Drive Motor operates. Y N Enter the Diagnostic Mode. Enter Component Control Code [05-01]. The Document Drive Motor operates. Y N There is +24 VDC at connector CN2 pin 1 and pin 4 on the DADF PWB. Y N 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 rotates. Y N Enter the Diagnostic Mode. Enter Component Control Code [05-62]. The Document Feed Clutch operates. Y N 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. Y N Enter the Diagnostic Mode. Enter Component Control Code [05-62]. The Document Feed Clutch operates. Y N Check the connector of the Document Feed Clutch (PL 13.9) If the connector is good, replace the Document Feed Clutch (PL 13.9). A B C Reissue June, 2008 WorkCentre 5016, 5020

2-37


005-170

A

005-171 DADF Regi / Exit Failure BSD-Reference:

CH 5.8

B

C Replace the Document Feed Clutch (PL 13.9)

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

Explanation

Enter the Diagnostic Mode. Enter Component Control Code [05-206]. Actuate the Document Registration Sensor acutator. The display changes from High to Low. Y N Replace the Document Registration Sensor. (PL 13.7)

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 Enter the Diagnostic Mode. Enter Component Control Code [05-205]. Actuate the Exit/Invert Sensor actuator. The display changes from High to Low. Y N Replace the Exit/Invert Sensor. (PL 13.7)

Check for obstructions in the Document Tray. Clean the Feed Roll. Confirm that a document is feeding into the document handler. The Feed Roller feeds paper into the document handler. Y N The Document Drive Motor operates. Y N Enter the Diagnostic Mode. Enter Component Control Code [05-01]. The Document Drive Motor operates. Y N There is +24 VDC at connector CN2 pin 1 and pin 4 on the DADF PWB. Y N Check the following in order: 1. Check the connectors CN1 and CN2 on the DADF PWB for proper connections 2.


3.


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

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 rotates. Y N Enter the Diagnostic Mode. Enter Component Control Code [05-62]. The Document Feed Clutch operates. Y N 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. Y N Enter the Diagnostic Mode. Enter Component Control Code [05-62]. The Document Feed Clutch operates. Y N Check the connector of the Document Feed Clutch (PL 13.9) If the connector is good, replace the Document Feed Clutch (PL 13.9). A B C Status Indicator RAPS June, 2008

005-171

2-38


A

005-172 DADF Inverted Document Jam BSD-Reference:

B Y

CH 5.8

Explanation

N 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)

When inverting documents, the control logic detected a failure of a document at the Feed Sensor after turning off the Feedout Forward or document failure 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. The Feed Roller feeds paper into the document handler. Y N The Document Drive Motor operates. Y N Enter the Diagnostic Mode. Enter Component Control Code [05-01]. The Document Drive Motor operates. Y N There is +24 VDC at connector CN2 pin 1 and pin 4 on the DADF PWB. Y N Check the following in order: 1. Check the connectors CN1 and CN2 on the DADF PWB for proper connections 2.


3.


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. The display changes from High to Low. Y N Replace the Document Feed Sensor. (PL 13.9) Enter the Diagnostic Mode. Enter Component Control Code [05-205]. Actuate the Exit/Invert Sensor actuator. The display changes from High to Low. Y N 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)

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

A B Reissue WorkCentre 5016, 5020

Docu-

June, 2008 2-39


005-172

005-198 Short Scan Jam

005-199 Long Scan Jam

BSD-Reference:

BSD-Reference:

CH 6.2

CH 6.2

Explanation

Explanation

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

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

Procedure

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. Y N Replace the Document Registration Sensor. (PL 13.7)

Choose a document size equal to or less than A3 paper or 294mm SEF or less in the Document Tray. The problem is solved. Y N Replace the Document Registration Sensor. (PL 13.7)

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

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


005-198, 005-199

June, 2008 2-40


005-305 Feeder Top Cover Open

005-920 Static Jam

BSD-Reference:

BSD-Reference:

CH 5.6

CH 5.6

Explanation

Explanation

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

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 Close the Feeder Top Cover. The problem continues. Y N Adjust or repair the Feeder Top Cover latch. (REP 13.4.1) Replave the Feeder Top Cover Switch. (PL 13.9)


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.

June, 2008 2-41


005-305, 005-920


005-305, 005-920

June, 2008 2-42


3 Image Quality Image Quality RAPs 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 Bands, 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..................................................................................


3-3 3-3 3-4 3-4 3-5 3-5 3-6 3-6 3-7 3-7 3-8 3-8 3-9 3-9 3-10 3-10 3-16

June, 2008 3-1

Image Quality

Image Quality

June, 2008 3-2


IQ1 IOT Image Quality Entry RAP

IQ2 IIT Image Quality Entry RAP

Initial Actions

Initial Actions

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

Clean the IIT Upper Cover (PL 10.2) (REP 10.2.1). Clean the mirrors and lens with a lint-free cloth.

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

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

Table 1 IIT Image Quality Problems

Table 1 IOT Image Quality Problems Image Quality Problem

Symptom

RAP

Image Quality Problem

Symptom

RAP

Low image density

Overall low density of images.

IQ3

Low image density


Wrinkled images

The printed paper is creased, folded or torn.

IQ4

Background contamination

Ghost images

Ghost images appear on the paper. Parts of the IQ5 previous page or current page appear as ghost images on the paper.

The whole page or part of the page is contamiIQ6 nated by toner. The contamination appears as a very light grayish color.

IQ3

Background contamination

The whole page or part of the page is contami- IQ6 nated by toner. The contamination appears as a very light grayish color.

Black lines, blank areas, or Black lines or white streaks running parallel to smears in the process direction. the direction of paper transport.

IQ9

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

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

IQ11

Deletion

Part of the image is missing.

IQ7

Skew/Misregistration

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

IQ8

Spotted blanks

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

IQ13

Black lines, blank areas, or Black lines or white streaks running parallel to smears in the process direction the direction of paper transport.

IQ9

Solid black copy

The output is completely black.

IQ14

Improper fusing, offset

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

IQ10

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


IQ11

Mottle

Uneven printed image density.

IQ12

Spotted blanks

Toner spots and blank areas are spread irregu- IQ13 larly over the whole page.

Solid black copy

The output is completely black.

IQ14

Blank copy

The output is completely white.

IQ15


June, 2008 3-3

Image Quality

IQ1, IQ2

IQ3 Low Image Density RAP

IQ4 Wrinkled Image RAP


The output is creased, folded or torn.

Procedure

Procedure

Check for dirt on the Platen Glass. The Platen Glass is clean. Y N 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 paper type. The paper used is within specifications. Y N Use paper that is within specifications. Use paper from a freshly opened packet. The problem recurs. Y N Completed

Check the drum ground contact. The drum ground contact is clean and not damaged. Y N 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. The problem recurs. Y N 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. Y N 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. The problem recurs. Y N Completed Check for foreign substances and damaged components in the paper transport path. No foreign substances or damaged components are found in the paper transport path. Y N Remove the foreign substances. Reshape or replace any damaged components. Replace the Fuser (PL 5.1) (REP 5.1.1).

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. There is a considerable amount of toner left on the surface of the Drum. Y N 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).

Image Quality

IQ3, IQ4

June, 2008 3-4


IQ5 Residual Image (Ghosting) RAP

IQ6 Background RAP

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

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

Procedure

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. The problem recurs. Y N Completed

Check for dirt on the Platen Glass. The Platen Glass is clean. Y N 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).

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. Y N 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. The problem recurs. Y N 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. The surface of the Heat Roll is clean. Y N 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).

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


June, 2008 3-5

Image Quality

IQ5, IQ6

IQ7 Deletion RAP

IQ8 Skew/Misregistration RAP

Part of the image is missing.

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

Procedure

Procedure

Check the paper type. The paper used is within specifications. Y N Use paper that is within specifications.

Check the location where the machine is installed. The machine is installed on a stable, level surface. Y N Install the machine on a stable, level surface.

Use paper from a freshly opened packet. The problem recurs. Y N 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. The problem recurs. Y N 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. Y N Completed Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron is not damaged. Y N Replace the Transfer Corotron (PL 4.3) (REP 4.3.1).

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. The problem recurs. Y N Completed Check the Paper Cassette. The Paper Cassette is installed properly. Y N Install it properly. Check the paper transport path. There are no obstructions or damaged parts in the paper transport path. Y N Remove any obstructions. Reshape or replace any damaged parts. Replace the AIOC PWB (PL 8.1) (REP 8.1.1).


Image Quality

IQ7, IQ8

June, 2008 3-6


IQ9 Process Direction Bands, Streaks, and Smears RAP

IQ10 Unfused Copy/Toner Offset RAP

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

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

Procedure Check the IIT Carriage Mirrors. The mirrors are not dirty, scratched, or damaged. Y N 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). 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. The problem recurs. Y N 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. Y N Completed Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron is clean and not damaged. Y N 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. Y N Clean away the dirt.

Procedure Check the paper type. The paper used is within specifications. Y N Use paper that is within specifications. Use paper stored under room conditions. The problem recurs. Y N Completed Check the power supply voltages. The voltages are within the specified range. Y N 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. The problem recurs. Y N Completed Check the fusing temperature using the Diagnostics. A normal fusing temperature is set. Y N Set a normal fusing temperature using the Diagnostics. Replace the Fuser (PL 5.1) (REP 5.1.1).

Check the IIT Carriage Mirror. The mirror is clean and not damaged. Y N Clean the IIT Carriage Mirror (PL 10.3) (REP 10.3.1). If it is damaged, replace it. Remove the Fuser (PL 5.1) (REP 5.1.1), and check the Heat Roll. The surface of the Heat Roll is clean. Y N Remove any dirt. If you can’t clean the surface of the Heat 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. Y N Clean the Transfer Corotron (PL 4.3) (REP 4.3.1). If it is damaged, replace it. Check the ROS (PL 3.1) (REP 3.1.1). The ROS is clean and not scratched. Y N 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).


June, 2008 3-7

Image Quality

IQ9, IQ10

IQ11 Repeating Bands, Streaks, Spots, and Smears RAP

IQ12 Mottle RAP


Procedure

Procedure

Check the paper type. The paper used is within specifications. Y N Use paper that is within specifications.

Check the IIT Carriage. The carriage has no foreign substances or damaged parts. Y N 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. The problem recurs. Y N 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. Y N Completed Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron is clean and not damaged. Y N 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 approximately 78mm (circumference of the Heat Roll ). Y N Clean the surface of the Heat Roll. If you can’t, replace the Fuser (PL 5.1) (REP 5.1.1).

Use paper from a freshly opened packet. The problem recurs. Y N 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. The problem recurs. Y N 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. Y N Completed Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron is clean and not damaged. Y N 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. Y N Completed

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

Image Quality

IQ11, IQ12

June, 2008 3-8


IQ13 Spots RAP

IQ14 Black Prints RAP

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

The paper is printed completely black.

Procedure

Procedure

Check for dirt on the Platen Glass. The Platen Glass is clean. Y N Remove any dirt on the Platen. If you can’t remove the dirt, replace the IIT Upper Cover (PL 10.2) (REP 10.2.1).

Check the IIT Carriage for foreign substances and damaged parts. The carriage has no foreign substances or damaged parts. Y N 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. The problem recurs. Y N 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. Y N Completed Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron is clean and not damaged. Y N 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. Y N Clean away the dirt. Remove the Fuser (PL 5.1) (REP 5.1.1) and check the surface of the Heat Roll. The surface of the Heat Roll is clean. Y N 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. Y N Use paper that is within specifications. Use paper from a freshly opened packet. The problem recurs. Y N Completed Replace the AIOC PWB (PL 8.1) (REP 8.1.1).


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. The problem recurs. Y N 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. Y N 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. The problem recurs. Y N Completed Check the connectors of the HVPS (P/J520) and AIOC PWB (P/J406). The connectors are connected securely. Y N 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 open. Y N 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 PWB), as well as between J130 (ROS) and J403 (AIOC PCB), are not shorted or open. Y N Repair the wire(s). 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

Copy Quality Specification

The paper is printed completely white.

1. Copy Alignment How to measure

Procedure

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

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

Table 1 Copy Alignment: Measurement

Check the drum ground contact. The drum ground contact is clean and not damaged. Y N 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. The problem recurs. Y N 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. Y N 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. Y N Check the P/J140, P/J406, J403, and J140 connectors. The connectors are connected securely. Y N Connect the connectors securely. Check the ROS (PL 3.1) (REP 3.1.1). The ROS is installed correctly. Y N Install the ROS (PL 3.1) (REP 3.1.1) correctly.

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

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

Linearity (Horizontal) (mm) 280mm

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

Linearity (Skew) (mm) 280mm

Maximum difference between the [Intersection point of the 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.

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.

Measure the voltage between pin 1 and pin 2 of connector P403 on the AIOC PWB (PL 8.1) (REP 8.1.1). The voltage is +5VDC. Y N 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 open. Y N 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

IQ15,

June, 2008 3-10


Specification [System] IOT + IIT Table 2 Copy Alignment: Specification Item

Specification SYSTEM


+/- 2.90


+/- 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

Application

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

--

400mm

Magnification: H (%)

+/-0.95 (100%) +/-1.16 (50%-99%) +/-1.47 (101%-200%)

--

280mm


June, 2008 3-11

Image Quality

Figure 1 Copy Alignment Measurement Positions (Test Pattern STP3600)

2. Image Quality

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

How to measure

Table 4 Item


Text/Image Density Measure the 0.7G line image (10) at 3 locations. (100%/Normal mode only) Determine the maximum and minimum mean value measured (within the same copy).

Image Quality

June, 2008 3-12


Table 4 Item


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 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. color density (100% only) Determine the maximum and minimum mean value measured (within the same copy). Solid Density Reproduc- Measure the 1.0G solid 16 at 3 locations. ibility Determine the maximum and minimum mean value measured (100%/Normal mode only) (within the same copy). Background

Measure 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.


June, 2008 3-13

Image Quality

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

Image Quality

June, 2008 3-14


Table 5


Item

Reduce/ Enlarge (%)

INPUT

OUTPUT (Density Settings Button) Lighter 3

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 density

100

0.2 Blue

-

>=0.17

>=0.57

>=0.22

Blue Color Density Evenness

100

0.2 Blue

-

-

0.4 (Max)

-

Reproducibility of the blue color density

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)

100

NBS Target

-

-

-

4.3 Lo/mm (Min)


70

NBS Target

-

-

-

2.5 Lo/mm (Min)


141

NBS Target

-

-

-

3.5 Lo/mm (Min)


200

NBS Target

-

-

-

3.5 Lo/mm

Depth of Focus

100

NBS Target

-

-

-

3 Lo/mm (Min)*1

Skip/Smear

100

Ladder A3 Entire Page

-

-

-

2.5 Lo/mm (Min)*1

Skip/Smear

70


-

-

-

1.8 Lo/mm (Min)

Skip/Smear

141


-

-

-

2.5 Lo/mm (Min)

Skip/Smear

200


-

-

-

2.5 Lo/mm (Min)*1

June, 2008 3-15

OUTPUT (Density Settings Button) Normal

OUTPUT (Density Settings Button) Darker 3

OUTPUT (Density Settings Button) Auto

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.) (Figure 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 of Originals with Frames (Figure 10)

Image Quality

June, 2008 3-16


Auger Marks

Figure 1 Auger Marks Cause

Action

1.

Magnetic field failure in the Developer Magnetic Roll.

1.

2.

There was a drop in the level of developer material.


June, 2008 3-17

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.

Image Quality

Strobing (28mm or 14mm Pitch Density)

Figure 2 Strobing (28mm or 14mm Pitch Density) Cause 1.

Developer Magnetic Roll bias.

Action 1.


Image Quality

June, 2008 3-18


White Streaks (Process Direction)

Figure 3 White Streaks (Process Direction) Cause

Action

1.

Foreign substances are blocking the ROS Laser.

1.

2.

Developer material clogging on the Developer Magnetic Roll due to foreign substances.

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.



June, 2008 3-19

Image Quality

Black Bands

Figure 4 Black Bands Cause 1.

The developer material is not well mixed.

Action 1.

Mix the developer material by processing blank paper.

Image Quality

June, 2008 3-20


Toner Contamination

Figure 5 Toner Contamination Cause 1.

2.


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.


June, 2008 3-21

Image Quality

Toner Splattering

Figure 6 Toner Splattering Cause

Action

1.

Paper size mismatch (tray settings and paper size are different).

1.

Check the tray settings.

2.

Increased paper resistance due to dry conditions.

2.

Use paper from a freshly opened packet.

Image Quality

June, 2008 3-22


White Spots (Irregular)

Figure 7 White Spots Cause 1.

Increased paper resistance due to dry conditions.

Action 1.

Use paper from a freshly opened packet.


June, 2008 3-23

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

4.

1.

94mm Pitch (Drum): Scratches or foreign substances.

Action

2.

57mm Pitch (Developer Roll): Developer material clogging on the Magnetic Roll.

1.

3.

44mm Pitch (Charger): Scratches or foreign substances.

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).

Image Quality

June, 2008 3-24

80mm Pitch (Fuser Heat Roll): Scratches or foreign substances.


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

Action

1.

94mm Pitch (Drum): Scratches or foreign substances.

1.

2.

57mm Pitch (Magnetic Roll): Developer material clogging on the Magnetic Roll.

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).

3.

44mm Pitch (Charger): Scratches or foreign substances.

2.

2,3: Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).

4.

80mm Pitch (Heat Roll): Scratches or foreign substances.

5.

19mm Pitch (Fuser Roll-Exit): Dirt.

6.

44mm Pitch (Registration): Dirt.


June, 2008 3-25

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 may also cause moire. Action 1.

Reduce sharpness.

2.

Make copies at a different Reduce/Enlarge ratio.

3.

Change the orientation of the original.

Secondary defect: Text is blurred.

Fluctuation in Background Suppression Values for Copies of 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 conversion process between the original and the printer driver. Action Reduce sharpness. Secondary defect: Text is blurred.

Image Quality

June, 2008 3-26


Light Background in Copies of Originals with Frames When [Auto] is selected for originals with dark frames along the Lead Registration Edge, the background suppression value is set so large that areas of medium density appear extremely light.

Figure 10 Light Background in Copies of Originals with Frames Cause

Action

[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 Exposure cannot detect the original background density. Therefore, Background Suppression is calculated based on the density of the frames.

Select [Off] for [Auto].


June, 2008 3-27

Image Quality

Image Quality

June, 2008 3-28


4 Repairs and Adjustments Introduction Introduction .....................................................................................................................

4-3

Repairs 1. Drive REP 1.1.1 IOT Motor (SCC)............................................................................................

4-7 4-9 4-10 4-12 4-13 4-17

4. CRU REP 4.1.1 Drum Cartridge .............................................................................................. REP 4.2.1 Toner Empty Sensor...................................................................................... REP 4.2.2 Erase Lamp ................................................................................................... REP 4.3.1 Transfer Module............................................................................................. REP 4.4.1 Corotron Wire ................................................................................................

4-19 4-20 4-21 4-23 4-27

5. Fuser REP 5.1.1 Fuser (SCC)................................................................................................... REP 5.1.2 Temperature Control Sensor Assembly......................................................... REP 5.1.3 Fuser Lamp.................................................................................................... REP 5.1.4 Fuser Roll ...................................................................................................... REP 5.1.5 Fuser Pressure Roll .......................................................................................

4-29 4-31 4-32 4-35 4-38

6. Exit REP 6.1.1 Exit Transport (Simplex) ................................................................................ REP 6.1.2 Exit Transport (Duplex)..................................................................................

4-39 4-42

7. Simplex Module and Bypass Tray REP 7.1.1 Simplex, Duplex Module ................................................................................ REP 7.5.1 Bypass Feed Roll...........................................................................................

4-45 4-47

8. Electrical REP 8.1.1 AIOC PWB (SCC).......................................................................................... REP 8.1.2 LVPS (SCC)................................................................................................... REP 8.1.3 AIOC/Network PWB (DADF/Network Only)................................................... REP 8.2.1 HVPS (SCC) .................................................................................................. REP 8.2.2 Duplex PWB (SCC) ....................................................................................... REP 8.3.1 Control Panel (SCC) ...................................................................................... REP 8.4.1 User Interface PWB (SCC) ............................................................................

9. Cover Reissue WorkCentre 5016, 5020

REP 10.1.1 IIT Platen Cover ........................................................................................... REP 10.2.1 IIT Upper Cover (SCC) ................................................................................ REP 10.3.1 IIT Carriage (SCC) ....................................................................................... REP 10.3.2 Flexible Print Cable (SCC)........................................................................... REP 10.6.1 Exposure Lamp............................................................................................ REP 10.7.1 Carriage Cable and Drum ............................................................................ REP 10.7.2 Inverter PWB................................................................................................

4-71 4-72 4-73 4-79 4-81 4-82 4-85

11. Single Tray Module

3. ROS REP 3.1.1 ROS (SCC) ....................................................................................................

4-67 4-68 4-69 4-70

10. IIT 4-5

2. Paper Transport 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).........................................................................................

REP 9.1.1 Output Tray .................................................................................................... REP 9.1.2 Front Left Cover ............................................................................................. REP 9.2.1 Rear Cover..................................................................................................... REP 9.2.2 Right Cover ....................................................................................................

4-49 4-52 4-55 4-58 4-61 4-62 4-64

REP 11.1.1 Tray 2........................................................................................................... REP 11.1.2 Single Tray Module (Separation from IOT) .................................................. REP 11.4.1 Tray 2 Feed Roll .......................................................................................... REP 11.4.2 Tray 2 Retard Roll........................................................................................ REP 11.5.1 STM Feed Sensor........................................................................................ REP 11.5.2 STM PWB (SCC) ......................................................................................... REP 11.6.1 STM Feed Clutch ......................................................................................... REP 11.6.2 STM Feed Motor .......................................................................................... REP 11.7.1 STM No Paper Sensor.................................................................................

4-89 4-89 4-91 4-93 4-96 4-97 4-98 4-99 4-100

13. ADF REP 13.1.1 ADF Assembly ............................................................................................. REP 13.1.2 ADF/DADF Platen Cushion.......................................................................... REP 13.2.1 Document Tray Assembly (ADF) ................................................................. REP 13.2.2 ADF Feeder Assembly................................................................................. REP 13.2.3 Front Cover .................................................................................................. REP 13.2.4 Rear Cover................................................................................................... REP 13.2.5 DADF Eject Roller Solenoid......................................................................... REP 13.2.6 DADF Assembly........................................................................................... REP 13.2.7 Document Tray Assembly (DADF)............................................................... REP 13.2.8 DADF Feeder Assembly .............................................................................. REP 13.3.1 ADF Control PWB ........................................................................................ REP 13.3.2 Left Counter Balance (SCC) ........................................................................ REP 13.3.3 Right Counter Balance (SCC)...................................................................... REP 13.3.4 DADF PWB .................................................................................................. REP 13.4.1 Top Cover .................................................................................................... REP 13.8.1 Retard Roll ................................................................................................... REP 13.9.1 Pickup Roll, Feed Roll..................................................................................

4-101 4-102 4-104 4-106 4-109 4-110 4-111 4-112 4-113 4-116 4-119 4-121 4-122 4-124 4-125 4-126 4-128

Adjustments ADJ 8.1.1 Edge Erase Adjustment.................................................................................. ADJ 8.1.2 Controller Firmware Version Upgrade ............................................................ ADJ 10.3.1 IIT Lead Edge/Side Edge Registration .........................................................

June, 2008 4-1

4-131 4-131 4-132

Repairs and Adjustments

ADJ 11.1.1 Carriage Assembly Alignment (Parallelism) ................................................. ADJ 13.1.1 ADF/DADF Positional Adjustment ................................................................


4-133 4-134

June, 2008 4-2


Introduction

Terms and Symbols

This section contains procedures required for parts replacement and adjustment.

Terms and symbols used throughout this section are explained here.

WARNING

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.

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.

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.

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.

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 or adjustment procedure can easily be referred to a PL No. and vice versa. For example, the replacement or adjustment procedure of Component PL 1.1 is REP 1.1.X or ADJ 1.1.X.

CAUTION

4.

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):

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.

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.

Example 1: REP X.X.X Main PWB [Models with 1V] indicates that the entire procedure under this title applies to machines with Tag 1V.

Important Information Stored Component (ISC):

Example 2: See Table 1.

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.

Table 1 Symbol

Description Illustration 1: Indicates that a specific part has been modified by the tag number within the circle.

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.


June, 2008 4-29



June, 2008 4-30


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.

Figure 1


June, 2008 4-31


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.


REP 1.1.1

June, 2008 4-32


REP 2.2.1 Tray 1 Feed Clutch (SCC)

3.

Remove the screws (3) that secure the Clutch Bracket (Figure 2). 1 Remove the screws (3).

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.


2.

Disconnect the connector (Figure 1). 1 Disconnect the connector. 2 Release the wire harness from the clamp.

Figure 2

Figure 1


June, 2008 4-33


REP 2.2.1

4.

Remove the Tray 1 Feed Clutch (Figure 3).

Replacement

1 Remove the Clutch Bracket.

1.


2 Remove the bearing.

2.

When installing the Tray 1 Feed Clutch, place the tab of Clutch Bracket in the notch of Tray 1 Feed Clutch (Figure 4).

3 Remove the Tray 1 Feed Clutch. 4 Pull out the wire harness through the hole.

Figure 4

Figure 3


REP 2.2.1

June, 2008 4-34


REP 2.3.1 Tray 1 Feed Roll (SCC)

4.

Remove the Tray 1 Feed Roll (Figure 2). 1 Gently lift up the tab to remove the Tray 1 Feed Roll.


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.

Figure 2

Figure 1


June, 2008 4-35


REP 2.3.1

Replacement

REP 2.5.1 Tray 1 Feed Sensor

1.


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).


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.

Figure 3


REP 2.3.1, REP 2.5.1

June, 2008 4-36


5.

Remove the Tray 1 Feed Sensor (Figure 1).

Replacement

1 Remove the Tapping Screw.

1.


2 Remove the cable bands (2).

2.

3 Release the wire harness from the clamps (2).

Insert the Connector Housing of the Tray 1 Interlock Switch into the square hole of the frame (Figure 2).

4 Move the wire harness toward you and disconnect the connector.

A Square hole

5 Remove the Tray 1 Feed Sensor.

Figure 2 Figure 1


June, 2008 4-37


REP 2.5.1

REP 2.7.1 Tray 1 No Paper Sensor

4.

Remove the Tray 1 No Paper Sensor (Figure 2). 1 Remove the Actuator.

Parts List on PL 2.7 Removal

2 Release the tabs to remove the Tray 1 No Paper Sensor.

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.


3.

Remove the Sensor Housing (Figure 1). 1 Disconnect the connector. 2 Release the tabs (2) to remove the Sensor Housing.

Figure 2

Replacement 1.


Figure 1


REP 2.7.1

June, 2008 4-38


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.


2.


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).

Figure 1


June, 2008 4-39


REP 2.8.1

5.

Remove the Connector Housing (Figure 2).

6.

1 Remove the wire harness from the guide.

Remove the Front Stopper (Figure 3). 1 Remove the Front Stopper.

2 Slide the Connector Housing through the hole.

Figure 3 Figure 2


REP 2.8.1

June, 2008 4-40


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.



June, 2008 4-41


REP 2.8.1


REP 2.8.1

June, 2008 4-42


REP 3.1.1 ROS (SCC)

1.

Open the Front Cover.


2.

Remove the Output Tray (REP 9.1.1).

3.


4.

Remove the HVPS and Contact Block (REP 8.2.1).

5.

Remove the Laser Housing (Figure 2).

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 Tapping Screw. 2 Remove the Laser Housing.

NOTE: Attach the attachment in the ROS Replacement Kit to a Stubby Driver to remove the screws (Figure 1).

Figure 2

Figure 1


June, 2008 4-43


REP 3.1.1

6.

Disconnect the ROS connectors (Figure 3).

7.

Remove the ROS (Figure 4).

1 Disconnect the Ground connectors (2).

1 Remove the Tapping Screws (5).

2 Disconnect the connectors (2).

2 Remove the ROS.

3 Disconnect the connector. 4 Remove the wire harness from the hook.

Figure 4 Figure 3

Replacement 1.

To install, do the removal steps in reverse order. NOTE: When powering up to perform operations with the ROS installed, read the warning label pasted on the ROS before proceeding with the operation.


REP 3.1.1

June, 2008 4-44


REP 4.1.1 Drum Cartridge

2.


When installing the Drum Cartridge, align the protruding end of the Drum Cartridge with the cavity in the frame (Figure 2).


Open the Simplex/Duplex Module.

2.


3.

Remove the Drum Cartridge (Figure 1). 1 Release the tab. 2 Remove the Drum Cartridge.

Figure 2

Figure 1

Replacement 1.



June, 2008 4-45


REP 4.1.1

REP 4.2.1 Toner Empty Sensor

5.

Remove the Toner Empty Sensor (Figure 2). 1 Release the tabs (2) to remove the Toner Empty Sensor.



2.

Remove Tray 1.

3.


4.

Disconnect the connector (Figure 1). 1 Release the wire harness from the clamp. 2 Disconnect the connector.

Figure 2

Figure 1


REP 4.2.1

June, 2008 4-46


Replacement

REP 4.2.2 Erase Lamp

1.


2.

Insert the Connector Housing of the Toner Empty Sensor into the square hole of the frame (Figure 3).

Parts List on PL 4.2 Removal WARNING

A Square hole

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.


2.


3.


4.


5.

Remove the HVPS and Contact Block (REP 8.2.1).

Figure 3


June, 2008 4-47


REP 4.2.1, REP 4.2.2

6.

Release the Erase Lamp tabs (7) (Figure 1).

7.

1 Release the tabs (upper: 3).

Remove the Erase Lamp (Figure 2). 1 Remove the Erase Lamp.

2 Release the tabs (lower: 4).

Figure 2 Figure 1


REP 4.2.2

June, 2008 4-48


Replacement

REP 4.3.1 Transfer Module

1.


2.

Insert the Connector Housing of the Erase Lamp into the square hole in the frame (Figure 3).


A Square hole



2.


3.


4.

Remove the Exit Transport (REP 6.1.1).

5.

Remove the Fuser (REP 5.1.1).

Figure 3


June, 2008 4-49


REP 4.2.2, REP 4.3.1

6.

Remove the Transfer Corotron Housing (Figure 1).

7.

Remove the Tapping Screws that secure the Corotron Block (Figure 2).

1 Release the hooks (2).


2 Remove the Transfer Corotron Housing by pulling its front side in the direction of the

2 Move the Fuser Connector Bracket.

arrow.


Figure 1


REP 4.3.1

Figure 2

June, 2008 4-50


8.

Remove the Corotron Block (Figure 3).

9.

Disconnect the Corotron Block cables (Ground/Detack/Transfer) (Figure 4).

1 Press the Spring Plate.

1 Disconnect the Ground Cable (white).

2 Remove the Corotron Block by pulling it in the direction of arrow.

2 Remove the Ground Cable (white) from the guides (2). 3 Remove the Detack Cable (black). 4 Remove the Detack Cable (black) from the guides (2). 5 Disconnect the Transfer Cable (white). 6 Remove the Transfer Cable (white) from the guides (3).

Figure 3

Figure 4


June, 2008 4-51


REP 4.3.1

Replacement

3.

1.


2.

Perform the following steps to install the Corotron Block (Figure 5).

Attach the cables (Ground/Detack/Transfer) to the Corotron Block hooks as shown in Figure 6.

1 Press the Spring Plate. 2 Install the Corotron Block.

Figure 6

Figure 5


REP 4.3.1

June, 2008 4-52


4.

When installing the Transfer Corotron Housing, insert the tabs of Transfer Corotron Housing into the square holes of the Corotron Bracket (Figure 7).

REP 4.4.1 Corotron Wire Parts List on PL 4.4 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.


2.


3.

Remove the Inboard/Outboard Cover (Figure 1). 1 Remove the Inboard Cover in the direction of the arrow. 2 Release the tabs (2) to remove the Outboard Cover.

Figure 7

Figure 1


June, 2008 4-53


REP 4.3.1, REP 4.4.1

4.

Attach the Corotron Wire (Figure 2).

5.

1 Attach the Corotron Wire.

Attach the spring (Figure 3). 1 Attach the spring to the Corotron Wire. 2 Attach the spring.

Figure 2 Figure 3

Replacement 1.


REP 4.4.1

June, 2008 4-54



REP 5.1.1 Fuser (SCC)

3.

Disconnect the connectors (Figure 2). 1 Disconnect the connectors (2).

Parts List on PL 5.1 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.

WARNING The Fuser and Exit Transport are hot. Do not work on them until they are cool enough. 1.

Open the Left Side Cover.

2.

Remove the Connector Cover (Figure 1). 1 Remove the Tapping Screw. 2 Remove the Connector Cover.

Figure 2

Figure 1


June, 2008 4-55


REP 5.1.1

4.

Remove the Fuser (Figure 3).

Replacement


1.

2 Remove the Fuser by shifting it in the direction of the arrow.

2.

To install, do the removal steps in reverse order. When installing the Connector Cover, do the following (Figure 4): 1 Insert the wire harness into the U-groove of the Fuser Frame. 2 Insert the stud of the Connector Cover into the hole in the frame.

Figure 3 Figure 4


REP 5.1.1

June, 2008 4-56


REP 5.1.2 Temperature Control Sensor Assembly

3.

Remove the Temperature Control Sensor Assembly (Figure 2). 1 Remove the Screw.


2 Remove the Harness.




2.

Slide the Cover to the left and remove (Figure 1).

Harness Screw

Cover

Figure 2 Removing the Temperature Control Sensor Assembly

Figure 1 Removing the Cover


June, 2008 4-57


REP 5.1.2

Replacement

REP 5.1.3 Fuser Lamp

1.


To install, do the removal steps in reverse order. NOTE: Before tightening the Screw, make sure that the Tab on the Sensor Block is inserted in the notch of the Frame (Figure 3).




2.

Slide the Cover to the left and remove (Figure 1).

Screw

Sensor Block

Tab

Notch

Figure 3 Installing the Temperature Control Sensor Assembly

Cover

Figure 1 Removing the Cover


REP 5.1.2, REP 5.1.3

June, 2008 4-58


3.

Disconnect the hot side of the Fuser Lamp (Figure 2).

4.

Disconnect the neutral side of the Fuser Lamp (Figure 3).

1 Disconnect the Terminal.

1 Disconnect the white wire from theTerminal.

2 Remove the Screw.

2 Remove the Screw.

White Wire

Screw

Terminal

Screw

Terminal

Figure 2 Disconnecting the hot side of the Fuser Lamp Figure 3 Disconnecting the neutral side of the Fuser Lamp


June, 2008 4-59


REP 5.1.3

5.

Remove the Fuser Lamp Housing (Figure 4).

6.

1 Remove 2 Screws.

Remove the Fuser Lamp by pulling it through the Fuser Roll (Figure 5). NOTE: Do not lose the Fuser Lamp Mount.

2 Carefully remove the Fuser Lamp Housing. Fuser Roll

Screws

Fuser Lamp Mount

Fuser Lamp

Fuser Lamp Housing

Figure 5 Removing the Fuser Lamp

Replacement Figure 4 Removing the Fuser Lamp Housing

CAUTION Do not touch the glass part of the Fuser Lamp unless you are are wearing gloves. 1.


REP 5.1.3

June, 2008 4-60



REP 5.1.4 Fuser Roll

3.

Remove the Stripper Finger Assembly (Figure 2 and Figure 3). 1 Remove the Screw.


2 Remove the Stripper Finger Assembly.


Cover Mount

Stripper Finger Assembly

WARNING The Fuser and Exit Transport are hot. Do not work on them until they are cool enough. CAUTION Do not touch the glass part of the Fuser Lamp unless you are are wearing gloves. 1.

Remove the Fuser Lamp (REP 5.1.3).

2.

