Xerox WorkCentre

WorkCentre 5020 Service Documentation WorkCentre 5020 Service Documentation 701P47442 Initial Issue July, 2007 ***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. 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. 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. Copyright 2007 Xerox Corporation. All rights reserved. Global Knowledge & Language Services 800 Phillips Road - Bldg. 845-17S Webster, New York 14580-9791 USA Printed in the United States of America. XEROX, The Document Company, the stylized X and the identifying product names and numbers herein are trademarks of XEROX CORPORATION. All non-Xerox brands and product names are trademarks or registered trademarks of their respective companies
CAUTION This equipment generates, uses and can radiate radio frequency energy, and if not installed and used in accordance with the instructions documentation, may cause interference to radio communications. It has been tested and 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.
WorkCentre 5020
July, 2007 i
WorkCentre 5020
July, 2007 ii
Introduction
How To Use This Manual................................................................................................ iii
Initial Issue WorkCentre 5020
July, 2007 i
Introduction
Introduction
July, 2007 ii
How To Use This Manual

This manual is used as the standard service manual for the WorkCentre 5020. Enter any comments and/or corrections regarding the WorkCentre 5020 service manual on the Publication Comment Sheet, and send it to the Technical Support Center SDEG. This manual describes the standard procedures for servicing the WorkCentre 5020. Refer to Section 1 Service Call Procedure for efficient and effective servicing during maintenance calls.
Chain 3 Machine Run Control Chain 4 Start Print Power Chain 6 Imaging Chain 7 Paper Supplying Chain 8 Paper Transportation Chain 9 Marking Chain 10 Fusing and Copy Transportation
Contents of Manual
This manual is divided into nine sections as described below. Section 1 Service Call Procedures This section describes the structured process for determining the type and sequence of actions that are performed during a service call. Section 2 Status Indicator RAPs This section contains the Repair Analysis Procedures (RAPs) necessary to repair all faults other than image quality faults. Section 3 Image Quality RAPs This section contains the Repair Analysis Procedures (RAPs) that are used to diagnose image quality defect problems. Section 4 Removal/Replacement and Adjustment Procedures
Description of Terminology and Symbols

The terminology and symbols used throughout this service manual are described as follows:
WARNING
A Warning statement indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in personal injury or loss of life. CAUTION A Caution statement indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in damage to, or destruction of, equipment. NOTE: A Note statement indicates an operating or maintenance procedure, practice, or condition that is necessary to accomplish a task efficiently. Reference: Used when other explanations are given. Purpose: Used to describe the purposes of adjustment and troubleshooting. REP:
This section contains the removal, replacement, and adjustment procedures for components of WorkCentre 5020. Section 5 Parts List This section contains a list of spare parts list for the WorkCentre 5020. Section 6 General Procedures/Information This section contains frequently used procedures that relate to the diagnosis, setup, or operation of the machine. It also contains pertinent information that will not be found in any other part of the service documentation. Section 7 Wiring Data This section contains the wiring information for the WorkCentre 5020. It contains a connector list/locator, wirenet diagrams, and Block Schematic Diagrams (BSDs) for the following chains: Chain 1 Standby Power Chain 2 Mode Selection Initial Issue WorkCentre 5020
Indicates the removal/replacement procedure for reference. ADJ: Indicates the adjustment procedure for reference. PL: Indicates the parts list for reference. ASSY: Means Assembly. Safety Critical Components (SCC): These are components, such as electrostatic-sensitive IC chips, which could be damaged if not handled properly. Follow the regulations regarding Safety Critical Components set by FUJI XEROX Co., Ltd.
July, 2007 iii
Introduction
Introduction
July, 2007 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
July, 2007 1-1
Service Call Procedures
July, 2007 1-2
1.1 Before Starting Service

1.1.1Safety
To prevent any accident that may occur during maintenance service, any warning or any caution regarding the service must be strictly observed. Do not perform any hazardous operation. 1. Power Supply To prevent electrical shocks, burns, or injury, etc., be sure to switch OFF the machine and disconnect the plug before starting the maintenance service. If the machine has to be switched ON, such as when measuring a voltage, take extra care to avoid an electrical shock. 2. Drive Area Never inspect, clear or lubricate the drive components, such as chain belts, chain wheels or gears, when the machine is in operation. 3. Heavy Parts When removing or installing heavy parts, keep your back straight and lift with your legs. Some parts should not be lifted by one person: IOT (Platen): 31.5kg (requires 3 persons) 2 Tray Modules: 8.6kg (requires 2 persons) Take extra care of your working posture to prevent backache. 4. Safety Devices See that safety devices for preventing accidents, such as fuses, circuit breakers, interlock switches, etc., and those for protecting customers from injury, such as panels and covers, function properly. Modifications that hinder the function of any safety devices are strictly prohibited. 5. Installing and Removing Parts The edges of parts and covers may be sharp, so take care not to touch them. Be careful not to touch those parts, and wipe off any oil that may have adhered to your fingers or hands before servicing. When pulling out parts, cables, etc., do it gently. Do not use excessive force. 6. 7. Specified Tools Follow the instructions when a particular tool is specified. 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. Check the Service Guide for more information on the earthquake preparedness kit. 9. Modifications to the Machine Before altering the machine, submit an irregular use license application. 10. Other Safety Precautions Follow the recommendations in WORKING PRACTICES FOR ENGINEERS issued by FXAP EH&S (Environmental Health and Safety).
1.1.2Things to Note When Handling Customer Data

1. Handling of copied/printed customer data. Before you bring back any sample for the purpose of investigation/analysis, always obtain permission from the customer. Make sure you assure them that the data will not be used for any other purpose. 2. Security-related NVM values that were changed during diagnostics. If any security-related NVM values, such as polling, were set for test purposes, make sure you restore them to their original values after the test. 3. Other things to note when handling customer data. Follow the safety guidelines established within the OpCo and ensure that customer data do not get compromised during service.
1.1.3 Other Precautions

To avoid performing wrong or unnecessary service, observe the following: 1. 2. Reference Materials Read all relevant service documentation, so that you can take a systematic approach. Disassembling Make sure to note the assembled condition of the machine before removing parts or disassembling it. 3. Installation and Adjustment After the installation or adjustment is complete, check that no parts or tools are left inside the machine. 4. Handling of replaced parts and consumables Make sure that any replaced parts or consumables, as well as the packaging materials, are taken back to the Service Center.
WARNING
Never discard the Drum/Toner Cartridges into a fire. Always keep them away from open flames to prevent them from igniting and causing a fire. NOTE: For separation and processing methods for replaced parts or consumables, refer to Common Technical Information No. 2-138 for all machines. If you have replaced the following consumables, affix the "U-TAG" so that the recyclable parts will be handled appropriately. a. b. 5. Drum Cartridge Toner Cartridge
For recyclable parts, fill in the necessary items on the "U-TAG." 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
General Precautions
July, 2007 1-3
1.1
1.2 Service Call Procedure

1.2.1 Initial Actions
1. 2. 3. 4. 1. 2. Ask the operator(s) about the machines condition. Record the billing meter readings. Inspect any faulty copies, then check the machine. Check the Service Log. Perform the service flow in Section 2 Status Indicator RAPs. Perform the applicable RAP in Section 2 Status Indicator RAPs. If there are no applicable RAPs, troubleshoot by referring to the BSD in Section 7 Wiring Data. 3. 4. Check the copy quality. Make several copies using the Test Pattern (499T247), then check the quality. Look at the last 20 error codes in order to understand the machine status. 5. 6. 1. 2. 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.
1.3 Service Call Details

1.3.1 Initial Actions
1. Ask the operator(s) about the machines condition. 2. 3. 4. 1. 2. 3. Frequency and location of recent paper jams Copy quality
Record the billing meter readings. Inspect any faulty copies, then check the machine. Check the copy sample and the Service Log from the last call. Perform the service flow in Section 2 Status Indicator RAPs. Perform the applicable RAP in Section 2 Status Indicator RAPs. If there are no applicable RAPs, troubleshoot by referring to the BSD in Section 7 Wiring Data. Make several copies using the Test Pattern (499T247), then check the quality. If there is a problem in copy quality, perform the applicable RAP in Section 3 Image Quality.
1.2.2 Actions to Take During UM (Unscheduled Maintenance)
1.3.2 Checking Reproducibility of Problem
1.3.3 Checking Copy Quality

1. 2.
1.3.4 TRIM Servicing

Perform TRIM servicing during the maintenance call. 1. 2. Perform the necessary TRIM items using the TRIM Checklist. 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 Func.
Repair all the secondary problems. Perform TRIM servicing. Check the copy quality. Make several copies using the Test Pattern (499T247), then check the quality. Look at the last 20 error codes in order to understand the machine status. Enter Diagnostic Mode. Enter [40-01] (Display Error History How to Enter the 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.
1.2.3 Actions to Take During SM (Scheduled Maintenance)
3. 1. 2. 3. 4. 5.
Perform TRIM servicing. Check overall machine operation/features. Check the machine exterior and consumables. Train the operator as required. Complete the Service Log and Service Report. Keep the copy samples with the Service Log.
1.2.4 Final Actions
1.2, 1.3
July, 2007 1-4
1.4 TRIM Checklist

A: Check. Clean, replace, or replenish if necessary. B: Always check and clean. *: Always replace at the specified interval. Table 1 No. 1.1 1.2 2 Service Items Every time Service Details Turn on the machine, and make sure that there are no abnormal sounds. Make several copies using the Test Pattern (499T247), then check the image quality. Clean the paper dust and toner residue in the paper path and on the jam sensor. 5 Safety Precautions B Clean the Platen Glass surface and the Platen Cushion with the optical cleaning cloth. Clean the Reflector, back of the Platen Glass, mirrors and lens with the optical cleaning cloth. 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.
1.5 Periodic Replacement Parts/Consumables List

When servicing the machine, check the number of copies and the replacement interval for the consumables and parts that require periodical cleaning/replacement. Clean or replace them if necessary. The IOT history can be checked at Chain-Function > NVRAM R/W, while the IIT history can be checked in the Counters (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). CAUTION Do not keep toner and drum cartridges in your car for long periods of time. Table 1 No 1 Parts/Consumables Name/PL No. Tray 1 Feed Roll/ Retard Pad Tray 2 Feed Roll/ Retard Roll MSI Feed Roll/ Retard Pad Fuser Unit Toner Cartridge Drum Cartridge Replacement Interval (copies) Counters Check 50,000 [29/34] [29/24] [29/14] [29/4] Count up 1 for every feed. Replace both at the same time. [29/25] [29/15] [29/5] Count up 1 for every feed. Replace both at the same time. [29/39] [29/29] [29/19] [29/9] Count up 1 for every feed. Replace both at the same time. [21/39] [21/29] [21/19] [21/9] Count up 1 for every feed. 31,000 (Warning) 36,000 (Machine Stops)
Check before servicing A (check machine operation) Check before Servicing (copy the Test Pattern) Clean the interior of the machine (paper transport system) Clean the IIT A A
100,000
50,000
4 5 6
100,000 6,000 36,000
6.1 6.2 Check after servicing (copy quality check) A
Make several copies using the Test Pattern (499T247), then check the image quality. Check the paper feed. Make sure that there are no abnormal sounds.
Check after servicing A (check machine operation) Check after servicing (check the meter) A
6.3
Create the Service Log and Service Report.
CAUTION Do not touch the Drum of the Drum Cartridge.
July, 2007 1-5
1.4, 1.5
1.4, 1.5
July, 2007 1-6
2 Status Indicator RAPS

Error Codes
Fault Repair Overview and List of Error Codes............................................................... 2-3 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
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..............................................................................................................
July, 2007 2-1
Status Indicator RAPS
July, 2007 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
July, 2007 2-3
Check the Status of Installation Before starting to troubleshoot, always check the following items: The voltage of the power supply (measure the voltage at the power outlet to see if it is within specification). The power cord for damage, short circuits, open circuits, and wrong internal connections. The machine for proper grounding. The machine is not installed in a place with high temperature, high humidity, low temperature, low humidity, or a place with drastic changes in temperature. The machine is not installed near a water outlet, humidifier, heater or fire source, dusty areas, or under the direct draft of an air conditioner. The machine is not installed in a place where volatile or flammable gas is generated. The machine is not installed in a place exposed to direct sunlight. The machine is installed in a well-ventilated place. The machine is installed on a stable level surface. The paper is within specification (standard paper is recommended). The machine for any improper handling. The Periodic Replacement Parts are replaced at the proper intervals. 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. 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.
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.
Safety Considerations
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
July, 2007 2-4
Ask the operator about the problem Did the operator operate the machine correctly? No
Yes
Turn the Power Switch OFF then ON
Explain how to operate the machine
Does the error recur when operating the machine in the same way as before (when the problem originally occurred)? Yes
No
Procedure is complete
Does the Control Panel display an Error Code?
Yes
Refer to the Error Code List and perform the relevant troubleshooting
Figure 2 RAP Flow
July, 2007 2-5
Error Code List