Remove the Fuser Cover (Figure 1). 1 Remove the 2 Screws. 2 Remove the Fuser Cover. NOTE: Do not lose the Cover Mount (Figure 2).

Fuser Cover

Figure 2 Fuser Cover Removed

Fuser Cover

Stripper Finger Assembly

Screw

Screws

Figure 1 Removing the Fuser Cover

Figure 3 Removing the Stripper Finger Assembly


June, 2008 4-61


REP 5.1.4

4.

Remove the Fuser Roll Retaining Rings and Drive Gear (Figure 4).

5.

Remove the Fuser Roll by pulling it through the Bushings in the Frame (Figure 5).

1 Remove the Retaining Ring. 2 Remove the Drive Gear. 3 Remove the Retaining Ring from the other end of the Fuser Roll.

Bushing Fuser Roll Frame

Fuser Roll

Drive Gear Figure 5 Removing the Fuser Roll Retaining Ring

Figure 4 Removing the Retaining Rings and Drive Gear


REP 5.1.4

June, 2008 4-62


Replacement

CAUTION Make sure the stripper fingers are oriented correctly when reinstalling the Stripper Finger Assembly, as shown in Figure 7.

CAUTION Do not touch the glass part of the Fuser Lamp unless you are wearing gloves. 1.

To install, do the removal steps in reverse order. NOTE: When installing the Drive Gear, make sure that the Locating Key is oriented as shown in Figure 6.

Figure 7 Setting the Stripper Fingers Locating Key

Figure 6 Installing the Drive Gear


June, 2008 4-63


REP 5.1.4

REP 5.1.5 Fuser Pressure Roll

3.

Remove the Fuser Pressure Roll (Figure 2). 1 Remove the Levers.


2 Remove the Spring Mount Assemblies. 3 Remove the Fuser Pressure Roll.


WARNING The Fuser and Exit Transport are hot. Do not work on them until they are cool enough. CAUTION Levers

Do not touch the glass part of the Fuser Lamp unless you are are wearing gloves. 1.

Remove the Fuser Roll (REP 5.1.4).

2.

Remove the Bushings (Figure 1).

Fuser Pressure Roll

Spring Mount Assemblies Bushings

Figure 2 Removing the Fuser Pressure Roll

Replacement CAUTION Do not touch the glass part of the Fuser Lamp unless you are wearing gloves. NOTE: When installing the Fuser Roll, see REP 5.1.4. 1.


Figure 1 Removing the Bushings


REP 5.1.5

June, 2008 4-64


REP 6.1.1 Exit Transport (Simplex)

3.

Disconnect the connector (Figure 1). 1 Disconnect P/J 505.


2 Remove the wire harness from the hook. 3 Remove the wire harness from the guides (2).

WARNING

4 Release the wire harness from the clamps (2).

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.



2.


Figure 1


June, 2008 4-65


REP 6.1.1

4.

Remove the Connector Cover (Figure 2).

5.


Lower the Fuser levers (2) (Figure 3). 1 Lower the levers (2).

2 Remove the Connector Cover.

Figure 3 Figure 2


REP 6.1.1

June, 2008 4-66


6.

Remove the Exit Transport (Figure 4).

Replacement


1.


2 Remove the Exit Transport.

2.

When installing the Connector Cover, insert the stud of the Connector Cover into the hole in the frame (Figure 5).

3 Remove the Belt from the Exit Transport Drive Gear, and disconnect J153 from the Fuser Exit Sensor. 4 Remove the J153 wire harness from the Exit Transport.

J153

Figure 5 Figure 4


June, 2008 4-67


REP 6.1.1

REP 6.1.2 Exit Transport (Duplex)

3.

Disconnect the connectors (Figure 1). 1 Disconnect P/J 505.


2. Disconnect P/J 551. 3 Remove the wire harness from the hook.

WARNING

4 Remove the wire harness from the guides (2).


5 Release the wire harness from the clamp.


Open the Duplex Module.

2.


Figure 1


REP 6.1.2

June, 2008 4-68


4.

Remove the Connector Cover (Figure 2).

5.


Lower the Fuser levers (2) (Figure 3). 1 Lower the levers (2).

2 Remove the Connector Cover.

Figure 3 Figure 2


June, 2008 4-69


REP 6.1.2

6.

Remove the Exit Transport (Figure 4).

Replacement


1.


2 Remove the Exit Transport.

2.

When installing the Connector Cover, insert the stud of the Connector Cover into the hole in the frame (Figure 5).

3 Remove the Wire Harness through the hole.

Figure 4


REP 6.1.2

June, 2008 4-70


REP 7.1.1 Simplex, Duplex Module

3.


Parts List on PL 7.1, PL 7.3 Removal

4.

Disconnect the connector (Figure 2). 1 Disconnect P/J 502. 2 Remove the wire harness from the hook.

WARNING

3 Remove the wire harness from the groove in the frame.



2.

Tape the Bypass Tray so that it cannot open by itself (Figure 1).

4 Remove the wire harness from the guides (5). 5 Remove the wire harness from the groove in the frame. 6 Remove the wire harness from the hooks (3).

1 Apply 2 pieces of tape as shown.

Figure 2 Figure 1


June, 2008 4-71


REP 7.1.1

5.

Remove the Front Stopper (Figure 3).

6.

1 Remove the Front Stopper from the Registration.

Remove the Rear Stopper (Figure 4). 1 Release the tab to remove the Rear Stopper.

2 Release the tab to remove the Front Stopper.

Figure 4 Figure 3


REP 7.1.1

June, 2008 4-72


7.

Remove the Simplex Module (Figure 5).

REP 7.5.1 Bypass Feed Roll

1 Loosen the Tapping Screws (2).


2 Move the Pivot Retainers (2) in the direction of the arrow. 3 Remove the Simplex Module.


Open the Bypass Tray.

2.

Remove the Feed Roll Cap (Figure 1). 1 Release the tab to remove the Feed Roll Cap.

Figure 5 Removing the Left Hand Cover Assembly

Replacement 1.


Figure 1


June, 2008 4-73


REP 7.1.1, REP 7.5.1

3.

Remove the Bypass Feed Roll (Figure 2). 1 Release the hook to remove the Bypass Feed Roll.

Figure 2

Replacement 1.



REP 7.5.1

June, 2008 4-74


REP 8.1.1 AIOC PWB (SCC)

3.

Remove the Core Clip (Figure 2). 1 Remove the Core Clip.

Parts List on PL 8.1 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. CAUTION Static electricity may damage electrical parts. Always wear an anti-static wrist band during service. If a wrist band is not available, touch a metallic section to discharge the static electricity. 1.


2.

Disconnect the AIOC PWB connectors (9) (Figure 1).

Figure 2 Removing the Core Clip

Figure 1


June, 2008 4-75


REP 8.1.1

4.

Disconnect the Flexible Print Cables (2) from the AIOC PWB (Figure 3).

5.

1 Disconnect the Flexible Print Cables (2).

Remove the screw of the USB connector (Figure 4). 1 Remove the screw.

2 Remove the Cores (2).

Figure 4 Figure 3


REP 8.1.1

June, 2008 4-76


6.

Remove the AIOC PWB (Figure 5)

Replacement

1 Remove the screws (2).

1.



2.

When replacing the AIOC PWB, transfer the EP ROM (U2) from the old board to the new one (Figure 6).

3 Slide the the AIOC PWB up and out of P/J 407.

A EP ROM (U2)

Figure 5 Figure 6


June, 2008 4-77


REP 8.1.1

REP 8.1.2 LVPS (SCC)

5.

Remove the IIT Ground Plate (Figure 2). 1 Remove the Screws (4).


2 Remove the IIT Ground Plate.



2.

Remove the Right Cover (REP 9.2.2).

3.

Remove the AIOC PWB (REP 8.1.1).

4.

Remove the PWB Bracket (Figure 1). 1 Remove the screws (4). 2 Remove the PWB Bracket.

Figure 2 Removing the IIT Ground Plate

Figure 1


REP 8.1.2

June, 2008 4-78


6.

Move the Inlet Bracket (Figure 3).

7.

1 Disconnect the connector (wire: blue).

Disconnect the connectors (Figure 4). 1 Disconnect the connectors (2).

2 Disconnect the connector (wire: brown). 3 Remove the Tapping Screws (2). 4 Remove the screws (2). 5 Move the Power Inlet Bracket.

Figure 4

Figure 3


June, 2008 4-79


REP 8.1.2

8.

Disconnect the connectors (7) (Figure 5).

9.

Remove the LVPS (Figure 6). 1 Remove the screw to remove the Ground Wire. 2 Remove the Tapping Screws (2). 3 Remove the LVPS.

Figure 5

Figure 6

Replacement 1.


REP 8.1.2

June, 2008 4-80



REP 8.1.3 AIOC/Network PWB (DADF/Network Only)

3.

Remove the EMI Cover (Figure 2). 1 Remove the Screws (10).


2 Remove the EMI Cover. 3 Remove the Cable Clip from the EMI Cover.

NOTE: The following procedure is for the WorkCentre 5020 (DADF/Network) only. If you have a WorkCentre 5016, or 5020 with Platen only, see REP 8.1.1. Screw (10)

WARNING

EMI Cover

Cable Clip

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. CAUTION Static electricity may damage electrical parts. Always wear an anti-static wrist band during service. If a wrist band is not available, touch a metallic section to discharge the static electricity. 1.


2.

On the right of the machine, remove the Screws holding the USB Connectors (Figure 1). 1 Remove the Screws (2).

Figure 1 Removing the Screws Holding the USB Connectors Figure 2 Removing the EMI Cover


June, 2008 4-81


REP 8.1.3

4.

Remove the SLCC PWB (Figure 3). a.

Disconnect the Flexible Print Cables (2) from the AIOC PWB (Figure 4). 1 Disconnect the Flexible Print Cables (2). 2 Remove the Cores (2).

b.

Disconnect all the Connectors from the right side of the SLCC PWB.

c.

Remove 6 Screws and disconnect the SLCC PWB from the LVPS.

AIOC PWB

Flexible Print Cables

Connectors

Figure 4 Disconnecting the Flexible Print Cables

Screw (6)

Connectors

LVPS

Figure 3 SLCC PWB for DADF/Network


REP 8.1.3

June, 2008 4-82


Replacement

NOTE: If you do not transfer the EPROMs, the existing NVM values for skew, copy quality, etc. will be lost.

1.


2.

When replacing the SLCC PWB, transfer the EPROMs (3) from the old PWB to the new one (Figure 5).

NOTE: If one or more of the EPROMs are damaged during replacement or the information is courpt after replacement, refer to the Reprogaming the EPROMS on the SLCC PWB Table 1 in Section 6, to reprogram the EPROMs. Customer settings must be reprogramed manually.

EPROM

EPROM

EPROM Figure 5 Transferring the EPROMs


June, 2008 4-83


REP 8.1.3

REP 8.2.1 HVPS (SCC)

NOTE: When removing the HVPS, use a Stubby Driver (499T00353).


5.

Remove the Tapping Screws that secure the Contact Block (Figure 2). 1 Release the hook to remove the Harness Block. 2 Remove the Tapping Screws (2).



2.

Disconnect the AIOC PWB connector (Figure 1). 1 Disconnect P/J 406. 2 Remove the wire harness from the clamp. 3 Slide the Connector Housing that was removed in step 1 through the square hole.

Figure 2

Figure 1 3.


4.



REP 8.2.1

June, 2008 4-84


6.

Remove the HVPS and Contact Block (Figure 3).

7.


Separate the HVPS from the Contact Block (Figure 4). 1 Remove the Contact Block in the direction of the arrow.

2 Disconnect the connector at the inner side of the HVPS. 3 Remove the HVPS and Contact Block.

Figure 4 Figure 3


June, 2008 4-85


REP 8.2.1

Replacement

3.

1.


2.

Insert the wire harness of the HVPS into the slot of the Laser Housing (Figure 5).

When installing the HVPS and Contact Block, insert the slot of the Contact Block into the guide of the frame (Figure 6).

A Slot

Figure 6

Figure 5


REP 8.2.1

June, 2008 4-86


REP 8.2.2 Duplex PWB (SCC)

3.

Remove the Duplex PWB (Figure 2). 1 Remove the Tapping Screw.


2 Remove the Guide. 3 Disconnect the Connector.

WARNING




2.

Disconnect the Connector (Figure 1).

5 Remove the Duplex PWB.

1 Disconnect P/J 416. 2 Remove the Wire Harness from the Hook. 3 Remove the Wire Harness from the Guides (3).

Replacement 1.


June, 2008 4-87



REP 8.2.2

REP 8.3.1 Control Panel (SCC)

3.

Remove the screws that secure the Control Panel (Figure 2). 1 Remove the screws (3).


Remove the Front Left Cover (REP 9.1.2).

2.

Remove the Control Panel Cover (Figure 1). 1 Remove the Tapping Screws (2). 2 Press the tabs (2) to release them. 3 Remove the Control Panel Cover towards the front.

Figure 2

Figure 1


REP 8.3.1

June, 2008 4-88


4.

Remove the Control Panel (Figure 3).

Replacement

1 Slide the rear of the Control Panel in the direction of the arrow.

1.



2.

When installing the Control Panel, attach the Control Panel hooks (3) to the IIT Frame (Figure 4).

3 Remove the Cable Band from the Control Panel Hook (Figure 4, B).

A Spring - On top B Hook - Below

Figure 3 Figure 4


June, 2008 4-89


REP 8.3.1

3.

Thread the wire harness of the Control Panel as shown (Figure 5).

REP 8.4.1 User Interface PWB (SCC) Parts List on PL 8.4 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 Control Panel (REP 8.3.1).

2.

Turn the Control Panel upside down.

3.

Remove the Support Brackets (Figure 1). 1 Remove the Tapping Screws (6). 2 Remove the Support Brackets (3).

Figure 5

Figure 1


REP 8.3.1, REP 8.4.1

June, 2008 4-90


4.

Remove the User Interface PWB (Figure 2). 1 Remove the Tapping Screws (12). 2 Remove the User Interface PWB.

Figure 2

Replacement 1.



June, 2008 4-91


REP 8.4.1


REP 8.4.1

June, 2008 4-92


REP 9.1.1 Output Tray

Replacement


1.


2.

Perform the following steps to install the Output Tray (Figure 2). 1 Insert the tabs (2) into the square hole of the frame.

WARNING

2 Attach the hook.



2.

Remove the Output Tray (Figure 1). 1 Remove the Tapping Screws (2). 2 Remove the Output Tray by pulling it in the direction of the arrow.

Figure 2

Figure 1


June, 2008 4-93


REP 9.1.1

REP 9.1.2 Front Left Cover

Replacement


1. 2.

To install, do the removal steps in reverse order. When installing the Front Left Cover, attach the hooks (Figure 2). A Hooks (3)



2.

Remove the Front Left Cover (Figure 1). 1 Remove the Tapping Screw. 2 Remove the Front Left Cover by pulling in the direction of the arrow.

Figure 2

Figure 1


REP 9.1.2

June, 2008 4-94


REP 9.2.1 Rear Cover

2.

Remove the Rear Cover (Figure 2). 1 Remove the Tapping Screws (4).


2 Remove the Rear Cover.

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. NOTE: After removing the Rear Cover, it is not necessary to save the Data Plate with the machine serial number. The serial number can also be obtained by opening Left Side Cover and looking toward the back (bar code label) or by entering Diagnostics. See GP1. 1.

Disconnect the connector (Figure 1). 1 Disconnect the connector. 2 Remove the cable band.

Figure 2

Replacement 1.


Figure 1


June, 2008 4-95


REP 9.2.1

REP 9.2.2 Right Cover

Replacement


1. 2.

To install, do the removal steps in reverse order. When installing the Right Cover, insert the tabs (Figure 2). A Tabs (5)



2.


3.

Remove the Right Cover (Figure 1). 1 Unplug the Power Cord. 2 Unplug the USB connector. 3 Remove the Tapping Screws (2). 4 Remove the Right Cover by pulling it in the direction of the arrow.

Figure 2

Figure 1


REP 9.2.2

June, 2008 4-96


REP 10.1.1 IIT Platen Cover

Replacement


NOTE: The Platen Cover comes as a kit, consisting of a Platen Cover and a Platen Cushion (Figure 1).

WARNING

1.

Place the Platen Cushion on the Platen Glass, with the adhesive strips facing up.


2.

Remove the backing from the adhesive strips.

3.

Position the Platen Cushion against the back left corner of the Platen Glass (Figure 1).

1.

4.

Insert the mounting posts (Figure 1) of Platen Cover into the mounting holes.

5.

Carefully lower the Platen Cover down onto the Platen Cushion. Press down evenly to ensure good adhesion.

Remove the Platen Cover (PL 10.1) (Figure 1) by lifting it straight up. Platen Cover

mounting posts

Platen Cushion

When installing a new Platen Cushion, place it against this corner

Figure 1


June, 2008 4-97


REP 10.1.1

REP 10.2.1 IIT Upper Cover (SCC)

3.

1 Press the tabs (2) to release them.


NOTE: The tabs are visible through the Platen Glass.

WARNING

2 Open the right side of the IIT Upper Cover. 3 Press the tabs (2) to release them, and remove the IIT Upper Cover.


2.

Remove the IIT Upper Cover (Figure 2).

Remove the following parts: •

Platen Cover (PL 10.1)

•

Control Panel (REP 8.3.1)

Remove the screws that secure the IIT Upper Cover (Figure 1). 1 Remove the screws (7). 2 Remove the Tapping Screws (2). 3 Remove the cap.

Figure 2

Replacement 1.


Figure 1


REP 10.2.1

June, 2008 4-98


REP 10.3.1 IIT Carriage (SCC)

4.


At the right side of the IIT Carriage, secure the Carriage Cable with tape so that it does not come loose (Figure 2). 1 Secure the Carriage Cable with 2 pieces of tape.




•


2.

Remove the IIT Upper Cover (REP 10.2.1).

3.

At the left side of the IIT Carriage, secure the Carriage Cable with tape so that it does not come loose (Figure 1). 1 Move the IIT Carriage to the rear notch of the IIT Frame. 2 Secure the Carriage Cable with 2 pieces of tape.

Figure 2

Figure 1 Reissue WorkCentre 5016, 5020

June, 2008 4-99


REP 10.3.1

5.

While maintaining tension on the Carriage Cable (silver) at the front left side, disconnect it (Figure 3).

6.

Use pieces of tape to secure the Carriage Cable (silver) that was disconnected in step 5 so that it does not get separated from the pulley of the IIT Carriage (Figure 4).

1 Disconnect the Carriage Cable.

A Secure the Carriage Cable with tape

2 Remove the Cable Spring.

1 Pulley

3 Remove the Carriage Cable from the pulley. 4 Remove the Carriage Cable from the guide.

Figure 4 Figure 3


REP 10.3.1

June, 2008 4-100


7.

While maintaining tension on the Carriage Cable (black) at the front right side, disconnect it (Figure 5).

8.

Use pieces of tape to secure the Carriage Cable (black) that was disconnected in step 7 so that it does not get separated from the pulley of the IIT Carriage (Figure 6).

1 Disconnect the Carriage Cable (black).

A Pulley

2 Remove the Carriage Cable (black) from the guide.

1 Secure the Carriage Cable with tape

3 Remove the Carriage Cable (black) from the guide.

Figure 6 Figure 5


June, 2008 4-101


REP 10.3.1

9.

While maintaining tension on the Carriage Cable (black) at the rear left side, disconnect it (Figure 7).

10. Use tape to secure the Carriage Cable (black) that was disconnected in step 9 so that it does not get separated from the Cable Supply Drum (Figure 8).

1 Remove the Cable Spring.

1 Secure the Carriage Cable with tape.

2 Disconnect the Carriage Cable. 3 Remove the Carriage Cable from the pulley.

Figure 8 Figure 7


REP 10.3.1

June, 2008 4-102


11. While maintaining tension on the Carriage Cable (silver) at the rear right side, disconnect it (Figure 9).

12. Use tape to secure the Carriage Cable (silver) that was disconnected in step 11 so that it does not get separated from the Cable Supply Drum (Figure 10).

1 Disconnect the Carriage Cable.

1 Secure the Carriage Cable with tape.

Figure 9


Figure 10

June, 2008 4-103


REP 10.3.1

13. Turn the left side of the IIT Carriage face up.

Replacement

14. Disconnect the Flexible Print Cable connectors (2) (Figure 11).

1.


2.

Do not allow the Rail Contact of the IIT Carriage to bend in the direction of the arrow (Figure 12). A Rail Contact

Figure 11

Figure 12


REP 10.3.1

June, 2008 4-104


3.

Attach the Carriage Cables (black and silver) to the IIT Frame in the sequence shown (Figure 13).

REP 10.3.2 Flexible Print Cable (SCC) Parts List on PL 10.3 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.



•


2.


3.

Remove the IIT Carriage (REP 10.3.1).

4.

Remove the Core Clip (Figure 1). 1 Remove the Core Clip.

Figure 13 Figure 1 Removing the Core Clip


June, 2008 4-105


REP 10.3.1, REP 10.3.2

5.

Disconnect the Flexible Print Cables (2) from the AIOC PWB (Figure 2).

6.

Remove the Flexible Print Cable (Figure 3).

1 Disconnect the Flexible Print Cables (2).

1 Peel off the pieces of tape to remove the Flexible Print Cable.

2 Remove the Cores (2).

2 Slide the Flexible Print Cable through the hole in the IIT Frame.

Figure 2

Figure 3

Replacement 1.


REP 10.3.2

June, 2008 4-106



REP 10.6.1 Exposure Lamp

4.

Disconnect the connector (Figure 2). 1 Release the wire harness from the clamp.


2 Disconnect the connector.




•


2.


3.

Remove the Inverter PWB Bracket 2 (Figure 1). 1 Remove the screw. 2 Remove the Inverter PWB Bracket 2.

Figure 2

Figure 1


June, 2008 4-107


REP 10.6.1

5.

Remove the Exposure Lamp (Figure 3).

REP 10.7.1 Carriage Cable and Drum

1 Remove the screw.


2 Remove the Exposure Lamp from the Lamp Holder.




•


2.


3.

Remove the IIT Carriage (REP 10.3.1).

4.

Turn the IIT Carriage upside down.

Figure 3

Replacement 1.



REP 10.6.1, REP 10.7.1

June, 2008 4-108


5.

Remove the Carriage Cables (black and silver) (Figure 1).

Replacement

1 Peel off the pieces of tape to remove the Carriage Cables.

1.


2.

Attach the Carriage Cables (black/silver) to the holes in the Drum (Figure 2).

Figure 1 Figure 2


June, 2008 4-109


REP 10.7.1

3.

Wind the Carriage Cables around the Drum and secure them with tape (Figure 3).

4.

Wind the Carriage Cables around the pulleys (Figure 4). See also the Cable Winding Schematic (Figure 5).

5.

Secure the Cables with pieces of tape so that they do not become loose (see Figure 1).

Figure 3 Figure 4


REP 10.7.1

June, 2008 4-110


REP 10.7.2 Inverter PWB Parts List on PL 10.7 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.



•


2.


3.

Remove the Inverter PWB Bracket 2 (Figure 1). 1 Remove the screw. 2 Remove the Inverter PWB Bracket 2.

Figure 5 Cable Winding Schematic

Figure 1


June, 2008 4-111


REP 10.7.1, REP 10.7.2

4.

Disconnect the connector (Figure 2).

5.

Remove the Inverter PWB Bracket 1 (Figure 3).

1 Release the wire harness from the clamp.

1 Remove the screw.


2 Remove the Inverter PWB Bracket 1.

Figure 2


REP 10.7.2

Figure 3

June, 2008 4-112


6.

Remove the Inverter PWB (Figure 4). 1 Remove the Tapping Screw. 2 Remove the Inverter PWB.

Figure 4

Replacement 1.



June, 2008 4-113


REP 10.7.2


REP 10.7.2

June, 2008 4-114


REP 11.1.1 Tray 2

REP 11.1.2 Single Tray Module (Separation from IOT)



WARNING



WARNING

1.

Remove all paper from Tray 2.

2.

Pull out Tray 2.

The IOT is heavy. Do this procedure with 2 persons.

3.

Lift the front side of Tray 2 and remove the tray (Figure 1).

1.

Disconnect the connector. (Figure 1). 1 Disconnect the connector. 2 Pull out the cable clamp.

Figure 1

Replacement •

Figure 1



June, 2008 4-115


REP 11.1.1, REP 11.1.2

2.

Remove the Countersunk Head Screws at the rear (Figure 2).

3.

1 Remove the Countersunk Head Screws (2).

Remove the Countersunk Head Screws at the front (Figure 3). 1 Pull out Tray 1. 2 Remove the Countersunk Head Screws (2).

Figure 2 Figure 3


REP 11.1.2

June, 2008 4-116


4.

Hold onto A (2) and B (2), and remove the IOT from the Single Tray Module (Figure 4).

REP 11.4.1 Tray 2 Feed Roll Parts List on PL 11.4 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.


2.

Remove the Feed Shaft (Figure 1). 1 Remove the KL-Clip. 2 Remove the bearing. 3 Slide the Feed Shaft towards the rear to remove it.

Figure 4

Replacement 1.


Figure 1


June, 2008 4-117


REP 11.1.2, REP 11.4.1

3.

Remove the Tray 2 Feed Roll (Figure 2).

Replacement

1 Remove the KL-Clip.

1.


2 Remove the Tray 2 Feed Roll.

2.

When installing the Tray 2 Feed Roll, align the pin on the Feed Shaft with the groove in the Tray 2 Feed Roll (Figure 3).

Figure 2 Figure 3


REP 11.4.1

June, 2008 4-118


REP 11.4.2 Tray 2 Retard Roll

3.

Remove the Tray 2 Retard Roll Housing (Figure 2). 1 Release the hooks (2).


2 Remove the Tray 2 Retard Roll Housing from the tabs (2).



2.

Remove the Tray 2 Feeder (Figure 1). 1 Remove the Tapping Screws (4). 2 Remove the Tray 2 Feeder.

Figure 2

Figure 1


June, 2008 4-119


REP 11.4.2

4.

Remove the Retard Shaft (Figure 3).

5.

1 Remove the Retard Shaft.

1 Release the tab to remove the Tray 2 Retard Roll.

Figure 3


REP 11.4.2

Remove the Tray 2 Retard Roll (Figure 4).

Figure 4

June, 2008 4-120


Replacement

3.

1.


2.

When installing the Tray 2 Retard Roll, align the coupling of the Friction Clutch with the Tray 2 Retard Roll (Figure 5).


A Holder Arm B Tray 2 Retard Roll

Figure 6

Figure 5

Reissue

When installing the Tray 2 Retard Roll Housing, check that the Tray 2 Retard Roll rises when the Holder Arm is pressed (Figure 6).

June, 2008 4-121


REP 11.4.2

REP 11.5.1 STM Feed Sensor

Replacement


1.



Remove the IOT from the Single Tray Module (REP 11.1.2).

2.


3.

Open Access Cover 2.

4.

Remove the STM Feed Sensor (Figure 1). 1 Pull out the cable clamp. 2 Disconnect the connector. 3 Release the tabs, and remove the STM Feed Sensor.

Figure 1


REP 11.5.1

June, 2008 4-122


REP 11.5.2 STM PWB (SCC)

Replacement


1.



Remove the STM Rear Cover (PL 11.5).

2.

Remove the STM PWB (Figure 1). 1 Disconnect the connectors (3). 2 Remove the screws (2). 3 Remove the STM PWB.

Figure 1


June, 2008 4-123


REP 11.5.2

REP 11.6.1 STM Feed Clutch

3.

Remove the STM Feed Clutch (Figure 2). 1 Release the wire harness from the clamp.


2 Disconnect the connector. 3 Remove the screws (2).

WARNING

4 Release the tab on the gear, and remove the gear together with the STM Feed Clutch.



2.

Remove the gears (Figure 1).

5 Slide the wire harness through the hole.

1 Remove the E-rings. 2 Release the tabs.

Figure 2

Replacement 1.


Figure 1


REP 11.6.1

June, 2008 4-124


REP 11.6.2 STM Feed Motor

3.

Remove the STM Feed Motor (Figure 2). 1 Release the wire harness from the clamp.


2 Disconnect the connector. 3 Remove the screws (4).

WARNING

4 Remove the STM Feed Motor.



2.

Remove the gears (Figure 1). 1 Release the tab, and remove the gear. 2 Release the tab, and remove the gear.

Figure 2

Replacement 1.


Figure 1


June, 2008 4-125


REP 11.6.2

REP 11.7.1 STM No Paper Sensor Parts List on PL 11.7 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.


3.

Remove the STM No Paper Sensor (Figure 1). 1 Disconnect the connector. 2 Release the tabs, and remove the STM No Paper Sensor.

Figure 1

Replacement 1.



REP 11.7.1

June, 2008 4-126


REP 13.1.1 ADF Assembly

3.

Remove the Screws (Figure 2). 1.


Remove the Screws (2).



2.

Disconnect the Connector (Figure 1). 1.

Disconnect the Connector.

2.

Remove the Cable Band.

Figure 2 (j0hu41302)

Figure 1 (johu41301)


June, 2008 4-127


REP 13.1.1

2.

Remove the ADF (Figure 3).

REP 13.1.2 ADF/DADF Platen Cushion

1.


Remove the ADF.


Remove the Platen Cushion ([Figure 1]). 1.

Remove the Platen Cushion.


Replacement 1.




REP 13.1.1, REP 13.1.2

June, 2008 4-128


Replacement 1.

Paste the Platen Cushion ([Figure 2]). 1.

Place the Platen Cushion on the Platen Glass.

2.

Adjust the Platen Glass for the correct gap between it and the Registration Guide.

3.

Slowly lower the ADF/DADF and press it onto the Platen Cushion.



June, 2008 4-129


REP 13.1.2

REP 13.2.1 Document Tray Assembly (ADF)

4.


Remove the Support Bracket (Figure 2) . i.

Release the Wire Harness from the Clamp.

ii.

Remove the Tapping Screw.

iii.


WARNING

iv.

Remove the Ground Wire.


v.

Remove the Support Bracket.

1.


Front Cover (REP 13.2.3)

•

Rear Cover (REP 13.2.4)

2.

Open the Top Cover.

3.

Remove the Tapping Screw (Figure 1) . i.

Remove the Screw.




REP 13.2.1

June, 2008 4-130


5.

Disconnect the Connector (Figure 3) . i.


ii.

Remove the Cable Tie.

6.

Remove the Ground Wires (Figure 4) . i.

Remove the Screw to remove the Ground Wires (2).

Figure 4 (j0hu41309) Figure 3 (j0hu41308)


June, 2008 4-131


REP 13.2.1

7.

Remove the Document Tray Assembly (Figure 5) .

REP 13.2.2 ADF Feeder Assembly

1.


Remove the Document Tray Assembly.


Remove the following covers. •


•


2.

Open the Top Cover.

3.

Remove the Document Tray Assembly (REP 13.2.1).


Replacement 1.



REP 13.2.1, REP 13.2.2

June, 2008 4-132


4.

Remove the Rear Blind Cover (Figure 1).

3.

Disconnect the ADF PWB Connectors ([Figure 2]):

1.


CN2

2.

Remove the Rear Blind Cover.

CN3 CN5 NOTE: The configuration of the ADF PWB on the WorkCentre 5020 (DADF/Network) is slightly different, but the Connector reference numbers are the same. i.

Disconnect the Connectors (3).




June, 2008 4-133


REP 13.2.2

4.

Remove the Screws at the front ([Figure 3]).

3.


1.

Remove the Screw (short).

1.

2.

Remove the Screw (long).

2.

Remove the Screws at the rear ([Figure 4]). Remove the Screw (long).

3.

Remove the Tapping Screw to remove the Ground Wire. NOTE: There is no Ground Wire on the WorkCentre 5020 (DADF/Network).




REP 13.2.2

June, 2008 4-134


4.

Remove the ADF Feeder Assembly ([Figure 5]).

REP 13.2.3 Front Cover

1.


Remove the ADF Feeder Assembly.


Remove the Front Cover while pressing the sections indicated by the arrows ([Figure 1]). 1.

Remove the Screw.

2.

Remove the Tapping Screws (3).

3.

Remove the Front Cover.


Replacement 1.




June, 2008 4-135


REP 13.2.2, REP 13.2.3

Replacement

REP 13.2.4 Rear Cover

1.




Remove the Rear Cover while pressing the sections indicated by the arrow ([Figure 1]). 1.

Remove the Screw.

2.


3.

Remove the Rear Cover.



REP 13.2.3, REP 13.2.4

June, 2008 4-136


Replacement

REP 13.2.5 DADF Eject Roller Solenoid

1.




Remove the Front Cover. (REP 13.2.3)

2.

Remove the Eject Roller Solenoid. (Figure 1) a.

Disconnect the connector.

b.

Remove the screws (2).

c.

Remove the wire from the harness clamp.

d.

Remove the Solenoid.

1

3

2

4

Disconnect the connector

Remove wire clamp

Remove the screws (2)

Remove the Solenoid

Figure 1 Removing the Eject Roller Solenoid

Replacement


1.

Install the DADF Eject Roller Solenoid and ensure that the Solenoid linkage is properly install into the Eject Roller control arm.

2.

Perform the remainder of the replacement procedure in reverse order of the removal procedure.

June, 2008 4-137


REP 13.2.4, REP 13.2.5

REP 13.2.6 DADF Assembly

3.

Remove the Screws (Figure 2). 1.





2.

If you have a WorkCentre 5020 (DADF/Network), you must remove the EMI Cover (10 Screws) and then remove the Cable Band from the EMI Cover (REP 8.1.3)

3.

Disconnect the Connector (Figure 1). 1.


2.

Remove the DADF Cable. Disconnect the connectors (2)

Figure 2 (j0hu41302) Figure 1 Disconnecting the DADF Cable


REP 13.2.6

June, 2008 4-138


2.

Remove the DADF (Figure 3).

REP 13.2.7 Document Tray Assembly (DADF)

1.


Remove the DADF.




•


2.

Open the Top Cover.

3.

Loosen the Tapping Screw (Figure 1). a.

Loosen the Screw.

Figure 3 (j0hu41303) Loosen the screw (1)

Replacement 1.


Figure 1 Loosening the screw 4.


June, 2008 4-139

Remove the Support Bracket (Figure 2). i.

Release the Wire Harness from the Clamp.

ii.


iii.


iv.

Remove the Ground Wire.

v.

Remove the Support Bracket.


REP 13.2.6, REP 13.2.7

5.

Disconnect the Connector (Figure 3). i.


ii.

Remove the Cable Tie.


Remove cable tie

Figure 3 Disconnecting the connecgor



REP 13.2.7

June, 2008 4-140


6.

Remove the Ground Wires (Figure 4). i.

7.

Remove the Screw to remove the Ground Wires (2).

Remove the Document Tray Assembly (Figure 5). 1.

Remove the Document Tray Assembly.



Replacement 1.


June, 2008 4-141



REP 13.2.7

REP 13.2.8 DADF Feeder Assembly

4.


Remove the Rear Blind Cover (Figure 1). i.


ii.

Remove the Rear Blind Cover.


Remove the following covers. •


•


2.

Open the Top Cover.

3.

Remove the Document Tray Assembly (REP 13.2.7).



REP 13.2.8

June, 2008 4-142


5.

Disconnect the ADF PWB Connectors (Figure 2): CN2

3

CN3

Remove the Solenoid Bracket

CN5 CN7 i.


1

2


Remove the screws (3)

Figure 3 Removing the Eject Roller Solenoid Bracket 7.

Remove the Screws at the front ([Figure 3]). i.

Remove the Screw (short).

ii.


Disconnect the connectors Figure 2 Disconnect the connectors (4) 6.

Remove the DADF Eject Roller Solenoid. a.

Disconnect the connector.

b.


c.

Remove the Eject Roller Solenoid.


June, 2008 4-143


REP 13.2.8

8.

Remove the Tapping Screw. i.