NOTE: In the Record in Error Log column, O = yes and X = no. Error Code Record in Error Log
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name Tray1 F/O#1 SNR on JAM Explanation Timeout between Tray1 Feed Clutch ON and Tray1 Feed Sensor ON. I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [08-07] Tray1 Feed Sensor [08-12] Tray1 Feed Clutch Check Items Feed Roll or Retard Pad dirty, contaminated with paper dust, worn, or faulty Tray1 Feed Sensor dirty and Sensor Actuator deformed or damaged Paper damaged, not within specification, or not loaded correctly Foreign matter, burrs, or paper in the paper path Drive gear worn or damaged Tray1 Feed Clutch faulty Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Tray 1 Feed Sensor (PL 2.5)(REP 2.5.1). Wire between Tray 1 Feed Sensor J158-3 ( P/J158) and LVPS J501-6 ( P/J501) Wire between Tray 1 Feed Sensor J158-2 and LVPS J501-7 Wire between Tray 1 Feed Sensor J158-1 and LVPS J501-8
RAP
BSD
C1-1
CH8.1 Figure 1
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.
July, 2007 2-6
Error Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name Tray1 Regi SNR on JAM Explanation Timeout between Tray1 Feed Sensor ON and IOT Registration Sensor ON. I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [08-07] Tray1 Feed Sensor [08-05] IOT Registration Sensor [08-10] IOT Registration Clutch
Record in Error Log
RAP
BSD
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 Paper damaged, not within specification, or not loaded correctly Foreign matter, burrs, or paper in the paper path Drive gear worn or damaged IOT Registration Clutch faulty Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Tray 1 Feed Sensor (PL 2.5) (REP 2.5.1). Wire between Tray 1 Feed Sensor J158-3 ( P/J158) and LVPS J501-6 ( P/J501) Wire between Tray 1 Feed Sensor J158-2 and LVPS J501-7 Wire between Tray 1 Feed Sensor J158-1 and LVPS J501-8 O CH8.1 Figure 1 CH8.4 Figure 4
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.
July, 2007 2-7
Error Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name STM F/O#2 SNR on JAM Explanation Timeout between STM Feed Motor ON and STM Feed Sensor ON. I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [08-06] STM Feed Sensor [08-11] STM Feed Clutch [08-13] STM Feed Motor
Record in Error Log
RAP
BSD
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 Paper damaged, not within specification, or not loaded correctly Foreign matter, burrs, or paper in the paper path Drive gear worn or damaged STM Feed Clutch faulty STM Feed Motor faulty Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the STM Feed Sensor (PL 11.5) (REP 11.5.1 ). - Wire between STM Feed Sensor J172-3 ( P/J172) and STM PWB J542-6 ( P/J542) - Wire between STM Feed Sensor J172-2 and STM PWB J542-7 - Wire between STM Feed Sensor J172-1 and STM PWB J542-8 O CH8.2 Figure 2
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.
July, 2007 2-8
Error Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name Tray1 F/O#1 SNR on JAM from STM feed Explanation Timeout between STM Feed Out Sensor ON and Tray 1 Feed Out Sensor ON. I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [08-06] STM Feed Sensor [08-07] Tray1 Feed Sensor [08-11] STM Feed Clutch [08-13] STM Feed Motor
Record in Error Log
RAP
BSD
Check Items Take Away Roll 2 dirty, contaminated with paper dust, worn, or faulty C2-2 STM Feed Sensor dirty and Sensor Actuator deformed or damaged Paper damaged, not within specification, or not loaded correctly Foreign matter, burrs, or paper in the paper path Drive gear worn or damaged STM Feed Clutch faulty STM Feed Motor faulty Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the STM Feed Sensor (PL 11.5) (REP 11.5.1). Wire between STM Feed Sensor J172-3 ( P/J172) and STM PWB J542-6 ( P/J542) Wire between STM Feed Sensor J172-2 and STM PWB J542-7 Wire between STM Feed Sensor J172-1 and STM PWB J542-8 O CH8.1 Figure 1 CH8.2 Figure 2
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Tray 1 Feed Sensor (PL 2.5) (REP 2.5.1). Wire between Tray 1 Feed Sensor J158-3 ( P/J158) and STM PWB J501-6 ( P/J501) Wire between Tray 1 Feed Sensor J158-2 and STM PWB J501-7 Wire between Tray 1 Feed Sensor J158-1 and STM PWB J501-8
Replace the STM Feed Clutch (PL 11.6) (REP 11.6.1), the STM Feed Motor (PL 11.6) (REP 11.6.2), and the STM PWB (PL 11.5) (REP 11.5.2) in that order.
July, 2007 2-9
Error Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name STM Regi SNR on JAM Explanation When feeding paper from the STM, timeout between Tray1 Feed Sensor ON and IOT Registration Sensor ON. I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [08-05] IOT Registration Sensor [08-10] IOT Registration Clutch Check Items Take Away Roll 1 dirty, contaminated with paper dust, worn, or faulty IOT Registration Sensor dirty and Sensor Actuator deformed or damaged Paper damaged, not within specification, or not loaded correctly Foreign matter, burrs, or paper in the paper path Drive gear worn or damaged IOT Registration Clutch faulty Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Tray 1 Feed Sensor (PL 2.5) (REP 2.5.1). Wire between Tray 1 Feed Sensor J158-3 ( P/J158) and LVPS J501-6 ( P/J502) Wire between Tray 1 Feed Sensor J158-2 and LVPS J501-7 Wire between Tray 1 Feed Sensor J158-1 and LVPS J501-8
Record in Error Log
RAP
BSD
C2-3
CH8.1 Figure 1 CH8.4 Figure 4
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the IOT Registration Sensor (PL 2.9). Wire between Tray 1 Feed Sensor J156-3 ( P/J156) and LVPS J503-1 ( P/J503) Wire between Tray 1 Feed Sensor J156-2 and LVPS J503-2 Wire between Tray 1 Feed Sensor J156-1 and LVPS J503-3
Replace the IOT Registration Clutch (PL 2.9) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Error Name No paper in the selected paper tray (Tray1) Explanation No paper is detected in Tray1 when ATS function is disabled and Tray1 is selected during a copy job. No paper is detected in Tray1 when Tray1 is selected during a print job (the paper size setting matches the one specified for the job). I/O Diagnostic Codes [07-07] Tray1 No Paper Sensor 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 X CH7.1 Figure 1
Replace the AIOC PWB (PL 8.1) (REP 8.1.1).
July, 2007 2-10
Error Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name Tray1 Paper Size Mismatch 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. Check Items Press the [Stop] button on the Control Panel. Change the paper size of Tray 1 to the one specified by the job. Error Name No paper in the selected paper tray (Tray2) Explanation No paper is detected in the STM when ATS function is disabled and STM is selected during a copy job. No paper is detected in the STM when STM is selected during a print job (the paper size setting matches the one specified for the job). I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [07-08] STM No Paper Sensor
Record in Error Log
RAP
BSD
C5-1
C6-0
Check Items Press the [Stop] button on the Control Panel. Load the correct paper into the STM. STM No Paper Sensor dirty and Sensor Actuator deformed or damaged. Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the STM No Paper Sensor (PL 11.7) (REP 11.7.1). Wire between STM No Paper Sensor J171-3 ( P/J171) and STM PWB J542-3 ( P/J542) Wire between STM No Paper Sensor J171-2 and STM PWB J542-4 Wire between STM No Paper Sensor J171-1 and STM PWB J542-5
CH7.2 Figure 2
Replace the STM PWB (PL 11.5) (REP 11.5.2) and the AIOC PWB (PL 8.1) (REP 8.1.1).
Error Name Tray2 Paper Size Mismatch Explanation Paper that is different from the one in the Tray Settings is detected when feeding. Or, paper size setting in the STM is different from the paper size specification of the job when STM is selected during a print job. Check Items Press the [Stop] button on the Control Panel. Change the paper size of STM to the one specified by the job. Error Name MSI Paper Size Mismatch Explanation Paper that is different from the one in the Tray Settings is detected when feeding. Or, paper size setting in the MSI is different from the paper size specification of the job when MSI is selected during a print job. Check Items Press the [Stop] button on the Control Panel. Change the paper size of Bypass to the one specified by the job.
C6-1
C7-1
July, 2007 2-11
Error Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name APS NG Unselected Explanation Either Tray 1 or STM is in one of the "paper settings is of a size that causes missing image" states when APS is selected during a copy job.
Record in Error Log
RAP
BSD
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.
CH3.2 Figure 2
Check Items Press the [Stop] button on the Control Panel. Change the paper size of Tray 1 or STM to the one specified by the job. Error Name MSI Regi SNR on JAM Explanation Timeout between Bypass Solenoid ON and IOT Registration Sensor ON. I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [08-05] IOT Registration Sensor [08-17] Bypass Solenoid Check Items Bypass Feed Roll, Retard Pad, or Bypass Take Away Roll dirty, contaminated with paper dust, worn, or faulty C9-3 IOT Registration Sensor dirty and Sensor Actuator deformed or damaged Paper damaged, not within specification, or not loaded correctly Foreign matter, burrs, or paper in the paper path Drive gear worn or damaged Bypass Solenoid faulty Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the IOT Registration Sensor (PL 2.9). Wire between Tray 1 Feed Sensor J156-3 ( P/J156) and LVPS J503-1 ( P/J503) Wire between Tray 1 Feed Sensor J156-2 and LVPS J503-2 Wire between Tray 1 Feed Sensor J156-1 and LVPS J503-3 O CH8.3 Figure 3 CH8.4 Figure 4
Check that the Bypass Solenoid and the LVPS J502-1/3 ( P/J502) pins are connected securely with good electrical contact. If there is no problem, replace the Bypass Solenoid (PL 7.5). Replace the AIOC PWB (PL 8.1) (REP 8.1.1).
July, 2007 2-12
Error Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name F/O#1 SNR Static JAM Explanation Tray1 Feed Sensor ON is detected during standby. I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [08-07] Tray1 Feed Sensor
Record in Error Log
RAP
BSD
C8-1
Check Items Tray1 Feed Sensor dirty and Sensor Actuator deformed or damaged Foreign matter, burrs, or paper in the paper path Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Tray 1 Feed Sensor (PL 2.5) (REP 2.5.1). Wire between Tray 1 Feed Sensor J158-3 ( P/J158) and STM PWB J501-6 ( P/J501) Wire between Tray 1 Feed Sensor J158-2 and STM PWB J501-7 Wire between Tray 1 Feed Sensor J158-1 and STM PWB J501-8
CH8.1 Figure 1
Error Name F/O#2 SNR Static JAM Explanation STM Feed Sensor ON is detected during standby. I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [08-06] STM Feed Sensor C8-2 Check Items STM Feed Sensor dirty and Sensor Actuator deformed or damaged Foreign matter, burrs, or paper in the paper path Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the STM Feed Sensor (PL 11.5) (REP 11.5.1). Wire between STM Feed Sensor J172-3 ( P/J172) and STM PWB J542-6 ( P/J542) Wire between STM Feed Sensor J172-2 and STM PWB J542-7 Wire between STM Feed Sensor J172-1 and STM PWB J542-8 O CH8.2 Figure 2
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. O -
July, 2007 2-13
Error Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name Regi SNR Static JAM Explanation IOT Registration Sensor ON is detected during standby. I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [08-05] IOT Registration Sensor
Record in Error Log
RAP
BSD
E1-6
Check Items Sensor dirty Foreign matter, burrs, or paper in the paper path Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the IOT Registration Sensor (PL 2.9). Wire between Tray 1 Feed Sensor J156-3 ( P/J156) and LVPS J503-1 ( P/J503) Wire between Tray 1 Feed Sensor J156-2 and LVPS J503-2 Wire between Tray 1 Feed Sensor J156-1 and LVPS J503-3
CH8.4 Figure 4
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 Foreign matter, burrs, or paper in the paper path Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Fuser Exit Sensor (PL 6.2). Wire between Fuser Exit Sensor J153-3 ( P/J153) and LVPS J505-1 ( P/J505) Wire between Fuser Exit Sensor J153-2 and LVPS J505-2 Wire between Fuser Exit Sensor J153-1 and LVPS J505-3 O CH10.2 Figure 2
July, 2007 2-14
Error Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name IOT L/H Cover open Explanation The Left Hand Cover is open. I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [01-01] LH Cover Interlock Switch
Record in Error Log
RAP
BSD
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
CH1.2 Figure 2
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 X CH1.2 Figure 2
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 X CH7.1 Figure 1
July, 2007 2-15
Error Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name STM L/H Cover open Explanation Access Cover 2 is open. I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [01-10] STM Interlock Switch
Record in Error Log
RAP
BSD
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
CH7.2 Figure 2
Replace the STM PWB (PL 11.5) (REP 11.5.2), the LVPS (PL 8.1) (REP 8.1.2), and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Error Name Nup NG Out Of Range Explanation The magnification is not within the range of 50 to 200% during Nup. E8-1 Check Items Press the [Stop] button on the Control Panel. Press the [Paper Supply] button on the Control Panel. Press the [Special Copy] button on the Control Panel. Press the [Original Size Input] button on the Control Panel. Press the [Clear All] button on the Control Panel. X CH3.2 Figure 2
Error Name Nup Paper direction mismatch Explanation The paper orientation of the document and the tray are not aligned during Nup. E8-2 Check Items Press the [Stop] button on the Control Panel. Press the [Paper Supply] button on the Control Panel. Press the [Special Copy] button on the Control Panel. Press the [Original Size Input] button on the Control Panel. Press the [Clear All] button on the Control Panel. X CH3.2 Figure 2
July, 2007 2-16
Error Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name Exit SNR on JAM Explanation Timeout between IOT Registration Clutch ON and Fuser Exit Sensor ON. I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [08-10] IOT Registration Clutch [10-23] Fuser Exit Sensor Check Items Registration Roll dirty, contaminated with paper dust, worn, or faulty Fuser Exit Sensor dirty and Sensor Actuator deformed or damaged Paper damaged or not within specification Foreign matter, burrs, or paper in the paper path Drive gear worn or damaged IOT Registration Clutch faulty Check that the IOT Registration Clutch and the LVPS J503-4/5 ( P/J503) pins are connected securely with good electrical contact. If there is no problem, replace the IOT Registration Clutch (PL 2.9). Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Fuser Exit Sensor (PL 6.2). Wire between Fuser Exit Sensor J153-3 ( P/J153) and LVPS J505-1 ( P/J505) Wire between Fuser Exit Sensor J153-2 and LVPS J505-2 Wire between Fuser Exit Sensor J153-1 and LVPS J505-3
Record in Error Log
RAP
BSD
E1-2
CH10.2 Figure 2
Error Name Exit SNR off JAM Explanation Timeout between Fuser Exit Sensor ON and Fuser Exit Sensor OFF. I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [10-23] Fuser Exit Sensor Check Items Fuser Exit Sensor dirty and Sensor Actuator deformed or damaged E3-1 Paper damaged or not within specification Foreign matter, burrs, or paper in the paper path Drive gear worn or damaged Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Fuser Exit Sensor (PL 6.2). Wire between Fuser Exit Sensor J153-3 ( P/J153) and LVPS J505-1 ( P/J505) Wire between Fuser Exit Sensor J153-2 and LVPS J505-2 Wire between Fuser Exit Sensor J153-1 and LVPS J505-3 O CH10.2 Figure 2
July, 2007 2-17
Error Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name MCU-STM comm. error 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.
Record in Error Log
RAP
BSD
H9-7
CH3.1 Figure 1
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). Replace the AIOC PWB (PL 8.1) (REP 8.1.1). X X CH3.2 Figure 2
Error Name Toner Empty Explanation The Toner Cartridge is empty. 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). Replace the AIOC PWB (PL 8.1) (REP 8.1.1). CH9.2 Figure 2
J1-2
July, 2007 2-18
Error Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name No Drum Cartridge Explanation Unable to detect the Drum Cartridge. I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [09-02] Drum Cartridge Check Items Turn the power OFF then ON.
Record in Error Log
RAP
BSD
J3-1
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Drum Cartridge (PL 4.1) (REP 4.1.1). Wire between Drum Cartridge P610-7 ( P610) and AIOC PWB J402-1 ( P/J402) Wire between Drum Cartridge P610-3 and AIOC PWB J402-4 Wire between Drum Cartridge P610-2 and AIOC PWB J402-5 Wire between Drum Cartridge P610-5 and AIOC PWB J402-2 Wire between Drum Cartridge P610-4 and AIOC PWB J402-3 Wire between Drum Cartridge P610-1 and AIOC PWB J402-6
CH9.2 Figure 2
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). O X -
July, 2007 2-19
Error Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name Drum CRUM comm. Error Explanation The AIOC PWB is unable to communicate with the Drum Cartridge. I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [09-02] Drum Cartridge Check Items Turn the power OFF then ON.
Record in Error Log
RAP
BSD
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) Wire between Drum Cartridge P610-3 and AIOC PWB J402-4 Wire between Drum Cartridge P610-2 and AIOC PWB J402-5 Wire between Drum Cartridge P610-5 and AIOC PWB J402-2 Wire between Drum Cartridge P610-4 and AIOC PWB J402-3 Wire between Drum Cartridge P610-1 and AIOC PWB J402-6
CH9.2 Figure 2
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. Replace the Drum Cartridge (PL 4.1) (REP 4.1.1). 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. O O CH9.2 Figure 2 O CH9.2 Figure 2
July, 2007 2-20
Error Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name No Response from USB-Host 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
Record in Error Log
RAP
BSD
N4-0
CH3.2 Figure 2
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
CH3.2 Figure 2
N4-2
Explanation There is an abnormal Product ID or there is a checksum error in the download file. Check Items Press the [Stop] button on the Control Panel. Error Name Download Flash Write Error
N4-3
Explanation Unable to write the downloaded file into flash memory. Check Items Press the [Stop] button on the Control Panel. Error Name CPM Image Lost
E0-1
Explanation During a copy job in CPM Priority Mode, the paper containing an image cannot be output after the image is deleted. Check Items Press the [Stop] button on the Control Panel. Error Name Push Scan TimeOut
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.
July, 2007 2-21
Error Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Name Controller Logic fail
Record in Error Log
RAP
BSD
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
CH3.2 Figure 2
N9-1
Explanation The AIOC PWB has detected a Type-Di communication error. Check Items Turn the power OFF then ON. 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
CH3.2 Figure 2
U0-1
U0-1
CH4.1 Figure 1
U1-1
U1-1
CH4.1 Figure 1
U2-1
U2-1
CH6.2 Figure 2
U3-5
Explanation The ROS Motor is unable to rotate. Or, the laser output is not normal. Error Name Fuser On Time Fail
U3-5
CH6.3 Figure 3
U4-1
Explanation The lamp did not turn OFF within the specified time after turning ON. Or, Warm Up was not completed within the specified time after power ON. Error Name Over Heat Temp Fail Explanation A temperature above 250C is continuously detected for 480ms. Error Name FS1 thermistor defect Explanation FS1 cannot be monitored any more.
U4-1
CH10.1 Figure 1
U4-2
U4-2
CH10.1 Figure 1
U4-3
U4-3
CH10.1 Figure 1
July, 2007 2-22
Error Code
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. Error Name NVM data defect
Record in Error Log
RAP
BSD CH10.3 Figure 3
U4-9
U4-9
U6-2
U6-2
CH3.2 Figure 2
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.
U6-3
CH3.2 Figure 2
Error Name NVM read/write cannot be executed U6-4 Explanation An NVM Ack NG is detected during NVM Read. An NVM Write Error is detected 5 times during NVM Recovery. Error Name 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. 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. O U8-1 O U6-4
CH3.2 Figure 2
U6-5
U6-5
CH3.2 Figure 2
U7-0
U7-0
CH2.1 Figure 1
U7-1
U7-1
CH2.1 Figure 1
CH3.2 Figure 2
U9-0
U9-0
CH9.1 Figure 1
July, 2007 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 1 (Highest) 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 27 27 29 30 32 33 34 35 Error Code U7-0 U7-1 H9-7 N9-1 N9-0 U0-1 U1-1 U2-1 U3-5 U4-1 U4-2 U4-3 U4-9 U6-2 U6-3 U6-4 U6-5 U8-1 U9-0 E9-1 E9-2 E8-1 E8-2 L9-0 N4-0 N4-1 N4-2 N4-3 N5-0 A5-1 E5-1 E5-2 E6-1 E6-2
Priority Order 36 37 38 39 40 41 42 43 44 46 47 48 49 50 51 52 53 54 56 57 58 59 60 61 62 63 64 65 66 67
Error Code A1-1 A2-2 A4-1 A4-2 C1-1 C1-2 C2-1 C2-2 C2-3 C9-3 E1-2 E3-1 C8-1 C8-2 E1-6 E3-6 E0-1 C0-1 C5-1 C6-1 C7-1 C5-0 C6-0 J1-2 J3-1 J6-1 J7-1 J7-2 J7-3 N1-1
Error Name Doc Misfeed Jam No Supported Doc Size Short Length Detect Long Length Detect Tray1 F/O#1 SNR on JAM Tray1 Regi SNR on JAM STM F/O#2 SNR on JAM Tray1 F/O#1 SNR on JAM from STM feed STM Regi SNR on JAM MSI Regi SNR on JAM Exit SNR on JAM Exit SNR off JAM F/O#1 SNR Static JAM F/O#2 SNR Static JAM Regi SNR Static JAM Exit SNR JAM CPM Image Lost APS NG Unselected Tray1 Paper Size Mismatch Tray2 Paper Size Mismatch MSI Paper Size Mismatch No paper in the select paper tray (Tray1) No paper in the select paper tray (Tray2) Toner Empty No Drum cartridge Drum cartridge life end Drum CRUM comm. Error Drum CRUM Market Identity Mismatch Drum CRUM ID error EPC Memory Full
Error Characteristic
Document Jam
Error Name UI Communication TimeOut UI Communication Error MCU-STM comm. error IOT Communication Error Controller Logic fail Main Motor stop error Main Motor rotation error Carriage Module Fail Laser Power or ROS Motor Fail Fuser On Time Fail Over Heat Temp Fail FS1 thermistor defect Fuser Fan defect RAM read/write check error NVM data defect NVM read/write cannot be executed RAM read/write check error Billing Counter Defect HVPS fail AMS NG Out Of Range Paper direction mismatch Nup NG Out Of Range Nup Paper direction mismatch Copy Counter Full No Response from USB-Host HBPL or XPJL Syntax Error Download File Error Download Flash Write Error Push Scan TimeOut Platen Cover Open IOT L/H Cover open IOT Front Cover open L/H Low Cover open STM L/H Cover open
Error Characteristic Unable to control the display at the Controller
Paper Jam
Fatal Error
Tray-related errors
Dynamic Error (Job Cancel)
Resolvable by replacing parts
An error that only stops scanning
Document Cover Open
Paper Cover Open
July, 2007 2-24
U0-1 Main Motor Stop Error

BSD-Reference: CH4.1 (Figure 1)
U1-1 Main Motor Rotation Error

Explanation
The motor runs for over 120 seconds without any paper being fed.
Explanation
500 ms after the IOT Motor starts, the IOT Motor Lock signal is Low.
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. Replace the IOT Motor (PL 1.1) (REP 1.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order. Completed
Procedure
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. 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). 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.
July, 2007 2-25
U0-1, U1-1
U2-1 Carriage Module Fail

U3-5 Laser Power Or ROS Motor Fail

Explanation
A carriage fault was detected.
Explanation
The ROS Motor does not turn, or the laser output is not normal.
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. 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 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. Replace the IIT Carriage (PL 10.3) (REP 10.3.1).
Procedure
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. Replace the ROS (PL 3.1) (REP 3.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order. Measure the voltage between the AIOC PWB P403-1 ( P/J403) (+) and GND (-). 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.
U2-1, U3-5
July, 2007 2-26
U4-1 Fuser On Time Fail

U4-2 Over Heat Temp Fail

Explanation
The lamp did not turn OFF within the specified time after turning ON. Or, Warm Up was not completed within the specified time after power ON.
Explanation
A temperature of 250C or higher was detected continuously for 480 ms.
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
Procedure
When U4-2 occurs, [NVM 50-20 FSR Reset FuserOverTemp] becomes "1." Run [NVM 50-20 FSR Reset FuserOverTemp] using "0" to reset it. (How to Enter the Diagnostic Mode) Check ( 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.
July, 2007 2-27
U4-1, U4-2
U4-3 FS1 Thermistor Defect

U4-9 Fuser Fan Defect

Explanation
Thermistor FS1 cannot be monitored any more.
Explanation
After the start of Fan Fail Signal monitoring, the signal level was Low not more than 30 times.
Procedure
Check the condition of the Fuser. The Fuser is installed properly. Y N Install the Fuser properly. Check the resistance of the Thermistor. There is no open circuit between J601-1 ( P/J601) and J601-2, and the resistance is a minimum of 228k ohms (cold). 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 is not shorted or open. Y N Repair the wire. Replace the Fuser (PL 5.1) (REP 5.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Procedure
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). Replace the NOHAD Fan (PL 9.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order. Measure the voltage between the AIOC PWB P405-2 P/J405 (+) and GND (-). The voltage is 0. 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 AIOC PWB (PL 8.1) (REP 8.1.1).
U4-3, U4-9
July, 2007 2-28
U6-2 RAM Read/Write Check Error

U6-3 NVM Data Defect

Explanation
When the AIOC PWB checked RAM read/write at activation, a mismatch of read and write data was detected.
Explanation
NVM Header data and NVM 3 page data are mismatched. Or, the NVM Write & Read area is not found. Or, the NVM or Counter area is full.
Procedure
Check each AIOC PWB connector. Each connector is connected securely 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).
July, 2007 2-29
U6-2, U6-3
U6-4 NVM Read/Write Cannot Be Executed

U6-5 CPU Power To Access NVM Is Not Enough

Explanation
During NVM read/write, the NVM Ack NG state was detected. Or, during NVM repairs, an NVM write error was detected five times.
Explanation
At NVM write, the NVM queue full state was detected.
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 Replace the AIOC PWB (PL 8.1) (REP 8.1.1).
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. Replace the AIOC PWB (PL 8.1) (REP 8.1.1). (How to Enter the Diagnostic
U6-4, U6-5
July, 2007 2-30
U7-0 UI Communication TimeOut

U7-1 UI Communication Error

Explanation
At Power ON, the AIOC PWB does not communicate with the User Interface PWB.
Explanation
The User Interface PWB detected a communication failure.
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 the wire between J401 ( P/J401) and J710 ( P/J710). The wire is neither shorted nor open. Y N Repair the wire. Replace the User Interface PWB (PL 8.4) (REP 8.4.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Procedure
Check each User Inferface PWB connector. Each connector is connected securely. Y N Connect each connector securely. Turn the power OFF and ON. U7-1 recurs. Y N Completed Replace the User Interface PWB (PL 8.4) (REP 8.4.1).
July, 2007 2-31
U7-0, U7-1
U8-1 Billing Counter Defect

U9-0 HVPS Fail

Explanation
TBD An illegal Billing Counter value was detected. Or, the AIOC PWB failed to read the Billing Counter.
Explanation
A 500 ms cycle of HVPS#ERR=High was detected twice in a row.
Procedure
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
July, 2007 2-32
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
July, 2007 3-1
Image Quality
Image Quality
July, 2007 3-2
IQ1 IOT Image Quality Entry RAP

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.
IQ2 IIT Image Quality Entry RAP

Initial Actions
Clean the IIT Upper Cover (PL 10.2) (REP 10.2.1). Clean the mirrors and lens with a lint-free cloth.
Procedure
Determine the image quality problem and go to the relevant RAP. Table 1 IOT Image Quality Problems Image Quality Problem Low image density Wrinkled images Ghost images Symptom Overall low density of images. The printed paper is creased, folded or torn. RAP IQ3 IQ4 Image Quality Problem Low image density Background contamination
Determine the image quality problem and go to the relevant RAP.

Table 1 IIT Image Quality Problems Symptom Overall low density of images. RAP IQ3
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 contami- IQ6 nated by toner. The contamination appears as a very light grayish color. Part of the image is missing. Printed images are not parallel to the edges of the paper. IQ7 IQ8 IQ9 IQ10
The whole page or part of the page is contamiIQ6 nated by toner. The contamination appears as a very light grayish color. IQ9 IQ11
Background contamination
Black lines, blank areas, or Black lines or white streaks running parallel to smears in the process direction. the direction of paper transport. Black lines, blank areas, or smears at right angles to the process direction. Spotted blanks Solid black copy Black lines or white streaks running at right angles to the direction of paper transport. Toner spots and blank areas are spread irregularly over the whole page. The output is completely black.
Deletion Skew/Misregistration
IQ13 IQ14
Black lines, blank areas, or Black lines or white streaks running parallel to smears in the process direction the direction of paper transport. Improper fusing, offset Printed images are not properly fused onto the paper. When rubbed, the image comes off easily. Black lines or white streaks running at right angles to the direction of paper transport. Uneven printed image density.
Black lines, blank areas, or smears at right angles to the process direction. Mottle Spotted blanks Solid black copy Blank copy
IQ11
IQ12
Toner spots and blank areas are spread irregu- IQ13 larly over the whole page. The output is completely black. The output is completely white. IQ14 IQ15
July, 2007 3-3
Image Quality
IQ1, IQ2
IQ3 Low Image Density RAP

Overall low density of images.
IQ4 Wrinkled Image RAP

The output is creased, folded or torn.
Procedure
Check for dirt on the Platen Glass. The Platen Glass is clean. 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 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 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).
Procedure
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 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).
Image Quality
IQ3, IQ4
July, 2007 3-4
IQ5 Residual Image (Ghosting) RAP

Ghost images appear on the paper. Parts of the previous page or current page appear as ghost images on the paper.
IQ6 Background RAP

The whole page or part of the page is contaminated by toner. The contamination appears as a very light grayish color.
Procedure
Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF then ON and make a print. 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), 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 cant clean the surface of the Heat Roller, replace the Fuser (PL 5.1) (REP 5.1.1). Replace the AIOC PWB (PL 8.1) (REP 8.1.1).
Procedure
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). 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) 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).
July, 2007 3-5
Image Quality
IQ5, IQ6
IQ7 Deletion RAP

Part of the image is missing.
IQ8 Skew/Misregistration RAP

Printed images are not parallel to the edges of the paper.
Procedure
Check the paper type. The paper used is within specifications. Y N Use paper that is within specifications. 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). Replace the AIOC PWB (PL 8.1) (REP 8.1.1).
Procedure
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. 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
July, 2007 3-6
IQ9 Process Direction Bands, Streaks, and Smears RAP

Black lines or white streaks running parallel to the direction of paper transport.
IQ10 Unfused Copy/Toner Offset RAP

Printed images are not properly fused onto the paper. When rubbed, the image comes off easily.
Procedure
Check the IIT Carriage Mirrors. The mirrors are not dirty, scratched, or damaged. Y N Clean the mirrors. If the mirrors cant 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. 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 cant 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).
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).
July, 2007 3-7
Image Quality
IQ9, IQ10
IQ11 Repeating Bands, Streaks, Spots, and Smears RAP

Black lines or white streaks running at right angles to the direction of paper transport.
IQ12 Mottle RAP

Procedure
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 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 AIOC PWB (PL 8.1) (REP 8.1.1).
Procedure
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 cant, replace the Fuser (PL 5.1) (REP 5.1.1). Replace the ROS (PL 3.1) (REP 3.1.1), followed by the AIOC PWB (PL 8.1) (REP 8.1.1).
Image Quality
IQ11, IQ12
July, 2007 3-8
IQ13 Spots RAP

Toner spots and blank areas are spread irregularly over the whole page.
IQ14 Black Prints RAP

The paper is printed completely black.
Procedure
Check for dirt on the Platen Glass. The Platen Glass is clean. Y N Remove any dirt on the Platen. If you cant remove the dirt, replace the IIT Upper Cover (PL 10.2) (REP 10.2.1). Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF then ON and make a print. 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 cant 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).
Procedure
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 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).
July, 2007 3-9
Image Quality
IQ13, IQ14
IQ15 Blank Image RAP