Remove the Screws at the rear ([Figure 4]).

ii.


iii.

Remove the Tapping Screw to remove the Ground Wire.




REP 13.2.8

June, 2008 4-144


9.

Remove the ADF Feeder Assembly ([Figure 5]).

REP 13.3.1 ADF Control PWB

1.


Remove the ADF Feeder Assembly.



2.

Raise the Document Tray Assembly in the direction of the arrow ([Figure 1]). 1.

Raise the Document Tray Assembly in the direction of the arrow.


Replacement 1.




June, 2008 4-145


REP 13.2.8, REP 13.3.1

2.

Disconnect the PWB Connectors ([Figure 2]). 1.

2.

Disconnect the PWB Connectors (5).

Remove the ADF Control PWB ([Figure 3]). 1.


2.


3.


4.

Remove the ADF Control PWB.



Replacement 1.


REP 13.3.1

June, 2008 4-146



REP 13.3.2 Left Counter Balance (SCC) Parts List on PL 13.3 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.

WARNING The ADF must be removed. There is danger when removing a Counter Balance that is in closed state because the compressed spring may get released suddenly. 1.

Remove the ADF (REP 13.1.1).

2.


3.

Open the Top Cover.

4.

Remove the Film Cover (Figure 1). 1.

Remove the Film Cover.



June, 2008 4-147


REP 13.3.2

2.

Remove the Left Counter Balance (Figure 2).

REP 13.3.3 Right Counter Balance (SCC)

1.


2.

Remove the Left Counter Balance.

Parts List on PL 13.3 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.

WARNING The ADF/DADF must be removed. There is danger when removing a Counter Balance that is in closed state because the compressed spring may get released suddenly. 1.

Remove the ADF/DADF (REP 13.1.1).

2.

Remove the Rear Cover (PL 13.2).


Replacement 1.



REP 13.3.2, REP 13.3.3

June, 2008 4-148


3.

Remove the Film Cover (Figure 1). 1.

2.

Remove the Film Cover.

Remove the screws that secure the Right Counter Balance (Figure 2). 1.

Use the marking tool and make a marking line.

2.


3.

Remove the Right Counter Balance.


Replacement


1.


2.

Check the ADF/DADF Positional Adjustment (ADJ 13.1.1).

June, 2008 4-149


REP 13.3.3

REP 13.3.4 DADF PWB

3.

Disconnect the PWB Connectors (Figure 2). 1.


Disconnect the PWB Connectors (5).

Disconnect the connectors



2.

Raise the Document Tray Assembly in the direction of the arrow (Figure 1). i.

Raise the Document Tray Assembly in the direction of the arrow.

Disconnect the connectors Figure 2 (j0hu41318)



REP 13.3.4

June, 2008 4-150


2.

Remove the DADF Control PWB (Figure 3).

REP 13.4.1 Top Cover

1.


2.



3.


4.

Remove the DADF Control PWB.


1 Remove screws (2)

4

3

2

Remove the PWB

Remove the screw (1)

Remove the screw (1)

1.

Open the Upper Feeder Assembly.

2.

Remove the Top Cover (Figure 1). 1.


2.

Release the Hooks (2).

3.

Push in the Hooks (3).

4.

Remove the Top Cover.

Figure 3 Removing the DADF Control PWB

Replacement 1.




June, 2008 4-151


REP 13.3.4, REP 13.4.1

Replacement

REP 13.8.1 Retard Roll

1.




Open the Top Cover.

2.

Open the Retard Roll Assembly (Figure 1). 1.

Open the Retard Roll Assembly.



REP 13.4.1, REP 13.8.1

June, 2008 4-152


2.

Remove the Plate (Figure 2).

3.

a.


b.

Remove the Plate.

Remove the Retard Roll together with the Bearings (Figure 3). 1.

Remove the Retard Roll.



June, 2008 4-153


REP 13.8.1

2.

Remove the Retard Roll (Figure 4).

REP 13.9.1 Pickup Roll, Feed Roll

1.


Remove the Bearings (2).


Open the Upper Feeder Assembly.

2.

Remove the Top Cover (REP 13.4.1).

3.

Remove the Sensor Holder (Figure 1). 1.


2.

Remove the Sensor Holder.


Replacement 1.


2.

After a replacement, enter the Diagnostic Mode How to Enter the Diagnostic Mode and clear the simplex and duplex feed counters.



REP 13.8.1, REP 13.9.1

June, 2008 4-154


3.

Remove the E-Clip and the Bearing.

4.

Remove the Feed Roll Assembly (Figure 3).

a.

Remove the Spring (Figure 2).

1.

Move the Shaft.

b.

Remove the E-Clips (2).

2.

Remove the Feed Roll Assembly.

c.

Remove the Spring.



June, 2008 4-155


REP 13.9.1

3.

Remove the Feed Roll (Figure 4).

4.

Remove the Pickup Roll (Figure 5).

1.

Remove the E-Clip.

a.

Remove the Bearing.

2.

Remove the Shaft.

b.

Remove the Pickup Roll.

3.

Remove the Feed Roll.


Replacement 1.


2.

After a replacement, enter the Diagnostic Mode and clear the simplex and duplex feed counters.


REP 13.9.1

June, 2008 4-156


ADJ 8.1.1 Edge Erase Adjustment

ADJ 8.1.2 Controller Firmware Version Upgrade

Purpose

Purpose

To set the right amount of edge erase at the lead edge and trail edge, as well as at both sides (left/right) of the image.

To upgrade the version of the Controller.

Check NOTE: Do the IOT Lead Edge/Side Edge Registration adjustment first.

Check the current version:

Check 1.

Specify a tray that contains paper, leave the platen cover open, and make a completely black copy by not putting any document on the glass.

2.

Check that the white portion at the lead edge, trail edge, and both sides of the copy are all 2mm wide.

Adjustment 1.

Enter the Diagnostic Mode and adjust the following NVM. Increasing the value will increase the amount of edge erase. Table 1

Chain Func

Name

Min

Initial

Max

Step

6

Normal Side Edge Erase Adjustment

0

16

32

0.254mm

59

6

60

Normal Lead Edge Erase Adjustment

0

16

32

0.145mm

6

63

Normal Trail Edge Erase Adjustment

0

16

32

0.145mm


Enter the Diagnostic Mode and check the Controller Firmware version xxx using Chain-Function [29-50].

Adjustment [USB Connection] 1.

Download the Firmware from our home page.

2.

Decompress the Firmware.

3.

Connect the PC to the USB connector at the Right Cover.

4.

Turn the power ON, and the Add USB Device window will appear on the PC. Click the [Cancel] button when the New Hardware Detected Wizard window is displayed.

5.

Double-click the executable file of the decompressed Firmware to run it.

6.

The [Firmware Update Tool (Printer Model And File Selection)] is displayed. Select the machine model and the downloaded Firmware file, and then click [Next].

7.

The [Firmware Update Tool (Communication Interface Selection)] is displayed. Select [USB Port] and click [Next].

8.

The [Firmware Update Tool (Updating...)] window is displayed indicating the data transfer in progress. Once the upgrade is completed, the [Firmware Update Tool (Result)] window is displayed. Click the [Finish] button.

June, 2008 4-157


ADJ 8.1.1, ADJ 8.1.2

ADJ 10.3.1 IIT Lead Edge/Side Edge Registration

3.

Purpose

Check that the measured values for lead edge (A) and side edge (B) meet the specifications of the corresponding mode.

To obtain the home position in the IIT lead edge (slow scan)/IIT side edge (fast scan) direction.

Check 1.

Set the Test Pattern 499T247 (A3) on the platen, so that there is no gap between it and the Rear Registration Guide. Make 3 copies using 100% R/E and A3 SEF paper.

2.

Measure the lead edge and side edge of the 3rd copy (Figure 1).

Table 1 Specification Item

Simplex

MSI

Lead edge (A)

10 1.6mm

10 2.2mm

Side edge (B)

5 2.1mm

5 3.0mm

Lead edge: part A in the figure

Adjustment

Side edge: part B in the figure

1.

Enter the Diagnostic Mode, and use the following Chain Functions to perform adjustments until the measured values for lead edge (A) and side edge (B) registration are within the specifications. When the measured value is short, reduce the setting value. When the measured value is long, increase the setting value. Table 2

Chain Func

Sub Name System

Value

Initial Max. Value

1 Count

Min.

20

1

PH

REGI ADJUSTMENT - ALL

0

60

30

0.146mm

20

41

PH

TRAY 1 for Normal LEAD REGI 0 ADJ

60

30

0.146mm

20

42

PH

TRAY 2 for Normal LEAD REGI 0 ADJ

60

30

0.146mm

20

43

PH

MSI for Normal LEAD REGI ADJ

0

60

30

0.146mm

6

20

ROS

ALL TRAY - LASER SIDE REGI 1 ADJUSTMENT

99

50

0.254mm

6

21

ROS

TRAY 1 - LASER SIDE REGI ADJUSTMENT

1

99

50

0.254mm

6

22

ROS

TRAY 2 - LASER SIDE REGI ADJUSTMENT

1

99

50

0.254mm

6

26

ROS

MSI - LASER SIDE REGI ADJUSTMENT

1

99

50

0.254mm

2.

After the adjustment, again set the Test Pattern 499T247 (A3) on the platen so that there is no gap between it and the Rear Registration Guide. Make a copy using 100% R/E and A3 SEF paper.

3.

Repeat the procedure until the measured values for lead edge (A) and side edge (B) are within the specifications.

Figure 1 IIT Lead Edge/Side Edge Registration


ADJ 10.3.1

June, 2008 4-158


ADJ 11.1.1 Carriage Assembly Alignment (Parallelism) Purpose •

To align the Carriage Assembly with the IIT Upper Cover.

•

To prevent optical image skew in Platen Glass Mode.


Adjustment 1.

2.



•


•

IIT Upper Cover (REP 10.2.1)

Adjust until the Carriage Assembly and the IIT Under Cover are parallel (Figure 1). 1 Loosen the Stop Screw. 2 Move the Carriage Assembly all the way to the right. 3 Turn the Adjustment Screw to adjust. 4 Tighten the Stop Screw. Reference: Turning the Adjustment Screw counterclockwise moves the front of the Carriage Assembly to the left.

Figure 1 Carriage Assembly Alignment (Parallelism)


3.

Return the machine to its original state, and make a copy in Platen Mode.

4.

Check for optical skew, and repeat from step 1 as needed.

June, 2008 4-159


ADJ 11.1.1

ADJ 13.1.1 ADF/DADF Positional Adjustment

•

Result when the ADF/DADF is moved in direction A (Figure 2):

Purpose To correct the alignment of the ADF/DADF and correct the movement of the document.

Adjustment 1.

Remove the ADF/DADF Rear Cover (PL 13.2).

2.

Change the position of the Right Counter Balance to adjust the skew amount (Figure 1). 1.

Loosen the Screws (4).

2.

Move the DADF/ADF in direction of A or B.

3.

Tighten the Screws (4).

Figure 2 ADF Adjustment - Direction A (j0hu41335)

Figure 1 ADF Adjustment - 1 (j0hu41334)


ADJ 13.1.1

June, 2008 4-160


•

Result when the ADF/DADF is moved in direction B (Figure 3):

Figure 3 ADF Adjustment - Direction B (j0hu41336)


June, 2008 4-161


ADJ 13.1.1


ADJ 13.1.1

June, 2008 4-162


5 Parts List Overview Introduction ..................................................................................................................... Subsystem Information ................................................................................................... Symbology ......................................................................................................................

PL 8.4 Control Panel Component.................................................................................... 5-3 5-4 5-5

Parts Lists 5-7

Paper Transport PL 2.1 Tray 1................................................................................................................... PL 2.2 Tray 1 Frame Accessory...................................................................................... PL 2.3 Tray 1 Components (1 OF 2) ............................................................................... PL 2.4 Tray 1 Components ( 2 OF 2).............................................................................. PL 2.5 Tray 1 Frame Components.................................................................................. PL 2.6 Tray 1 Frame Components (2 OF 2) ................................................................... PL 2.7 No Paper Sensor Housing ................................................................................... PL 2.8 Registration.......................................................................................................... PL 2.9 Registration Component ......................................................................................

5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16

ROS PL 3.1 ROS .....................................................................................................................

5-17

CRU PL 4.1 Drum Cartridge .................................................................................................... PL 4.2 Toner Empty Sensor and Erase Lamp ................................................................ PL 4.3 Transfer ............................................................................................................... PL 4.4 Transfer Corotron Housing Component...............................................................

5-22

Exit Transport PL 6.1 Exit Transport ...................................................................................................... PL 6.2 Exit Transport Component (Simplex)................................................................... PL 6.3 Exit Transport Component (Duplex) ....................................................................

5-23 5-24 5-25

Simplex / Duplex Module and Bypass Tray PL 7.1 Simplex Module ................................................................................................... PL 7.2 Left Hand Cover Assembly .................................................................................. PL 7.3 Duplex Module Component (1 OF 2)................................................................... PL 7.4 Duplex Module Component (2 OF 2)................................................................... PL 7.5 Bypass Tray Accessory ....................................................................................... PL 7.6 Bypass Tray Component .....................................................................................

5-36 5-37

PL 10.1 IIT Accessory ..................................................................................................... PL 10.2 IIT Component (1 OF 2)..................................................................................... PL 10.3 IIT Component (2 OF 2)..................................................................................... PL 10.4 IIT Upper Cover Cover Component ................................................................... PL 10.5 IIT Under Cover Component.............................................................................. PL 10.6 IIT Carriage Component .................................................................................... PL 10.7 Center Plate Component ...................................................................................

5-38 5-39 5-40 5-41 5-42 5-43 5-44

Single Tray Module PL 11.1 Single Tray Module ............................................................................................ PL 11.2 Tray 2 Component (1 OF 3)............................................................................... PL 11.3 Tray 2 Component (2 OF 3)............................................................................... PL 11.4 Tray 2 Component (3 OF 3)............................................................................... PL 11.5 Single Tray Frame Component (1 OF 2) ........................................................... PL 11.6 Single Tray Frame Component (2 OF 2) ........................................................... PL 11.7 STM No Paper Sensor.......................................................................................

5-45 5-46 5-47 5-48 5-49 5-50 5-51

Stand 5-18 5-19 5-20 5-21

Fuser PL 5.1 Fuser....................................................................................................................

Cover PL 9.1 Front / Top Cover................................................................................................. PL 9.2 Rear / Right Cover and NOHAD Fan ...................................................................

IIT

Drive PL 1.1 IOT Motor.............................................................................................................

5-35

5-26 5-27 5-28 5-29 5-30 5-31

PL 12.1 Stand Component ..............................................................................................

5-52

ADF/DADF PL 13.1 ADF/DADF Accessory ....................................................................................... PL 13.2 Component, Cover............................................................................................. PL 13.3 Base Cover Component..................................................................................... PL 13.4 Feeder Component ............................................................................................ PL 13.5 Lower Feeder Component ................................................................................. PL 13.6 Retard Roll Component ..................................................................................... PL 13.7 Lower Feeder Assembly .................................................................................... PL 13.8 Retard Roll Assembly ........................................................................................ PL 13.9 Upper Feeder Assembly .................................................................................... PL 13.10 Document Tray ................................................................................................

5-53 5-54 5-55 5-56 5-57 5-58 5-59 5-60 5-61 5-62

Common Hardware Common Hardware ......................................................................................................... Part Number Index ..........................................................................................................

5-63 5-64

Electrical PL 8.1 AIOC PWB, LVPS, Power Switch........................................................................ PL 8.2 HVPS, Interlock Switch, Duplex PWB ................................................................. PL 8.3 Control Panel Accessory ..................................................................................... Reissue WorkCentre 5016, 5020

5-32 5-33 5-34

June, 2008 5-1

Parts Lists

Parts Lists

June, 2008 5-2


Introduction

Table 1

Overview

Abbreviation

The Parts List section identifies all part numbers and the corresponding location of all spared subsystem components.

R/E

Reduction/Enlargement

REF:

Refer to

SCSI

Small Computer Systems Interface

Organization

W/

With

Parts Lists

W/O

Without

Each item number in the part number listing corresponds to an item number in the related illustration. All the parts in a given subsystem of the machine will be located in the same illustration or in a series of associated illustrations.

Meaning

Table 2 Operating Companies

Electrical Connectors and Fasteners

Abbreviation

This section contains the illustrations and descriptions of the plugs, jacks, and fasteners used in the machine. A part number listing of the connectors is included.

AO

Americas Operations

NASG - US

North American Solutions Group - US

Common Hardware

NASG Canada

North American Solutions Group Canada

XE

Xerox Europe

The common hardware is listed in alphabetical order by the letter or letters used to identify each item in the part number listing and in the illustrations. Dimensions are in millimeters unless otherwise identified.

Meaning

Symbology Part Number Index

Symbology used in the Parts List section is identified in the Symbology section.

This index lists all the spared parts in the machine in numerical order. Each number is followed by a reference to the parts list on which the part may be found.

Service Procedure Referencing If a part or assembly has an associated repair or adjustment procedure, the procedure number will be listed at the end of the part description in the parts lists e.g. (REP 5.1, ADJ 5.3)

Other Information Abbreviations Abbreviations are used in the parts lists and the exploded view illustrations to provide information in a limited amount of space. The following abbreviations are used in this manual: Table 1 Abbreviation

Meaning

A3

297 x 594 Millimeters

A4


A5


AD

Auto Duplex

AWG

American Wire Gauge

EMI

Electro Magnetic Induction

GB

Giga Byte

KB

Kilo Byte

MB

Mega Byte

MM

Millimeters

MOD

Magneto Optical Drive

NOHAD

Noise Ozone Heat Air Dirt

PL

Parts List

P/O

Part of


June, 2008 5-3

Parts Lists

Introduction

Subsystem Information Use of the Term “Assembly” The term “assembly” will be used for items in the part number listing that include other itemized parts in the part number listing. When the word “assembly” is found in the part number listing, there will be a corresponding item number on the illustrations followed by a bracket and a listing of the contents of the assembly.

Brackets A bracket is used when an assembly or kit is spared, but is not shown in the illustration. The item number of the assembly or kit precedes the bracket; the item numbers of the piece parts follow the bracket.

Tag The notation “W/Tag” in the parts description indicates that the part configuration has been updated. Check the change Tag index in the General Information section of the Service Data for the name and purpose of the modification. In some cases, a part or assembly may be spared in two versions: with the Tag and without the Tag. In those cases, use whichever part is appropriate for the configuration of the machine on which the part is to be installed. If the machine does not have a particular Tag and the only replacement part available is listed as “W/Tag”, install the Tag kit or all of the piece parts. The Change Tag Index tells you which kit or piece parts you need. Whenever you install a Tag kit or all the piece parts that make up a Tag, mark the appropriate number on the Tag matrix.

Parts Lists

Subsystem Information

June, 2008 5-4


Symbology A Tag number within a circle pointing to an item number shows that the part has been changed by the tag number within the circle (Figure 1). Information on the modification is in the Change Tag Index.

A Tag number within a circle having a shaded bar and pointing to an item number shows that the configuration of the part shown is the configuration before the part was changed by the Tag number within the circle (Figure 2).

Figure 2 Without Tag Symbol Figure 1 With Tag Symbol


June, 2008 5-5

Parts Lists

Symbology

A tag number within a circle with no apex shows that the entire drawing has been changed by the tag number within the circle (Figure 3). Information on the modification is in the Change Tag Index.

A tag number within a circle with no apex and having a shaded bar shows that the entire drawing was the configuration before being changed by the tag number within the circle (Figure 4).

Figure 3 Entire Drawing With Tag Symbol

Figure 4 Entire Drawing Without Tag Symbol

Parts Lists

Symbology

June, 2008 5-6


Overview Introduction ..................................................................................................................... Subsystem Information ................................................................................................... Symbology ......................................................................................................................

PL 9.2 Rear / Right Cover and NOHAD Fan ................................................................... 5-3 5-4 5-5

Parts Lists Drive PL 1.1 IOT Motor.............................................................................................................

5-7

Paper Transport PL 2.1 Tray 1................................................................................................................... PL 2.2 Tray 1 Frame Accessory...................................................................................... PL 2.3 Tray 1 Components (1 OF 2) ............................................................................... PL 2.4 Tray 1 Components ( 2 OF 2).............................................................................. PL 2.5 Tray 1 Frame Components.................................................................................. PL 2.6 Tray 1 Frame Components (2 OF 2) ................................................................... PL 2.7 No Paper Sensor Housing ................................................................................... PL 2.8 Registration.......................................................................................................... PL 2.9 Registration Component ......................................................................................

5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16

5-18 5-19 5-20 5-21 5-22 5-23 5-24 5-25

Simplex / Duplex Module and Bypass Tray PL 7.1 Simplex Module ................................................................................................... PL 7.2 Left Hand Cover Assembly .................................................................................. PL 7.3 Duplex Module Component (1 OF 2)................................................................... PL 7.4 Duplex Module Component (2 OF 2)................................................................... PL 7.5 Bypass Tray Accessory ....................................................................................... PL 7.6 Bypass Tray Component .....................................................................................

5-52

ADF/DADF

Exit Transport PL 6.1 Exit Transport ...................................................................................................... PL 6.2 Exit Transport Component (Simplex)................................................................... PL 6.3 Exit Transport Component (Duplex) ....................................................................

5-45 5-46 5-47 5-48 5-49 5-50 5-51

5-17

Fuser PL 5.1 Fuser....................................................................................................................

5-38 5-39 5-40 5-41 5-42 5-43 5-44

Single Tray Module PL 11.1 Single Tray Module ............................................................................................ PL 11.2 Tray 2 Component (1 OF 3)............................................................................... PL 11.3 Tray 2 Component (2 OF 3)............................................................................... PL 11.4 Tray 2 Component (3 OF 3)............................................................................... PL 11.5 Single Tray Frame Component (1 OF 2) ........................................................... PL 11.6 Single Tray Frame Component (2 OF 2) ........................................................... PL 11.7 STM No Paper Sensor....................................................................................... PL 12.1 Stand Component ..............................................................................................

CRU PL 4.1 Drum Cartridge .................................................................................................... PL 4.2 Toner Empty Sensor and Erase Lamp ................................................................ PL 4.3 Transfer ............................................................................................................... PL 4.4 Transfer Corotron Housing Component...............................................................

IIT PL 10.1 IIT Accessory ..................................................................................................... PL 10.2 IIT Component (1 OF 2)..................................................................................... PL 10.3 IIT Component (2 OF 2)..................................................................................... PL 10.4 IIT Upper Cover Cover Component ................................................................... PL 10.5 IIT Under Cover Component.............................................................................. PL 10.6 IIT Carriage Component .................................................................................... PL 10.7 Center Plate Component ...................................................................................

Stand

ROS PL 3.1 ROS .....................................................................................................................

5-37

PL 13.1 ADF/DADF Accessory ....................................................................................... PL 13.2 Component, Cover............................................................................................. PL 13.3 Base Cover Component..................................................................................... PL 13.4 Feeder Component ............................................................................................ PL 13.5 Lower Feeder Component ................................................................................. PL 13.6 Retard Roll Component ..................................................................................... PL 13.7 Lower Feeder Assembly .................................................................................... PL 13.8 Retard Roll Assembly ........................................................................................ PL 13.9 Upper Feeder Assembly .................................................................................... PL 13.10 Document Tray ................................................................................................

5-53 5-54 5-55 5-56 5-57 5-58 5-59 5-60 5-61 5-62

Common Hardware Common Hardware ......................................................................................................... Part Number Index ..........................................................................................................

5-63 5-64

5-26 5-27 5-28 5-29 5-30 5-31

Electrical PL 8.1 AIOC PWB, LVPS, Power Switch........................................................................ PL 8.2 HVPS, Interlock Switch, Duplex PWB ................................................................. PL 8.3 Control Panel Accessory ..................................................................................... PL 8.4 Control Panel Component ...................................................................................

5-32 5-33 5-34 5-35

Cover PL 9.1 Front / Top Cover.................................................................................................


5-36

June, 2008 5-1

Parts Lists

Parts Lists

June, 2008 5-2


PL 1.1 IOT Motor Item 1 2 3 4 5 6

Part

Description

007K94880 120E22470 – – – –

IOT Motor (REP 1.1.1) Push Tie Gear Pulley (Not Spared) Cover (Not Spared) Belt (Not Spared) Traceability Label (Not Spared)


June, 2008 5-3

Parts Lists

PL 1.1

PL 2.1 Tray 1 Item 1 2 3 4

Part

Description

050K62940 – – –

Tray 1 Assembly Tray Stopper (Not Spared) Label (P/O Item 1) Tray 1 (P/O Item 1)

Parts Lists

PL 2.1

June, 2008 5-4


PL 2.2 Tray 1 Frame Accessory Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Part

Description

– 848K01660 007K97780 – – – 007K97790 807E19430 809E73520 – 807E19440 013E25920 121K40770 801K25580

Tray 1 Frame (P/O PL2.1 Item 1) No Paper Sensor Drive Gear Assembly Bracket (P/O Item 3) Gear (37T/23T) (P/O Item 3) Gear (41T/22T) (P/O Item 3) Link Gear Gear (61T) Link Spring Clutch Bracket (Not Spared) Gear (29T/29T) Bearing Tray 1 Feed Clutch (REP 2.2.1) Interlock Switch Frame Assembly


June, 2008 5-5

Parts Lists

PL 2.2

PL 2.3 Tray 1 Components (1 OF 2) Item

Part

Description

1 2 3

– – –

4 5 6 7 8 9 10 11 12 13 14

– – 013E25881 059K33051 – 059K32773 – – – – –

Tray (Not Spared) Tray Front Cover (Not Spared) Bottom Plate Assembly (Not Spared) Bottom Plate (P/O Item 3) Bottom Pad (P/O Item 3) Bearing Roll And Shaft Assembly Feed Shaft (P/O Item 7) Feed Roll (REP 2.3.1) Cover (Not Spared) End Guide (Not Spared) Pivot (Not Spared) Spring (Not Spared) Stopper (Not Spared)

Parts Lists

PL 2.3

June, 2008 5-6


PL 2.4 Tray 1 Components ( 2 OF 2) Item 1 2 3 4 5 6 7 8 9 10 11

Part

Description

– – – – – 019K07086 – – – 809E54170 –

Front Side Guide (Not Spared) Paper Guide (Not Spared) Rear Side Guide (Not Spared) Retard Shaft (Not Spared) Pad Spring (Not Spared) Retard Pad Label (Max) (Not Spared) Pinion Gear (Not Spared) Bottom Stopper (Not Spared) Stopper Spring Earth Plate (Not Spared)


June, 2008 5-7

Parts Lists

PL 2.4

PL 2.5 Tray 1 Frame Components Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Part

Description

– 110E11580 130E87090 120E29540 – – – – – – – – – –

Sensor Block (Not Spared) Tray 1 Interlock Switch Tray 1 Feed Sensor (REP 2.5.1) Actuator Feed Chute (Not Spared) Upper Baffle (Not Spared) Plate Spring (P/O Item 6) Shaft (P/O Item 6) Roll (P/O Item 6) Upper Baffle (P/O Item 6) Eliminator (Not Spared) Sensor Bracket (Not Spared) Feed Sensor Spring (Not Spared) Access Cover 1 (Not Spared)

Parts Lists

PL 2.5

June, 2008 5-8


PL 2.6 Tray 1 Frame Components (2 OF 2) Item 1 2 3 4 5 6 7 8 9 10 11 12 13

Part

Description

– – – 005E26740 006K25751 807E19460 059K48200 413W77559 809E54180 013E90840 013E32690 807E19450 –

Tray Spacer (Not Spared) Enclosure Plate (Not Spared) Earth Plate (Not Spared) Coupling Clutch Drive Feed Shaft Gear (21T) Take Away Roll Assembly Bearing Coupling Spring Bearing Coupling Bearing Gear (16T/29T) Sensor Wire Harness (Not Spared)


June, 2008 5-9

Parts Lists

PL 2.6

PL 2.7 No Paper Sensor Housing Item

Part

Description

1 2 3

120E23791 – 130E87090

4 5

– –

No Paper Actuator Sensor Housing (Not Spared) Tray 1 No Paper Sensor (REP 2.7.1) Bracket (Not Spared) Sensor Wire Harness (Not Spared)

Parts Lists

PL 2.7

June, 2008 5-10


PL 2.8 Registration Item 1

Part

Description

059K48250

Registration Roll Assembly (REP 2.8.1)


June, 2008 5-11

Parts Lists

PL 2.8

PL 2.9 Registration Component Item

Part

Description

1

–

2

–

3 4 5 6

– 130K71230 – –

7 8 9

– 121K39710 –

10

–

11

–

12 13 14 15 16 17 18

– – – – – 059K53230 –

Corotron Bracket (P/O PL2.8 Item 1) Registration Frame (P/O PL2.8 Item 1) Sensor Plate (P/O PL2.8 Item 1) Registration Sensor Assembly Wire Harness (P/O PL2.8 Item 1) Registration Press Spring (P/O PL2.8 Item 1) Ground Spring (P/O PL2.8 Item 1) Registration Clutch Assembly Press Level Arm (P/O PL2.8 Item 1) Corotron Press Spring (P/O PL2.8 Item 1) Transfer Corotron Spring (P/O PL2.8 Item 1) Ground Sleeve (P/O PL2.8 Item 1) Washer (P/O PL2.8 Item 1) Press Roll (P/O PL2.8 Item 1) Closing Roll (P/O PL2.8 Item 1) Bearing (P/O PL2.8 Item 1) Registration Roll Clamp (P/O PL2.8 Item 1)

Parts Lists

PL 2.9

June, 2008 5-12


PL 3.1 ROS Item 1 2 3 4 5

Part

Description

062K18161 – – – –

ROS Assembly (REP 3.1.1) Laser Housing (Not Spared) Label (Not Spared) ROS Wire Harness (Not Spared) Ground Harness (Not Spared)


June, 2008 5-13

Parts Lists

PL 3.1

PL 4.1 Drum Cartridge Item 1 2 3 4 5

Part

Description

101R00432 – – 106R01277 604K43851

Drum Cartridge (REP 4.1.1) Spring (P/O Item 5) CRU Block (P/O Item 5) Toner Bottle CRU Blocker Kit

Parts Lists

PL 4.1

June, 2008 5-14


PL 4.2 Toner Empty Sensor and Erase Lamp Item 1 2

Part

Description

130K71400 122K94091

Toner Empty Sensor (REP 4.2.1) Erase Lamp (REP 4.2.2)


June, 2008 5-15

Parts Lists

PL 4.2

PL 4.3 Transfer Item

Part

Description

1

–

2 3

125K93751 014K83123

Transfer Module (Not Spared) (REP 4.3.1) Transfer Corotron Housing Corotron Block Assembly

Parts Lists

PL 4.3

June, 2008 5-16


PL 4.4 Transfer Corotron Housing Component Item 1 2 3 4 5 6

Part

Description

125K93751 604K43810 – – – –

Transfer Corotron Housing Corotron Wire Kit (REP 4.4.1) Spring (P/O Item 2) Outboard Cover (Not Spared) Latch (Not Spared) Corotron Wire (P/O Item 2)


June, 2008 5-17

Parts Lists

PL 4.4

PL 5.1 Fuser Item

Part

Description

1 2

– 126K23581

–

126K24411

3 4 5 6 – 7 8

– – – 122E92530 122E92550 022E30121 022K74110

9

130K71361

Connector Cover (Not Spared) Fuser Assembly (220V) (REP 5.1.1) Fuser Assembly (110V) (REP 5.1.1) AC Fuser Harness (Not Spared) DC Fuser Harness (Not Spared) Baffle Clip (Not Spared) Fuser Lamp (220V) (REP 5.1.3) Fuser Lamp (110V) (REP 5.1.3) Fuser Roll (REP 5.1.4) Pressure Roll Assembly (REP 5.1.5) Temperature Control Sensor (REP 5.1.2)

Parts Lists

PL 5.1

June, 2008 5-18


PL 6.1 Exit Transport Item

Part

Description

1

059K48230

2

059K48240

3

–

Exit Transport Assembly (Simplex) (REP 6.1.1) Exit Transport Assembly (Duplex) (REP 6.1.2) Label (Not Spared)


June, 2008 5-19

Parts Lists

PL 6.1

PL 6.2 Exit Transport Component (Simplex) Item

Part

Description

1 2 3 4

– 059K43000 059E99331 –

5 6 7

809E76520 013E30050 –

8 9 10 11 12 13 14 15 16 17 18

– – – – – – 130E87090 – – – 604K43840

Lower Chute (P/O PL6.1 Item 1) Exit Roll Pinch Roll Pinch Roll Support (P/O PL6.1 Item 1) Pinch Spring Bearing Sensor Wire Harness (P/O PL6.1 Item 1) Bearing (P/O PL6.1 Item 1) Earth Plate (P/O PL6.1 Item 1) Gear (19T) (P/O PL6.1 Item 1) Gear Pulley (P/O PL6.1 Item 1) Cap (P/O PL6.1 Item 1) Sensor Support (P/O Item 18) Fuser Exit Sensor Actuator (P/O Item 18) Actuator Spring (P/O Item 18) Insulator (P/O Item 18) Exit Sensor Kit

Parts Lists

PL 6.2

June, 2008 5-20


PL 6.3 Exit Transport Component (Duplex) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Part

Description

– 059K43000 059E99331 – 809E76520 013E30050 – – – – – – 130E87090 – – – 127K51590 423W06555 – 604K43840

Lower Chute (Not Spared) Exit Roll Pinch Roll Pinch Roll Support (Not Spared) Pinch Spring Bearing Sensor Wire Harness (Not Spared) Bearing (Not Spared) Earth Plate (Not Spared) Gear Pulley Gear (24T) (Not Spared) Sensor Support (P/O Item 19) Fuser Exit Sensor Actuator (P/O Item 19) Actuator Spring (P/O Item 19) Motor Frame (Not Spared) Exit Motor Belt Insulator (P/O Item 20) Exit Sensor Kit


June, 2008 5-21

Parts Lists

PL 6.3

PL 7.1 Simplex Module Item 1

Part

Description

802K99450

Simplex Module (REP 7.1.1)

Parts Lists

PL 7.1

June, 2008 5-22


PL 7.2 Left Hand Cover Assembly Item

Part

Description

1 2

– –

3 4 5 6 7 8 9 10 11 12 13 14

– – – – – – – – – 604K43860 604K43870 –

Left Hand Cover (Not Spared) Left Hand Upper Chute (Not Spared) Left Hand Chute (Not Spared) Front Stopper (P/O Item 12) Pivot Retainer (P/O Item 12) Latch Handle (P/O Item 13) Latch (P/O Item 13) Latch Shaft (P/O Item 13) Main Baffle (Not Spared) Rear Stopper (P/O Item 12) Latch Spring (P/O Item 13) Left Hand Door Kit Left Hand Door Latch Kit Jam Clear Label (P/O Item 1)


June, 2008 5-23

Parts Lists

PL 7.2

PL 7.3 Duplex Module Component (1 OF 2) Item

Part

Description

1

802K97500

2 3 4 5

059E03090 – – –

6 7 8 9 10 11 12 13 14

– – 013E33260 – 023E26660 – – 604K43860 –

Left Hand Cover Assembly (REP 7.1.1) Pinch Roll Pinch Spring (P/O Item 1) Left Hand Chute (P/O Item 1) Left Hand Upper Chute (P/O Item 1) Front Stopper (P/O Item 1) Duplex Roll 1 (P/O Item 1) Bearing Pulley (P/O Item 1) Belt Pivot Retainer (P/O Item 13) Rear Stopper (P/O Item 13) Left Hand Door Kit Left Hand Cover (P/O Item 1)