The paper is printed completely white.
Copy Quality Specification

1. Copy Alignment
How to measure Make a copy of the Test Pattern STP3600 (A3) (Figure 1) and measure. Table 1 Copy Alignment: Measurement Item Lead Edge Registration (mm) Side Edge Registration (mm) Lead Skew (mm) Vertical Ratio (%) Horizontal Ratio (%) Perpendicularity (mm) Linearity (Vertical) (mm) 400mm Linearity (Horizontal) (mm) 280mm Linearity (Skew) (mm) 280mm How to measure (Refer to Figure 1) (P1~P2) Standard Value *1 (P7~P19) Standard Value *1: A3S (P5~P6) (P3~P4) ((P2~P14) - 200) / 200 x 100: A3S ((P8~P13) - 280) / 280 x 100 Difference between the perpendicular line of the intersection point between the line that connects P4 and P6, and P14. Maximum difference between the [Intersection point of the vertical line A and each vertical line] and the line that connects P2 and P14. Maximum difference between the [Intersection point of the horizontal line C and each horizontal line] and the line that connects P10 and P15. 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. (P10~P12) (P15~P16)
Procedure
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. 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. 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).
Parallelism (mm)
*1: Measure the length of the position of FX STP#3600 and use it as the Standard Value in the table.
Image Quality
IQ15,
July, 2007 3-10
Specification [System] IOT + IIT Table 2 Copy Alignment: Specification Item Lead Edge Registration (mm) Side Edge Registration (mm) Lead Skew (mm) Vertical Ratio (%) 100% Horizontal Ratio (%) 100% Perpendicularity (mm) Linearity (Vertical) (mm) Linearity (Horizontal) (mm) Linearity (Skew) (mm) Parallelism [DC] IOT + IIT Table 3 Copy Alignment: Specification Item Simplex Skew H Perpendicularity Linearity: V Linearity: H Linearity: D Registration: Lead Registration: Side Magnification: V (%) +/-1.9 +/-2.8 1.4 1.4 1.4 +/-2.4 +/-3.0 +/-0.95 (100%) +/-1.16 (50%-99%) +/-1.47 (101%-200%) +/-0.95 (100%) +/-1.16 (50%-99%) +/-1.47 (101%-200%) Specification MSI +/-2.2 +/-3.0 ---+/-3.1 +/-3.2 -400mm 200mm 400mm 400mm 280mm 283mm Measurement Length Specification SYSTEM +/- 2.90 +/- 3.40 +/- 2.30 +/- 1.40 +/- 1.40 +/- 3.40 +/- 2.00 +/- 1.40 +/- 1.42 +/- 3.70 280 mm 400 mm 280 mm 400 mm 400 mm 280 mm 280 mm 400 mm Application
Magnification: H (%)
--
280mm
July, 2007 3-11
Image Quality
Figure 1 Copy Alignment Measurement Positions (Test Pattern STP3600)
2. Image Quality
How to measure
Make a copy of the Test Pattern 499T247 (A3) and measure. See Table 5 for specifications. Table 4 Item How to measure (Refer to Figure 2)
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
July, 2007 3-12
Table 4 Item Low Contrast (100% only) How to measure (Refer to Figure 2) 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 Resolution Skip and Smear Measure the margin. 70.7, 100%: Measure the resolution target 17 at 3 locations. 141.4%: Measure the resolution target 17 at 2 locations. 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.
July, 2007 3-13
Image Quality
Figure 2 Image Quality Measurement Positions (Test Pattern 499T247) Image Quality Specification Total System
Image Quality
July, 2007 3-14
Table 5 OUTPUT (Density Settings Button) Lighter 3 Does not reproduce Does not reproduce OUTPUT (Density Settings Button) Normal >=1.08 =<0.2 >=0.17 >=0.17 >=1.0 =<0.3 =<1.2 OUTPUT (Density Settings Button) Darker 3 >=0.46 =<0.4 >=0.57 0.4 (Max) OUTPUT (Density Settings Button) Auto >=1.08 =<0.2 >=0.22 >=0.22 >=1.0 =<0.3 =<1.2 4.3 Lo/mm (Min) 2.5 Lo/mm (Min) 3.5 Lo/mm (Min) 3.5 Lo/mm 3 Lo/mm (Min)*1 2.5 Lo/mm (Min)*1 1.8 Lo/mm (Min) 2.5 Lo/mm (Min) 2.5 Lo/mm (Min)*1
Item Text/Image Density Text/Image Density Evenness Low Contrast Reproducibility Low Contrast Evenness Low Contrast Reproducibility Reproducibility of the blue color density Blue Color Density Evenness Reproducibility of the blue color density Solid Density Reproducibility Solid Density Evenness Background (SIR#302) Resolution (Excluding Skip/Smear) Resolution (Excluding Skip/Smear) Resolution (Excluding Skip/Smear) Resolution (Excluding Skip/Smear) Depth of Focus Skip/Smear Skip/Smear Skip/Smear Skip/Smear
Reduce/ Enlarge (%) 100 100 100 100 100 100 100 100 100 100 100 100 70 141 200 100 100 70 141 200
INPUT 0.7 Gray 0.7 Gray 0.2 Gray 0.2 Gray 0.1 Gray 0.2 Blue 0.2 Blue 0.1 Blue 1.0 Solid 1.0 Solid NBS Target NBS Target NBS Target NBS Target NBS Target Ladder A3 Entire Page Ladder A3 Entire Page Ladder A3 Entire Page Ladder A3 Entire Page
July, 2007 3-15
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
July, 2007 3-16
Auger Marks
Figure 1 Auger Marks Cause 1. 2. Magnetic field failure in the Developer Magnetic Roll. There was a drop in the level of developer material. Action 1. Replace the Drum Cartridge (PL 4.1) (REP 4.1.1). The problem may occur immediately after you install a new Drum Cartridge. This can be corrected by feeding a few sheets of paper.
July, 2007 3-17
Image Quality
Strobing (28mm or 14mm Pitch Density)
Figure 2 Strobing (28mm or 14mm Pitch Density) Cause 1. 1. Developer Magnetic Roll bias. Replace the Drum Cartridge (PL 4.1) (REP 4.1.1). Action
Image Quality
July, 2007 3-18
White Streaks (Process Direction)
Figure 3 White Streaks (Process Direction) Cause 1. 2. Foreign substances are blocking the ROS Laser. Developer material clogging on the Developer Magnetic Roll due to foreign substances. 2. Action 1. Clean the optical path between the ROS (PL 3.1) (REP 3.1.1) and the Drum Cartridge (PL 4.1) (REP 4.1.1), and clean the seal glass. Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).
July, 2007 3-19
Image Quality
Black Bands
Figure 4 Black Bands Cause 1. 1. The developer material is not well mixed. Mix the developer material by processing blank paper. Action
Image Quality
July, 2007 3-20
Toner Contamination
Figure 5 Toner Contamination Cause 1. 1. Cloud of toner falling from the Drum Cartridge (PL 4.1) (REP 4.1.1). Mix the developer material by processing blank paper. Action 2. Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).
July, 2007 3-21
Image Quality
Toner Splattering
Figure 6 Toner Splattering Cause 1. 2. Paper size mismatch (tray settings and paper size are different). Increased paper resistance due to dry conditions. Action 1. 2. Check the tray settings. Use paper from a freshly opened packet.
Image Quality
July, 2007 3-22
White Spots (Irregular)
Figure 7 White Spots Cause 1. 1. Increased paper resistance due to dry conditions. Use paper from a freshly opened packet. Action
July, 2007 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 1. 2. 3. 94mm Pitch (Drum): Scratches or foreign substances. 57mm Pitch (Developer Roll): Developer material clogging on the Magnetic Roll. 44mm Pitch (Charger): Scratches or foreign substances. 2. Image Quality July, 2007 3-24 4. 1. 80mm Pitch (Fuser Heat Roll): 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). 2,3: Replace the Drum Cartridge (PL 4.1) (REP 4.1.1). Initial Issue WorkCentre 5020
Action
Regular Toner Contamination In the Process Direction (Spots, Streaks, Bands, etc.)
Figure 9 Regular Toner Contamination In the Process Direction (Spots, Streaks, Bands, etc.) Cause 1. 2. 3. 4. 5. 6. 94mm Pitch (Drum): Scratches or foreign substances. 57mm Pitch (Magnetic Roll): Developer material clogging on the Magnetic Roll. 44mm Pitch (Charger): Scratches or foreign substances. 80mm Pitch (Heat Roll): Scratches or foreign substances. 19mm Pitch (Fuser Roll-Exit): Dirt. 44mm Pitch (Registration): Dirt. 2. Action 1. 1,4,5,6: Clean or replace the Drum Cartridge (PL 4.1) (REP 4.1.1)/Fuser (PL 5.1) (REP 5.1.1). 2,3: Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).
July, 2007 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. 2. 3. Reduce sharpness. Secondary defect: Text is blurred. Make copies at a different Reduce/Enlarge ratio. Change the orientation of the original.
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
July, 2007 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 [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. Action Select [Off] for [Auto].
July, 2007 3-27
Image Quality
Image Quality
July, 2007 3-28
4 Repairs and Adjustments

Introduction
Introduction ..................................................................................................................... 4-3 REP 9.2.2 Right Cover .................................................................................................... 4-64 4-65 4-66 4-67 4-73 4-75 4-76 4-79 4-83 4-83 4-85 4-87 4-90 4-91 4-92 4-93 4-94 4-95 4-95 4-96 4-97
10. IIT
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................................................................................................
Repairs 1. Drive
REP 1.1.1 IOT Motor (SCC)............................................................................................ 4-5 4-7 4-9 4-10 4-12 4-13 4-17 4-19 4-20 4-21 4-23 4-27 4-29 4-31 4-32 4-35 4-38 4-39 4-43 4-45 4-47 4-50 4-53 4-56 4-58 4-61 4-62 4-63
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).........................................................................................
11. Single Tray Module

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.................................................................................
3. ROS
REP 3.1.1 ROS (SCC) ....................................................................................................
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 ................................................................................................
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 ......................................................... ADJ 11.1.1 Carriage Assembly Alignment (Parallelism) .................................................
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 .......................................................................................
6. Exit
REP 6.1.1 Exit Transport ................................................................................................
7. Simplex Module and Bypass Tray

REP 7.1.1 Simplex Module ............................................................................................. REP 7.5.1 Bypass Feed Roll...........................................................................................
8. Electrical
REP 8.1.1 AIOC PWB (SCC).......................................................................................... REP 8.1.2 LVPS (SCC)................................................................................................... REP 8.2.1 HVPS (SCC) .................................................................................................. REP 8.3.1 Control Panel (SCC) ...................................................................................... REP 8.4.1 User Interface PWB (SCC) ............................................................................
9. Cover
REP 9.1.1 Output Tray.................................................................................................... REP 9.1.2 Front Left Cover............................................................................................. REP 9.2.1 Rear Cover ....................................................................................................
July, 2007 4-1
Repairs and Adjustments
July, 2007 4-2
Introduction
This section contains procedures required for parts replacement and adjustment.
Terms and Symbols

Terms and symbols used throughout this section are explained here.
How to Use the Replacement and Adjustment Section

For installation procedures, only NOTEs are described here since installation procedures are the reverse of removal ones. 1. 2. 3. (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. (REP X.X.X) at the end of a procedure indicates the replacement procedure to be referred to. 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. When replacement/adjustment procedures or title items vary by modification or model, the modification number or the model is indicated at the beginning or the end of the respective titles or procedures. Example 1: REP X.X.X Main PWB [Models with 1V] indicates that the entire procedure under this title applies to machines with Tag 1V. Example 2: See Table 1. Table 1 Symbol Description Illustration 1: Indicates that a specific part has been modified by the tag number within the circle.
WARNING
A Warning statement indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in personal injury or loss of life. CAUTION A Caution statement indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in damage to, or destruction of, equipment. NOTE: A Note statement indicates an operating or maintenance procedure, practice, or condition that is necessary to accomplish a task efficiently. Reference: Used when other explanations are given. Purpose: Used to describe the purpose of the Adjustment. Safety Critical Components (SCC): Safety Critical Components are components, such as static-sensitive integrated circuit chips, that require special precautions to prevent them from being damaged. Follow the regulations regarding Safety Critical Components set by FUJI XEROX Co., Ltd. Important Information Stored Component (ISC): This component stores all the important customer information that is input after the installation. When replacing this component, follow the procedures in Section 4 Repairs and Adjustments. Make absolutely sure that no customer information gets revealed.
4.
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. b. c. d. Front: Front of the machine. Right: Right-hand side facing the machine. Left: Left-hand side facing the machine. Rear: Rear of the machine.
July, 2007 4-3
July, 2007 4-4
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. 2. 3. Remove the Drum Cartridge (REP 4.1.1). Remove the Rear Cover (REP 9.2.1). 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
July, 2007 4-5
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
July, 2007 4-6
REP 2.2.1 Tray 1 Feed Clutch (SCC)

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 Rear Cover (REP 9.2.1). Disconnect the connector (Figure 1). 1 Disconnect the connector. 2 Release the wire harness from the clamp.
3.
Remove the screws (3) that secure the Clutch Bracket (Figure 2). 1 Remove the screws (3).
Figure 2
Figure 1
July, 2007 4-7
REP 2.2.1
4.
Remove the Tray 1 Feed Clutch (Figure 3). 1 Remove the Clutch Bracket. 2 Remove the bearing. 3 Remove the Tray 1 Feed Clutch. 4 Pull out the wire harness through the hole.
Replacement
1. 2. To install, do the removal steps in reverse order. When installing the Tray 1 Feed Clutch, place the tab of Clutch Bracket in the notch of Tray 1 Feed Clutch (Figure 4).
Figure 3
Figure 4
REP 2.2.1
July, 2007 4-8
REP 2.3.1 Tray 1 Feed Roll (SCC)

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 all paper from Tray 1. Remove Tray 1. Remove the Feed Shaft (Figure 1). 1 Lower the Bottom Plate. 2 Release the Feed Shaft from the bearing by pressing down on the white tab. 3 Remove the Feed Shaft by pulling it in the direction of the arrow.
4.
Remove the Tray 1 Feed Roll (Figure 2). 1 Gently lift up the tab to remove the Tray 1 Feed Roll.
Figure 2
Figure 1
July, 2007 4-9
REP 2.3.1
Replacement
1. 2. To install, do the removal steps in reverse order. When installing the Tray 1 Feed Roll, align the pin of the Feed Shaft with the slot in the Tray 1 Feed Roll (Figure 3).
REP 2.5.1 Tray 1 Feed Sensor