Parts Lists

PL 7.3

June, 2008 5-24


PL 7.4 Duplex Module Component (2 OF 2) Item

Part

Description

1

–

2 3 4 5 6 7 8 9 10 11 12 13 14

– 809E76630 – 059E03650 – – – 013E33260 – 807E21180 006K86440 – 604K43870

Duplex Main Baffle (P/O PL7.3 Item 1) Duplex in Chute (P/O PL7.3 Item 1) Idler Spring Idler Shaft (P/O PL7.3 Item 1) Idler Roll Latch Spring (P/O Item 14) Latch Handle (P/O Item 14) Latch (P/O Item 14) Bearing Latch Shaft (P/O Item 14) Gear (18T) Duplex Roll 2 Label (Jam Clear) (Not Spared) Left Hand Door Latch Kit


June, 2008 5-25

Parts Lists

PL 7.4

PL 7.5 Bypass Tray Accessory Item

Part

Description

1 2 3 4 5

– – – – –

6

–

7

–

8 9 10 11 12 13

– – – – – –

14

–

15 16 17 18 19 20

807E17870 – – 121E20950 059K54730 –

21 22 23 24 25 26 27 28 29

– 059K48260 – 604K43820 022E29860 604K45750 604K45770 604K45780 604K45790

Bypass Feed Shaft (P/O Item 22) Bearing (P/O Item 22, Item 27) Idler Roll (P/O Item 22, Item 28) Idler Shaft (P/O Item 22, Item 28) Bypass Idler Spring (P/O Item 22, Item 24, Item 28) Drive Support Bracket (P/O Item 22, Item 26) Gear (42/30T) (P/O Item 22, Item 26) Shaft (P/O Item 22, Item 26) Idler Arm (P/O Item 22, Item 26) Gear (49T) (P/O Item 22, Item 26) Shaft (P/O Item 22, Item 26) Shaft (P/O Item 22, Item 26) Sector Gear Spring (P/O Item 22, Item 24, Item 26) Idler Arm Spring (P/O Item 22, Item 24, Item 26) Gear Pulley Sector Gear (P/O Item 22, Item 27) Cam (P/O Item 22, Item 27) Bypass Solenoid Bypass Feed Roll (REP 7.5.1) Feed Roll Cap (P/O Item 22, Item 29) Bypass Tray (P/O Item 22) Bypass Feeder Assembly Label (Not Spared) MSI Spring Kit Nudge Roller MSI Assembly No. 2 Repair Kit MSI Assembly No. 4 Repair Kit MSI Assembly No. 5 Repair Kit MSI Assembly No. 6 Repair Kit

Parts Lists

PL 7.5

June, 2008 5-26


PL 7.6 Bypass Tray Component Item

Part

Description

1 2 3

050K58051 – –

4 5 6 7

– – – –

8 9 10 11 12 13 14 15

– – – 019K08890 – 604K43830 604K45740 604K45760

Bypass Tray Assembly Bearing (P/O Item 15) Bypass Take Away Roll (P/O Item 15) Lower Baffle (P/O Item 15) Nudger Plate (P/O Item 14) Nudger Pad (P/O Item 13, Item 14) Nudger Spring (P/O Item 13, PL7.5 Item 29) Gear (18T) (P/O Item 15) Roll (Not Spared) Retard Spring (P/O PL7.5 Item 24) Retard Pad Assembly Pre Shingler Bracket (P/O Item 15) Bypass Retard Kit MSI Assembly No. 1 Repair Kit MSI Assembly No. 3 Repair Kit


June, 2008 5-27

Parts Lists

PL 7.6

PL 8.1 AIOC PWB, LVPS, Power Switch Item

Part

Description

1 2 3 4 5 6 7 8

110E11320 – – – – – – –

9 –

960K43421 960K44250

10 – – – 11 12 13

105E17391 105E17411 105E18010 105E18020 – – 960K28611

Power Switch Screw (With Washer) (Not Spared) Inlet Bracket (Not Spared) PWB Bracket (Not Spared) Inlet (Not Spared) CRUM ID Harness (Not Spared) Inlet Wire Harness (Not Spared) Billing Counter Harness (Not Spared) AIOC PWB (REP 8.1.1) AIOC/Network PWB ((DADF Only)) (REP 8.1.3) LVPS (220V) (REP 8.1.2) LVPS (110V) (REP 8.1.2) DADF LVPS (220V) (REP 8.1.2) DADF LVPS (110V) (REP 8.1.2) Choke Coil (Not Spared) Power Cord (Not Spared) Exit PWB

Parts Lists

PL 8.1

June, 2008 5-28


PL 8.2 HVPS, Interlock Switch, Duplex PWB Item

Part

Description

1 2 3 4

014K83141 105E17401 801K25570 –

5 6 7

– – –

8 9 10 11

– – – –

HV Contact Block HVPS (REP 8.2.1) Left Hand Interlock Switch Interlock Switch Wire Harness (Not Spared) Core (Not Spared) Earth Plate (Not Spared) Front Cover Interlock Switch (Not Spared) Earth Plate (Not Spared) Harness Block (Not Spared) Harness Block (Not Spared) Core Clip (Not Spared)


June, 2008 5-29

Parts Lists

PL 8.2

PL 8.3 Control Panel Accessory Item

Part

Description

1 2 3 4

– – 962K66150 802K97694

–

848K04904

5

896E58070

Support Bracket (Not Spared) Control Panel Cover (Not Spared) Control Panel Wire Harness Control Panel (ADF, DADF Only) (REP 8.3.1) Control Panel (110V, 220V) (REP 8.3.1) Label (WorkCentre 5020)

Parts Lists

PL 8.3

June, 2008 5-30


PL 8.4 Control Panel Component Item

Part

Description

1

–

2

960K32602

–

960K32783

–

960K38300

3 4

– –

Control Panel Panel Case (With Key) (P/O PL8.3 Item 4) UI Platen PWB Assembly (REP 8.4.1) UI PWB Assembly (ADF Only) (REP 8.4.1) UI PWB Assembly (DADF Only) (REP 8.4.1) Middle Panel (P/O PL8.3 Item 4) Label (P/O PL8.3 Item 4)


June, 2008 5-31

Parts Lists

PL 8.4

PL 9.1 Front / Top Cover Item

Part

Description

1 2 3 4

848E04480 848K17300 – –

5 6 7 8 9 10 11

– – – – 848E04511 801E04660 105E12210

Exit Cover Front Cover Assembly Front Left Cover (REP 9.1.2) Output Tray (Not Spared) (REP 9.1.1) Right Top Cover (Not Spared) Xerox Badge Plate (P/O Item 2) IIT Support Bracket (Not Spared) Duct (Not Spared) Front Cover Strap Static Eliminator

Parts Lists

PL 9.1

June, 2008 5-32


PL 9.2 Rear / Right Cover and NOHAD Fan Item

Part

Description

1

848E04501

2 3 4 5

848E04451 127K51632 053E93650 –

Rear Cover (Remove Data Plate and Place on New Rear Cover) (REP 9.2.1) Right Cover (REP 9.2.2) NOHAD Fan Ozone Filter Data Plate (Not Spared) (Remove Data Plate and Place on New Rear Cover)


June, 2008 5-33

Parts Lists

PL 9.2

PL 10.1 IIT Accessory Item 1 2 3 4 5 6 7 8

Part

Description

– – – – – – 604K47130 604K46500

IIT Right Bracket (Not Spared) IIT (Not Spared) Label (Not Spared) Platen Cover (P/O Item 8) Platen Cushion (P/O Item 8) Cap (Not Spared) Error Code Label Kit Platen Cover Kit (REP 10.1.1)

Parts Lists

PL 10.1

June, 2008 5-34


PL 10.2 IIT Component (1 OF 2) Item 1 2 3 4

Part

Description

848K07410 604K44330 – –

IIT Upper Cover (REP 10.2.1) Hinge Kit Blind Cover (Not Spared) Plate Spring (P/O Item 2)


June, 2008 5-35

Parts Lists

PL 10.2

PL 10.3 IIT Component (2 OF 2) Item 1 2 3 4 5 6 7

Part

Description

041K95870 – 962K59950 – 809E79910 809E79920 –

IIT Carriage (REP 10.3.1) IIT Under Cover (Not Spared) Flexible Print Cable (REP 10.3.2) Plate Spring (Not Spared) Cable Spring (Rear) Cable Spring (Front) Pulley (Not Spared)

Parts Lists

PL 10.3

June, 2008 5-36


PL 10.4 IIT Upper Cover Cover Component Item 1 2 3 4 5 6 7

Part

Description

802K71882 090E02380 090E91720 815E08650 815E42250 – –

IIT Upper Cover Small Platen Glass Platen Glass White Referance Sheet (Black and White) Label (Not Spared) Label (Not Spared)


June, 2008 5-37

Parts Lists

PL 10.4

PL 10.5 IIT Under Cover Component Item 1 2 3 4 5 6 7 8

Part

Description

– 801K30780 – 801E05970 – – – 110E11551

Under Cover (P/O PL10.3 Item 2) Front Rail Rear Frame (P/O PL10.3 Item 2) Rear Rail Hinge Sleeve (P/O PL10.3 Item 2) Pulley (P/O PL10.3 Item 2) Cable Bracket (P/O PL10.3 Item 2) Platen Open Switch

Parts Lists

PL 10.5

June, 2008 5-38


PL 10.6 IIT Carriage Component Item

Part

Description

1 2

– –

3

–

4 5

– –

6

–

7

–

8

–

9 10

– –

11

–

12 13 14

– – –

15

–

16 17 18 19 20 21 22 23 24

868E12730 – – 121K41690 122E92570 127K57140 – – –

Center Plate (P/O PL10.3 Item 1) Front Mirror Frame (P/O PL10.3 Item 1) Rear Mirror Frame (P/O PL10.3 Item 1) Mirror Clip (P/O PL10.3 Item 1) Mirror 2 Damper (P/O PL10.3 Item 1) Mirror 3 Damper (P/O PL10.3 Item 1) Rear Mirror Stopper (P/O PL10.3 Item 1) Rear Mirror Stopper (P/O PL10.3 Item 1) Mirror Weight (P/O PL10.3 Item 1) Front Lamp Holder (P/O PL10.3 Item 1) Rear Lamp Holder (P/O PL10.3 Item 1) Sensor Plate (P/O PL10.3 Item 1) Reflector (P/O PL10.3 Item 1) IIT Carriage Cover (P/O PL10.3 Item 1) Reflector Cover (P/O PL10.3 Item 1) Sensor Plate Spring Rail Contact (P/O PL10.3 Item 1) Mirror Weight (P/O PL10.3 Item 1) Carriage Sensor Exposure Lamp (REP 10.6.1) Carriage Motor Mirror 1 (P/O PL10.3 Item 1) Mirror 2 (P/O PL10.3 Item 1) Mirror 3 (P/O PL10.3 Item 1)


June, 2008 5-39

Parts Lists

PL 10.6

PL 10.7 Center Plate Component Item

Part

Description

1 2

– –

3 4 5 6 7 8 9 10 11 12

– – – – – – – – – –

13 14 15

– – –

16

–

17 18 19 20 21

– 140E88751 – – –

22

–

23

–

Len Assembly (P/O PL10.3 Item 1) Drum and Carriage Cable (P/O PL10.3 Item 1) (ACO) (REP 10.7.1) Pulley (P/O PL10.3 Item 1) Mirror Clip (P/O PL10.3 Item 1) Mirror Frame (P/O PL10.3 Item 1) Side Slider (P/O PL10.3 Item 1) Rail Contact (P/O PL10.3 Item 1) Rail Slider (P/O PL10.3 Item 1) Front Slider (P/O PL10.3 Item 1) Gear (P/O PL10.3 Item 1) Gear (P/O PL10.3 Item 1) Mirror Frame Bracket (P/O PL10.3 Item 1) CCD Support (P/O PL10.3 Item 1) Lock Plate (P/O PL10.3 Item 1) Inverter PWB Bracket 1 (P/O PL10.3 Item 1) Inverter PWB Bracket 2 (Not Spared) Bracket (P/O PL10.3 Item 1) Inverter PWB (REP 10.7.2) Mirror 4 (P/O PL10.3 Item 1) Wire Harness (P/O PL10.3 Item 1) Carriage Cable (Black) (Not Spared) Carriage Cable (Silver) (P/O PL10.3 Item 1) Drum (P/O PL10.3 Item 1)

Parts Lists

PL 10.7

June, 2008 5-40


PL 11.1 Single Tray Module Item 1 2 3 4

Part

Description

050K57701 – 896E41981 896E42140

Tray 2 (REP 11.1.1) Single Tray Frame (Not Spared) End Guide Label Install Label


June, 2008 5-41

Parts Lists

PL 11.1

PL 11.2 Tray 2 Component (1 OF 3) Item

Part

Description

1 2 3

– – –

4

–

5 6 7

– – –

8

–

9 10

– –

End Guide (P/O PL11.1 Item 1) Tray (P/O PL11.1 Item 1) Tray Front Cover (P/O PL11.1 Item 1) End Guide Spring (P/O PL11.1 Item 1) Earth Plate (P/O PL11.1 Item 1) Cover (P/O PL11.1 Item 1) End Guide Lock (P/O PL11.1 Item 1) Mini Bottom Plate (P/O PL11.1 Item 1) Spring (Side) (P/O PL11.1 Item 1) Spring (Center) (P/O PL11.1 Item 1)

Parts Lists

PL 11.2

June, 2008 5-42


PL 11.3 Tray 2 Component (2 OF 3) Item 1 2 3 4 5 6 7 8

Part

Description

038K89761 038K89821 – – – – – –

Front Side Guide Rear Side Guide Tapping Screw (P/O PL11.1 Item 1) Rack (P/O PL11.1 Item 1) Latch (P/O PL11.1 Item 1) Pinion (P/O PL11.1 Item 1) Latch Spring (P/O PL11.1 Item 1) Rack (P/O PL11.1 Item 1)


June, 2008 5-43

Parts Lists

PL 11.3

PL 11.4 Tray 2 Component (3 OF 3) Item

Part

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

059K48430 – 059K48660 – 013E90840 – – – 003K15530 – – 019K09250 – – – – –

18 19 20 21 22

– – – 003K15540 –

Tray 2 Feeder Assembly Feed Chute (P/O Item 1) Tray 2 Feed Roll (REP 11.4.1) Feed Shaft (P/O Item 1) Bearing Earth Spring (P/O Item 1) Core Roll (P/O Item 1) Holder Seal (P/O Item 1) Front Latch Assembly Holder Arm (Not Spared) Spring (Not Spared) Retard Roll Housing Retard Housing (P/O Item 12) Retard Holder (P/O Item 12) Retard Shaft (P/O Item 12) Friction Clutch (P/O Item 12) Tray 2 Retard Roll (P/O Item 12) (REP 11.4.2) Retard Plate (P/O Item 12) Retard Spring (P/O PL11.1 Item 1) Latch Cover (P/O PL11.1 Item 1) Rear Latch Assembly Spring (P/O PL11.1 Item 1)

Parts Lists

PL 11.4

June, 2008 5-44


PL 11.5 Single Tray Frame Component (1 OF 2) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Part

Description

– – – – 110E11580 – 130E87090 120E28091 055K31090 – – – – – 960K28562 – – – – 809E74030 – –

STM Rear Cover (Not Spared) STM Wire Harness (Not Spared) Earth Cushion (Not Spared) Earth Plate (Not Spared) STM Interlock Switch Sensor Block (Not Spared) STM Feed Sensor (REP 11.5.1) Feed Sensor Actuator STM Baffle Assembly Roll (P/O Item 9) Plate Spring (P/O Item 9) Shaft (P/O Item 9) Baffle (P/O Item 9) Eliminator (P/O Item 9) STM PWB (REP 11.5.2) Guide Spring (Not Spared) Arm Guide (Not Spared) Tray Stopper (Not Spared) Upper Feed Chute (Not Spared) Feed Sensor Spring Access Cover 2 (Not Spared) Sensor Wire Harness (Not Spared)


June, 2008 5-45

Parts Lists

PL 11.5

PL 11.6 Single Tray Frame Component (2 OF 2) Item 1 2 3 4 5 – 6 7 8 9 10 11 12 13 14

Part

Description

– 807E18360 059K48440 848K02140 013E32180 013E90840 807E18410 068K53590 127K52180 807E18380 807E18390 807E18400 – – –

Harness Holder (Not Spared) Gear (Helical 21T) Take Away Roll No Paper Sensor Assembly Bearing (220v) Bearing (110V) Gear (Helical 20T/36T) STM Feed Clutch (REP 11.6.1) STM Feed Motor (REP 11.6.2) Gear (Helical 51T/15T) Gear (Helical 40T/18T) Gear (Helical 37T) Tray Rear Stopper (Not Spared) Earth Plate (Not Spared) Bearing (Not Spared)

Parts Lists

PL 11.6

June, 2008 5-46


PL 11.7 STM No Paper Sensor Item

Part

Description

1

–

2 3 4

120E29630 130E87090 –

Actuator Support (P/O PL11.6 Item 4) No Paper Sensor Actuator No Paper Sensor (REP 11.7.1) Sensor Housing (P/O PL11.6 Item 4)


June, 2008 5-47

Parts Lists

PL 11.7

PL 12.1 Stand Component Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Part

Description

– 017K93121 017K93132 017E12010 121E93360 – – – – 017E98760 – – – – –

Stand (Not Spared) Caster Caster (With Stopper) Locator Peg Catch Magnet Front Door (Not Spared) Stand Hinge (Not Spared) Door Hinge (Not Spared) Guide (Not Spared) Support Screw (Not Spared) Foot Cover (Not Spared) Adjuster Foot (Not Spared) Front Foot (Not Spared) Foot Bracket (Not Spared)

Parts Lists

PL 12.1

June, 2008 5-48


PL 13.1 ADF/DADF Accessory Item

Part

Description

1

022K74860

2 3 4

004E17510 – –

ADF Assembly (with Item 2) (REP 13.1.1, ADJ 13.1.1) Platen Cushion (REP 13.1.2) Screw (Not Spared) Push Tie (Not Spared)


June, 2008 5-49

Parts Lists

PL 13.1

PL 13.2 Component, Cover Item

Part

Description

1 –

022K75730 059K55590

2 3 4

– – 050K60800

– 5 6 7 8

050K63270 – – – –

DADF Scanner Assembly ADF Scanner Assembly (REP 13.2.2) Rear Cover (Not Spared) Front Cover (Not Spared) ADF Document Tray Assembly (REP 13.2.1) DADF Document Tray Assembly Front Blind Cover (Not Spared) Rear Blind Cover (Not Spared) Support Bracket (Not Spared) Base Cover Assembly (Not Spared)

Parts Lists

PL 13.2

June, 2008 5-50


PL 13.3 Base Cover Component Item

Part

Description

1 – 2 3 4 5 6 7 8 9 10 11

960K42980 960K32370 – 962K60840 – – – 604K44340 059K55600 016E93560 – 003K86760

12

003K13560

–

003K15950

13 14 15

– 604K44350 –

16 17 18 19 20 21 22

– – – – – – 059K55860

DADF PWB (REP 13.3.4) ADF PWB (REP 13.3.1) Bracket (Not Spared) ADF Cable Exit Chute (Not Spared) Stamp Cover (Not Spared) Lead In Pinch Roller (Not Spared) Spring Plate Kit (5/Kit) Exit Pinch Roller Bush Base Cover (Not Spared) Right Counter Balance (REP 13.3.3) Left Counter Balance (ADF Only) (REP 13.3.2) Left Counter Balance (DADF Only) (REP 13.3.2) Pinch Roll Bracket (Not Spared) Read Out Pinch Roller Kit (5/Kit) Spring Plate (Read Out) (Not Spared) Interlock Magnet (Not Spared) Bottom Plate (Not Spared) ADF Earth Spring (Not Spared) Film Cover (Not Spared) Film Cover (Not Spared) Earth Wire (Not Spared) Pinch Roll Assembly


June, 2008 5-51

Parts Lists

PL 13.3

PL 13.4 Feeder Component Item

Part

Description

1

–

2 3

– –

4 5

– –

Upper Feeder Assembly (P/O PL13.2 Item 1) Top Cover (Not Spared) ADF Lower Feeder Assembly (P/O PL13.2 Item 1) Pin (P/O PL13.2 Item 1) Stopper Belt (P/O PL13.2 Item 1)

Parts Lists

PL 13.4

June, 2008 5-52


PL 13.5 Lower Feeder Component Item

Part

Description

1

–

2 3 4 5 6 7 8 9

– – – – – – – –

10 11

– –

12

–

13 14 15 16 17 18

– – – – – –

19

–

20

–

21

–

22

–

23

–

24 – 25 26

127K58700 127K57120 – –

Document Drive Motor (P/O Item 24) (ADF Only) Motor Plate (P/O Item 24) Gear (40T-21T) (P/O Item 24) Bracket (P/O Item 24) Gear (30T-21T) (P/O Item 24) Gear (16T-35T) (P/O Item 24) Bearing (P/O PL13.4 Item 3) Gear (28T) (P/O PL13.4 Item 3) Gear (39T-26T) (P/O PL13.4 Item 3) Bush (P/O PL13.4 Item 3) Gear (28T-18T) (P/O PL13.4 Item 3) Gear (22T-16T) (P/O PL13.4 Item 3) Gear (16T) (P/O PL13.4 Item 3) Bearing (P/O PL13.4 Item 3) Gear (17T) (P/O PL13.4 Item 3) Gear (24T) (P/O PL13.4 Item 3) Gear (19T) (P/O PL13.4 Item 3) Gear (51T-30T) (P/O PL13.4 Item 3) Gear (52T-21T) (P/O PL13.4 Item 3) Registration Clutch (P/O PL13.4 Item 3) Eject Torque Limiter (P/O PL13.4 Item 3) Cable Fence (P/O PL13.4 Item 3) (DADF Only) Exit/Invert Clutch (P/O PL13.4 Item 3) (DADF Only) Motor Assembly (DADF Only) Motor Assembly (ADF Only) Gear Plate (P/O PL13.4 Item 3) Gear (21T-18T) (P/O Item 24) (DADF Only)


June, 2008 5-53

Parts Lists

PL 13.5

PL 13.6 Retard Roll Component Item

Part

Description

1 2 3 4

– – – –

5 6 7 8 9 10

– – – – – –

Retard Roll Assembly (Not Spared) Registration Mylar (P/O Item 1) Retard Mylar (P/O Item 1) Base Lower Feeder Assembly (Not Spared) Arm Pin (Not Spared) Shaft (Not Spared) Paper Guide Plate (Not Spared) Bearing (Oil Less) (Not Spared) Gear (15T) (Not Spared) Roll Assembly (P/O Item 1)

Parts Lists

PL 13.6

June, 2008 5-54


PL 13.7 Lower Feeder Assembly Item

Part

Description

1 2 3 4 5 6 7 8 9 10 11 12 13

– – – – 059K55620 059K55630 – 059K55610 – – – – –

14

–

15

–

16

–

17

–

18

–

19

–

20

–

21

–

22

–

Bottom Chute (Not Spared) White Sheet (Not Spared) Bottom Sheet (Not Spared) Base Frame (Not Spared) Lead In Roll Lead Out Roll Bearing (Not Spared) Registration Roll Front Bracket (Not Spared) Rear Bracket (Not Spared) ADF Invert Gate (Not Spared) Seal (Not Spared) Exit/Invert Sensor (Not Spared) (DADF Only) Sensor Holding Bracket (Not Spared) (DADF Only) Registration Sensor (Not Spared) (DADF Only) Registration Sensor Actuator (Not Spared) (DADF Only) Registratin Sensor Spring (Not Spared) (DADF Only) Exit/Invert Sensor Spring (Not Spared) (DADF Only) Exit/Invert Sensor Actuator (Not Spared) (DADF Only) Exit/Invert Solenoid Bracket (Not Spared) (DADF Only) Solenoid Bracket (Not Spared) (DADF Only) Exit/Invert Solenoid (Not Spared) (DADF Only)


June, 2008 5-55

Parts Lists

PL 13.7

PL 13.8 Retard Roll Assembly Item

Part

Description

1 2 3 4 5 6 7 8 9 10 11 12 13

– – – – – 809E56440 – – – – – – –

14

–

15 16 17 18 19

– – – 059E04080 –

Plate (Not Spared) Gear (18T) (Not Spared) Bearing (Not Spared) Exit Roller (Not Spared) Rear Exit Arm (Not Spared) Spring (Coil) Front Exit Arm (Not Spared) Gear (18T) (Not Spared) Exit Roll Drive Shaft (Not Spared) Spring Plate (Not Spared) Spring Plate (Not Spared) Plate (Not Spared) Retard Roll Chute (Not Spared) (REP 13.8.1) Retard Roll Drive Shaft (Not Spared) Bush (Not Spared) Bush (Not Spared) Spring (Coil) (Not Spared) Retard Roll (REP 13.8.1) Gear (20T) (Not Spared)

Parts Lists

PL 13.8

June, 2008 5-56


PL 13.9 Upper Feeder Assembly Item

Part

Description

1 2 3 4 5

– – – – –

6 7 8 9

– – – –

10 11 12 13 14

– – – – –

15

–

16 17 18 19

– – – –

20

–

21

–

22 23 24

059K55640 – –

25

–

26 27 28 29 30 31 32 33 34 35 36 37

– 121K41670 – 059E99690 – 110E11570 121K41650 121K41600 – – – 121K41660

Lock Lever (P/O PL13.4 Item 1) Spring (P/O PL13.4 Item 1) Main Shaft (P/O Item 22) Bearing (P/O Item 22) Pickup Roll (P/O Item 22) (REP 13.9.1) Pickup Roll Shaft (P/O Item 22) Housing (P/O Item 22) Gear (18T-22T) (P/O Item 22) Feed Roll (P/O Item 22) (REP 13.9.1) Gear (22T) (P/O Item 22) Plate (P/O PL13.4 Item 1) Spring Box (P/O PL13.4 Item 1) Spring (Coil) (P/O PL13.4 Item 1) Spring Housing (P/O PL13.4 Item 1) Front Lock Arm (P/O PL13.4 Item 1) Top Frame (P/O PL13.4 Item 1) Rear Lock Arm (P/O PL13.4 Item 1) Sensor Holder (P/O Item 32) Document Set Sensor Actuator (P/O Item 32) Document Feeder Width Sensor Actuator (P/O Item 32) Document Feeder Width Sensor, Document Set Sensor (P/O Item 32) Feeder Assembly Sensor Holder (P/O Item 37) Document Feed Sensor (P/O Item 37) Document Feed Sensor Actuator (P/O Item 37) Spring (P/O Item 37) Clutch (One Way) Shaft (P/O PL13.4 Item 1) Registration Pinch Roller Plate (P/O PL13.4 Item 1) DADF/ADF Top Cover Switch Document Set Sensor Assembly Document Feed Clutch Gear (20T) (P/O PL13.4 Item 1) Adjust Plate (P/O PL13.4 Item 1) Spring (P/O PL13.4 Item 1) Read Sensor Assembly


June, 2008 5-57

Parts Lists

PL 13.9

PL 13.10 Document Tray Item

Part

Description

1 2

– –

3

–

4

–

5 6 7 8

– – – –

9

–

10 11

– –

12

–

13

–

Earth Plate (P/O PL13.2 Item 4) Front Side Guide (P/O PL13.2 Item 4) Rear Side Guide (P/O PL13.2 Item 4) Width Sensor Actuator (P/O PL13.2 Item 4) Eliminator (P/O PL13.2 Item 4) Pinion Gear (P/O PL13.2 Item 4) Pinion Spring (P/O PL13.2 Item 4) Lower Document Tray (P/O PL13.2 Item 4) Document Tray Width Sensor 1, Document Tray Width Sensor 2 (P/O PL13.2 Item 4) Actuator (P/O PL13.2 Item 4) Document Tray Length Sensor 1, Document Tray Length Sensor 2 (P/O PL13.2 Item 4) Upper Document Tray (P/O PL13.2 Item 4) Wire Harness (P/O PL13.2 Item 4)

Parts Lists

PL 13.10

June, 2008 5-58


Common Hardware Item

Part

Description

AA AB AC AD AE AF AG AH AJ AK AL AM AN AP AQ AR AS AT AU AV AW AX AY AZ BA BB BC BD BE BF

102W37178 102W38278 112W27898 113W20878 113W21478 113W27688 114W27678 114W27878 153W16088 153W16288 153W17688 153W17888 153W18088 153W18288 153W18488 153W27678 153W27878 153W28078 158W27678 158W27878 252W27450 354W15278 354W18278 354W19278 354W21278 354W24278 354W27254 354W27278 158W36878 158W36078

Countersunk Head Screw (M4x25) Countersunk Head Screw (M4x45) Pan Head Screw (M3x8) Screw (M3x8) Screw (M3x14) Pan Head Screw (M3x6) Bind Head Tapping Screw (M3x6) Bind Head Tapping Screw (M3x8) Tapping Screw (M4x10) Tapping Screw (4Mx12) Tapping Screw (3Mx6) Tapping Screw (3Mx8) Tapping Screw (3Mx10) Tapping Screw (3Mx12) Tapping Screw (3Mx14) Bind Head Tapping Screw (M3x6) Bind Head Tapping Screw (M3x8) Bind Head Tapping Screw (M3x10) Screw (M3x6) Screw (M3x8) Nylon Washer (6) E-Clip E-Clip E-Clip E-Clip E-Clip KL-Clip E-Clip Screw (M4x8) Screw (M4x10)


June, 2008 5-59

Parts Lists

Common Hardware

Part Number Index

Table 1 Part Number Index Table 1 Part Number Index

Part Number

Part List

038K89761

PL 11.3

Part Number

Part List

038K89821

PL 11.3

003K13560

PL 13.3

041K95870

PL 10.3

003K15530

PL 11.4

050K57701

PL 11.1

003K15540

PL 11.4

050K58051

PL 7.6

003K15950

PL 13.3

050K60800

PL 13.2

003K86760

PL 13.3

050K62940

PL 2.1

004E17510

PL 13.1

050K63270

PL 13.2

005E26740

PL 2.6

053E93650

PL 9.2

006K25751

PL 2.6

055K31090

PL 11.5

006K86440

PL 7.4

059E03090

PL 7.3

007K94880

PL 1.1

059E03650

PL 7.4

007K97780

PL 2.2

059E04080

PL 13.8

007K97790

PL 2.2

059K32773

PL 2.3

013E25881

PL 2.3

059K33051

PL 2.3

013E25920

PL 2.2

059K43000

PL 6.2

013E30050

PL 6.2

059K43000

PL 6.3

013E30050

PL 6.3

059K48200

PL 2.6

013E32180

PL 11.6

059K48230

PL 6.1

013E32690

PL 2.6

059K48240

PL 6.1

013E33260

PL 7.3

059K48250

PL 2.8

013E33260

PL 7.4

059K48260

PL 7.5

013E90840

PL 11.4

059K48430

PL 11.4

013E90840

PL 2.6

059K48440

PL 11.6

013E90840

PL 11.6

059K48660

PL 11.4

014K83123

PL 4.3

059K53230

PL 2.9

014K83141

PL 8.2

059K54730

PL 7.5

016E93560

PL 13.3

059K55590

PL 13.2

017E12010

PL 12.1

059K55600

PL 13.3

017K93121

PL 12.1

059K55610

PL 13.7

017K93132

PL 12.1

059K55620

PL 13.7

017E98760

PL 12.1

059K55630

PL 13.7

019K07086

PL 2.4

059K55640

PL 13.9

019K08890

PL 7.6

059K55860

PL 13.3

019K09250

PL 11.4

059E99331

PL 6.2

022E29860

PL 7.5

059E99331

PL 6.3

022E30121

PL 5.1

059E99690

PL 13.9

022K74110

PL 5.1

062K18161

PL 3.1

022K74860

PL 13.1

068K53590

PL 11.6

022K75730

PL 13.2

090E02380

PL 10.4

023E26660

PL 7.3

090E91720

PL 10.4

Parts Lists

Part Number Index

June, 2008 5-60


Table 1 Part Number Index


Part Number

Part List

Part Number

Part List

101R00432

PL 4.1

130K71230

PL 2.9

105E12210

PL 9.1

130K71361

PL 5.1

105E17391

PL 8.1

130K71400

PL 4.2

105E17401

PL 8.2

130E87090

PL 11.5

105E17411

PL 8.1

130E87090

PL 11.7

105E18010

PL 8.1

130E87090

PL 6.3

105E18020

PL 8.1

130E87090

PL 6.2

106R01277

PL 4.1

130E87090

PL 2.7

110E11320

PL 8.1

130E87090

PL 2.5

110E11551

PL 10.5

140E88751

PL 10.7

110E11570

PL 13.9

413W77559

PL 2.6

110E11580

PL 11.5

423W06555

PL 6.3

110E11580

PL 2.5

604K43810

PL 4.4

120E22470

PL 1.1

604K43820

PL 7.5

120E23791

PL 2.7

604K43830

PL 7.6

120E28091

PL 11.5

604K43840

PL 6.2

120E29540

PL 2.5

604K43840

PL 6.3

120E29630

PL 11.7

604K43851

PL 4.1

121E20950

PL 7.5

604K43860

PL 7.2

121K39710

PL 2.9

604K43860

PL 7.3

121K40770

PL 2.2

604K43870

PL 7.2

121K41600

PL 13.9

604K43870

PL 7.4

121K41650

PL 13.9

604K44330

PL 10.2

121K41660

PL 13.9

604K44340

PL 13.3

121K41670

PL 13.9

604K44350

PL 13.3

121K41690

PL 10.6

604K45740

PL 7.6

121E93360

PL 12.1

604K45750

PL 7.5

122E92530

PL 5.1

604K45760

PL 7.6

122E92550

PL 5.1

604K45770

PL 7.5

122E92570

PL 10.6

604K45780

PL 7.5

122K94091

PL 4.2

604K45790

PL 7.5

125K93751

PL 4.3

604K46500

PL 10.1

125K93751

PL 4.4

604K47130

PL 10.1

126K23581

PL 5.1

801E04660

PL 9.1

126K24411

PL 5.1

801E05970

PL 10.5

127K51590

PL 6.3

801K25570

PL 8.2

127K51632

PL 9.2

801K25580

PL 2.2

127K52180

PL 11.6

801K30780

PL 10.5

127K57120

PL 13.5

802K71882

PL 10.4

127K57140

PL 10.6

802K97500

PL 7.3

127K58700

PL 13.5

802K97694

PL 8.3


June, 2008 5-61

Parts Lists

Part Number Index



Part Number

Part List

Part Number

Part List

802K99450

PL 7.1

960K32783

PL 8.4

807E17870

PL 7.5

960K38300

PL 8.4

807E18360

PL 11.6

960K42980

PL 13.3

807E18380

PL 11.6

960K43421

PL 8.1

807E18390

PL 11.6

960K44250

PL 8.1

807E18400

PL 11.6

962K59950

PL 10.3

807E18410

PL 11.6

962K60840

PL 13.3

807E19430

PL 2.2

962K66150

PL 8.3

807E19440

PL 2.2

807E19450

PL 2.6

807E19460

PL 2.6

807E21180

PL 7.4

809E54170

PL 2.4

809E54180

PL 2.6

809E56440

PL 13.8

809E73520

PL 2.2

809E74030

PL 11.5

809E76520

PL 6.2

809E76520

PL 6.3

809E76630

PL 7.4

809E79910

PL 10.3

809E79920

PL 10.3

815E08650

PL 10.4

815E42250

PL 10.4

848K01660

PL 2.2

848K02140

PL 11.6

848E04451

PL 9.2

848E04480

PL 9.1

848E04501

PL 9.2

848E04511

PL 9.1

848K04904

PL 8.3

848K07410

PL 10.2

848K17300

PL 9.1

868E12730

PL 10.6

896E41981

PL 11.1

896E42140

PL 11.1

896E58070

PL 8.3

960K28562

PL 11.5

960K28611

PL 8.1

960K32370

PL 13.3

960K32602

PL 8.4

Parts Lists

Part Number Index

June, 2008 5-62


6 General Procedures Diagnostics Diagnostic Mode ............................................................................................................. Basic Operations of the Diagnostic Mode ....................................................................... IOT Diagnostics...............................................................................................................