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. Remove Tray 1. Remove Tray 2 (REP 11.1.1). Remove the Sensor Housing of the Tray 1 No Paper Sensor (REP 2.7.1). Open the Tray 1 Access Cover on the left side of the machine.
Figure 3
REP 2.3.1, REP 2.5.1
July, 2007 4-10
5.
Remove the Tray 1 Feed Sensor (Figure 1). 1 Remove the Tapping Screw. 2 Remove the cable bands (2). 3 Release the wire harness from the clamps (2). 4 Move the wire harness toward you and disconnect the connector. 5 Remove the Tray 1 Feed Sensor.
Replacement
1. 2. To install, do the removal steps in reverse order. Insert the Connector Housing of the Tray 1 Interlock Switch into the square hole of the frame (Figure 2). A Square hole
Figure 2 Figure 1
July, 2007 4-11
REP 2.5.1
REP 2.7.1 Tray 1 No Paper Sensor

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 Tray 1. Remove Tray 2 (REP 11.1.1). Remove the Sensor Housing (Figure 1). 1 Disconnect the connector. 2 Release the tabs (2) to remove the Sensor Housing.
4.
Remove the Tray 1 No Paper Sensor (Figure 2). 1 Remove the Actuator. 2 Release the tabs to remove the Tray 1 No Paper Sensor.
Figure 2
Replacement
Figure 1
REP 2.7.1
July, 2007 4-12
REP 2.8.1 Registration (SCC)

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. Remove the Drum Cartridge (REP 4.1.1). Remove the Rear Cover (REP 9.2.1). Remove the Transfer Corotron Housing (REP 4.3.1). 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
July, 2007 4-13
REP 2.8.1
5.
Remove the Connector Housing (Figure 2). 1 Remove the wire harness from the guide. 2 Slide the Connector Housing through the hole.
6.
Remove the Front Stopper (Figure 3). 1 Remove the Front Stopper.
Figure 3 Figure 2
REP 2.8.1
July, 2007 4-14
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
July, 2007 4-15
REP 2.8.1
REP 2.8.1
July, 2007 4-16
REP 3.1.1 ROS (SCC)

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: Attach the attachment in the ROS Replacement Kit to a Stubby Driver to remove the screws (Figure 1).
1. 2. 3. 4. 5.
Open the Front Cover. Remove the Output Tray (REP 9.1.1). Remove the Rear Cover (REP 9.2.1). Remove the HVPS and Contact Block (REP 8.2.1). Remove the Laser Housing (Figure 2). 1 Remove the Tapping Screw. 2 Remove the Laser Housing.
Figure 2
Figure 1
July, 2007 4-17
REP 3.1.1
6.
Disconnect the ROS connectors (Figure 3). 1 Disconnect the Ground connectors (2). 2 Disconnect the connectors (2). 3 Disconnect the connector. 4 Remove the wire harness from the hook.
7.
Remove the ROS (Figure 4). 1 Remove the Tapping Screws (5). 2 Remove the ROS.
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
July, 2007 4-18
REP 4.1.1 Drum Cartridge

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. Open the Simplex/Duplex Module. Open the Front Cover. Remove the Drum Cartridge (Figure 1). 1 Release the tab. 2 Remove the Drum Cartridge.
2.
When installing the Drum Cartridge, align the protruding end of the Drum Cartridge with the cavity in the frame (Figure 2).
Figure 2
Figure 1
Replacement
1. To install, do the removal steps in reverse order. July, 2007 4-19 Repairs and Adjustments
REP 4.1.1
REP 4.2.1 Toner Empty Sensor

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. Remove the Drum Cartridge (REP 4.1.1). Remove Tray 1. Remove Tray 2 (REP 11.1.1). Disconnect the connector (Figure 1). 1 Release the wire harness from the clamp. 2 Disconnect the connector.
5.
Remove the Toner Empty Sensor (Figure 2). 1 Release the tabs (2) to remove the Toner Empty Sensor.
Figure 2
Figure 1
REP 4.2.1
July, 2007 4-20
Replacement
1. 2. To install, do the removal steps in reverse order. Insert the Connector Housing of the Toner Empty Sensor into the square hole of the frame (Figure 3). A Square hole
REP 4.2.2 Erase Lamp

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 Drum Cartridge (REP 4.1.1). Remove the Output Tray (REP 9.1.1). Remove the Rear Cover (REP 9.2.1). Remove the Transfer Corotron Housing (REP 4.3.1). Remove the HVPS and Contact Block (REP 8.2.1).
Figure 3
July, 2007 4-21
REP 4.2.1, REP 4.2.2
6.
Release the Erase Lamp tabs (7) (Figure 1). 1 Release the tabs (upper: 3). 2 Release the tabs (lower: 4).
7.
Remove the Erase Lamp (Figure 2). 1 Remove the Erase Lamp.
Figure 2 Figure 1
REP 4.2.2
July, 2007 4-22
Replacement
1. 2. To install, do the removal steps in reverse order. Insert the Connector Housing of the Erase Lamp into the square hole in the frame (Figure 3). A Square hole
REP 4.3.1 Transfer Module

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 Drum Cartridge (REP 4.1.1). Remove the Output Tray (REP 9.1.1). Remove the Rear Cover (REP 9.2.1). Remove the Exit Transport (REP 6.1.1). Remove the Fuser (REP 5.1.1).
Figure 3
July, 2007 4-23
REP 4.2.2, REP 4.3.1
6.
Remove the Transfer Corotron Housing (Figure 1). 1 Release the hooks (2). 2 Remove the Transfer Corotron Housing by pulling its front side in the direction of the arrow.
7.
Remove the Tapping Screws that secure the Corotron Block (Figure 2). 1 Remove the Tapping Screws (2). 2 Move the Fuser Connector Bracket. 3 Remove the Tapping Screw.
Figure 1
Figure 2
REP 4.3.1
July, 2007 4-24
8.
Remove the Corotron Block (Figure 3). 1 Press the Spring Plate. 2 Remove the Corotron Block by pulling it in the direction of arrow.
9.
Disconnect the Corotron Block cables (Ground/Detack/Transfer) (Figure 4). 1 Disconnect the Ground Cable (white). 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
July, 2007 4-25
REP 4.3.1
Replacement
1. 2. To install, do the removal steps in reverse order. Perform the following steps to install the Corotron Block (Figure 5). 1 Press the Spring Plate. 2 Install the Corotron Block.
3.
Attach the cables (Ground/Detack/Transfer) to the Corotron Block hooks as shown in Figure 6.
Figure 6
Figure 5
REP 4.3.1
July, 2007 4-26
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

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). Remove the Drum Cartridge (REP 4.1.1). 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
July, 2007 4-27
REP 4.3.1, REP 4.4.1
4.
Attach the Corotron Wire (Figure 2). 1 Attach the Corotron Wire.
5.
Attach the spring (Figure 3). 1 Attach the spring to the Corotron Wire. 2 Attach the spring.
Figure 2 Figure 3
Replacement
REP 4.4.1
July, 2007 4-28
REP 5.1.1 Fuser (SCC)

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.
3.
Disconnect the connectors (Figure 2). 1 Disconnect the connectors (2).
WARNING
The Fuser and Exit Transport are hot. Do not work on them until they are cool enough. 1. 2. Open the Left Side Cover. Remove the Connector Cover (Figure 1). 1 Remove the Tapping Screw. 2 Remove the Connector Cover.
Figure 2
Figure 1
July, 2007 4-29
REP 5.1.1
4.
Remove the Fuser (Figure 3). 1 Remove the Tapping Screws (2). 2 Remove the Fuser by shifting it in the direction of the arrow.
Replacement
1. 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
July, 2007 4-30
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.
WARNING
The Fuser and Exit Transport are hot. Do not work on them until they are cool enough. 1. 2. Remove the Fuser (REP 5.1.1). 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
July, 2007 4-31
REP 5.1.2
Replacement
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).
REP 5.1.3 Fuser Lamp

WARNING
The Fuser and Exit Transport are hot. Do not work on them until they are cool enough. 1. 2. Remove the Fuser (REP 5.1.1). 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
July, 2007 4-32
3.
Disconnect the hot side of the Fuser Lamp (Figure 2). 1 Disconnect the Terminal. 2 Remove the Screw.
4.
Disconnect the neutral side of the Fuser Lamp (Figure 3). 1 Disconnect the white wire from theTerminal. 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
July, 2007 4-33
REP 5.1.3
5.
Remove the Fuser Lamp Housing (Figure 4). 1 Remove 2 Screws. 2 Carefully remove the Fuser Lamp Housing.
6.
Remove the Fuser Lamp by pulling it through the Fuser Roll (Figure 5). NOTE: Do not lose the Fuser Lamp Mount.
Fuser Roll
Screws
Fuser Lamp Mount
Fuser Lamp Housing
Fuser Lamp
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. To install, do the removal steps in reverse order.
REP 5.1.3
July, 2007 4-34
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. 2. Remove the Fuser Lamp (REP 5.1.3). 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
Fuser Cover
Figure 2 Fuser Cover Removed
Stripper Finger Assembly
Screw
Screws
Figure 1 Removing the Fuser Cover
Figure 3 Removing the Stripper Finger Assembly
July, 2007 4-35
REP 5.1.4
4.
Remove the Fuser Roll Retaining Rings and Drive Gear (Figure 4). 1 Remove the Retaining Ring. 2 Remove the Drive Gear. 3 Remove the Retaining Ring from the other end of the Fuser Roll.
5.
Remove the Fuser Roll by pulling it through the Bushings in the Frame (Figure 5).
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
July, 2007 4-36
Replacement
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.
CAUTION Make sure the stripper fingers are oriented correctly when reinstalling the Stripper Finger Assembly, as shown in Figure 7.
Figure 7 Setting the Stripper Fingers Locating Key
Figure 6 Installing the Drive Gear
July, 2007 4-37
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 Do not touch the glass part of the Fuser Lamp unless you are are wearing gloves. 1. 2. Remove the Fuser Roll (REP 5.1.4). Remove the Bushings (Figure 1). Levers
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. To install, do the removal steps in reverse order.
Figure 1 Removing the Bushings
REP 5.1.5
July, 2007 4-38
REP 6.1.1 Exit Transport

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). 4 Release the wire harness from the clamps (2).
WARNING
The Fuser and Exit Transport are hot. Do not work on them until they are cool enough. 1. 2. Open the Left Side Cover. Remove the Rear Cover (REP 9.2.1).
Figure 1
July, 2007 4-39
REP 6.1.1
4.
Remove the Connector Cover (Figure 2). 1 Remove the Tapping Screw. 2 Remove the Connector Cover.
5.
Lower the Fuser levers (2) (Figure 3). 1 Lower the levers (2).
Figure 3 Figure 2
REP 6.1.1
July, 2007 4-40
6.
Remove the Exit Transport (Figure 4). 1 Remove the Tapping Screws (3). 2 Remove the Exit Transport. 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.
Replacement
1. 2. To install, do the removal steps in reverse order. When installing the Connector Cover, insert the stud of the Connector Cover into the hole in the frame (Figure 5).
J153
Figure 5 Figure 4
July, 2007 4-41
REP 6.1.1
REP 6.1.1
July, 2007 4-42
REP 7.1.1 Simplex Module

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 Rear Cover (REP 9.2.1). Tape the Bypass Tray so that it cannot open by itself (Figure 1). 1 Apply 2 pieces of tape as shown.
3. 4.
Open the Left Side Cover. Disconnect the connector (Figure 2). 1 Disconnect P/J 502. 2 Remove the wire harness from the hook. 3 Remove the wire harness from the groove in the frame. 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).
Figure 2 Figure 1
July, 2007 4-43
REP 7.1.1
5.
Remove the Front Stopper (Figure 3). 1 Remove the Front Stopper from the Registration. 2 Release the tab to remove the Front Stopper.
6.
Remove the Rear Stopper (Figure 4). 1 Release the tab to remove the Rear Stopper.
Figure 4 Figure 3
REP 7.1.1
July, 2007 4-44
7.
Remove the Simplex Module (Figure 5). 1 Loosen the Tapping Screws (2). 2 Move the Pivot Retainers (2) in the direction of the arrow. 3 Remove the Simplex Module.
REP 7.5.1 Bypass Feed Roll