6-3 6-4 6-7

General Procedures GP1 Serial Number Locations......................................................................................... GP 2 Viewing the Six Digit Error Code............................................................................

6-43 6-43

General Information Specifications .................................................................................................................. Tools ............................................................................................................................... Consumables .................................................................................................................. Glossary of Terms...........................................................................................................


6-45 6-52 6-52 6-53

June, 2008 6-1

General Procedures

General Procedures

June, 2008 6-2


Diagnostic Mode This mode is used by service engineers to solve problems in the field and is intended to identify the fault areas in terms of replaceable components. In the Diagnostic Mode, the following diagnostic functions can be run from the Control Panel: Function

Parts Diagnostics

Program Function

NVM Check and Change of Settings


Overview

Input Diagnostics

This can be used to check the status of the various sensors in the engine, IIT, and Trays. Refer to Input Diagnostics for the sensors that can be checked and their Chain Function Codes.

Output Diagnostics

This can be used to operate the various motors, solenoids and clutches in the engine, IIT, and Trays. Refer to Output Diagnostics for the components that can be operated and their Chain Function Codes.

Initialization

This can be used to initialize the NVM, Counters, and Error Histories. Refer to Program Function for the items that can be initialized.

Test Print

This can be used to generate an independent test print from the MCU or through the Controller. Refer to Program Function.

Check

This can be used to check the total print counter, serial/product number, SW version, Error Histories, etc. Refer to Program Function.

Checking the NVM value and changing the settings

This is used to check and change the values of the various parameters in NVM.

June, 2008 6-3

General Procedures

Diagnostic Mode

Basic Operations of the Diagnostic Mode

Once in the Diagnostic Mode, "C_ " (Chain Code input screen) is shown on the display. The "_" is blinking.

C _ How to Exit the Diagnostic Mode Switch the machine OFF and then ON again.

How to Input the Chain and Function (WC 5016, 5020 w/Platen, ADF)

Display: Displays the menus and their results.

The following shows the Chain and Function input method in the Diagnostic Mode.

Keypad: Inputs Chain Function Codes.

A Chain/Function Code must be input as 2 digits. If the Chain/Function Code is "1," it must be input as "01." Any input value that goes beyond the 2nd digit will be ignored.

[Start] button: Displays the Diagnostics Menu. [Stop] button: Pauses/Stops the diagnostic.

To clear the Chain/Function Code that was input, press the "C" button. Both digits will be cleared, and you will be returned to the Code input screen. When inputting the Function Code, pressing the [Start] button after inputting a Function Code that is out of the specified range will transfer you to the initial screen of Function input.

How to Enter the Diagnostic Mode

Enter the Diagnostic Mode and check that the "C_ " (Chain Code input screen) is shown on the display. The "_" should be blinking.

There are 2 ways to enter the diagnostic mode depending on the model of the IOT. The procedure below entitled WC 5016, 5020 (with platen or ADF) Entering the Diagnostic Mode is for IOT models with a platen, or with an ADF. The procedure following entitled WC 5020 is for IOT models with a DADF.

C _

WC 5016, 5020 (with Platen or ADF) Entering the Diagnostic Mode Press and hold down the [0] button on the keypad for 4 seconds or longer, and then press (and quickly release) the [Start] button while still keeping the [0] button pressed.

Use the keypad to enter the 2-digit Chain Code. The first number will appear in the first digit space, and the "_" will move to the right.

C 1 _ General Procedures

June, 2008 6-4


Input the next number, and it will appear in the second digit space.

Once in the Diagnostic Mode, "C_ " (Chain Code input screen) is shown on the display. The "_" is blinking.

C 1 2 Pressing the [Start] button will show the "F_ " (Function Code input screen) on the display. An "F" and the blinking "_" are shown on the Function Code input screen.

How to Exit the Diagnostic Mode Switch the machine OFF and then ON again.

How to Input the Chain and Link (WC 5020 w/DADF)

F _

The following shows the Chain and Link input method in the Diagnostic Mode. A Chain/Link Code can be up to 3 digits. If the Chain/Function Code is "1," it must be input as "1." Do necessary to “0” fill. Any input value that goes beyond the 3rd digits will be ignored.

Use the keypad to enter the 2-digit Function Code.

To clear the Chain/Link Code that was input, press the "AC" button. Both digits will be cleared, and you will be returned to the Chain Code input screen. When inputting the Link Code, pressing the [Start] button after inputting a Link Code that is out of the specified range will transfer you to the initial screen of Link input.

F 2 _

Enter the Diagnostic Mode and check that the "C_ " (Chain Code input screen) is shown on the display. The "_" should be blinking. Pressing the [Start] button will then run the specified Diagnostic Code.

F 2 3 WC 5020 Entering the Diagnostic Mode Press and hold down the [0] button on the keypad for 4 seconds or longer, and then press (and quickly release) the [Start] button while still keeping the [0] button pressed.

Use the keypad to enter the Chain Code. The first number will appear in the right hand digit space, and the "_" will move to the left and the “C” will disappear.

Enter 6, 7, 8, and 9 then press the Start button.


June, 2008 6-5

General Procedures

Input the next number, and it will appear in the right hand digit space.

Input the next number and it will appear in the right hand digit space.


Pressing the [Start] button will then run the specified Diagnostic Code. NOTE: If in NVM, the value of that NVM location will flash waiting for a new input. After inputing a new NVM code press the START button and the Link Code input screen will appear on the display waiting for a new Lind Code.

How to Interrupt a Diagnostic Press the [Stop] button when the diagnostic is still running. Stopping a diagnostic that is running will return you to the Link Code input screen. Pressing the [Start] button will show the "L_ " (Link Code input screen) on the display. An "L" and the blinking "_" are shown on the Link Code input screen.

Pressing the [AC] button will return you to the Chain Code input screen (“C_”).

Use the keypad to enter the Link Code first digit.


General Procedures

June, 2008 6-6


Input Component Control Codes

IOT Diagnostics Input Diagnostics The Input Diagnostics can be used to check the status of the various sensors in the engine, IIT, and Trays. For Platen and ADF model machines; Pressing the [Stop] button will stop the operation of the component and return you to the Function Code input screen. For DADF model machines; Pressing the [Stop] button will stop the operation of the component and return to the Link Code inpit screen.

Chain

Func or Link

Sub

Contents of Data

Meaning

05

33

ADF

Document Tray Width Sensor 2

L: No document H: Document present

05

34

ADF

Document Tray Length Sensor 1


05

35

ADF



05

36

ADF

Document Feed Sensor


07

07

TRAY

Tray1 No Paper Sensor

L: Paper present H: No paper

07

08

TRAY

STM No Paper Sensor

L: Paper present H: No paper

08

05

PH

IOT Regi Sensor

L: No paper H: Paper present

08

06

TRAY

STM Feed Sensor


08

07

TRAY

Tray1 Feed Sensor


08

47

TRAY

FEED READY SIGNAL

Level is high Hot-Line Control

09

02

XERO

Drum Cartridge Detected

L: No Drum Cartridge H: Cartridge present

09

07

XERO

Toner Empty Sensor

L: Toner available H: Toner depleted

10

23

PH

Fuser Exit Sensor


10

60

FUSER

Nohad Fan Fail Monitor L: Able to monitor FUSER FAN FAIL H: Unable to monitor FUSER FAN FAIL


Chain

Func or Link

Sub

Contents of Data

Meaning

01

01

PH

L/H (Left Side) COVER

L: Cover is closed H: Cover is open

01

10

TRAY

STM (Tray 2) L/H COVER


01

11

PH

L/H (Tray 1) LOW COVER

L: Cover is closed H: FCover is open

01

12

PH

FRONT COVER


05

10

IIT

Platen COVER Open


05

11

IIT

Carriage Home Sensor

L: Sensor is exposed H: Sensor is blocked

05

29

ADF

ADF Top Cover Open

L: Cover is open H: Cover is closed

05

30

ADF

Document Set Sensor


05

31

ADF

Document Feeder Width Sensor


05

32

ADF




June, 2008 6-7

General Procedures


Chain

Func or Link

Sub

Contents of Data

Meaning

05

217

DADF

Document Width Sensor

L: H:

62

212

IIT

Regi Sensor

L: H:

62

272

IIT

Scan Start

L: H:

62

300

IIT

Platen I/L Switch

L: H:

5

212

DADF

Feeder Cover Switch

L: H:

5

102

DADF

Document Set Sensor

L: H:

5

215

DADF

Doc Feeder Width Sensor

L: H:

5

216

DADF

Doc Tray Width Sensor 1

L: H:

5

217

DADF

Doc Tray Width Sensor 2

L: H:

5

218

DADF

Doc Tray Length Sensor 1

L: H:

5

219

DADF

Doc Tray Length Sensor 2

L: H:

5

204

ADF/ DADF

Document Feed Sensor

L: H:

5

206

ADF/ DADF

Doc Regi Sensor

L: H:

5

205

ADF/ DADF

Doc Feedout Sen sor/ Exit Invert Sensor

L: H:

General Procedures

Output Diagnostics The Output Diagnostics can be used to operate and check the status of the various motors, solenoids and clutches in the engine, IIT, and Trays. The operation can be enabled for every component, and whether or not the component is operating properly can be determined by checking the operation from outside. When a component is operating, "run" is displayed.

r u n For Platen and ADF model machines; Pressing the [Stop] button will stop the operation of the component and return you to the Function Code input screen.

F 2 3 For DADF model machines; Pressing the [Stop] button will stop the operation of the component and return to the Link Code inpit screen.

To resume the operation of the specified component, press the [Start] button again.

Output Component Control Codes Chain

Func

Sub

Contents of Data

04

01

PH

IOT Motor ON

04

02

FUSER

Nohad Fan Motor (HIGH SPEED)

June, 2008 6-8

Meaning

Fuser Fan changes from Low to High speed


Output Component Control Codes

Output Component Control Codes

Chain

Func

Sub

Contents of Data

Meaning

Chain

Func

Sub

Contents of Data

05

20

IIT

Carriage Motor High Speed scan

Move the Carriage in the scan direction at 80mm/ sec. NOTE: After the scan, the Carriage stops beyond the end position. Pressing the [Start] button again returns the Carriage to the home position. After another scan, the Carriage stops beyond the end position. Turn the power off and on to return the Carriage to the home position.

08

11

TRAY

STM Feed Clutch

08

12

TRAY

Tray1 Feed Clutch

08

13

TRAY

STM Feed Motor

08

17

PH

Bypass Solenoid

09

04

XERO

HVPS ON (LOW VOLTAGE)

09

05

XERO

HVPS ON (HIGH VOLTAGE)

09

06

XERO

Pre-Charge Erase Lamp

10

08

PH

Exit Motor Forward

10

09

PH

Exit Motor Reverse

05

62

DADF

Paper Feed Clutch

05

63

DADF

Registration Clutch

05

64

DADF

Output Inverting Clutch

05

65

DADF

Output Spacing Solenoid

62

05

IIT

Scan Motor, Scan Direction

Used with locking position Used with locking position

05

05

05

05 05

21

22

23

40 41

IIT

IIT

IIT

ADF ADF

Carriage Motor High Speed return

Move the Carriage toward home position at 80mm/sec. NOTE: See 05-20.

Carriage Motor Low Speed scan

Move the Carriage in the scan direction at 40mm/ sec. NOTE: See 05-20.

Carriage Motor Low Speed return

Move the Carriage toward home position at 40mm/sec. NOTE: See 05-20.

Document Drive Motor High Speed

Run the Document Drive Motor at 80 mm/sec.

62

06

IIT

Scan Motor Return Direction

Document Drive Motor Low Speed

Run the Document Drive Motor at 40 mm/sec.

62

07

IIT

Scan Locking Position

05

01

DADF

DADF Motor

62

2

IIT

Exposure Lamp

62

86

IIT

Image Area H8_PS

05

42

ADF

Document Feed Clutch

Turn the Document Feed Clutch on.

06

15

ROS

ROS Motor ON

ROS Motor Start & Stop.

08

10

PH

IOT Registration Clutch


June, 2008 6-9

Meaning

NOTE: Ejects paper.

General Procedures

Program Function

Clearing the error will return you to the Function Code input screen.

The Program Function can access the NVM (the EEPROM on the AIOC PWB) to perform the following functions: •

Test Print

•

Initialize NVM

•

Check Error History

•

Check Print Count

•

Display Version

•

Clear Error History

•

Display Serial Number, Product Number

F _ To resume the test print, press the [Start] button again. Pressing the [Stop] button in the middle of a test print will stop the feeding of additional paper, output any paper that was already fed, and return you to the Function Code input screen. Initialize NVM [20-58]

Test Print [23-10], [23-01] There are two test print modes: one that outputs the Controller built-in pattern, and another that outputs the MCU built-in pattern.

This will return the NVM settings to their default values. While the NVM is being initialized, "run" is displayed.

NOTE: Before running either of these test prints, you must check and make sure that the applicable NVM settings are correct. See Summary of Program Functions. During a test print, "run" is displayed.

r u n

r u n

When NVM initialization is complete, you will be returned to the Function Code input screen.

Once the test print starts, an error code will be displayed if an error occurs while printing.

C 1

General Procedures

June, 2008 6-10


Display Error History [40-01]

Display Firmware Version [29-49]

This can be used to check for the last 20 errors.

This can be used to check the firmware versions of the Controller and the MCU.

Pressing the [Start] button will display the error codes, starting with the most recent error.

Pressing the [Start] button will display the firmware version, starting from the highest order (leftmost) digit. Once everything has been displayed, you will be returned to the Function Code input screen.

E 1 J 6 6 1 F

When the last error is displayed, press the [Start] key to return to the Function Code input screen.

1 a 2

Clear Error History [20-59] This can be used to clear the Error History.

F _

While the Error History is being cleared, "run" is displayed.

Pressing the [Stop] key during the display will stop it and return you to the Function Code input screen.

r u n

Check Print Count [25-01] This can be used to check the total print count. The display is in decimal numbers. The initial display shows the first 3 digits of the print count. Pressing the [Start] button will show you the next 3 digits.

Once the Error History has been cleared, you will be returned to the Function Code input screen. Display Serial Number [25-20]

Pressing the [Start] button again will return you to the Function Code input screen. This can be used to display the serial number of the machine.

7 1 1 6 F


Pressing the [Start] button will display the serial number, starting from the highest order (leftmost) digit. Once the whole serial number has been displayed, you will be returned to the Function Code input screen.

2 9 5 8 F 3 1 6 4 7 0

1

June, 2008 6-11

General Procedures

Display Product Code [25-21] This can be used to display the product code of the machine. Pressing the [Start] button will display the product code, starting from the highest order (leftmost) digit. Once the whole product code has been displayed, you will be returned to the Function Code input screen.

F _

General Procedures

June, 2008 6-12


Summary of Program Functions

Chain

Function

Sub

Contents of Data

Meaning

05

22

IIT

Move Scanner

Moves the Scanner to the home position.

05

23

IIT

Move Scanner

Moves the Scanner to the maintenance position.

20

58

Initialize

MCU NVM Initialize

Sets the initial value in the MCU's system data.

20

59

Initialize

Clear Error History

Clears the Error History.

20

60

Initialize

MCU NVM Update

Sets the initial value in additional system data between old and new MCU versions. Use "DIAG EXECUTE" command.

23

10

Test Print

Test Print

Executes test pattern printing.

23

01

Test Print

Print Controller built-in pattern

Prints the Controller built-in grid, using the following NVM settings: 1-Sided or 2-Sided: 23-20 Paper Source: 23-21 Number of prints: 23-27 (high-order digits) and 23-26 (low-order digits)

25

01

Check

Display total print counter

Displays the total print count (6 digits). The display is divided into 2 portions: the high-order digits and the low-order digits.

25

20

Check

Display machine serial number

Displays the machine serial number (10 digits). The display is divided into 4 portions: the highest-order digit, followed by 3 sets of 3 digits.

25

21

Check

Display machine product code

Displays the machine product code (8 digits). The display is divided into 3 portions: the 2 highest-order digits, followed by 2 sets of 3 digits.

29

50

Check

Display Controller firmware version

Displays the firmware version of the Controller. The display is divided into 3 portions, starting from the highest-order digit.

29

49

Check

Display MCU firmware version

Displays the firmware version of the MCU. The display is divided into 3 portions, starting from the highest-order digit.

40

01

Check

Display Error History

Displays the Error History, starting with the most recent error code.


June, 2008 6-13

General Procedures

NVM Settings Mode Basic Operations of the NVM Settings Mode The NVM Settings Mode allows you to check or change the value of each NVM setting. Initially, the current value of the specified NVM item is shown as blinking.

3 Using the keypad to input a value shows the value as blinking.

3 1 3 Pressing the [C] button clears the value that was input and leaves the current value as blinking.

3 Pressing the [Start] button sets the value that was input, stops the blinking, and returns you to the Function Code input screen after 2 seconds has passed.

3 If the [Start] button is pressed when "_" is displayed, or when the input value is outside the range of possible settings, the input value is treated as invalid while the current value is shown as blinking. You will then be returned to the Function Code input screen after 4 seconds has passed. See List of NVM Settings (WC 5016, 5020 ADF).

General Procedures

June, 2008 6-14


List of NVM Settings (WC 5016, 5020 ADF) NOTE: In the “CE Access” columns, “O” = yes and “X” = no. CE Access Chain

Func tion

Sub

Contents of Data

Range

Unit

Initial Value

R

W

Init

06

20

ROS

ALL TRAY-LASER SIDE REGI ADJUSTMENT

1~99

0.254 mm

50

O

O

O

06

21

ROS

TRAY1-LASER SIDE REGI ADJUSTMENT

1~99

0.254 mm

50

O

O

O

06

22

ROS

TRAY2-LASER SIDE REGI ADJUSTMENT

1~99

0.254 mm

50

O

O

O

06

26

ROS

MSI-LASER SIDE REGI ADJUSTMENT

1~99

0.254 mm

50

O

O

O

06

28

ROS

DUP ALL TRAY-LASER SIDE REGI ADJUSTMENT

1~99

0.254 mm

50

O

O

O

06

29

ROS

DUP TRAY1-LASER SIDE REGI ADJUSTMENT

1~99

0.254 mm

50

O

O

O

06

30

ROS

DUP TRAY2-LASER SIDE REGI ADJUSTMENT

1~99

0.254 mm

50

O

O

O

06

34

ROS

DUP MSI-LASER SIDE REGI ADJUSTMENT

1~99

0.254 mm

50

O

O

O

06

52

ROS

IMAGE AREA

0~1

-

0

O

O

O

0:Normal Image Area 1:Wide Image Area

07

46

TRAY

Tray1-paper size

0~254

1mm

2

O

O

O

value paper type 1: 11”x17” SEF 2: A3 SEF 3: 8K SEF*1 5: B4SEF 6: 8.5”x14” SEF(Legal) 7: 8.5”x13.4” SEF(Mexico Folio) 8: 8.5”x13” (Folio) 10: A4 SEF 11: 8.5”x11” SEF(Letter) 12: 16K SEF*1 15: B5 SEF 17: 8.5”x11” LEF(Letter)


June, 2008 6-15

Remarks

General Procedures

CE Access Chain

Func tion

Sub

Contents of Data

Range

Unit

Initial Value

R

W

Init

Remarks

07

47

TRAY

Tray2-paper size

0~254

1mm

2

O

O

O

value paper type 1: 11”x17” SEF 2: A3 SEF 3: 8K SEF*1 5: B4SEF 6: 8.5”x14” SEF(Legal) 7: 8.5”x13.4” SEF(Mexico Folio) 8: 8.5”x13” (Folio) 10: A4 SEF 11: 8.5”x11” SEF(Letter) 12: 16K SEF*1 15: B5 SEF 17: 8.5”x11” LEF(Letter)

07

48

TRAY

MSI Paper size

0~254

1mm

2

O

O

O

value paper type 1: 11”x17” SEF 2: A3 SEF 3: 8K SEF*1 5: B4SEF 6: 8.5”x14” SEF(Legal) 7: 8.5”x13.4” SEF(Mexico Folio) 8: 8.5”x13” (Folio) 10: A4 SEF 11: 8.5”x11” SEF(Letter) 12: 16K SEF*1 15: B5 SEF 17: 8.5”x11” LEF(Letter) 18: 5.5”x8.5” S 19: A5 S

20

01

PH

LEAD REGI ADJUSTMENT - ALL TRAY

0~60

0.146 mm

30

O

O

O

Image input is delayed when Set Value is increased. Min(0)=-4.46mm, Max(66)=4.46mm, Initial(33)=0mm

20

41

PH

TRAY1 for Normal LEAD REGI ADJ

0~60

0.146 mm

30

O

O

O

Image input is delayed when Set Value is increased.

20

42

PH

TRAY2 for Normal LEAD REGI ADJ

0~60

0.146 mm

30

O

O

O


General Procedures

June, 2008 6-16


CE Access Chain

Func tion

Sub

Contents of Data

Range

Unit

Initial Value

R

W

Init

Remarks

20

43

PH

SMH for Normal LEAD REGI ADJ

0~60

0.146 mm

30

O

O

O


20

45

PH

DUP ALL SIZE for Normal LEAD REGI ADJ

0~60

0.146 mm

30

O

O

O


20

46

PH

ALL TRAY - REGI LOOP TIMER

0~66

0.438 mm

33

O

O

O

Loop increases when Set Value is increased.

20

47

PH

TRAY1 for Normal Paper REGI LOOP TIMER

0~66

0.438 mm

33

O

O

O


20

48

PH

TRAY2 for Normal Paper REGI LOOP TIMER

0~66

0.438 mm

33

O

O

O


20

49

PH

SMH for Normal Paper - REGI LOOP TIMER

0~66

0.438 mm

11

O

O

O


20

51

PH

DUP for Normal Paper - REGI LOOP TIMER

0~66

0.438 mm

33

O

O

O


21

09

HFSI

Last 2 of Fuser discharging Number

0~99

1

0

O

O

X

Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.)

21

19

HFSI

5th & 6th Fuser discharging Number

0~99

1

0

O

O

X


21

29

HFSI

3rd & 4th Fuser discharging Number

0~99

1

0

O

O

X


21

39

HFSI

1st 2 of Fuser discharging Number

0~3

1

0

O

O

X


23

20

PH

Simplex/Duplex

0~1

1

O

O

O

0: Simplex 1: Duplex


June, 2008 6-17

General Procedures

CE Access Chain

Func tion

Sub

Contents of Data

Range

Initial Value

R

W

Init

Remarks

23

21

PH

Feed Tray

1~6

1

O

O

O

1: Tray1. 2: Tray2. 3: Tray3. 4: Tray4. 5: HCF. 6: MSI

23

22

PH

Output Tray

0~4

0

O

O

O

0: FACE DOWN TRAY#1. 1: FACE DOWN TRAY#2. 2: FACE UP TRAY. 3: FINISHER Bin1. 4: FINISHER Top Tray

23

26

PH

Test Print Run Length Low Byte

0~99

1

O

O

O

Number of Test Prints

23

27

PH

Test Print Run Length High Byte

0~99

0

O

O

O

Number of Test Prints

29

01

Billing

Last 2 Dig Total Copy Counter(8 Digits)

0~99

0

O

X

X

29

11

Billing

3rd & 4th Dig Total Copy Counter(8 Digits)

0~99

0

O

X

X

29

21

Billing

1st 2 Dig Total Copy Counter(8 Digits)

0~99

0

O

X

X

29

04

HFSI

Tray1 Last 2 Digits of Feed Capacity (8 Digits)

0~99

1

0

O

O

X


29

14

HFSI

Tray1 5th & 6th Digits of Feed Capacity (8 Digits)

0~99

1

0

O

O

X


29

24

HFSI

Tray1 3rd & 4th Digits of Feed Capacity (8 Digits)

0~99

1

0

O

O

X


29

34

HFSI

Tray1 1st 2 Digits of Feed Capacity (8 Digits)

0~3

1

0

O

O

X


General Procedures

Unit

June, 2008 6-18


CE Access Chain

Func tion

Sub

Contents of Data

Range

Unit

Initial Value

R

W

Init

Remarks

29

05

HFSI


0~99

1

0

O

O

X


29

15

HFSI


0~99

1

0

O

O

X


29

25

HFSI


0~99

1

0

O

O

X


29

09

HFSI

MSI Last 2 Digits of Feed Capacity (8 Digits)

0~99

1

0

O

O

X


29

19

HFSI

MSI 5th & 6th Digits of Feed Capacity (8 Digits)

0~99

1

0

O

O

X


29

29

HFSI

MSI 3rd & 4th Digits of Feed Capacity (8 Digits)

0~99

1

0

O

O

X


29

39

HFSI

MSI 1st 2 Digits of Feed Capacity (8 Digits)

0~3

1

0

O

O

X


30

04

Recycle

Last 2 Digits of MSI Feed Capacity (8 Digits)

0~99

1

0

O

X

X

30

14

Recycle

5th & 6th Digits of MSI Feed Capacity (8 Digits)

0~99

1

0

O

X

X

30

24

Recycle

3rd & 4th Digits of MSI Feed Capacity (8 Digits)

0~99

1

0

O

X

X


June, 2008 6-19

General Procedures

CE Access Chain

Func tion

Sub

Contents of Data

Range

Unit

Initial Value

R

W

Init

30

34

Recycle

1st 2 Digits of MSI Feed Capacity (8 Digits)

0~3

1

0

O

X

X

30

05

Recycle

Last 2 of IOT Starting Number

0~99

1

0

O

X

X

30

15

Recycle

3rd & 4th IOT Starting Number

0~99

1

0

O

X

X

30

25

Recycle

1st 2 of IOT Starting Number

0~99

1

0

O

X

X

30

06

Recycle


0~99

1

0

O

X

X

30

16

Recycle


0~99

1

0

O

X

X

30

26

Recycle


0~99

1

0

O

X

X

30

36

Recycle


0~3

1

0

O

X

X

30

07

Recycle


0~99

1

0

O

X

X

30

17

Recycle


0~99

1

0

O

X

X

30

27

Recycle


0~99

1

0

O

X

X

30

37

Recycle


0~3

1

0

O

X

X

30

41

HFSI

Last 2 Digits of the number of Sheets Reaching BIAS transfer Roll (8 Digits)

0~99

1

0

O

O

X


30

42

HFSI

5th & 6th Digits of the number of Sheets Reaching BIAS transfer Roll (8 Digits)

0~99

1

0

O

O

X


General Procedures

June, 2008 6-20

Remarks


CE Access Chain

Func tion

Sub

Contents of Data

Range

Unit

Initial Value

R

W

Init

Remarks

30

43

HFSI

3rd & 4th Digits of the number of Sheets Reaching BIAS transfer Roll (8 Digits)

0~99

1

0

O

O

X


30

44

HFSI

1st Two Digits of the number of Sheets Reaching BIAS transfer Roll (8 Digits)

0~3

1

0

O

O

X


30

61

Recycle

Tray Feed Capacity MAX Over

0~1

1

0

O

X

X

It is shown whether the Recycle Tray Feed Capacity NVM was written more than 4000000 times. 0: not exceed 1: exceeded.

30

62

Recycle

IOT Starting Number MAX Over

0~1

1

0

O

X

X

It is shown whether the IOT Starting Number NVM was written more than 1000000 times. 0: not exceed 1: exceeded.

33

04

CRU

CRU Remain

0~100

1%

100

O

X

X

CRU Remain percentage

33

05

ESS IF

UI Auto Clear Time

0~4

-

3

O

O

O

0=OFF(Disabled), 1=20sec 2=30sec, 3=60sec, 4=90sec

33

06

ESS IF

Priority Paper Tray

1~3

-

1

O

O

O

1=Tray1 2=Tray2 3=MSI

33

07

ESS IF

Document Type

1~3

-

1

O

O

O

1=Text 2=Text & Photo 3=Photo

33

08

ESS IF

Density Adjustment

0~4

-

2

O

O

O

0=Lightest 1=Light 2=Normal 3=Dark 4=Darkest


June, 2008 6-21

General Procedures

CE Access Chain

Func tion

Sub

Contents of Data

Range

Unit

Initial Value

R

W

Init

Remarks

33

09

ESS IF

Default Reduction / Enlargement

0~4

-

0

O

O

O

0=100% 1=50% 2=70%(Metic),78%(Inch13&14) 3=129%(Metic),141%(Inch13&14) 4=200%

33

11

ESS IF

Auto Tray Switch

0~1

-

1

O

O

O

0=Disable 1=Enable

33

12

ESS IF

Auto Paper Selection

0~1

-

1

O

O

O

0=Disable 1=Enable

33

13

ESS IF

Default Customizing Reduction / Enlargement

50~200

-

82

O

O

O

China 82=82%(=82) XC 64=64%(=64)

33

14

ESS IF

Sharpness Adjustment for Copy Job

0~4

-

2

O

O

O

0=Weakest 1=Weaker 2=Normal 3=Stronger 4=Strongest

33

15

ESS IF

Sharpness Adjustment for Scan Job

0~4

-

2

O

O

O

0=Weakest 1=Weaker 2=Normal 3=Stronger 5=Strongest

33

16

ESS IF

MCU Low Power Mode

1~254

-

2

O

O

O

0=0min(Shift immediately) 1=5min 2=20min 3=60min 4=120min 5=240min 254=OFF(Disable)

33

17

ESS IF

MCU Sleep Mode

0~254

-

2

O

O

O


General Procedures

June, 2008 6-22


CE Access Chain

Func tion

Sub

Contents of Data

Range

Unit

Initial Value

R

W

Init

Remarks

33

18

ESS IF

Device Power Off Mode

0~254

-

0

O

O

O


33

19

ESS IF

Background removal for COPY

0~5

-

2

O

O

O

0=OFF 1=Level1 2=Level2 3=Level3 4=Level4 5=Level5

33

20

ESS IF

Background removal for SCAN

0~5

-

2

O

O

O

0=OFF 1=Level1 2=Level2 3=Level3 4=Level4 5=Level5

33

21

ESS IF

Account Mode

0~2

-

0

O

O

O

0=Disable 1=Single User Password Mode 2=Multi User Password Mode

33

22

ESS IF

Paper Class

0~2

-

0

O

O

O

0=Metric 1=Inch13 2=Inch14

33

23

ESS IF

Add Original Auto Clear Time 0~4

-

3

O

O

O

0=OFF(Disabled) 1=20sec 2=30sec 3=60sec 4=90sec

33

24

ESS IF

Wait Time After MSI Jam Clear

0~60

1sec

8

O

O

O

0- 60sec

33

25

ESS IF

Carriage Return Default Position

0~60

1sec

7

O

O

O

0- 60sec


June, 2008 6-23

General Procedures

CE Access Chain

Func tion

Sub

Contents of Data

Range

Unit

Initial Value

R

W

Init

Remarks

33

26

ESS IF

Platen Fast Scan REGI Adjustment

0~144

1dot (600dpi)

72

O

O

O

0-71=-72 to -1dot 72=0dot 73-144=1 to 72dot

33

27

ESS IF

Platen Slow scan REGI Adjustment

0~151

1dot (600dpi)

24

O

O

O

0-23=-24 to -1dot 24=0dot 25-144=1 to 151dot

33

28

ESS IF

ADF Fast Scan REGI Adjustment

0~144

1dot (600dpi)

72

O

O

O

0-71=-72 to -1dot 72=0dot 73-144=1 to 72dot

33

29

ESS IF

ADF Slow scan REGI Adjustment

0~79

0.1mm

40

O

O

O

0-39=-4.0 to -0.1mm 40=0mm 41-80=0.1 to 4.0mm

33

30

ESS IF

Shading Offset for ADF

1~254

1

100

O

O

O

complement 100=x1 1-99=x0.01-x0.99 (dark) 101-254=x1.01-x2.54 (light)

33

31

ESS IF

Shading Offset for ADF

1~254

1

100

O

O

O

complement 100=x1 1-99=x0.01-x0.99 (dark) 101-254=x1.01-x2.54 (light)

33

33

ESS IF

Platen Slow Scan scale Adjustment

0~20

0.10%

10

O

O

O

0-9=-1.0% to -0.1% 10=0% 11-20=0.1% to 1.0%

33

35

ESS IF

ADF Slow Scan scale Adjustment

0~20

0.10%

10

O

O

O

0-9=-1.0% to -0.1% 10=0% 11-20=0.1% to 1.0%

33

36

ESS IF

ADF Loop Adjustment

0~10

1mm

5

O

O

O

0-4=-5 to -1mm 5=0mm 1-5=1 to 5mm

33

37

ESS IF

M/C config

0~1

-

1

O

X

X

0 : DC 1 : CPS

33

38

ESS IF

ADF installation

0~1

-

0

O

O

X

0 : not installed 1 : installed

General Procedures

June, 2008 6-24


CE Access Chain

Func tion

Sub

Contents of Data

Range

Unit

Initial Value

R

W

Init

Remarks

34

01

ESS IF

Administrator User Login Password Low byte

48~57

-

49

O

O

O

48-57

34

11

ESS IF

Administrator User Login Password Mid byte

48~57

-

49

O

O

O

34

21

ESS IF

Administrator User Login Password High Byte

48~57

-

49

O

O

O

34

02

ESS IF

User1 Login Password Low Byte

48~57

-

48

O

O

O

34

12

ESS IF

User1 Login Password Mid byte

48~57

-

48

O

O

O

34

22

ESS IF

User1 Login Password High byte

48~57

-

48

O

O

O

34

03

ESS IF


48~57

-

48

O

O

O

34

13

ESS IF


48~57

-

48

O

O

O

34

23

ESS IF


48~57

-

48

O

O

O

34

04

ESS IF


48~57

-

48

O

O

O

34

14

ESS IF


48~57

-

48

O

O

O

34

24

ESS IF


48~57

-

48

O

O

O

34

05

ESS IF


48~57

-

48

O

O

O

34

15

ESS IF


48~57

-

48

O

O

O

34

25

ESS IF


48~57

-

48

O

O

O


June, 2008 6-25

General Procedures

CE Access Chain

Func tion

Sub

Contents of Data

Range

Unit

Initial Value

R

W

Init

34

06

ESS IF


48~57

-

48

O

O

O

34

16

ESS IF


48~57

-

48

O

O

O

34

26

ESS IF


48~57

-

48

O

O

O

34

07

ESS IF


48~57

-

48

O

O

O

34

17

ESS IF


48~57

-

48

O

O

O

34

27

ESS IF


48~57

-

48

O

O

O

34

08

ESS IF


48~57

-

48

O

O

O

34

18

ESS IF


48~57

-

48

O

O

O

34

28

ESS IF


48~57

-

48

O

O

O

34

09

ESS IF


48~57

-

48

O

O

O

34

19

ESS IF


48~57

-

48

O

O

O

34

29

ESS IF


48~57

-

48

O

O

O

35

01

ESS IF


48~57

-

48

O

O

O

35

11

ESS IF


48~57

-

48

O

O

O

35

21

ESS IF


48~57

-

48

O

O

O

General Procedures

June, 2008 6-26

Remarks


CE Access Chain

Func tion

Sub

Contents of Data

Range

Unit

Initial Value

R

W

Init

35

02

ESS IF


48~57

-

48

O

O

O

35

12

ESS IF


48~57

-

48

O

O

O

35

22

ESS IF


48~57

-

48

O

O

O

35

23

ESS IF

User1 Copy Credit

0~60

1000

0

O

O

O

35

24

ESS IF

User2 Copy Credit

0~60

1000

0

O

O

O

35

25

ESS IF

User3 Copy Credit

0~60

1000

0

O

O

O

35

26

ESS IF

User4 Copy Credit

0~60

1000

0

O

O

O

35

27

ESS IF

User5 Copy Credit

0~60

1000

0

O

O

O

35

28

ESS IF

User6 Copy Credit

0~60

1000

0

O

O

O

35

29

ESS IF

User7 Copy Credit

0~60

1000

0

O

O

O

35

30

ESS IF

User8 Copy Credit

0~60

1000

0

O

O

O

35

31

ESS IF

User9 Copy Credit

0~60

1000

0

O

O

O

35

32

ESS IF

User10 Copy Credit

0~60

1000

0

O

O

O

36

01

ESS IF

User1 Copy Count Low byte

0~99

-

0

O

O

O

36

11

ESS IF

User1 Copy Count Mid byte

0~99

-

0

O

O

O

36

21

ESS IF

User1 Copy Count High byte

0~99

-

0

O

O

O

36

02

ESS IF


0~99

-

0

O

O

O

36

12

ESS IF


0~99

-

0

O

O

O

36

22

ESS IF


0~99

-

0

O

O

O

36

03

ESS IF


0~99

-

0

O

O

O

36

13

ESS IF


0~99

-

0

O

O

O

36

23

ESS IF


0~99

-

0

O

O

O

36

04

ESS IF


0~99

-

0

O

O

O

36

14

ESS IF


0~99

-

0

O

O

O


June, 2008 6-27

Remarks

General Procedures

CE Access Chain

Func tion

Sub

Contents of Data

Range

Unit

Initial Value

R

W

Init

36

24

ESS IF


0~99

-

0

O

O

O

36

05

ESS IF


0~99

-

0

O

O

O

36

15

ESS IF


0~99

-

0

O

O

O

36

25

ESS IF


0~99

-

0

O

O

O

36

06

ESS IF


0~99

-

0

O

O

O

36

16

ESS IF


0~99

-

0

O

O

O

36

26

ESS IF


0~99

-

0

O

O

O

36

07

ESS IF


0~99

-

0

O

O

O

36

17

ESS IF


0~99

-

0

O

O

O

36

27

ESS IF


0~99

-

0

O

O

O

36

08

ESS IF


0~99

-

0

O

O

O

36

18

ESS IF


0~99

-

0

O

O

O

36

28

ESS IF


0~99

-

0

O

O

O

36

09

ESS IF


0~99

-

0

O

O

O

36

19

ESS IF


0~99

-

0

O

O

O

36

29

ESS IF


0~99

-

0

O

O

O

36

10

ESS IF


0~99

-

0

O

O

O

36

20

ESS IF

User10 Copy Count Mid Byte

0~99

-

0

O

O

O

36

30

ESS IF

User10 Copy Count High Byte 0~99

-

0

O

O

O

42

01

ESS IF

Last 20 Fault History 1st Last

48~122

-

48

O

O

O

42

11

ESS IF

Last 20 Fault History 1st 2nd

48~122

-

48

O

O

O

42

21

ESS IF

Last 20 Fault History 1st 1st

48~122

-

48

O

O

O

42

02

ESS IF

Last 20 Fault History 2nd Last

48~122

-

48

O

O

O

42

12

ESS IF

Last 20 Fault History 2nd 2nd

48~122

-

48

O

O

O

42

22

ESS IF

Last 20 Fault History 2nd 1st

48~122

-

48

O

O

O

42

03

ESS IF

Last 20 Fault History 3rd Last

48~122

-

48

O

O

O

General Procedures

June, 2008 6-28

Remarks


CE Access Chain

Func tion

Sub

Contents of Data

Range

Unit

Initial Value

R

W

Init

42

13

ESS IF

Last 20 Fault History 3rd 2nd

48~122

-

48

O

O

O

42

23

ESS IF

Last 20 Fault History 3rd 1st

48~122

-

48

O

O

O

42

04

ESS IF

Last 20 Fault History 4th Last

48~122

-

48

O

O

O

42

14

ESS IF

Last 20 Fault History 4th 2nd

48~122

-

48

O

O

O

42

24

ESS IF

Last 20 Fault History 4th 1st

48~122

-

48

O

O

O

42

05

ESS IF


48~122

-

48

O

O

O

42

15

ESS IF


48~122

-

48

O

O

O

42

25

ESS IF


48~122

-

48

O

O

O

42

06

ESS IF


48~122

-

48

O

O

O

42

16

ESS IF


48~122

-

48

O

O

O

42

26

ESS IF


48~122

-

48

O

O

O

42

07

ESS IF


48~122

-

48

O

O

O

42

17

ESS IF


48~122

-

48

O

O

O

42

27

ESS IF


48~122

-

48

O

O

O

42

08

ESS IF


48~122

-

48

O

O

O

42

18

ESS IF


48~122

-

48

O

O

O

42

28

ESS IF


48~122

-

48

O

O

O

42

09

ESS IF


48~122

-

48

O

O

O

42

19

ESS IF


48~122

-

48

O

O

O

42

29

ESS IF


48~122

-

48

O

O

O

42

10

ESS IF

Last 20 Fault History 10th Last 48~122

-

48

O

O

O

42

20

ESS IF

Last 20 Fault History 10th 2nd 48~122

-

48

O

O

O

42

30

ESS IF


48~122

-

48

O

O

O

43

01

ESS IF


-

48

O

O

O

43

11

ESS IF


48~122

-

48

O

O

O

43

21

ESS IF


48~122

-

48

O

O

O


June, 2008 6-29

Remarks

General Procedures

CE Access Chain

Func tion

Sub

Contents of Data

Unit

Initial Value

R

W

Init

43

02

ESS IF


-

48

O

O

O

43

12

ESS IF


-

48

O

O

O

43

22

ESS IF


48~122

-

48

O

O

O

43

03

ESS IF


-

48

O

O

O

43

13

ESS IF


-

48

O

O

O

43

23

ESS IF


48~122

-

48

O

O

O

43

04

ESS IF


-

48

O

O

O

43

14

ESS IF


-

48

O

O

O

43

24

ESS IF


48~122

-

48

O

O

O

43

05

ESS IF


-

48

O

O

O

43

15

ESS IF


-

48

O

O

O

43

25

ESS IF


48~122

-

48

O

O

O

43

06

ESS IF


-

48

O

O

O

43

16

ESS IF


-

48

O

O

O

43

26

ESS IF


48~122

-

48

O

O

O

43

07

ESS IF


-

48

O

O

O

43

17

ESS IF


-

48

O

O

O

43

27

ESS IF


48~122

-

48

O

O

O

43

08

ESS IF


-

48

O

O

O

43

18

ESS IF


-

48

O

O

O

43

28

ESS IF


48~122

-

48

O

O

O

43

09

ESS IF


-

48

O

O

O

43

19

ESS IF


-

48

O

O

O

43

29

ESS IF


48~122

-

48

O

O

O

43

10

ESS IF


-

48

O

O

O

43

20

ESS IF


-

48

O

O

O

General Procedures

Range

June, 2008 6-30

Remarks


CE Access Chain

Func tion

Sub

Contents of Data

Range

Unit

Initial Value

R

W

Init

43

30

ESS IF


48~122

-

48

O

O

O

43

40

ESS IF

Offset to the latest error

0~19

-

0

O

O

O

50

15

EXIT

Enable OCT & Inverter

0~2

-

2

O

O

O

0:Disable 1:Inverter+OCT 2:Inverter Only

50

20

FUSER

FSR Reset FuserOverTemp

0~3

-

0

O

O

O

0:reset 1:FS1 Detected over temp 2:FS2 Detected over temp 3:On time Fail 5:Cold Sagging Fail(Only reset is possible in the diagnostics mode.)

60

01

ESS IF

MCU VERSION

0~1

-

-

O

X

X

60

02

ESS IF

MCU Release Number

0~99

-

-

O

X

X

60

03

ESS IF

MCU Patch Level

0~99

-

-

O

X

X

60

06

ESS IF

STM Version

0~99

-

-

O

X

X

60

07

ESS IF

STM Release Number

0~99

-

-

O

X

X

60

18

General

CPM

0~99

-

-

O

X

X

20:20PPM Other:PPM NG

60

19

General

Market Identity

0~254

-

-

O

X

X

22: DMO

60

26

MC Code

Serial Code1

0~254

1

0

O

X

X

60

27

MC Code

Serial Code2

0~254

1

0

O

X

X

60

28

MC Code

Serial Code3

0~254

1

0

O

X

X

60

29

MC Code

Serial Code4

0~254

1

0

O

X

X

60

30

MC Code

Serial Code5

0~254

1

0

O

X

X

60

31

MC Code

Serial Code6

0~254

1

0

O

X

X

60

32

MC Code

Serial Code7

0~254

1

0

O

X

X

60

33

MC Code

Serial Code8

0~254

1

0

O

X

X

60

34

MC Code

Serial Code9

0~254

1

0

O

X

X


June, 2008 6-31

Remarks

General Procedures

CE Access Chain

Func tion

Sub

Contents of Data

Range

Unit

Initial Value

R

W

Init

60

35

MC Code

Serial Code10

0~254

1

0

O

X

X

60

36

Product

Product code 1

0~254

1

0

O

X

X

60

37

Product

Product code 2

0~254

1

0

O

X

X

60

38

Product

Product code 3

0~254

1

0

O

X

X

60

39

Product

Product code 4

0~254

1

0

O

X

X

60

40

Product

Product code 5

0~254

1

0

O

X

X

60

41

Product

Product code 6

0~254

1

0

O

X

X

60

42

Product

Product code 7

0~254

1

0

O

X

X

60

43

Product

Product code 8

0~254

1

0

O

X

X

Remarks

Reprograming the DADF EPROMS on the SLCC PWB when replacing them with new ones. Table 1 Reprogaming the EPROMS on the SLCC PWB (DADF) XC(DMO-W) 110 V 100S12656 Serial No. KMA469001MMA484000

XC(DMO-W) 220 V 100S12657 Serial No. KMX484001KMX494000

XC(DMO-E) 220 V 100S12655 Serial No. 331494001x331524000x

Chain

Link

700

339

700

340

700

341

700

342

700

343

700

344

700

348

700

349

700

350

700

165

840

840

826

Country Code

840:USA 826:UK

This list

700

402

2

2

4

Paper Size Group

1: Japan, 2:NA, 4:AP, 5:SA

This list

700

337

15

15

15

Device Type

CPFS:15

This list

700

338

2

2

2

Territory

0x01:FX 0x02:XC 0x03:XE 0x04:AP

This list

700

700

6

6

6

Machine serial number format

6

This list

General Procedures

NVM Destination

Remarks

Reference

Get the information from the latest soft ware version.

June, 2008 6-32


Table 1 Reprogaming the EPROMS on the SLCC PWB (DADF)

Chain

Link

XC(DMO-W) 110 V 100S12656 Serial No. KMA469001MMA484000

700

329

75

75

75

Product Code #1

700

330

77

77

76

Product Code #2

700

331

65

88

66

Procuct Code #3

700

332

0

0

o

Product Code #4

700

333

0

0

0

Product Code #5

700

334

0

0

0

Product Code #6

700

335

0

0

0

Product Code #7

700

336

0

0

0

Product Code #8

700

701

3

3

3

DMP Indication

709

11

85

85

85

XJ Code #1

709

12

67

67

67

XJ Code #2

709

13

78

80

77

XJ Code #3

709

14

0

0

0

XJ Code #4

700

297

75

75

51

Upper 3Byte Serial No. #1

This list or the Serial Number Plate

700

298

77

77

51


This list or the Serial Number Plate

700

299

65

88

49


780

203

1:LEF

1:LEF

1:LEF

Tray 1 Standard paper size-Orientation

780

204

44:8.5 x 11 (Letter) 44:8.5x11 (Letter)

5:A4

Tray 1 Standard paper size-Size

This list

780

205

1:LEF

1:LEF

1:LEF

Tray2 Standard paper size-Orientation

This list

780

206

5:A4

5:A4

5:A4

Tray2 Standard paper size-Size

This list

780

232

2:SEF

2:SEF

2:SEF

MSI Standard paper size-Orientation

This list

780

233

39:11x17

39:11x17

4:A3

MSI Standard paper size-Size

715

21

Platen Fast Scan REGI Adjustment

Initial Value: 120

Refer to the NEC Serial Number Plate which is on the back of the IIT

715

20

Platen Slow Scan REGI Adjustment

Iniatial Value: 120

Refer to the NEC Serial Number Plate which is on the back of the IIT

650

15

EXIT

0: Simplex M/C 1: 2: Duplex M/C

This list

606

020

All Tray-Laser Side REGI

Initial Value: 50

620

001

Lead REGI Adjustment-All Tray

606

058


2

14

XC(DMO-W) 220 V 100S12657 Serial No. KMX484001KMX494000

XC(DMO-E) 220 V 100S12655 Serial No. 331494001x331524000x

NVM Destination

2

14

2

14

END Video Enable Timing Adjustment

June, 2008 6-33

Remarks

Reference

Refer to this list or the Serial Number Plate.

2:DMP5/6 3:DMP7

This list

This list

This list or the Serial Number Plate 0:none specified, 1:LEF, 2:SEF

This list

This list

Initial Value: 6

This list

General Procedures

List of NVM Settings (WC 5020 DADF) NOTE: In the “CE Access” columns, “O” = yes and “X” = no. Table 2 Chain

Link

Name of data

Range

Unit

Initial Value

R

715

1

IISS Major Version

0 ~ 65535

-

65535

O

O

O

IISS Major Version number

715

2

IISS Minor Version

0 ~ 65535

-

65535

O

O

O

IISS Minor Version number

715

3

IISS Revision Version

0 ~ 65535

-

65535

O

O

O

IISS Revision Version number

715

10

Platen/DADF

0~1

-

1

O

O

O

Switch Platen model and DADF Model 0: Platen 1: DADF

715

11

Change Size Table

0~3

-

0

O

O

O

Switch document size detection table of DADF 0: mm (AP) 1: inch 13-12 (EU/South America) 2: inch 14 (North America) 3: Mexico

715

20

Platen SS Registration Adjustment

80 ~ 260

1 dot

120

O

O

O

Platen SS Registration Correction Value. NVM initial value is Adjustment Value 0. Adjust by 1 dot. (Not include the adjustment value from Module Sensor ~ Registration)

715

21

Platen PRadjF

0 ~ 240

1 dot

120

O

O

O

Platen FS Registration Correction Value. NVM value 120 is Adjustment Value 0. Adjust by 1 dot.

715

22

CVT Image Reading Position

0 ~ 500

0.1 mm

100

O

O

O

DADF Reading Position Correction Value

715

23

SS Feed Position Correction (Side 1)

400 ~ 600

0.1 mm

505

O

O

O

SS Feed Position Correction Value (Side 1) Includes the adjustment value from Doc Regi Sensor (SNS8) ON~Start of Reading Side 1

715

24

SS Feed Position Correcation (Side 2)

400 ~ 600

0.1 mm

505

O

O

O

SS Feed Position Correction Value (Side 2) Includes the adjustment value from Doc Regi Sensor (SNS8) ON~Start of Reading Side 2.

715

25

SS Tail Registration Corerection (Side 1)

400~600

0.1 mm

446

O

O

O

Includes the adjustment value from Doc Regi Sensor (SNS8) OFF~Finish of Reading Side 1.

715

26

SS Tail Registration Correction (Side 2)

400~600

0.1 mm

446

O

O

O

Includes the adjustment value from Doc Regi Sensor (SNS8) Off~Finish of Reading Side 2.

715

27

Registration Loop Degree Adjustment A

50~200

0.1 mm

89

O

O

O

Feed Sensor (SNS7) ON~Feed CL (EMC1) OFF after feeding the document (Adjustment Value A)

715

28

Registration Loop Degree Adjustment B

50~200

0.1 mm

150

O

O

O

Feed Sensor (SNS7) ON~Regi Cl (ENC2) ON when inverting document. (Adjustment Value B)

715

29

Feed Clutch Timing Adjustment (output)

700~1000

0.1 mm

940

O

O

O

Feedout Sensor OFF~Feedout Clutch OFF when outputting

715

30

Feedout Clutch Timing Adjustment (invert) 0~500

0.1 mm

210

O

O

O

Feedout Sensor) OFF~Feedout Clutch OFF when inverting

715

31

CVT FS OFFset Side 1

1 dot

120

O

O

O

CVT FS Registration Correction Value for Side 1 (front side) NVM value 120 is Adjustment Value 0. Adjust by 1 dot.

General Procedures

0~240

June, 2008 6-34

CE Access W Init Remarks


Table 2 Chain

Link

Name of data

Range

Unit

Initial Value

R

715

32

CVT FS OFFset Side 2

0~240

1 dot

120

O

O

O

CVT FS Registration Correction Value for Side 2 (back side) NVM value 120 is Adjustment Value 0. Adjust by 1 dot.

715

40

FS Magnification Adjustment

0~100

0.1%

50

O

O

O

Fine Adjustment Value of FS magnification. Shows =/5% (by 0.1%) fine adjustment value with 50 for 0%, ) for -5% and 100 for 5%.

715

41

Platen SS Magnification Adjustment

40~60

0.1%

50

O

O

O

Fine Adjustment Value of Platen SS Magnification. Shows +/- 1% (by 0.1%) fine adjustment value with 50 for 0%, 40 for -1% and 60 for +1%/

715

42

CVT SS Magnification Adjustment

40~60

0.1%

50

O

O

O

Fine Adjustment Value of CVT SS Magnification. Shows +/- 1% (by 0.1%) fine adjustment value with 50 for 0%, 40 for -1% and 60 for +1%.

715

90

Fail Bypass

0~1

-

0

O

O

O

0: With out Fail Bypass 1: With Fail Bypass

715

91

Error Information

0~65535

-

0

O

O

O

Debug information

715

92

Size detection: Sensor Information of Cus- 0~65535 tom Size

-

0

O

O

O

Sensor information in the case of the size detection result being “Custom Size”. If the result is not “Custom Size”, this NVM update will not be done. bit 0: Sensor 6 bit 1: Sensor 5 bit 2: Sensor 4 bit 3: Sensor 3 bit 4: Sensor 2 bit 5-15: (spare) Meaning of bit = 0: Sensor OFF, 1: Sensor ON

715

100

WREF ADJ Platen

50~255

-

111

O

O

O

Correction Factor of Blue W-Fef (for Platen)

715

101

Density Level ADJ RGBK

80~120

-

100

O

O

O

Highlight Fine Adjustment (x 1/100, dommon to RGBK)

715

102

102WDL STD CL 30 B

0~1023

-

0

O

O

O

Standard Data of White Variation Correction.

715

103

WREF ADJ CVT

50~255

-

78

O

O

O

Correction factor of Blue W-Fef (for CVT)

715

110

AGOC SHD NVM

0~8

-

0

O

O

O

0: PROM used 1: NVM of (*1) enabled.

715

111

FBLM

0~1023

-

984

O

O

O

AGC Maximum Allowable Value (*1)

715

112

FBLI

0~1023

-

64

O

O

O

AGC Minimum Allowable Value (81)

715

113

PLSnCL

0~255

-

32

O

O

O

Reading Line Number of Shading RGB. (*1)

715

114

FL CHK NG Count

0~65535

Once

0

O

O

O

Number of Lamp Check Failure (Reset by lamp replacement)

715

115

FL CHK NG Data

0~1023

-

0

O

O

O

Downloaded Dtaat at Lamp Check Failure (Get data when white is read, which is compared at the check)

715

120

AGC ADJ BW

1~200

-

100

O

O

O

AGC BW for Target Value Correction (x1/100: 100=x1)

715

121

Gap (1)

0~1023

-

128

O

O

O

CCD Ch-1 Gain Value

715

122

Gap (2)

0~1023

-

128

O

O

O

CCD Ch-2 Gain Value

715

123

AGCP (1)

0~511

-

128

O

O

O

CCD Ch-1 AGC Setting Value

715

124

AGCP (2)

0~511

128

O

O

O

CCD Ch-2 AGC Setting Value


June, 2008 6-35


General Procedures

Table 2 Initial Value

R

0~1023

0

O

O

O

CCD Ch-1 AGC Downloaded Data

0~1023

0

O

O

O

CCD Ch-2 AGC Downloaded Date

Gloop (1)

0~255

0

O

O

O

CCD CH-1 AGC Loop Number

128

Gloop (2)

0~255

0

O

O

O

CCD CH-2 AGC Loop Number

715

130

Oadj

0~255

0

O

O

O

AOC BW Level Correction Value (Complement of 2: 128” +127”)

715

131

AOCP (1)

0~1023

128

O

O

O

CCD Ch-1 AOC Setting Value

715

132

AOCP (2)

0~1023

128

O

O

O

CCD Ch-2 AOC Setting Value

715

133

Osmp (1)

0~1023

0

O

O

O

CCD Ch-1 AOC Downloaded Average Data

715

134

Osmp (2)

0~1023

0

O

O

O

CCD Ch-2 AOC Downloaded Average Data

715

135

Osmpx (1)

0~1023

0

O

O

O

CCD Ch-1 AOC Max Value Downloaded Average Data

715

136

Osmpx (2)

0~1023

0

O

O

O


715

137

Osmpn (1)

0~1023

0

O

O

O


715

138

Osmpn (2)

0~1023

0

O

O

O


715

139

AOCerr

0~255

0

O

O

O

Number of AOC Plow Abnormal End

715

150

BWPG Density

0~255

128

O

O

O

PG Density of Entire Solid Imagae (0: white)

715

161

PreIPS_Through 1

0~65535

0

O

O

O

bit 0: ALLCBTF bit 1: ALLKTF bit 2: ALLCTF bit 3: SSFCTF bit 4: MRCTF bit 5: WDVCTF0 bit 6: WDVCTF1 bit 7: DKCTF bit 8: FSFTF0 bit 9: FSFTF1 bit 10: DCBCTF bit 11: DCACTF bit 12: GPCTF bit 13: (SPARE) bit 14: (SPARE) bit 15: (SPARE) meaning of Bit 0: Through (Skip) Val;id. 1: Through (Skip) Invalid

Chain

Link

Name of data

Range

715

125

Gsmp (1)

715

126

Gsmp (2)

715

127

715

General Procedures

Unit

June, 2008 6-36



Table 2 Link

Name of data

Range

715

162

PreIPS_Through2

0~65535

0

715

163

PreIPS_Through3

0~65535

0


Unit

Initial Value

Chain

June, 2008 6-37

R

CE Access W Init Remarks bit 0: FMTF bit 1: IPCTF bit 2: EBTF bit 3: EATF bit 4: MKATF bit 5: GFATF bit 6: BFATF bit 7: (Spare) bit 8: (Spare) bit 9: WDVTF0 bit 10: WDVTF1 bit 11: DKBTF bit 12: DCBKTF bit 13: DCAKTF bit 14: GPBTF bit 15: (spare) Meaning of Bit 0: Through Valid, 1: Through Invalid

O

O

O

bit 0: BWTF bit 1: IPKTF bit 2: EETF bit 3: EDTF bit 4: MKKTF bit 5: GFBTF bit 6: BTBTF bit 7: MWTF bit 8: ECTF bit 9: MKBTF bit 10: FOBTF bit 11: SSRTF bit 12: (spare) bit 13: (spare) bit 14: (spare) bit 15: (spare) Meaning of Bit 0: Through Valid, 1: Through Invalid

General Procedures


R

0~65535

0

O

O

O

Make each function of image process block forcibly “through” (sk;ipped). Change values at S/W & H/W DEBUG. Should be “0” for usual use without fail. (Careful handling required). “Through setting” of each function is allocated by bit and multiple bit can be specified at once. D’0: AES D’1: DF39 D’2: SSR D’3: FSRE D’4: NSP D’5: 4DLUT D’6: 5AER D’7: 5MUL D’8: 5MWA D’9: 4AER D’10: 4MIL D’11: TRC D’12: ED D’13: DIRECT * D’14: AMAOSEL D’15: (SPARE) Meaning of Bit 0: Forcible Through Invalid, 1: Forcible Through Valid. *If D’13 is “1”, release all Masks.

S2X_OUT CONTROL

0~7

0

O

O

O

Specify the intake of image for scanning jig. 0: AMAO intake (Lab)* 1: AMAO intake (Shipping Inspection)* 2: DAIMAJIN intake 3: PRIDE intake 4: TOTODB intake (CMY) 5: WOZDB intake 6: FLC intake 7: TOTODB intake (YMC) *If NVM value is “0” or “1”, release athe Mask for AMAO.

202

VIPOUT Select

0~255

255

O

O

O

Switch the image path of VIPOUT. If this value is 255, nothing should be done. (Keep current SET VIP) VDO-MASK release will be carried out according to thie setting. Related register: SETVIP

715

205

AE FS External Area

0~65535

1dot

255

O

O

O

AE-FS Undetected Area INSTV For AES parameter calculation Related Register: SMPST, SMPED

715

206

0~65535

0.16mm

60

O

O

O

AE-SS Variation Fix Line-NCON AE detected amount of SS lead edge Sep number of NCON register=0.16mm

Chain

Link

Name of data

Range

715

200

Post IPS Bypass Setting

715

201

715

General Procedures

Unit

June, 2008 6-38




R

0~1

1

O

O

O

LIM Control Mode 0: Variaable Mode 1: Fixed Mode (NCON preferred mode) Related register: AESMOD

AE Control of FS Length

0~1

1

O

O

O

0: Minimum lenmgth of FS detection size will FS detection length 1: Input the document size or regard the result of automatic size detection as FS detected length. For AES parameter calculation Related registaer: SMPST, SMPED

209

Minimum FS Length for AE

0~65535

0.1mm

500

O

O

O

Minimum FS detection lengath (1 step=0.1mm) For AES parameter calculation

715

210

AE Upper Limit of SS Magnification adjust- 0~4000 ing

0.1%

4000

O

O

O

Maximum SS detection length (1 step=0.1%) For RAE.

715

211

SS Not Detect Area for Platen Job

0~65535

0

O

O

O

SS Dead Zone Setting Value at REal-Time AE for Platen Job Related registaer: BASE

715

212

SS Not Detect Area for ADF Job

0~65535

0

O

O

O

SS Dead Zone Setting Value at REal-Time AE for DADF Job Related register: BASE

715

213

Background removal for COPY

0~4

1

O

O

O

AE Remval Level for Copy Job 0: Standare 1: High +1 2: High +2 3: High +3 4: High +4 Since this NVM is written by Controller, direct modification of this value will be invalid. (Overwritten later) Refer to the procedire of Cont. side of Removal Level change.

715

219

Background removal for SCAN

0~4

1

O

O

O

AE Removal Level for Copy Job 0: Standard 1: High +1 2: High +2 3: High +3 4: High +4 Since the NVM is written by Conroller, direct modification of this value will be invalid. (Overwritten Later) Refer to the procedure of Cont. Side of Removal Level change.

715

230

AE Detection Level (Copy Platen)

0~4

2

O

O

O

Parameter Level of Detecxted Background Amount. (For Platen copy Job) 1: Low ~4: High 0: Ruby 1 Compatible Mode (not fully correspond)

Chain

Link

Name of data

Range

715

207

AE Detect Variation Control

715

208

715


Unit

June, 2008 6-39


General Procedures


R

0~4

2

O

O

O

Parameter Level of Detected Background Amount (For ADF copy job) 1: Low ~4: High 0: Ruby 1 Compatible Mode (Not fully correspond)

AE Detection Level (SCAN Platen)

0~4

2

O

O

O

Parameter Level of Detected Background Amount (For Platen scanning job) 0: Low ~4: High 0: Ruby 1 Compatible Mode (Not fully correspond)

233

AE Detection Level (SCAN ADF)

0~4

2

O

O

O

Parameter Lelel of Detected Background Amount (For ADF scanning job) 0: Low ~4: High 0: Ruby 1 Compatible Mode (Not fully correspond)

715

240

Density Correction LUT enaabling flag for Job Type

0~3

0

O

O

O

Select the job type applying the corrective LUT of A*X+B. 0(0x00)~3(0x03) Bit assign 0 bit: Copy Job 1 bit: Scan Job 2 - 7 bit: Not use. (0=disable, 1=enable)

715

241

Density Corrective LUT enabling flag for Org Type

0~7

0

O

O

O

Select the document mode applying the corrective LUT of A*X+B. 0(0x00)~7(0x07) Bit assign 0bit: TX Mode 1bit: T/P Mode 2bit: Photo Mode 3-7bit: Not use. (0=disable 1=enable)

715

242

Density Corrective LUT enabling flag for Density

0~31

0

O

O

O

Select the density level applying the corrective LUT of A*X+B. 0(0x00)~31(0x1f) Bit assign 0bit: Lighter2 1bit: Lighter1 2bit: Nomal Density 3bit: Darker1 4bit: Darker2 5-7bit: Not use. (0=disable, 1=enable)

715

243

Density Corrective LUT Parameter A

0~255

64

O

O

O

Paramaeeter A to create the corrective LUT of A*X+B. Settable range of A is 0~3.984375. 0(0x00)~3.984375(0xff) Bit assign 7-6bit: Interger number area. 5-0bit: decimal number area.

Chain

Link

Name of data

Range

715

231

AE Detection Level (Copy ADF)

715

232

715

General Procedures

Unit

June, 2008 6-40



Table 2 Chain

Link

Name of data

Range

715

244

Density Corrective LUT Parameter B

0~255


Unit

Initial Value

R

0

O

June, 2008 6-41

CE Access W Init Remarks O

O

Parameter B to create the corrective LUT of A*X+B. Settable range of B is -128~+127.Minus value shows complement number of 2. -128(0x80)~+127(0x7f)

General Procedures

General Procedures

June, 2008 6-42


GP1 Serial Number Locations

GP 2 Viewing the Six Digit Error Code

The Serial Number is located in three places on the machine:

If an error occurs, the two-digit error code, such as C1 and E2, appears in the display on the Control Panel. To view the six digit error code in the display, use the following procedudre.

NOTE: If the Rear cover has to be replaced, do not worry about saving the data plate (which has the machine serial number), since the serial number can be found in two other locations.

1.

When the two digit error code appears in the Display, press the Display Button.

2.

Press the Display Button.

3.

Press the Display Button.

a. •

On the Data Plate on the Rear Cover.

•

In software on the machine. The serial number can be displayed by accessing Diagnostics (How to Enter the Diagnostic Mode) and entering NVM code [25-20].

•

On a bar code sticker at the left rear of the machine, which can be seen by opening the Left Side Cover and looking toward the back.


a.

June, 2008 6-43

a.

The first three digits of the six digit error code appears in the display. The second half of the six digit error code appears in the display. The display switches back to the two digit error codes.

General Procedures

GP1, GP 2

General Procedures

GP1, GP 2

June, 2008 6-44


Specifications

Standard Specification of IIT, IOT, and Control UI

This subsection contains the performance specifications of the WorkCentre 5020, the multifunctional machine that has copier, printer, and scanner functions.

Table 1 IIT

CCD Image Sensor capable of scanning at multi-level 600 dpi

IOT

20 PPM 600 dpi Paper Feeding: 1 tray 250 sheets MSI 50 sheets Paper Output: Face down tray (250 sheet capacity)

Writes video data on paper for copying and printing. A laser xerography system is applied. Images can be written at 600dpi on paper up to 11"x17"/ A3 size.

PANEL

LED

UI (User Interface)

Standard Specification of Controller

System Overview The WorkCentre 5020 consists of IIT, IOT, PANEL, Controller, and Printer I/F. The summary of each system is as follows: 1.

IIT (Image Input Terminal)

2.

IOT (Image Output Terminal)

Scans documents for copying and scanning. The IIT resolution is 600 dpi at multi-level.

3.

Displays various settings, errors. 4.

5.

6.

Controller

Table 2

Controls the whole machine. Processes and stores input from IIT, printer I/F, and images to be output to IOT. Controls UI as well.

Item

GDI Controller

NW Controller

Notes

Printer I/F (GDI)

CPU

OTI4110

MPC8311E

--

Receives data from the computer and passes it to the IOT (printer). In scan mode, outputs image data to the computer.

Standard memory

SDRAM 64M

--

Serial EEPROM 4Mbit

--

I/F (NetWork)

Extended slot

Not supported

--

Network I/F receives data from the computer and passes the data to IOT (printer).

Standard Specification of Host

For scanning, Network I/F outputs image data to the network. 7.

User Registration and Department Management Table 3

Administrators can register users who can use a machine, so that only limited users can use the machine and that each user’s operation history can be managed and recorded.

Item

Description

GDI

•

Host I/F

USB (2.0) x 1

Yes

GDI Number of Account: 10 users Password: 3 digits, Numerical only

•

Product Codes

Network Number of Account: 99

Table 4

Password: 4-12 columns digits, Numerical only, ommissible 8.

Product Code Code

Duplex Copy

XJ IOT Prt/ CODE Model speed Scan Dup IIT

Platen ADF FINAL ASSY

Duplex copies can be made using simplex documents or duplex documents. Simplex copies can be made using duplex documents. Side images (input:output): Simp:simp, *Dup:Simp, Simp:Dup, *Dup:Dup. *Dup (DADF needed)


June, 2008 6-45

General Procedures

Options

FCOT shall be 7.5 sec or less. FCOT (Warm Start) is measured from the time the Start button is pressed (when the engine receives a START command in the "STAND-BY" state) till the trail edge of the first sheet is fed out, under the following conditions:

Table 5 Product name

Installation User

Code

STM (500sheets)

O

EL200735

Stand

O

EL200736

–

Documents are placed on Platen

–

Power is on

–

Engine motor is not running

–

Fuser is ready

–

Laser scanner motor (ROS: Raster Output Scanner) is ready

–

Paper size and feeding orientation: A4 or 8.5x11 LEF

In an ambient environment of 22°C and 55% R.H. and in the power off or power save mode, the machine will reach a "ready to copy" condition within 45 seconds.

–

Paper tray: Tray 1

Low Power Mode

FPOT

When the machine is not operated for a certain period of time, the machine enters Low Power Mode automatically.

FPOT: First Print Output Time

Warm-up Time

FPOT shall be 12sec or less Control Panel: LED: ON

Resolution Device Control: The fuser reduces its temperature.

Copy print: 600 X 600 dpi. Printer print: 600 X 600 dpi.

Printer I/F: Activated status.

Software Download

After a certain amount of time in Standby Mode, the machine enters Low Power Mode. This time can be changed by a software program (setting range: 0-240 minutes). The factory default is 5 minutes.

Controller Part: User can upgrade the software by downloading the object from the PC.

IOT Engine Part MCU: Replacing the board. Optional Tray: Replacing the board.

Low Power Mode is cancelled when a button is pressed on the Control Panel or when a printer job is received.

Sleep Mode (Off Mode) The machine operates as follows to save power when the machine is in Low Power Mode for a specified time: •

Control Panel: LED: OFF, Power Save Button: ON

•

Device Control: Power is turned off (except for warm-up).

After a certain amount of time in Low Power Mode, the machine enters Sleep Mode. This time can be changed by a software program (setting range: 0-240 minutes). The factory default is 5 minutes. Sleep mode is cancelled when a button is pressed on the Control Panel or when a printer job is received. When Sleep Mode is cancelled, the machine returns to Standby Mode. Time to transfer to Standby Mode shall be 45 seconds or less (on standard configuration).

FCOT (Warm Start) FCOT: First Copy Output Time

General Procedures

June, 2008 6-46


Count-up for Print/Copy jobs: GDI

Electrical/Mechanical Characteristics

The purpose of the Count-up Meter is to categorize the number of sheets of print output by print job, copy job, and test prints (Diagnostic Mode). The NLM Count-up Meter is not guaranteed as a meter for billing purposes. The Count-up Meter is managed by the device unit and can be confirmed with device UI.

Electrical Characteristics Table 8 Input Voltage Frequency (VAC) (Hz)

Rated input cur- Power Conrent Max (A) sumption* Spec (VA)

220 - 240V

240+10% 220-10%

50/60+/-3 Hz

6A

110 - 127V

110+10% 110-10%

50/60 +/-3 Hz 12A

The Count-up Meter has only one total counter. Table 6 Job type

Counter type

Description

Copy

Total Counter

Counter of copy job

Print

Counter of print job

Diag

Test print in Diag mode (It doesn't contain the Diag test print with Type-Di.)