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. Open the Bypass Tray. Remove the Feed Roll Cap (Figure 1). 1 Release the tab to remove the Feed Roll Cap.
Figure 5
Replacement
Figure 1
July, 2007 4-45
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
REP 7.5.1
July, 2007 4-46
REP 8.1.1 AIOC PWB (SCC)

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. Remove the Rear Cover (REP 9.2.1). Disconnect the AIOC PWB connectors (9) (Figure 1).
3.
Remove the Core Clip (Figure 2). 1 Remove the Core Clip.
Figure 2 Removing the Core Clip
Figure 1
July, 2007 4-47
REP 8.1.1
4.
Disconnect the Flexible Print Cables (2) from the AIOC PWB (Figure 3). 1 Disconnect the Flexible Print Cables (2). 2 Remove the Cores (2).
5.
Remove the screw of the USB connector (Figure 4). 1 Remove the screw.
Figure 4 Figure 3
REP 8.1.1
July, 2007 4-48
6.
Remove the AIOC PWB (Figure 5) 1 Remove the screws (2). 2 Remove the Tapping Screws (2). 3 Slide the the AIOC PWB up and out of P/J 407.
Replacement
1. 2. To install, do the removal steps in reverse order. When replacing the AIOC PWB, transfer the EP ROM (U2) from the old board to the new one (Figure 6). A EP ROM (U2)
Figure 5 Figure 6
July, 2007 4-49
REP 8.1.1
REP 8.1.2 LVPS (SCC)

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. Remove the Rear Cover (REP 9.2.1). Remove the Right Cover (REP 9.2.2). Remove the AIOC PWB (REP 8.1.1). Remove the PWB Bracket (Figure 1). 1 Remove the screws (4). 2 Remove the PWB Bracket.
5.
Remove the IIT Ground Plate (Figure 2). 1 Remove the Screws (4). 2 Remove the IIT Ground Plate.
Figure 2 Removing the IIT Ground Plate
Figure 1
REP 8.1.2
July, 2007 4-50
6.
Move the Inlet Bracket (Figure 3). 1 Disconnect the connector (wire: blue). 2 Disconnect the connector (wire: brown). 3 Remove the Tapping Screws (2). 4 Remove the screws (2). 5 Move the Power Inlet Bracket.
7.
Disconnect the connectors (Figure 4). 1 Disconnect the connectors (2).
Figure 4
Figure 3
July, 2007 4-51
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
REP 8.1.2
July, 2007 4-52
REP 8.2.1 HVPS (SCC)

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 Rear Cover (REP 9.2.1). 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. 5.
NOTE: When removing the HVPS, use a Stubby Driver (499T00353). 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).
Figure 2
Figure 1 3. 4. Open the Front Cover. Remove the Output Tray (REP 9.1.1). Repairs and Adjustments
July, 2007 4-53
REP 8.2.1
6.
Remove the HVPS and Contact Block (Figure 3). 1 Remove the Tapping Screws (3). 2 Disconnect the connector at the inner side of the HVPS. 3 Remove the HVPS and Contact Block.
7.
Separate the HVPS from the Contact Block (Figure 4). 1 Remove the Contact Block in the direction of the arrow.
Figure 4 Figure 3
REP 8.2.1
July, 2007 4-54
Replacement
1. 2. To install, do the removal steps in reverse order. Insert the wire harness of the HVPS into the slot of the Laser Housing (Figure 5). A Slot
3.
When installing the HVPS and Contact Block, insert the slot of the Contact Block into the guide of the frame (Figure 6).
Figure 6
Figure 5
July, 2007 4-55
REP 8.2.1
REP 8.3.1 Control Panel (SCC)

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 Front Left Cover (REP 9.1.2). 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.
3.
Remove the screws that secure the Control Panel (Figure 2). 1 Remove the screws (3).
Figure 2
Figure 1
REP 8.3.1
July, 2007 4-56
4.
Remove the Control Panel (Figure 3). 1 Slide the rear of the Control Panel in the direction of the arrow. 2 Disconnect the connectors (2). 3 Remove the Cable Band from the Control Panel Hook (Figure 4, B).
Replacement
1. 2. To install, do the removal steps in reverse order. When installing the Control Panel, attach the Control Panel hooks (3) to the IIT Frame (Figure 4). A Spring - On top B Hook - Below
Figure 3 Figure 4
July, 2007 4-57
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)

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 Control Panel (REP 8.3.1). Turn the Control Panel upside down. 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
July, 2007 4-58
4.
Remove the User Interface PWB (Figure 2). 1 Remove the Tapping Screws (12). 2 Remove the User Interface PWB.
Figure 2
Replacement
July, 2007 4-59
REP 8.4.1
REP 8.4.1
July, 2007 4-60
REP 9.1.1 Output Tray

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. Open the Front Cover. 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.
Replacement
1. 2. To install, do the removal steps in reverse order. Perform the following steps to install the Output Tray (Figure 2). 1 Insert the tabs (2) into the square hole of the frame. 2 Attach the hook.
Figure 2
Figure 1
July, 2007 4-61
REP 9.1.1
REP 9.1.2 Front Left Cover

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. Open the Front Cover. 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.
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)
Figure 2
Figure 1
REP 9.1.2
July, 2007 4-62
REP 9.2.1 Rear Cover

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.
2.
Remove the Rear Cover (Figure 2). 1 Remove the Tapping Screws (4). 2 Remove the Rear Cover.
Figure 2
Replacement
Figure 1
July, 2007 4-63
REP 9.2.1
REP 9.2.2 Right Cover

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 Rear Cover (REP 9.2.1). Open the Front Cover. 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.
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)
Figure 2
Figure 1
REP 9.2.2
July, 2007 4-64
REP 10.1.1 IIT Platen Cover

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 Platen Cover (PL 10.1) (Figure 1) by lifting it straight up. Platen Cover
Replacement
NOTE: The Platen Cover comes as a kit, consisting of a Platen Cover and a Platen Cushion (Figure 1). 1. 2. 3. 4. 5. Place the Platen Cushion on the Platen Glass, with the adhesive strips facing up. Remove the backing from the adhesive strips. Position the Platen Cushion against the back left corner of the Platen Glass (Figure 1). Insert the mounting posts (Figure 1) of Platen Cover into the mounting holes. Carefully lower the Platen Cover down onto the Platen Cushion. Press down evenly to ensure good adhesion.
Platen Cushion
mounting posts
When installing a new Platen Cushion, place it against this corner
Figure 1
July, 2007 4-65
REP 10.1.1
REP 10.2.1 IIT Upper Cover (SCC)

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 following parts: 2. Platen Cover (PL 10.1) Control Panel (REP 8.3.1)
3.
Remove the IIT Upper Cover (Figure 2). 1 Press the tabs (2) to release them. NOTE: The tabs are visible through the Platen Glass. 2 Open the right side of the IIT Upper Cover. 3 Press the tabs (2) to release them, and remove the IIT Upper Cover.
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
Figure 1
REP 10.2.1
July, 2007 4-66
REP 10.3.1 IIT Carriage (SCC)

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 following parts: 2. 3. Platen Cover (PL 10.1) Control Panel (REP 8.3.1)
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.
Remove the IIT Upper Cover (REP 10.2.1). 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 Initial Issue WorkCentre 5020 July, 2007 4-67 Repairs and Adjustments
REP 10.3.1
5.
While maintaining tension on the Carriage Cable (silver) at the front left side, disconnect it (Figure 3). 1 Disconnect the Carriage Cable. 2 Remove the Cable Spring. 3 Remove the Carriage Cable from the pulley. 4 Remove the Carriage Cable from the guide.
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). A Secure the Carriage Cable with tape 1 Pulley
Figure 4 Figure 3
REP 10.3.1
July, 2007 4-68
7.
While maintaining tension on the Carriage Cable (black) at the front right side, disconnect it (Figure 5). 1 Disconnect the Carriage Cable (black). 2 Remove the Carriage Cable (black) from the guide. 3 Remove the Carriage Cable (black) from the guide.
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). A Pulley 1 Secure the Carriage Cable with tape
Figure 6 Figure 5
July, 2007 4-69
REP 10.3.1
9.
While maintaining tension on the Carriage Cable (black) at the rear left side, disconnect it (Figure 7). 1 Remove the Cable Spring. 2 Disconnect the Carriage Cable. 3 Remove the Carriage Cable from the pulley.
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 Secure the Carriage Cable with tape.
Figure 8 Figure 7
REP 10.3.1
July, 2007 4-70
11. While maintaining tension on the Carriage Cable (silver) at the rear right side, disconnect it (Figure 9). 1 Disconnect the Carriage Cable.
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 Secure the Carriage Cable with tape.
Figure 9
Figure 10
July, 2007 4-71
REP 10.3.1
13. Turn the left side of the IIT Carriage face up. 14. Disconnect the Flexible Print Cable connectors (2) (Figure 11).
Replacement
1. 2. To install, do the removal steps in reverse order. 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
July, 2007 4-72
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)

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 following parts: 2. 3. 4. Platen Cover (PL 10.1) Control Panel (REP 8.3.1)
Remove the IIT Upper Cover (REP 10.2.1). Remove the IIT Carriage (REP 10.3.1). Remove the Core Clip (Figure 1). 1 Remove the Core Clip.
Figure 13 Figure 1 Removing the Core Clip
July, 2007 4-73
REP 10.3.1, REP 10.3.2
5.
Disconnect the Flexible Print Cables (2) from the AIOC PWB (Figure 2). 1 Disconnect the Flexible Print Cables (2). 2 Remove the Cores (2).
6.
Remove the Flexible Print Cable (Figure 3). 1 Peel off the pieces of tape to remove the Flexible Print Cable. 2 Slide the Flexible Print Cable through the hole in the IIT Frame.
Figure 2
Figure 3
Replacement
REP 10.3.2
July, 2007 4-74
REP 10.6.1 Exposure Lamp

4.
Disconnect the connector (Figure 2). 1 Release the wire harness from the clamp. 2 Disconnect the connector.
Remove the IIT Upper Cover (REP 10.2.1). Remove the Inverter PWB Bracket 2 (Figure 1). 1 Remove the screw. 2 Remove the Inverter PWB Bracket 2.
Figure 2
Figure 1
July, 2007 4-75
REP 10.6.1
5.
Remove the Exposure Lamp (Figure 3). 1 Remove the screw. 2 Remove the Exposure Lamp from the Lamp Holder.
REP 10.7.1 Carriage Cable and Drum

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 following parts: 2. 3. 4. Platen Cover (PL 10.1) Control Panel (REP 8.3.1)
Remove the IIT Upper Cover (REP 10.2.1). Remove the IIT Carriage (REP 10.3.1). Turn the IIT Carriage upside down.
Figure 3
Replacement
REP 10.6.1, REP 10.7.1
July, 2007 4-76
5.
Remove the Carriage Cables (black and silver) (Figure 1). 1 Peel off the pieces of tape to remove the Carriage Cables.
Replacement
1. 2. To install, do the removal steps in reverse order. Attach the Carriage Cables (black/silver) to the holes in the Drum (Figure 2).
Figure 1 Figure 2
July, 2007 4-77
REP 10.7.1
3.
Wind the Carriage Cables around the Drum and secure them with tape (Figure 3).
4. 5.
Wind the Carriage Cables around the pulleys (Figure 4). See also the Cable Winding Schematic (Figure 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
July, 2007 4-78
REP 10.7.2 Inverter PWB

Remove the IIT Upper Cover (REP 10.2.1). 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
July, 2007 4-79
REP 10.7.1, REP 10.7.2
4.
Disconnect the connector (Figure 2). 1 Release the wire harness from the clamp. 2 Disconnect the connectors (2).
5.
Remove the Inverter PWB Bracket 1 (Figure 3). 1 Remove the screw. 2 Remove the Inverter PWB Bracket 1.
Figure 2
Figure 3
REP 10.7.2
July, 2007 4-80
6.
Remove the Inverter PWB (Figure 4). 1 Remove the Tapping Screw. 2 Remove the Inverter PWB.
Figure 4
Replacement
July, 2007 4-81
REP 10.7.2
REP 10.7.2
July, 2007 4-82
REP 11.1.1 Tray 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. 1. 2. 3. Remove all paper from Tray 2. Pull out Tray 2. Lift the front side of Tray 2 and remove the tray (Figure 1).
REP 11.1.2 Single Tray Module (Separation from IOT)