Sleep Mode (Off Mode) Reference

1320VA (Max) 6 W (Max) 1320VA (Max) 6 W (Max)

*Power consumption is specified assuming full configuration.

Rated Power Consumption Report: One (Printer).

[GDI]

GDI: not supported.

Table 9 GDI

Timing of Count-up MCU increments the billing counter when the trail edge of the paper passes the Exit Sensor. The number of counter increments is as follows: Table 7 Paper size

Number of counter increments Billing

Life

A3, B4, 8K, 11x17, Non-fixed

1

2

A4 or less (A4, Letter, ....)

1

1

Mode

Power consumption

Configuration

In Low Power Mode

CP: 107W or less 91W or less

20cpm 16cpm

In Sleep Mode (Off Mode)

DC: 6W or less CP: 20W or less

At operation (During printing operation)

110V 12A, 1320VA (Max) 220/240V 6A, 1320VA (Max)

Full configuration

Network Table 10 NetWork


Mode

Power consumption

In Low Power Mode

CP: 107W or less

In Sleep Mode (Off Mode)

CP: 20W or less

At operation (During printing operation)

110V 12A, 1320VA (Max) 220/240V 6A, 1320VA (Max)

June, 2008 6-47

Configuration

Full configuration

General Procedures

TEC Method (New E-Star)

Machine Size/Weight The machine specified below does not include a drum and toner cartridge. Table 11

Config DC20 CP20

TEC GDI

Network

3.0Kwh

-

6.0Kwh

-

1.

Size Table 12

Type

Width (mm)

Depth (mm)

Height (mm)

IOT

595+/-5

532+/-5

505+/-5

IOT+IIT (Platen Glass)

595+/-5

532+/-5

528+/-5

IOT+IIT+ADF/DADF/DUP

595+/-5

532+/-5

605+/-5

[Optional Devices] Table 13 Width (mm)

Depth (mm)

Height (mm)

STM (500 Sheets)

551+/-5

522+/-5

130+/-5

Stand

551+/-5

506+/-5

385+/-5

Size of Package:

2.

•

DC: 710x660x716 (mm)

•

IBG ADF, DADF: 710x660x840 (mm)

Weight Table 14

General Procedures

Main body

Configuration

Platen model: Net weight (including toner cartridge)

33.02 Kg

Platen/IIT/MSI/Std Tray (250sheets) including toner cartridge

STM

8.8 Kg

Optional tray: 500sheets

Toner cartridge

1.2 Kg

ADF Model

37.88 Kg

ADF/IIT/MSI/Std tray/Dup including Consumables

DADF Model

39 Kg

DADF/IIT/MSI/Std tray/Dup including Consumables

Net weight (full configuration)

38.0 Kg TBD IIT/MSI/Std Tray (250sheets) including toner cartridge

Stand

18 Kg TBD

June, 2008 6-48


Storage Environment (According to Egret)

Copy Speed

A machine (without CRU and Toner Cartridge)which has been stored in the following environment shall attain the specified performance when installed in the environment specified.

Continuous copy speed at 100% magnification.

1.

In operation (guaranteed copy quality environment): 10 - 32 degrees C @ 15 - 85% RH

2.

Shipping and storage conditions:

Measurement method: Make 11 continuous copies. Measure the time (T, in seconds) from the output of the trail edge of the first sheet of paper to the output of the trail edge of 11th sheet of paper, and convert into copies per 60 seconds: CPM = T/60 (normal paper mode). Table 18

Table 15 Type Temperature

Transit (48 hrs)

Storage (18 mo)

Comments

-29 to 66 degrees C -29 to 66 degrees C After storage or transit, (-20 to 150 degrees F) (-20 to 150 degrees F) the machine must normalize to the operating environment before power is applied (this could take up to 4 hours maximum at extreme values).

Humidity

10 - 95% RH

20 - 80% RH

Altitude

Up to 12,000 m

Up to 3,000 m

Noise (Sound Power Level: LWAd) Unit: B

Paper Size and Paper Orientation

Tray 1

STM (Add 1 Tray)

Paper Tray Plain Paper

Plain Paper

MSI Fixed Mode

A4 LEF

20

20

10

15

15

10

8.5"x13"SEF 8.5"x14" 12 SEF

12

10

10

10

Not supported

10

8.5" x 11" LEF 16K LEF B5 LEF A4 SEF 8.5" x 11" SEF 16K SEF B5 SEF

Mexico Folio (8.5" x13.4")

Table 16 Standby Mode

Operation Mode

A3 SEF 11" x 17" SEF

Base Machine

4.0

6.8

Full System

4.0

6.8

8K SEF B4 SEF

Impulse Sound Power (FX) Impulse Sound Power Level (LWAI) LWAI B(A)

A5 SEF 5.5" ( 8.5" SEF) A5 LEF

10

10 Not supported

5.5" x 8.5" LEF Table 17

Base Machine

6.6

Full system

7.1

Chemical Substances 1.

Levels of Ozone: Ozone formed from this product: less than 0.02 mg/m3 (according to C11-705) Eco-Mark Requirement: 0.02 mg/m3 2004 Version Green Target A Limit: 0.015 mg/m3

2.

Airborne Dust Concentration: Inhaled airborne dust from this product: less than 0.08 mg/m3 (according to C11-705) Eco-Mark Requirement: 0.075 mg/m3 2004 Version Green Target A Limit: 0.04 mg/m3


June, 2008 6-49

General Procedures

Alignment

Paper Supply

1.

All paper trays (excluding MSI) are universal trays, which are front-loading trays.

[Full System] IOT + IIT + ADF + DADF Table 19 Copy Alignment: Specification

1.

Specification SYSTEM 2 Sided


+/- 2.90

+/- 3.80


+/- 3.40

+/- 3.90

Lead Skew (mm)

+/- 2.30

+/- 2.70

280 mm

Vertical Ratio (%) 100%

+/- 1.40

-1.72

400 mm

Horizontal Ratio (%) 100%

+/- 1.40

-1.72

280 mm

Perpendicularity (mm) +/- 3.40

+/- 4.00

400 mm

Linearity (Vertical) (mm)

+/- 2.00

-

400 mm

Linearity (Horizontal) (mm)

+/- 1.40

-

280 mm

Item

The height of a stack of paper shall be 27mm or less. Application

STM (optional): 500 sheets (Busines 70gsm/sheet). 450 sheets (Business 80gsm/sheet). The height of a stack of paper shall be 54mm or less. 2.

Standard paper

3.

Weight

Standard paper is indicated by "Standard Paper" on "Paper List." Tray 1: 60gsm to 90gsm STM: 60gsm to 90gsm 4.

Size Standard paper sizes: A4L/S, A3, B5L/S, B4, 8K, 16KL/S, 8.5 x11L/S, 8.5 x 13, 8.5 x 13.4 (Mexico Folio), 8.5 x 14, 11 x 17

5.

Usage rate Tray 1: 60%

Linearity (Skew) (mm) +/- 1.42

-

280 mm

Parallelism

-4.00

400 mm

2.

Capacity Tray 1: 250 sheets (Business 80gsm/sheet).

Specification SYSTEM 1 Sided

+/- 3.70

STM: 30%

[DC] IOT+IIT Table 20 Copy Alignment: Specification

Item

Specification SYSTEM

Measurement Length

Simplex

Duplex

Skew H

+/-2.3

+/-2.7

200mm

Perpendicularity

+/-3.7

+/-4.0

400mm

Linearity: V

2.3

--

400mm

Linearity: H

2.3

--

280mm

Linearity: D

2.3

--

283mm

Registration: Lead

+/-2.9

+/-3.8

Registration: Side

+/-3.4

+/-3.9

Magnification: V (%)

+/-1.4 (100%) +/-1.72 (100%) +/-1.56 (50%-99%) +/-1.89 (50%-99%) +/-1.8 (101%-200%) +/-2.42 (101%200%)

400mm

Magnification: H (%)

+/-1.4 (100%) +/-1.72 (100%) +/-1.56 (50%-99%) +/-1.89 (50%-99%) +/-1.8 (101%-200%) +/-2.42 (101%200%)

280mm

General Procedures

June, 2008 6-50


Bypass Tray(MSI) 1.

Paper List

Capacity Table 21

50 sheets of paper (70 gsm) 2.

Media Type

Paper size and paper orientation Size and orientation of paper set on MSI shall be as follows: A4L/S, A3, B5L/S, B4, 8K, 16KL/S, 8.5 x11L/S, 8.5 x 13, 8.5 x 13.4 (Mexico Folio), 8.5 x 14, 11 x 17, 5.5 x 8.5"S, A5S

3.

Paper weight

Baseline Paper

Weight of paper that can be supplied from MSI is 60g/m2 to 110g/m2. 4.

Usage rate

Paper

Code

CIM

Bypass

Flag Ship (80 gsm)

O

O

Xerox Business Multipurpose 4200 20 lb

O

O

Xerox Xcite (80 gsm)

O

O

Xerox Xplore (70 gsm)

O

O

Xerox Premier (80 gsm)

O

O

Xerox Business (80 gsm)

O

O

Flag Ship (70/80 gsm)

O

O

Canary (70/80 gsm)

O

O

Transmate (70/80 gsm)

O

O

Jetset (70/80 gsm)

O

O

HOOPOE(70/80 gsm) [APP Co]

O

O

Colotec+ 90 gsm

O

O

10%

Standard Paper

Colotec+ 100 gsm

O

Topgun (70/80 gsm)

O

O

Plain

3R96002

Removable Bar Stripe

3R96023

0

Xerox

3R12050 (TBD)

O

O

Label

O

O

Recycle Paper

O

O

Transparency

Other

O

Business 80 gsm-4 Hole (Hole on TE) 3R91823

O

Primier A4 80 gsm-4 Hole (Hole on TE)

3R91723

O

3- Hole (hole on TE)

3R2193

O

Paperbacked OHP is out of quality assurance.

Paper Selection There are two methods of Paper Tray selection: 1.

Direct selection User selects the paper tray that contains the required type of paper (size and orientation).

2.

APS (Automatic Paper Selection) (ADF/DADF only) MC automatically selects the paper that matches the image size.


June, 2008 6-51

General Procedures

Tools

Consumables

Most maintenance procedures can be done with the following standard tools:

Machine CRU Strategy

Table 1 No.

TOOL NO. /TOOL NAME

No.

TOOL NO. /TOOL NAME

1

499T 1423 BOX DRIVER 5.5

8

499T 247 TEST PATTERN (A3)

2

499T 355 SCREWDRIVER (+)

9

499T 301 MINI DRIVER

3

499T 2004 ROUND NOSE PLIERS

10

499T 1901 SIDE CUTTING NIPPER

4

499T 2320 S/E TESTER SET

5

499T 2601 SILVER SCALE (ISO M/N) 12

499T 9507 TESTER LEAD WIRE (Red)

6

499T 8104 FLASHLIGHT (UM-2)

13

499T 9508 TESTER LEAD WIRE (Black)

7

499T 8902 BRUSH

14

499T 353 * STUBBY DRIVER

Machine LCB is designed to interface with a CRUM and Billing Counter on all configurations. The CRUM can be used to provide a "hard stop" capability for markets requiring this feature. The primary uses of the CRUM are to ensure that the CRU being used is correct for the market & service/warranty agreements, store the number of copies made on the CRU, and enforce the end-of-life point. The primary uses of the Counter are to indentify the machine's market location, electronically store the machine's serial number, and store the number of copies made on the machine.

Consumable Replacement Intervals (TBD) Table 1 ITEM

YIELD/LIFE

STRATEGY/REPLACEMENT

Toner

6K @ 5% area coverage of A4 size Test pattern

Warning/Hard Stop - Warning with approximately 100 copies of toner remaining.

Drum Cartridge

Hard Stop: 22K @ 5% A4 area coverage for XC Job Size = 4 pages

End of life Warning/Hard Stop - Warning at 16K Hard Stop at 22K (XC)

* 499T 353 STUBBY DRIVER should be used when replacing the ROS ASSEMBLY.

This specification is applied when the machine is operated under the following conditions:

General Procedures

–

Paper: A4 LEF

–

Paper Tray: Tray 1

–

Copy Mode (not Print Mode)

June, 2008 6-52


Glossary of Terms

Table 1 Table 1

Term

Description

Hz

Hertz (Cycles per second)

Term

Description

IIT

Image Input Terminal - the Scanner/CCD portion of the machine

A3

Paper size 297 millimeters (11.69 inches) x 420 millimeters (16.54 inches).

IOT

A4

Paper size 210 millimeters (8.27 inches) x 297 millimeters (11.69 inches).

Image Output Terminal - the ROS/Xero/paper handling/ fusing portion of the machine

AC

Alternating Current is type of current available at power source for machine.

IQ

Image Quality

ACT

Advanced Customer Training: teaches customers to perform some of service that is normally performed by Xerox Service Representative.

KC

1000 copies

LCD

Liquid Crystal Display

A/D

Analog to Digital refers to conversion of signal

LE

Lead Edge of copy or print paper, with reference to definition of term TE

ADF

Automatic Document Feeder

LED

Light Emitting Diode

ADJ

Adjustment Procedure

LEF

Long Edge Feed

Bit

Binary digit, either 1 or 0, representing an electrical state.

LTR

Letter size paper (8.5 x 11 inches)

CCD

Charge Coupled Device (Photoelectric Converter)

LUT

Look Up Table - array of NVM locations that store process control data

CD

1: Circuit Diagram; 2: Compact Disc

LVPS

Low Voltage Power Supply

CF

Copier Fax

MF

Multi-Function

CP

Copier Printer

MN

Multinational

CPF

Copier Printer Fax

MPT

Multi Purpose Tray

Chip

Integrated Circuit (IC)

NBCR

New Book Scanner Control Relay

CRU

Customer Replaceable Unit

NIC

Network Interface Card

CVT

Constant Velocity Transport

NSC

New Scanner Controller

DADF

Duplexing Automatic Document Feeder

NVM

Non Volatile Memory

DC

Direct Current is type of power for machine components. Machine converts AC power from power source to DC power.

OEM

Original equipment manufacturer

OGM

On-going Maintenance

DC

Digital Copier

PC

Personal Computer

DMM

Digital Multimeter is generic name for meter that measures voltage, current, or electrical resistance.

PL

Parts List

PO

Part of (Assembly Name)

Duplex 2-sided printing or copying

PS

Post Script

EME

PSW

Portable Standard Workstation

PWB

Printed Wiring Board

PWS

Portable Workstation for Service

PJ

Plug Jack (electrical connections)

Fax Scanner

RAM

Random Access Memory

FS

Fast Scan (direction) - Inboard - to - Outboard

RAP

ESS

Electronic Sub-System

Repair Analysis Procedure for diagnosis of machine status codes and abnormal conditions

ENG

English

R/E

Reduction/Enlargement refers to features selection or components that enable reduction or enlargement

2TM

Two Tray Module

REP

Repair Procedure for disassembly and reassembly of component on machine

FAX

Facsimile

RIS

Raster Input Scanner

FIC

Final Integration Center

ROM

Read Only Memory

GND

Ground

ROS

HFSI

High Frequency Service Item

Raster Output Scanner - Device that transfers digitally processed image, using laser light, to photoreceptor.

HVPS

High Voltage Power Supply

SAD

Solid Area Density

Electromagnetic Emissions are emitted from machine during normal operation and power of these emissions are reduced by machine design features.

ERU

Engineer Replaceable Unit

ESD

Electrostatic Discharge. A transfer of charge between bodies at different electrostatic potential.

FS


June, 2008 6-53

General Procedures

Glossary of Terms

Table 1 Term

Description

SCP

Service Call Procedure

SEF

Short Edge Feed

Selftest

An automatic process that is used to check Control Logic circuitry. Any fault that is detected during self-test is displayed by fault code or by LEDs on PWB.

SIMM

Single Inline Memory Module used to increase printing capacity

Simplex Single sided copies FS

Fast Scan (direction) - LE - to - TE

TE

Trail Edge of copy or print paper, with reference to definition of term LE

UM

Unscheduled Maintenance

UI

User Interface

USB

Universal Serial Bus

W/

With - indicates machine condition where specified condition is present

W/O

Without - indicates machine condition where specified condition is not present

XBRA

Xerox Brazil

XC

Xerox Corporation

XE

Xerox Europe - also referred to as ESG (European Solutions Group)

XLA

Xerox Latin America

XMEX

Xerox Mexico

General Procedures

Glossary of Terms

June, 2008 6-54


7 Wiring Data BSDs Chain 1 Standby Power ................................................................................................. Chain 2 Mode Selection ................................................................................................. Chain 3 Machine Run Control ........................................................................................ Chain 4 Start Power ....................................................................................................... Chain 5 ADF/DADF ........................................................................................................ Chain 6 Imaging ............................................................................................................. Chain 7 Paper Supplying ............................................................................................... Chain 8 Paper Transportation ........................................................................................ Chain 9 Marking ............................................................................................................. Chain 10 Fusing and Copy Transportation ....................................................................

7-3 7-5 7-6 7-8 7-9 7-18 7-21 7-23 7-28 7-31

Wirenets Wirenets ..........................................................................................................................

7-35

P/J Locations 7.1 P/J Locations............................................................................................................


7-45

June, 2008 7-1

Wiring Data

Wiring Data

June, 2008 7-2


Chain 1 Standby Power A

B

C

D

E

F

1.1 MAIN POWER GENERATION

G

AIOC PWB PL8.1

ALL

1

H

J414 B6 YEL

B1,B2 YEL

LVPS PL8.1

2 CHOKE COIL PL8.1

J5 BLK

BLK

3 POWER CORD PL8.1

POWER SWITCH FS11 ACHFS31 PL8.1 BLK

FS60

10.1

FS12 ACNFS33

FS34 ACN

WHT

WHT BLU

4

P/J407 A16,A17 ,B16,B1 7 A14,A15 ,B14,B1 5

+3.3VDC

1

ACH

10.1

DC COM ALL

2

+5VDC

DC COM P/J407 B18

ON/ OFF

1.2

ALL

+24VDC F1 DC COM

5

ALL 1

Wire Color BLK:100V M/C, BRN:200V M/C

2

Wire Color WHT:100V M/C, BLU:200V M/C

YEL

2

DC COM YEL

2

YEL

2

B8 B10,B 9

ALL ALL

+24VDC

B12,B11 ALL

DC COM YEL

J409 4,5 1,6,11,15,1 J410 7, 19,21,23,2 5,27,29,31, 34 J409 1,2

A11,B11 ALL

AIOC PWB PL8.1

ALL

+5VDC

A2,A1

DUPLEX PWB PL8.2 ALL J416 +5VDC J550 3 BLU 7 BLU ALL DC COM 4 BLU 6 BLU DC COM 2 BLU 8 BLU

1

GN/YL

T21

DC POWER GENERATION

2

FS32 ACH BLK BRN

A11,A12 YEL

ADF PWB PL13.3 ALL J731 B7 YEL

+3.3VDC

B5 YEL B3,B4 YEL

J

A12,A13 ,B12,B1 3

9,10,1 1

A9,A10, B9,B10

20,21

1 GRY 3 VIO 8 VIO

6

10 ORN

DC COM

DC COM +5VDC

6,7

A7,A8, B7,B8

J508

+3.3VDC

+5VDC

+24VDC

LENS ASSEMBLY PL10.7 IIT PWB ALL J721 18,1 7 J720 34,29,24,2 ALL 0,18,16,14 ,12,10,8,6, 4,1 ALL J721 21,2 0 ALL 16,1 5 ALL 13,12,11 ALL

DC COM

J540 GRY

2,1

STM PWB PL11.5 ALL 1 ALL

DC COM VIO

2 ALL

24VRTN VIO

5 ALL

+24V ORN

7

Figure 1 1.1 Main Power Generation


June, 2008 7-3

Wiring Data

A

B

C

D

E

F

G

H

J

1.2 INTERLOCK SWITCHING 1

LVPS PL8.1

LH COVER INTERLOCK SWITCH PL8.2 J506FS151

4 ORN

1-1

LVPS PL8.1

1

LH COVER INTERLOCK SWITCH

FS152 COVER OPEN(L) +24VDC

J506

3 ORN

FRONT COVER INTERLOCK SWITCH PL8.2 J506FS153

1-12

LVPS PL8.1

1

FRONT COVER INTERLOCK SWITCH

FS154 COVER OPEN(L) +24VDC

2 ORN

J506

1 ORN

+24VDC (1.1)

AIOC PWB PL8.1

4.1

10.1

J416 1 BLU

F2

2 AIOC PWB PL8.1 P/J407 A2

P/J407 A1

E5-2

B1

E5-1

INTLK +24VDC

INTLK +24VDC

3

Fail Code

4

E5-1

LH Cover Open

E5-2

Front Cover Open

DUPLEX PWB PL8.2

INTLK +24VDCJ550 BLU

1

5

10.2 9

The actual H/L level is displayed inversely on the UI display.

LH COVER INTERLOCK SWITCH FRONT COVER INTERLOCK SWITCH

6

Figure 2 1.2 Interlock Switching Wiring Data

June, 2008 7-4


Chain 2 Mode Selection A

B

C

D

E

F

G

H

J

2.1 CONTROL PANEL Fail Code

1

AIOC PWB PL8.1

USER INTERFACE PWB PL8.4

J401 8

7

BLU

BLU

WAKE UP

UI RESET

J710 BLU

BLU

1

U7-0

UI Communication Timeout

U7-1

UI Communication Error

AIOC PWB PL8.1

2

2 5

4

BLU

UI TXD

J710 BLU

BLU

BLU

BLU

BLU

3

4

UI RXD

U7-0

J401

BLU

BLU

6 U7-1

5 6.1

3

3

6

DC COM (1.1)

DC COM 2

1

BLU

BLU

BLU

BLU

+5VDC (1.1)

7

8 +5VDC

4

5

6

1 2

1

2

3

4

5

6

7

8

9

C

0

Figure 1 2.1 Control Panel


June, 2008 7-5

Wiring Data

Chain 3 Machine Run Control A

B

C

D

E

F

G

H

J

3.1 PWB COMMUNICATION (STM PWB) 1

AIOC PWB PL8.1

LVPS PL8.1

STM PWB PL11.5 LVPS PL8.1

P/ J407 B19

9

B20

7

J508

STM IIC SCL

YEL

J540 YEL

6

J540

STM IIC SDA YEL

AIOC PWB PL8.1

YEL

3

4

STM REQ

YEL

J508 YEL

6

P/ J407 B21

H9-7

2

Fail Code

3

H9-7

MCU (AIOC PWB) - STM PWB Communication Error

4

5

6

Figure 1 3.1 PWB Communication (STM PWB)

Wiring Data

June, 2008 7-6


A

B

C

D

E

3.2 BILLING AND MACHINE CONTROL

AIOC PWB PL8.1

9.2

J401 9 BLU

BILL ID

J630 BLU

2

1

1

2

P630

BILLING COUNTER PL8.1

2 U6-2

RAM

10 BLU

BLU

DC COM (1.1)

U6-3 U6-4 3

NVM

U6-5 N9-0 N9-1 E9-1

4

G

H

J

Fail Code

1

U8-1

F

P/J411 1,2,3 ,4,5

USB 2.0

E9-2 E8-1 E8-2 L9-0

U8-1

Billing Counter Defect

U6-2

RAM Read/Write Check Error

U6-3

NVM Data Defect

U6-4

NVM Read/Write Cannot be Excuted

U6-5

CPU Power to access NVM is not enough

N9-0

Controller Logic Fail

N9-1

IOT Communication Error

E9-1

AMS NG Out Of Range

E9-2

Paper Direction Mismatch

E8-1

Nup NG Out Of Range

E8-2

Paper Direction Mismatch

L9-0

Copy Counter Full

N4-0

No Response from USB-Host

N4-1

HBPL or XPJL Syntax Error

N4-2

CPM Image Lost

C0-1

APS NG Unselected

C0-2

ADF NG out of range

N4-0 5

N4-1 N4-2 C0-1 C0-2

6

Figure 2 3.2 Billing and Machine Control Reissue WorkCentre 5016, 5020

June, 2008 7-7

Wiring Data

Chain 4 Start Power A

B

C

D

E

F

G

H

J

4.1 MAIN DRIVE 1

AIOC PWB LVPS PL8.1 PL8.1 P/J407 B2

J504 4 BLU F3

2

IOT MOTOR PL1.1

4-1

INTLK +24VDC (1.2)

IOT MOTOR ON(H) +5VDC J201 BLU

1 RED

RED

2 BLK

BLK

Fuser

CRU

4

1

MOT

J201 3 YEL

IOT MOTOR LOCK(H) +5VDC

2

DC COM (1.1)

GN/YL

3

T82

LVPS PL8.1

T81

INLET FRAME

DRV ESD GND

+5VDC

J504 YEL

GRN

T30

4

AIOC PWB PL8.1

3

P/J407 B3

Regi

U0-1 U1-1

F155

DRV ESD GND

IOT ESD GND

Duplex Dupulex Fail Code

5

U0-1

IOT Motor Stop Error

U1-1

IOT Motor Rotation Error

Tray

6

Figure 1 4.1 Main Drive

Wiring Data

June, 2008 7-8


Chain 5 ADF/DADF

A

B

C

D

E

F

G

5.1 DOCUMENT SIZE SENSING DOCUMENT TRAY LENGTH SENSOR 1 PL13.10

1

5-34 2

BLU

ADF PWB PL13.3

2

+5VDC (1.1)

DOCUMENT TRAY LENGTH SENSOR 2 PL13.10

CN4 DF4 5 WHT

1

6 WHT

3

DC COM (1.1)

DF5 WHT

WHT

DOCUMENT TRAY WIDTH SENSOR 1 PL13.10

3

1 WHT +5VDC (1.1)

DF3

2 WHT

DC COM (1.1)

CN5 3 WHT +5VDC (1.1)

4 WHT

J731 A3 YEL

8

B5 YEL

B6 YEL

ADF SEL0 J414 YEL

A10

ADF SEL1 YEL

ADF SEL2 YEL

B8

A2-2

B7

3 1 +3.3VDC

DOCUMENT TRAY WIDTH SENSOR 1 DOCUMENT SENSED(H) +3.3VDC DOCUMENT TRAY WIDTH SENSOR 2 PL13.10

1

5-33 2

1

5-31 2

A2-2

Not Supported Doc Size

+3.3VDC

YEL

DOCUMENT FEEDER WIDTH SENSOR PL13.9

3

Fail Code

1

DOCUMENT TRAY WIDTH SENSOR 2 DOCUMENT SENSED(H) +3.3VDC

DF2

3

WHT

7

1

RED

DF2

+3.3VDC

+3.3VDC

BLK

DF3

WHT

5

2

AIOC PWB PL8.1

1

DOCUMENT TRAY LENGTH SENSOR 2 DOCUMENT SENSED(H) +3.3VDC

DF5

5-32 2

4

5-35

J

ADF PWB PL13.3

1

DOCUMENT TRAY LENGTH SENSOR 1 DOCUMENT SENSED(H) +3.3VDC CN4

DF4

H

4 DOCUMENT TRAY WIDTH SENSOR 2

1

DOCUMENT FEEDER WIDTH SENSOR DF8 DOCUMENT SENSED(H) +3.3VDC CN5 YEL

+3.3VDC

DOCUMENT TRAY LENGTH SENSOR 2

5

3 DF8

1

DOCUMENT FEEDER WIDTH SENSOR

3

DC COM (1.1)

6 1

A combination of H and L levels of these five sensors determines a document size. For the relation between H/L of each sensor and document size, see the marginal table under 5.4 DOCUMENT PATH.

DOCUMENT TRAY WIDTH SENSOR 1 DOCUMENT TRAY LENGTH SENSOR 1

Figure 1 Document Size Sensing


June, 2008 7-9

Wiring Data

A

B

C

D

E

F

G

H

J

5.2 DOCUMENT SETTING AND TRANSPORT 1 ADF PWB PL13.3 ADF PWB PL13.3 CN5

DF14

2 WHT

2

WHT

DC COM (1.1)

1

ADF TOP COVER SWITCH PL13.9

5-29 DF14

2 WHT

DOCUMENT SET SENSOR PL13.9

6 WHT +5VDC (1.1)

7 WHT

2 WHT

1

1

A5 YEL

8

J414 YEL

YEL

+3.3VDC

DOCUMENT FEED SENSOR DOCUMENT SENSED(L) +3.3VDC WHT

A5-2

A8

+3.3VDC

A4 YEL

A9

+3.3VDC

A1-1 10

A6 YEL

YEL

A7

A4-1 A4-2

3 DF10 WHT

9 WHT

+3.3VDC

J731

+3.3VDC

5-36 DF10

DC COM (1.1)

4

WHT

BLU

DOCUMENT FEED SENSOR PL13.9 DF9

CN5

5-30 2 BLU

3

+3.3VDC

ADF TOP COVER SWITCH COVER OPEN(L) +3.3VDC

DOCUMENT SET SENSOR DOCUMENT SENSED(H) +3.3VDC

DF9

AIOC PWB PL8.1

WHT

1 3

ADF TOP COVER SWITCH

DC COM (1.1)

DOCUMENT FEED SENSOR Fail Code

5

A5-2

ADF Cover Open

A1-1

Doc Misfeed Jam

A4-1

Short Length Detect

A4-2

Long Length Detect

DOCUMENT SET SENSOR

6

Figure 2 Document Setting and Transport

Wiring Data

June, 2008 7-10


A

B

C

D

E

F

G

H

J

5.3 DOCUMENT FEED AND TRANSPORT MECHANISM 1

AIOC PWB PL8.1

ADF PWB PL13.3

J414 A6 YEL

5-42

DOCUMENT FEED CLUTCH CN3 ON(L) +24VDCDF13

J731

A7 YEL

2 WHT

1

2

1 WHT

2

1

DOCUMENT FEED CLUTCH DF13 PL13.9

DOCUMENT FEED CLUTCH Feed Roller

DC COM

2

+24VDC

DOCUMENT DRIVE MOTOR

5-40 5-41

3

A1 YEL B12 YEL A2 YEL

MOT M1 YEL

MOT M2

A3 YEL

2 ORN

B1 YEL YEL

MOT CLOCK

4

A12 DC COM

MOT M3

B11 YEL

CN2

YEL

MOT ON YEL

A11

3 YEL DC COM

5 BRN B2

DC COM

6 BLK

A10

MOT RST YEL

DOCUMENT SET SENSOR


DOCUMENT DRIVE MOTOR ON +24V CLOCK DOCUMENT DRIVE MOTOR ON +24V CLOCK DOCUMENT DRIVE MOTOR ON +24V CLOCK

Exit Roller MOT

B4

Regi Roll

1 WHT

MOT CURR2 A4 YEL A9 YEL B9 YEL

DOCUMENT DRIVE MOTOR ON +24V CLOCK

DOCUMENT DRIVE MOTOR PL13.5

DC COM

MOT CURR1 B10 YEL B3 YEL

5

High Speed Low Speed

Reed Out Feed Out Roll Roll

4 BLK

Reed In Feed In Roll Roll

+24VDC (1.1)

MOT CW/CCW A5 YEL A8 YEL DOCUMENT LEAD EDGE SENSOR

6

Figure 3 Document Feed and Transport Mechanism


June, 2008 7-11

Wiring Data

A

B

C

D

E

F

G

H

J

5.4 DOCUMENT PATH DOCUMENT TRAY WIDTH SENSOR 1 Feed Roll

1

DOCUMENT SET SENSOR

DOCUMENT TRAY WIDTH SENSOR 2

DOCUMENT TRAY LENGTH SENSOR 1 DOCUMENT TRAY LENGTH SENSOR 2


Regi Roll

2

DOCUMENT FEED SENSOR

Read In Roll Read Out Roll

3

4

Exit Roller

The table at the right shows the relationship between High/Low of each document size sensor and document size . The standard size of a document is sensed at the tim e the DOCUMENT FEEDER WIDTH SENSOR detects it after it is fed.

5

6

Document Size






5.5"x8.5"SEF

L

L

L

L

L

A5 SEF

L

H

L

L

L

B5 SEF

L

H

L

H

L

A4 SEF

L

H

H

H

L

A5 LEF

L

H

H

L

L

5.5"x8.5"LEF

L

L

H

L

L

8.5"x11"SEF (Letter)

L

L

H

H

L

8.5"x13"SEF (Legal)

L

L

H

H

H H

8.5"x14"SEF (Legal)

L

L

H

H

B5 LEF

H

H

H

L

L

B4 SEF

H

H

H

H

H

Executive LEF

H

L

H

L

L

16K LEF

H

L

H

L

L

8K SEF

H

L

H

H

H

8.5"x11"LEF (Letter)

H

H

L

L

L

11"x17"SEF(Ledger)

H

H

L

H

H

A4 LEF

H

L

L

L

L

A3 SEF

H

L

L

H

H

Figure 4 Document Path

Wiring Data

June, 2008 7-12


Figure 5 BSD 5.5 Document Size Sensing - DADF/Network Configuration Reissue WorkCentre 5016, 5020

June, 2008 7-13

Wiring Data

Figure 6 BSD 5.6 Document Setting & Transport - DADF/Network Configuration

Wiring Data

June, 2008 7-14


Figure 7 BSD 5.7 Document Feed & Transport Mechanism- DADF/Network Configuration


June, 2008 7-15

Wiring Data

Figure 8 BSD 5.8 Document Inversion - DADF/Network Configuration

Wiring Data

June, 2008 7-16


Figure 9 BSD 5.9 Document Path - DADF/Network Configuration Reissue WorkCentre 5016, 5020

June, 2008 7-17

Wiring Data

Chain 6 Imaging A

B

C

D

E

F

G

H

J

6.1 IMAGE INPUT 1

AIOC PWB PL8.1

LENS ASSEMBLY PL10.7

AIOC PWB PL8.1

IIT PWB CCD J410 22

CCD SHFT CLK0

CCD SHFT CLK1

24

J720 2,3,4,5 ,7,8,9, 10, 12,13, 14,16, 18,20

11

2 CCD RST CLK

26

CCD CLMP CLK

28

CCD TRNSF CLK

30

J410

J720

13

VIDEO DATA

33,32, 31,30, 28,27, 26,25, 23,22, 21,19, 17,15

LENS ASSEMBLY

9

7

5

3

PLATEN OPEN SWITCH


PLATEN OPEN SWITCH PL10.5

4 MAGNET J711 1

BLK


5-10 PLATEN OPEN SWITCH COVER CLOSED(L) +5VDC

+5VDC J711 BLK

2

A5-1

DC COM (2.1)

5

Fail Code A5-1

Platen Cover Open

6

Figure 1 6.1 Image Input

Wiring Data

June, 2008 7-18


A

B

C

D

E

F

G

H

J

6.2 CARRIAGE SCAN 1

AIOC PWB PL8.1

12

J409 CLOCK A

2

CARRIAGE MOTOR ON +24V CLOCK

YEL

CARRIAGE MOTOR PL10.6

EXPOSURE LAMP

IIT5 1

2

CARRIAGE MOTOR ON +24V CLOCK ORN

2

3

CARRIAGE MOTOR ON +24V CLOCK BRN

MOT

3

Fail Code

5 4

4

CARRIAGE MOTOR ON +24V CLOCK BLK

U2-1

CARRIAGE SENSOR turns High with the carriage to the left side. With the carriage at any location other than the location, sensor level is Low. When trying to move the carriage, run CARRIAGE MOTOR in diag. Run DC [5-23] to move the carriage until it reaches the left side, and then stop it. It can then be detected that CARRIAGE SENSOR turns High.

3 5

5

RED

Carriage Module Fail

4 1

CLOCK B

19

CN4 1

6

CLOCK B

18

3

Low speed return

7

CLOCK /B

17

Low speed scan

5-23

8

CLOCK /B

16

5-22

IIT PWB

CARRIAGE MOTOR CARRIAGE SENSOR

9

CLOCK /A

15

High speed return

10

CLOCK /A

14

High speed scan

5-21

J721

CLOCK A

13

5-20 LENS ASSEMBLY PL10.7

+24VDC (1.1) INVERTER PWB PL10.7 J410

4

32

EXPOSURE CN3 LAMP ON 2 GRY

J720 3

INV CN1

EXPOSURE LAMP PL10.6 INV CN2

2

DC COM 1 +24VDC (1.1)

3

GRY

GRY

1 LENS ASSEMBLY PL10.7

3

DC COM (1.1)

CARRIAGE SENSOR PL10.6

‚压Œx CAUTION High Voltage

5

AIOC PWB PL8.1

IIT PWB IIT4 2

5-11

CN3 GRY

J720 4

2

CARRIAGE SENSOR BLOCKED(H) +5VDC

1

+3.3VDC J410 33

U2-1

IIT4 6

6

+5VDC (1.1)

5

GRY

GRY

1

3

DC COM (1.1)

Figure 2 6.2 Carriage Scan Reissue WorkCentre 5016, 5020

June, 2008 7-19

Wiring Data

A

B

C

D

E

F

G

H

J

6.3 LASER CONTROL AND SCANNING 1

AIOC PWB PL8.1

ROS PL3.1 LD PWB

2

J404

J160

RED

RED

SOS PWB J201

2

3

J2011 1

LD PWB

SOS SENSOR

LD INTLK +5VDC

LD INTLK +5VDC 1

BLU

BLU

J2011

1

1

2

2

3

AIOC PWB PL8.1

+5VDC

J201

SOS SENSED SIGNAL

J140 2

6

J403 3

U3-5

DC COM LD INTLK +5VDC J403 6

LASER DIODE ENABLE ON(L) +5VDC

J140

BLU

BLU

1

GRN

LASER DIODE

4

3

GRN

T24

LD INTLK +5VDC

F171

F156

F170

PD

POWER CONTROL ON(L) +5VDC BLU

BLU

INLET FRAME

5

ROS GND

IIT GND

ROS GND

LD

6-16 5

ROS VREF OUT SIGNAL

6-17

BLU

BLU

BLU

BLU

Fail Code

4 COM

U3-5

Laser Power or ROS Motor Fail

9.2 1

8 LD INTLK +5VDC

4

2

BLU

BLU

7 LD PWB

DC COM (1.1) ROS MOTOR

6-15

9

5

10

7

ROS MOTOR ON(L) +5VDC BLU

P620 BLU

ROS MOTOR CLOCK BLU

BLU

BLU

BLU

BLU

BLU

J620

J130

2

3

3

1

4

1

4

1

5

3

2

4

MOT

+24VDC (1.1) 8

6

DC COM (1.1)

ROS MOTOR

SOS PWB

Figure 3 6.3 Laser Control and Scanning Wiring Data

June, 2008 7-20


Chain 7 Paper Supplying A

B

C

D

E

F

G

H

J

7.1 TRAY1 PAPER STACKING LVPS PL8.1

1 TRAY1 NO PAPER SENSOR PL2.7

2

7-7 J157

LVPS PL8.1

AIOC PWB PL8.1

1

BLU

J203

P203 3

1

TRAY1 NO PAPER SENSOR PAPER SENSED(L) +5VDC

+5VDC J501 BLU

5

P/ J407 A19

C5-0

+5VDC (1.1) J501 3

4

BLU

BLU

P203

J203 3

1

2

2

J157 BLU

BLU

3

2

DC COM (1.1) TRAY1 INTERLOCK SWITCH PL2.5

3

1-11

J161 9

BLU

BLU

J161 2

1

+5VDC

TRAY1 INTERLOCK SWITCH COVER OPEN(H) +5VDC

BLU

BLU

B22

10

E6-1

DC COM (1.1)

4

Fail Code TRAY1 NO PAPER SENSOR

C5-0

No paper in the selected paper tray (Tray1)

E6-1

L/H Lower Cover open

TRAY1 INTERLOCK SWITCH

5

6

Figure 1 7.1 Tray 1 Paper Stacking


June, 2008 7-21

Wiring Data

A

B

C

D

E

F

G

H

J

7.2 STM PAPER STACKING STM PWB PL11.5

1 STM NO PAPER SENSOR PL11.7

7-8 J171

STM PWB PL11.5

1

STM NO PAPER SENSOR PAPER SENSED(L) +5VDC

BLU

+5VDC J542 BLU

5

C6-0

+5VDC (1.1)

2

3

4

J542

J171

BLU

BLU

BLU

BLU

3

2

DC COM (1.1) STM INTERLOCK SWITCH PL11.5

3

1-10

J173 9

BLU

BLU

J173 2

1

+5VDC

STM INTERLOCK SWITCH COVER OPEN(H) +5VDC

BLU

BLU

10

E6-2

DC COM (1.1)

4

Fail Code C6-0

No paper in the selected paper tray (Tray2)

E6-2

STM L/H Cover open

STM NO PAPER SENSOR STM INTERLOCK SWITCH

5

6

Figure 2 7.2 STM Paper Stacking Wiring Data

June, 2008 7-22


Chain 8 Paper Transportation A

B

C

D

E

F

G

H

J

8.1 TRAY1 PAPER FEEDING LVPS PL8.1

1

TRAY1 FEED SENSOR PL2.5

8-7 1 BLU

AIOC PWB LVPS PL8.1 PL8.1

1

TRAY1 FEED SENSOR PAPER SENSED(L) +5VDC

J158

AIOC PWB PL8.1 +5VDC

J501 BLU

8

P/J407 A20

C2-2

+5VDC (1.1)

C8-1 J501

2

J158

6 BLU

BLU

7 BLU

BLU

3 2

DC COM (1.1)

TRAY1 FEED CLUTCH PL2.2

8-12 P/J407 A18

3

C1-1

2 BLU

TRAY1 FEED CLUTCH ON(L) +24VDC

P202 BLU

2

1

1

2

J202

DC COM

1 BLU

BLU

IOT Motor

+24VDC (1.1)

4

Fail Code

1

C1-1

Tray1 Feed Sensor on JAM

C2-2

Tray1 Feed Sensor on JAM from STM Feed

C8-1

Tray1 Feed Sensor Static JAM


TRAY1 FEED CLUTCH

TRAY1 FEED SENSOR Take Away Roll 1 Tray 1 Feed Roll

5

6

Figure 1 8.1 Tray 1 Paper Feeding


June, 2008 7-23

Wiring Data

A

B

C

D

E

F

G

H

J

8.2 STM PAPER FEEDING STM PWB PL11.5

1

STM FEED SENSOR PL11.5

8-6 J172 1 BLU

STM PWB PL11.5

1

+5VDC

STM FEED SENSOR PAPER SENSED(L) +5VDC

J542 BLU

8

C2-1 C8-2

+5VDC (1.1)

J542 6 BLU

2

J172 BLU

7 BLU

BLU

3 2

DC COM (1.1)

STM FEED CLUTCH PL11.6

8-11 2 BLU

3

STM FEED CLUTCH P212 ON(L) +24VDC BLU

2

1

1

2

J212 STM FEED CLUTCH

DC COM

1 BLU

BLU

STM FEED MOTOR

+24VDC (1.1)

8-13 J541 1 YEL

4

2 RED 3 ORN 4 BRN

STM FEED MOTOR ON +24V CLOCK

STM FEED MOTOR PL11.6

Take Away Roll 2

STM FEED MOTOR ON +24V CLOCK STM FEED MOTOR ON +24V CLOCK

STM FEED SENSOR MOT

STM FEED MOTOR ON +24V CLOCK

5 Tray 2 Feed Roll

Fail Code

6

1

C2-1

STM Feed Sensor on JAM

C8-2

STM Feed Sensor Static JAM


Figure 2 8.2 STM Paper Feeding Wiring Data

June, 2008 7-24


A

B

C

D

E

F

G

H

J

8.3 MANUAL BYPASS 1 AIOC PWB PL8.1

LVPS PL8.1

8-17 P/ J407 A5

J502 3

2

BYPASS SOLENOID PL7.5

BYPASS SOLENOID ON(L) +24VDC

RED

DC COM 1

RED

+24VDC (1.1)

3

BYPASS SOLENOID

4

Bypass Feed Roll

5

Bypass Take Away Roll

6

Figure 3 8.3 Manual Bypass Reissue WorkCentre 5016, 5020

June, 2008 7-25

Wiring Data

A

B

C

D

E

F

G

H

J

8.4 PAPER REGISTRATION LVPS PL8.1

1

IOT REGI. SENSOR PL2.9

8-5 1 BLU

AIOC PWB LVPS PL8.1 PL8.1

1

IOT REGI. SENSOR PAPER SENSED(L) +5VDC

J156

C1-2

C6-2 J156

C9-3

3 BLU

2 BLU

BLU

E1-6

2

DC COM (1.1)

IOT REGI. CLUTCH PL2.9

8-10 P/J407 A6

3

P/J407 A4

C2-3 J503 1 BLU

3

+5VDC

J503 BLU

+5VDC (1.1)

2

AIOC PWB PL8.1

4 BLU

IOT REGI. CLUTCH ON(L) +24VDC

P640 BLU

1

2

2

1

J640

DC COM

5 BLU

BLU

+24VDC (1.1)

IOT Motor

4

5

Fail Code

1

C1-2

Tray1 Regi. Sensor on JAM

C2-3

STM IOT Regi. Sensor on JAM

C6-2

Duplex IOT Regi. Sensor on JAM

C9-3

Manual Bypass IOT Regi. Sensor on JAM

E1-6

IOT Regi. Sensor Static JAM


IOT REGI. CLUTCH

IOT REGI. SENSOR

Regi. Roll

6

Figure 4 8.4 Paper Registration Wiring Data

June, 2008 7-26


A

B

C

D

E

F

G

H

J

8.5 PAPER PATH 1

2

ExitExit RollRoll EXIT MOTOR FUSER EXIT SENSOR Duplex Roll 1

3

Fuser IOT MOTOR

Regi. Roll

Duplex Roll 2 IOT REGI. SENSOR

4

Bypass Feed Roll

Bypass Take Away Roll Take Away Roll 1

5

Drum

TRAY1 FEED SENSOR TRAY1 NO PAPER SENSOR

Tray 1 Feed Roll Take Away Roll 2

STM NO PAPER SENSOR

STM FEED SENSOR

6

STM FEED MOTOR

Tray 2 Feed Roll

Figure 5 8.5 Paper Path Reissue WorkCentre 5016, 5020

June, 2008 7-27

Wiring Data

Chain 9 Marking A

B

C

D

E

F

G

H

J

9.1 XEROGRAPHICS ChargeCorotron

1

Drum AIOC PWB PL8.1

HVPS PWB PL8.2 9-4

DRUM CARTRIDGE PL4.1

Paper

CHARGE

9-5 J406 2

2

CHARGE ON(L) +5VDC

BLU

J520 BLU

GRID 2 Detack Saw

GND

DC COM 4

DEVE BIAS AC/DC ON(L) +5VDC BLU

BLU

Grid

DEVE BIAS

4

DC COM 5

TRANSFER ON(L) +5VDC BLU

BLU

TRANSFER COROTRON HOUSING PL4.3

5

DC COM 3

3

BLU

BLU

BLU

3

DC COM

9.3 9

INTLK +24VDC

4

8

BLU

BLU

BLU

BLU

TRANSFER

Deve Bias

9

INTLK +24VDC 7

Transfer Corotron

DETACK

TRANSFER S/D ON BLU

Magnet Roll GND

7

8

AIOC PWB PL8.1

DC COM (1.1)

+5VDC J520 1

HVPS ERROR(L) +5VDC

RED

J406 RED

1

U9-0

5

Fail Code U9-0

HVPS fail

6

Figure 1 9.1 Xerographics

Wiring Data

June, 2008 7-28


A

B

C

D

E

F

G

H

J

9.2 TONER SENSE AND CRUM 1

TONER EMPTY SENSOR PL4.2

LVPS PL8.1 J509 1 BLU

P110 BLU

4

J110 1 RED

LVPS PL8.1 J110 WHT

2

P110 3 BLU

+24VDC (1.1)

3 BLU

BLU

2

3 BLK

GRN

4

1 BLU

J509 BLU

9-7

TONER EMPTY SENSOR TONER SENSED(L) +5VDC BLU

AIOC PWB PL8.1

2 +5VDC

4

P/J407 B4

J1-2

DC COM (1.1)

2

AIOC PWB PL8.1

DRUM CARTRIDGE PL4.1 CRUM

+12VDC

3.2

J402 1 BLU

CRU ID

P610 BLU

7

1

3

5

J610

J6-1 2

J7-1

3 4 BLU

BLU

DC COM (1.1) INTLK +5VDC +24VDC (1.2)

5 BLU 2 BLU

4

BLU

INTLK +5VDC BLU

2

6

5

3

J7-2

1

9-2 J610

P610

4

4 BLU

7

1 BLU

1

DRUM CARTRIDGE SENSED(L) +5VDC

+5VDC

J402 BLU

6.3

INTLK +5VDC BLU

6 INTLK +5VDC

5

6

1

J1-2

Toner Empty

J3-1

No Drum cartridge

J6-1

Drum cartridge life end

J7-1

Drum CRUM communication error

J7-2

Drum CRUM Market identity mismatch

J7-3

Drum CRUM ID error

J3-1

3

DC COM

Fail Code

J7-3


CRUM

TONER EMPTY SENSOR

DRUM CARTRIDGE

Figure 2 9.2 Toner Sense and CRUM Reissue WorkCentre 5016, 5020

June, 2008 7-29

Wiring Data

A

B

C

D

E

F

G

H

J

9.3 ERASE LAMP 1 AIOC PWB PL8.1

HVPS PWB PL8.2

J406 6

2

BLU

ERASE LAMP ON(L) +5VDC

ERASE LAMP PL4.2

+24VDC

9-6 J520 BLU

J521 6

1 DC COM

J210

BLU

1

DC COM 3

BLU

3

DC COM 2

BLU

2

ERASE LAMP

INTLK +24VDC (9.1)

3

4

5

6

Figure 3 9.3 Erase Lamp Wiring Data

June, 2008 7-30


Chain 10 Fusing and Copy Transportation A

B

C

D

E

F

G

H

J

10.1 FUSER TEMPERATURE CONTROL 1

AIOC PWB PL8.1

+5VDC

LVPS PL8.1

FUSER PL5.1 THERMOSTAT

P/ J407 B6

J3 3

BLK

J600

FUSER LAMP ON ACH

2

BLK

F28

F25

BLK

DC COM

2

ACH SWITCHED (1.1)

FUSER LAMP F26

B5

AIOC PWB PL8.1

DC COM F27 1

3

+24VDC INTLK (1.2)

WHT

WHT

1 U4-1

ACN (1.1)

10-20

THERMISTOR 2

J408

P601

BLU

BLU

J601 2

J601

1

P601 2

1

+5VDC

FUSER THERMISTOR SENSED SIGNAL

BLU

U4-2

J408 BLU

1

U4-3

DC COM (1.1)

4 Fail Code

FUSER LAMP

5

U4-1

Fuser On Time Fail

U4-2

Over Heat Temp Fail

U4-3

FS1 thermistor defect

THERMISTOR THERMOSTAT

6

Figure 1 10.1 Fuser Temperature Control


June, 2008 7-31

Wiring Data

A

B

C

D

E

F

G

H

10.2 EXIT AND DUPLEX 1

10-8 10-9

AIOC PWB PL8.1

LVPS AIOC PWB PL8.1 PL8.1

DUPLEX PWB PL8.2

EXIT MOTOR J416 CURR J550

1 BLU EXIT MOTOR ON CLOCK 8 BLU 2 BLU EXIT MOTOR ON CLOCK 7 BLU 3 BLU

9 BLU

2

6 BLU 5 BLU

EXIT MOTOR ON CLOCK BLU

EXIT MOTOR ON CLOCK BLU

J

EXIT MOTOR J551 ON +24V CLOCK

FUSER EXIT SENSOR PL6.3

EXIT MOTOR PL6.3

5 BLK

4

4 ORN

5

3 BRN

EXIT MOTOR ON +24V CLOCK

1

+5VDC

3 BLU

P/J407 A3

E1-2 E3-1 E3-6

+5VDC

J505J153 1 BLU BLU 3

EXIT MOTOR ON +24V CLOCK EXIT MOTOR ON +24V CLOCK

J153

1 BLU

LVPS PL8.1

6 YEL

10-23

FUSER EXIT SENSOR J505 PAPER SENSED(L) +5VDC

MOT

2 BLU

BLU

2

DC COM (1.1)

2 RED F1

3

1 RED

INTLK +24VDC (1.2)

Simplex Transport:

Duplex (Side 2) Transport:

Exit Roll is driven by IOT Motor.

Exit Roll is driven by EXIT Motor.

Fail Code

E1-2

4

Fuser Exit Sensor on JAM

E3-1 Fuser Exit Sensor off JAM

E3-6

EXIT MOTOR Exit Roll

Fuser Exit Sensor Static JAM

Exit Roll

5 1 The actual H/L level is displayed inversely on the UI display. IOT Motor

IOT Motor

6

FUSER EXIT SENSOR

FUSER EXIT SENSOR

Figure 2 10.2 Exit Wiring Data

June, 2008 7-32


A

B

C

D

E

F

G

H

J

10.3 MACHINE COOLING 1

AIOC PWB PL8.1 1

4-2

+24VDC J405 3

NOHAD FAN PL9.2

AIOC PWB PL8.1

NOHAD FAN ON(H) +24VDC

RED

2

2

+5VDC

10-60

MOT

NOHAD FAN FAIL(H) +5VDC BLK

J405 BLU

1

U4-9

DC COM (1.1)

Fail Code

3

U4-9

1 Nohad Fan defect

NOHAD FAN rotates at low speed when Diag is off, and at high speed when Diag is on. Voltage levels are as follows: Low Speed: approx. 15VDC High Speed: approx. 24VDC

4 NOHAD FAN

5

6

Figure 3 10.3 Machine Cooling Reissue WorkCentre 5016, 5020

June, 2008 7-33

Wiring Data

Wiring Data

June, 2008 7-34


Wirenets 7.2.1 WIRE NET AC POWER (HOT) POWER CORD

POWER SWITCH

FS11

FS31

LOW VOLTAGE POWER SUPPLY


1.1

CHOKE COIL J5

FS32

J5

1 BLK

FS60

BLK BRN

2 BLK

1

BLK

GN/YL WHT

(SEE WIRE NET AC POWER (NEUT)) FUSER J3

P600

3

J600 2

1

F28

THERMOSTAT

F25

10.1

F26 FUSER LAMP

BLK

BLK

Wire Color BLK: 100V M/C, BRN: 200V M/C

7.2.2 WIRE NET AC POWER (NEUT) POWER CORD

POWER SWITCH

FS12

FS33


FUSER

FS34

J3 1

WHT

FS60

WHT BLU

P600

J600 1

10.1

F27 FUSER LAMP

WHT 1

GN/YL BLK

1

(SEE WIRE NET AC POWER (HOT))

DC POWER GENERATION

Wire Color WHT: 100V M/C, BLU: 200V M/C


June, 2008 7-35

Wiring Data

7.2.3 WIRE NET +3.3VDC LOW VOLTAGE POWER SUPPLY

LENS ASSEMBLY AIOC PWB

+3.3VDC

IIT PWB

P/J407 A16

4

A17

5

J409

J721

17 FLAT CABLE

B16 B17 B6

Wiring Data

18

J414

June, 2008 7-36

YEL

J731

ADF PWB B7


7.2.4 WIRE NET +5VDC-1 LOW VOLTAGE POWER SUPPLY J501

P203

3

J203 3

J157

1

3 BLU

BLU

6

7.1

8.1

J158 +5VDC

TRAY1 NO PAPER SENSOR

3

TRAY1 FEED SENSOR

3

IOT REGISTRATION SENSOR

3

FUSER EXIT SENSOR

BLU J503

J156

1 BLU J505

8.4

10.2

J153

1 BLU

STM PWB J508

J540

1

J542 1

J171

3

3

STM NO PAPER SENSOR

3

STM FEED SENSOR

BLU

GRY

8.2

J172 6

7.2

BLU

AIOC PWB P/J407 A11

J401

USER INTERFACE PWB

J710

1

2.1

8 BLU

B11

2

7 BLU

(SEE WIRE NET +5VDC-2)


June, 2008 7-37

Wiring Data

7.2.5 WIRE NET +5VDC-2 (FROM WIRE NET +5VDC-1) LENS ASSEMBLY IIT PWB 6

J409

J721

7

16

6

CN3

IIT4

CARRIAGE 1 SENSOR

6.2

DF3

DOCUMENT TRAY 1 WIDTH SENSOR1

5.1

DF2


5.1

DF5

DOCUMENT TRAY 1 LENGTH SENSOR1

5.1

DF4


5.1

DF8

DOCUMENT 1 FEEDER WIDTH SENSOR

5.1

DF9

DOCUMENT SET 1 SENSOR

5.2

DOCUMENT LEAD 1 EDGE SENSOR

5.2

GRY

15 FLAT CABLE

3

B5

J416

J550

BLU

J414 YEL

J731

7 DUPLEX PWB

ADF PWB B8

1

CN4 WHT

WHT

AIOC PWB

5

WHT

WHT

3

6

CN5 WHT

WHT

DF10 WHT

Wiring Data

June, 2008 7-38


7.2.6 WIRE NET DC COM (+5V RTN)-1 LOW VOLTAGE POWER SUPPLY J501

P203

4

J203 2

J157

2

2 BLU

BLU

7

7.1

8.1

J158 +5VRTN

TRAY1 NO PAPER SENSOR

2

TRAY1 FEED SENSOR

2

TRAY1 INTERLOCK SWITCH

2

IOT REGISTRATION SENSOR

2

FUSER EXIT SENSOR

BLU J161 9 BLU J503

J156

2 BLU J505

7.1

8.4

10.2

J153

2 BLU

STM PWB J508

J540

3

J542 2

J171

4

VIO

2

STM NO PAPER SENSOR

2

STM FEED SENSOR

2

STM INTERLOCK SWITCH

BLU

8.2

J172 7

7.2

BLU J173 9 BLU

J509 3

P110

J110 2

BLU

3 BLK

TONER EMPTY SENSOR

7.2

9.2

(SEE WIRE NET DC COM (+5VRTN)-2)


June, 2008 7-39

Wiring Data

7.2.7 WIRE NET DC COM(+5V RTN)-2 (FROM WIRE NET DC COM(+5VRTN)-1) LOW VOLTAGE POWER SUPPLY

AIOC PWB P/J407 A12

A13

B12

DRUM CARTRIDGE 4

J402 BLU

5

4

P610

BLU

J416

J550

BLU

5

2

6

6

J610

1 CRUM

9.2

DUPLEX PWB

LENS ASSEMBLY IIT PWB J721 21

B13 1

3

J409

2

20 FLAT CABLE

+3.3VRTN

A14

A15

B14

B14

1

J410

J720

6

29

11

24

15

20

17

18

19

16

21

14

23

12

25

10

27

8

29

6

31

4

34 (SEE WIRE NET DC COM(+5VRTN)-3)

Wiring Data

34

5

CN3 GRY

IIT4

CARRIAGE 3 SENSOR

6.2

1 FLAT CABLE

June, 2008 7-40


7.2.8 WIRE NET DC COM(+5V RTN)-3 (FROM WIRE NET DC COM(+5VRTN)-2)

3

4

10

J401

J710

BLU

USER INTERFACE PWB

6

2

J711

PLATEN OPEN SWITCH

BLK

6.1

5

BLU

J630 BLU

1

2

P630

BILLING COUNTER

3.2

ROS 2

J403

J140

BLU

6.3

7 LD PWB

FUSER 2

J408

P601

BLU

2

1

J601

THERMISTOR

10.1

ADF PWB B3

J414 YEL

J731

B10

2

CN4

DF3


5.1

DF2


5.1

DF4


5.1

DF5


5.1

DF14

ADF TOP COVER 1 SWITCH

5.2

DF8

DOCUMENT 3 FEEDER WIDTH SENSOR

5.1

DF9

DOCUMENT SET 3 SENSOR

5.2

DOCUMENT LEAD 3 EDGE SENSOR

5.2

WHT

WHT

B4

YEL

B9

6

WHT

WHT

2

4

7

AIOC PWB


9

June, 2008 7-41

CN5 WHT

WHT

WHT

DF10 WHT

Wiring Data

7.2.9 WIRE NET +24VDC-1 LH COVER INTERLOCK SWITCH

LOW VOLTAGE POWER SUPPLY 4

+24VDC

J506

FS151

ORN

3

1

FRONT COVER INTERLOCK SWITCH

LOW VOLTAGE POWER SUPPLY FS152

J506

ORN

3

2

J506

FS153

ORN

3

1

FS154 ORN

F1

J506 ORN

F3

1

1

F2

J504

J201

BLU

4.1

1 IOT MOTOR

J508 N.C

4

AIOC PWB P/J407 A1

9

B1

1

J406

P520

BLU

J416

J550

BLU

9

HIGH VOLTAGE POWER SUPPLY

2

DUPLEX PWB 9

1 2

1

1

5

J501

P202

BLU

1

J502

J202

P640

BLU

2

1

TRAY1 FEED CLUTCH

8.1

IOT REGISTRATION CLUTCH

8.4

BLU

J210

2 ERASE LAMP

10.2

J551 RED

9.3

EXIT MOTOR

RED

8.3

BYPASS SOLENOID

RED

J503

2

J521

J640

STM PWB 10

J508 ORN

J540

7

1

J542

P212

BLU

1

2

J212

STM FEED CLUTCH

8.2

(SEE WIRE NET +24VDC-2)

Wiring Data

June, 2008 7-42


7.2.10 WIRE NET +24VDC-2 (FROM WIRE NET +24VDC-1)

J509

1

P110

BLU

4

1

J110 RED

AIOC PWB P/J407 A7

9.2

TONER EMPTY SENSOR ROS

7

J403

P620

BLU

4

1

J620

J130

6.3

5 ROS MOTOR

A8 LENS ASSEMBLY B7 9 B8

J409

J721

IIT PWB 13

10

12

11

11

5

1

FLAT CABLE

B1

B2

J414 YEL

YEL

J731

ADF PWB B12

1

B11

1

CN4

CN3


INV CN1

GRY

CN3 WHT

DF13

6.2

CARRIAGE 5 MOTOR INVERTER 1PWB

2

1

6.2

DF13

WHT

DOCUMENT FEED CLUTCH

5.3

5.3

CN2


4

IIT5

RED

DOCUMENT DRIVE MOTOR

BLK

June, 2008 7-43

Wiring Data

7.2.11 WIRE NET DC COM(+24V RTN) LOW VOLTAGE POWER SUPPLY

+24VRTN

J504

2

J201

BLU J508

8

J540

VIO

4.1 2 IOT MOTOR

5 STM PWB

AIOC PWB

ROS

P/J407 A7

8

A8

2

B1

7

B7

8

J403

P620

BLU

3

2

J620

6.3

J130

4 ROS MOTOR

10.3

J405

NOHAD FAN

BLK J406

J520

BLU

9.1

HIGH VOLTAGE 7 POWER SUPPLY

8

BLU

LENS ASSEMBLY

B8

20

J409

J721

21

IIT PWB 2

3

CN3 GRY

INV CN1

3

INVERTER PWB

6.2

1 FLAT CABLE

2

A11

A12

Wiring Data

J416

J550

BLU J414 YEL

YEL

J731

8 DUPLEX PWB

A2

ADF PWB

A1

June, 2008 7-44


7.1 P/J Locations 7.1.1 How to Use the P/J Locations The installation location of a connector can be checked by referring to its Fig No. and Item No. from the P/J No. in the 7.1.2 PJ List.


June, 2008 7-45

Wiring Data

7.1.2 P/J List

Table 1 Table 1

P/J No.

Figure No.

Item No.

Description

INV CN1

Figure 1

2

Inverter PWB

P/J No.

Figure No.

Item No.

Description

INV CN2

Figure 1

1

Inverter PWB

CN1

Figure 12

1

DADF Control PWB

J333

Figure 13

23

SLCC PWB

CN2

Figure 11

6

ADF PWB

J340

Figure 13

22

SLCC PWB

CN2

Figure 12

6

DADF Control PWB

J341

Figure 13

21

SLCC PWB

CN3

Figure 11

5

ADF PWB

J342

Figure 13

20

SLCC PWB

CN3

Figure 12

5

DADF Control PWB

J411

Figure 7

1

AIOC PWB

CN4

Figure 11

2

ADF PWB

J508

Figure 6

8

STM

CN4

Figure 12

2

DADF Control PWB

J610

Figure 8

2

CRU

CN5

Figure 11

4

ADF PWB

NBCR CN6

Figure 1

7

NBCR PWB

CN5

Figure 12

4

DADF Control PWB

NSC CN1

Figure 1

8

NSC PWB

CN6

Figure 12

3

DADF Control PWB

P412

Figure 7

14

AIOC PWB

CN7

Figure 12

7

DADF Control PWB

P417

Figure 7

16

AIOC PWB

DF2

Figure 10

3


P418

Figure 7

15

AIOC PWB

DF3

Figure 10

2


P419

Figure 7

2

AIOC PWB

DF4

Figure 10

4


P508

Figure 9

15

LVPS

DF5

Figure 10

5


P610

Figure 8

9

CRU

DF8

Figure 10

6

Document Feeder Width Sensor

P/J3

Figure 9

18

Fuser Lamp

DF9

Figure 10

7

Document Tray Set Sensor

P/J5

Figure 9

17

Choke Coil

DF10

Figure 10

8

Document Lead Edge Sensor

P/J5

Figure 13

3

SLCC PWB

DF13

Figure 10

1

ADF Top Cover Switch

P/J110

Figure 3

6

Toner Empty Sensor

DF14

Figure 11

3

ADF Top Cover Switch

P/J130

Figure 2

2

ROS MPA

DF14

Figure 12

14

Feeder Cover Switch

P/J140

Figure 2

5

ROS

F25

Figure 5

1

Fuser Thermostat

P/J153

Figure 4

1

Fuser Exit Sensor

F26

Figure 5

4

Fuser Lamp

P/J156

Figure 4

4

IOT Regi. Sensor

F27

Figure 5

3

Fuser Lamp

P/J157

Figure 3

7

Tray 1 No Paper Sensor

F28

Figure 5

2

Fuser Thermostat

P/J158

Figure 4

6

Tray 1 Feed Sensor

FS11

Figure 9

4

Inlet

P/J160

Figure 2

6

ROS, Video

FS12

Figure 9

6

Inlet

P/J161

Figure 4

5

Tray 1 Interlock Sensor

FS151

Figure 4

8

LH Cover Interlock Switch

P/J171

Figure 6

2

STM No Paper Sensor

FS152

Figure 4

7

LH Cover Interlock Switch

P/J172

Figure 6

1

STM Feed Sensor

FS153

Figure 3

4

Front Cover Interlock Switch

P/J173

Figure 6

3

STM Interlock Switch

FS154

Figure 3

5

Front Cover Interlock Switch

P/J201

Figure 8

6

IOT Motor

FS31

Figure 9

7

Power Switch

P/J201

Figure 2

4

ROS, SOS PWB

FS32

Figure 9

1

Power Switch

P/J2011

Figure 2

1

ROS, SOS PWB

FS33

Figure 9

3

Power Switch

P/J202

Figure 8

7

Tray 1 Feed Clutch

FS34

Figure 9

2

Power Switch

P/J203

Figure 8

8

Tray 1 No Paper Sensor

FS60

Figure 9

5

Inlet GND

P/J210

Figure 3

1

Erase Lamp

IIT4

Figure 1

5

Carriage Sensor

P/J212

Figure 6

4

STM Feed Clutch

IIT5

Figure 1

6

Carriage Motor

P/J380

Figure 13

6

SLCC PWB

Wiring Data

June, 2008 7-46


Table 1

Table 1

P/J No.

Figure No.

Item No.

Description

P/J No.

Figure No.

Item No.

Description

P391

Figure 13

24

SLCC PWB

P/J550

Figure 8

3

Duplex PWB

P/J401

Figure 7

6

UI

P/J551

Figure 8

4

Duplex PWB

P/J401

Figure 13

7

SLCC PWB

P/J600

Figure 4

2

Fuser Lamp

P/J402

Figure 7

11

CRU ID

P/J601

Figure 4

3

Fuser Thermistor

P/J402

Figure 13

13

SLCC PWB

P/J620

Figure 2

3

ROS MPA

P/J403

Figure 7

12

ROS

P/J630

Figure 8

1

Billing ID

P/J403

Figure 13

14

SLCC PWB

P/J640

Figure 8

5

IOT Regi Clutch

P/J404

Figure 7

5

ROS, Video

P/J710

Figure 1

9

UI

P/J404

Figure 13

19

SLCC PWB

P/J711

Figure 1

10

Platen Switch

P/J405

Figure 7

9

Nohad Fan

P/J720

Figure 1

4

IIT Data

P/J405

Figure 13

12

SLCC PWB

P/J721

Figure 1

3

IIT Power

P/J406

Figure 7

8

HVPS

P/J731A/B

Figure 11

1

ADF

P/J406

Figure 13

10

SLCC PWB

P/J801

Figure 12

11

Document Feed Clutch

P/J407

Figure 9

16

LVPS-AIOC PWB

P/J802

Figure 12

12

Exit/Invert Sensor

P/J407

Figure 13

18

LVPS-SLCC PWB

P/J803

Figure 12

13

Registration Sensor

P/J408

Figure 7

13

AIOC PWB

P/J804

Figure 12

10

Registration Clutch

P/J408

Figure 13

15

SLCC PWB

P/J805

Figure 12

9

Exit/Invert Clutch

P/J409

Figure 7

4

AIOC PWB

P/J806

Figure 12

8

Exit/Invert Solenoid

P/J409

Figure 13

5

SLCC PWB

P/J410

Figure 7

3

AIOC PWB

P/J410

Figure 13

4

SLCC PWB

P/J412

Figure 13

16

SLCC PWB

P/J414A/B

Figure 7

7

AIOC PWB

P/J414A/B

Figure 13

8

SLCC PWB

P/J415

Figure 13

9

SLCC PWB

P/J416

Figure 7

10

AIOC PWB

P/J416

Figure 13

11

SLCC PWB

P/J418

Figure 13

17

SLCC PWB

P/J501

Figure 9

13

LVPS

P/J502

Figure 9

10

LVPS

P/J503

Figure 9

12

LVPS

P/J504

Figure 9

9

LVPS

P/J505

Figure 9

14

LVPS

P/J506

Figure 9

11

LVPS

P/J509

Figure 9

8

LVPS

P/J520

Figure 3

3

HVPS

P/J521

Figure 3

2

HVPS

P/J540

Figure 6

7

STM

P/J541

Figure 6

5

STM Feed Motor

P/J542

Figure 6

6

STM (TOTAL CL, SNR, SW)


June, 2008 7-47

Wiring Data

Figure 1 IIT Wiring Data

June, 2008 7-48


Figure 2 ROS


June, 2008 7-49

Wiring Data

Figure 3 HVPS

Wiring Data

June, 2008 7-50


Figure 4 LH


June, 2008 7-51

Wiring Data

Figure 5 Fuser

Wiring Data

June, 2008 7-52


Figure 6 STM


June, 2008 7-53

Wiring Data

Figure 7 AIOC PWB

Wiring Data

June, 2008 7-54


Figure 8 Rear


June, 2008 7-55

Wiring Data

P/ J503

P/ J505

Figure 9 Inlet & LVPS Wiring Data

June, 2008 7-56


Figure 10 ADF/DADF


June, 2008 7-57

Wiring Data

Figure 11 ADF 2

Wiring Data

June, 2008 7-58


Figure 12 DADF Control PWB


June, 2008 7-59

Wiring Data

Figure 13 SLCC PWB

Wiring Data

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Xerox WorkCentre 5016 5020 Service manual

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