WARNING
The IOT is heavy. Do this procedure with 2 persons. 1. Disconnect the connector. (Figure 1). 1 Disconnect the connector. 2 Pull out the cable clamp.
Figure 1
Replacement
To install, do the removal steps in reverse order.
Figure 1
July, 2007 4-83
REP 11.1.1, REP 11.1.2
2.
Remove the Countersunk Head Screws at the rear (Figure 2). 1 Remove the Countersunk Head Screws (2).
3.
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
July, 2007 4-84
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

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 Tray 2 (REP 11.1.1). 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
Figure 1
July, 2007 4-85
REP 11.1.2, REP 11.4.1
3.
Remove the Tray 2 Feed Roll (Figure 2). 1 Remove the KL-Clip. 2 Remove the Tray 2 Feed Roll.
Replacement
1. 2. To install, do the removal steps in reverse order. 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
July, 2007 4-86
REP 11.4.2 Tray 2 Retard Roll

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 Tray 2 (REP 11.1.1). Remove the Tray 2 Feeder (Figure 1). 1 Remove the Tapping Screws (4). 2 Remove the Tray 2 Feeder.
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).
Figure 2
Figure 1
July, 2007 4-87
REP 11.4.2
4.
Remove the Retard Shaft (Figure 3). 1 Remove the Retard Shaft.
5.
Remove the Tray 2 Retard Roll (Figure 4). 1 Release the tab to remove the Tray 2 Retard Roll.
Figure 3
Figure 4
REP 11.4.2
July, 2007 4-88
Replacement
1. 2. To install, do the removal steps in reverse order. When installing the Tray 2 Retard Roll, align the coupling of the Friction Clutch with the Tray 2 Retard Roll (Figure 5).
3.
When installing the Tray 2 Retard Roll Housing, check that the Tray 2 Retard Roll rises when the Holder Arm is pressed (Figure 6). A Holder Arm B Tray 2 Retard Roll
Figure 5
Figure 6
July, 2007 4-89
REP 11.4.2
REP 11.5.1 STM Feed Sensor

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. Remove the IOT from the Single Tray Module (REP 11.1.2). Remove Tray 2 (REP 11.1.1). Open Access Cover 2. 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.
Replacement
Figure 1
REP 11.5.1
July, 2007 4-90
REP 11.5.2 STM PWB (SCC)

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 STM Rear Cover (PL 11.5). Remove the STM PWB (Figure 1). 1 Disconnect the connectors (3). 2 Remove the screws (2). 3 Remove the STM PWB.
Replacement
Figure 1
July, 2007 4-91
REP 11.5.2
REP 11.6.1 STM Feed Clutch

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 STM Rear Cover (PL 11.5). Remove the gears (Figure 1). 1 Remove the E-rings. 2 Release the tabs.
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). 4 Release the tab on the gear, and remove the gear together with the STM Feed Clutch. 5 Slide the wire harness through the hole.
Figure 2
Replacement
1. Figure 1 To install, do the removal steps in reverse order.
REP 11.6.1
July, 2007 4-92
REP 11.6.2 STM Feed Motor

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 STM Rear Cover (PL 11.5). Remove the gears (Figure 1). 1 Release the tab, and remove the gear. 2 Release the tab, and remove the gear.
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). 4 Remove the STM Feed Motor.
Figure 2
Replacement
Figure 1
July, 2007 4-93
REP 11.6.2
REP 11.7.1 STM No Paper Sensor

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 Tray 1. Remove Tray 2 (REP 11.1.1). 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. To install, do the removal steps in reverse order. July, 2007 4-94 Initial Issue WorkCentre 5020
REP 11.7.1
ADJ 8.1.1 Edge Erase Adjustment

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. NOTE: Do the IOT Lead Edge/Side Edge Registration adjustment first.
ADJ 8.1.2 Controller Firmware Version Upgrade

Purpose
To upgrade the version of the Controller.
Check
Check the current version: Enter the Diagnostic Mode and check the Controller Firmware version xxx using Chain-Function [29-50].
Check
1. 2. 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. Check that the white portion at the lead edge, trail edge, and both sides of the copy are all 2mm wide. Enter the Diagnostic Mode and adjust the following NVM. Increasing the value will increase the amount of edge erase. Table 1 Chain Func 6 6 6 59 60 63 Name Normal Side Edge Erase Adjustment Normal Lead Edge Erase Adjustment Normal Trail Edge Erase Adjustment Min 0 0 0 Initial 16 16 16 Max 32 32 32 Step 0.254mm 0.145mm
Adjustment
[USB Connection] 1. 2. 3. 4. 5. 6. 7. Download the Firmware from our home page. Decompress the Firmware. Connect the PC to the USB connector at the Right Cover. 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. Double-click the executable file of the decompressed Firmware to run it. The [Firmware Update Tool (Printer Model And File Selection)] is displayed. Select the machine model and the downloaded Firmware file, and then click [Next]. The [Firmware Update Tool (Communication Interface Selection)] is displayed. Select [USB Port] and click [Next]. 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.
Adjustment
1.
0.145mm 8.
July, 2007 4-95
ADJ 8.1.1, ADJ 8.1.2
ADJ 10.3.1 IIT Lead Edge/Side Edge Registration

Purpose
To obtain the home position in the IIT lead edge (slow scan)/IIT side edge (fast scan) direction.
3.
Check that the measured values for lead edge (A) and side edge (B) meet the specifications of the corresponding mode. Table 1 Specification
Check
1. 2. 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. Measure the lead edge and side edge of the 3rd copy (Figure 1). Lead edge: part A in the figure Side edge: part B in the figure
Item Lead edge (A) Side edge (B)
Simplex 10 1.6mm 5 2.1mm
MSI 10 2.2mm 5 3.0mm
Adjustment
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 20 20 20 20 6 6 6 6 1 41 42 43 20 21 22 26 Sub Name System PH PH PH PH ROS ROS ROS ROS REGI ADJUSTMENT - ALL Value Min. 0 Initial Max. Value 60 60 60 60 99 99 99 99 30 30 30 30 50 50 50 50 1 Count 0.146mm 0.146mm 0.146mm 0.146mm 0.254mm 0.254mm 0.254mm 0.254mm
TRAY 1 for Normal LEAD REGI 0 ADJ TRAY 2 for Normal LEAD REGI 0 ADJ MSI for Normal LEAD REGI ADJ 0
ALL TRAY - LASER SIDE REGI 1 ADJUSTMENT TRAY 1 - LASER SIDE REGI ADJUSTMENT TRAY 2 - LASER SIDE REGI ADJUSTMENT MSI - LASER SIDE REGI ADJUSTMENT 1 1 1
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. Repeat the procedure until the measured values for lead edge (A) and side edge (B) are within the specifications.
3.
Figure 1 IIT Lead Edge/Side Edge Registration
ADJ 10.3.1
July, 2007 4-96
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.
WARNING
Adjustment
1. Remove the following parts: 2. Platen Cover (PL 10.1) Control Panel (REP 8.3.1) 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. 4. Return the machine to its original state, and make a copy in Platen Mode. Check for optical skew, and repeat from step 1 as needed.
July, 2007 4-97
ADJ 11.1.1
ADJ 11.1.1
July, 2007 4-98
5 Parts Lists
Overview
Introduction ..................................................................................................................... Subsystem Information ................................................................................................... Symbology ...................................................................................................................... 5-3 5-4 5-5 PL 8.3 Control Panel Accessory...................................................................................... PL 8.4 Control Panel Component.................................................................................... 5-31 5-32 5-33 5-34 5-35 5-36 5-37 5-38 5-39 5-40 5-41 5-42 5-43 5-44 5-45 5-46 5-47 5-48 5-49 5-50 5-51
Cover
PL 9.1 Front / Top Cover................................................................................................. PL 9.2 Rear / Right Cover and NOHAD Fan ...................................................................
Parts Lists Drive

PL 1.1 IOT Motor............................................................................................................. 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-18 5-19 5-20 5-21 5-22 5-23 5-24 5-25 5-26 5-27 5-28 5-29 5-30
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 ...................................................................................
Paper Transport
PL 2.1 Tray 1................................................................................................................... PL 2.2 Tray 1 Frame Accessory......................................................................................
Paper Tray
PL 2.3 Tray 1 Components (1 OF 2) ...............................................................................
Paper Transport
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 ......................................................................................
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.......................................................................................
ROS
PL 3.1 ROS .....................................................................................................................
Stand
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...............................................................
Common Hardware
Common Hardware ......................................................................................................... Part Number Index ..........................................................................................................
Fuser
PL 5.1 Fuser....................................................................................................................
Exit Transport
PL 6.1 Exit Transport ...................................................................................................... PL 6.2 Exit Transport Component (Simplex)...................................................................
Simplex / Duplex Module and Bypass Tray

PL 7.1 Simplex Module ................................................................................................... PL 7.2 Left Hand Cover Assembly .................................................................................. PL 7.5 Bypass Tray Accessory ....................................................................................... PL 7.6 Bypass Tray Component .....................................................................................
Electrical
PL 8.1 AIOC PWB, LVPS, Power Switch........................................................................ PL 8.2 HVPS, Interlock Switch, Duplex PWB .................................................................
July, 2007 5-1
Parts Lists
Parts Lists
July, 2007 5-2
Introduction
Overview
The Parts List section identifies all part numbers and the corresponding location of all spared subsystem components. Abbreviation R/E REF: SCSI W/ W/O Refer to
Table 1 Meaning Reduction/Enlargement Small Computer Systems Interface With Without Table 2 Operating Companies Abbreviation AO NASG - US NASG Canada XE Meaning Americas Operations North American Solutions Group - US North American Solutions Group Canada Xerox Europe
Organization
Parts Lists 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. Electrical Connectors and Fasteners 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. Common Hardware 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.
Symbology
Part Number Index 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. Symbology used in the Parts List section is identified in the Symbology section.
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 A3 A4 A5 AD AWG EMI GB KB MB MM MOD NOHAD PL P/O Meaning 297 x 594 Millimeters 210 x 297 Millimeters 148 x 210 Millimeters Auto Duplex American Wire Gauge Electro Magnetic Induction Giga Byte Kilo Byte Mega Byte Millimeters Magneto Optical Drive Noise Ozone Heat Air Dirt Parts List Part of
WorkCentre 5020
07/26/2007 5-3
Parts List
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 List
Subsystem Information
07/26/2007 5-4
WorkCentre 5020
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
WorkCentre 5020
07/26/2007 5-5
Parts List
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 4 Entire Drawing Without Tag Symbol Figure 3 Entire Drawing With Tag Symbol
Parts List
Symbology
07/26/2007 5-6
WorkCentre 5020
PL 1.1 IOT Motor

Item 1 2 3 4 5 6 Part 007K94880 120E22470 Description IOT Motor (REP 1.1.1) Push Tie Gear Pulley Cover Belt Traceability Label (Not Spared)
WorkCentre 5020
07/26/2007 5-7
Parts List
PL 1.1
PL 2.1 Tray 1
Item 1 2 3 Part 050K57460 Description Tray 1 Assembly Tray Stopper Label (Not Spared)
Parts List
PL 2.1
07/26/2007 5-8
WorkCentre 5020
PL 2.2 Tray 1 Frame Accessory

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part 848K01660 007K97780 007K97790 807E19430 809E73520 807E19440 013E25920 121K40770 801K25580 Description Tray 1 Frame 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
WorkCentre 5020
07/26/2007 5-9
Parts List
PL 2.2
PL 2.3 Tray 1 Components (1 OF 2)

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part 013E25881 059K33051 059K32773 Description 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 List
PL 2.3
07/26/2007 5-10
WorkCentre 5020
PL 2.4 Tray 1 Components ( 2 OF 2)

Item 1 2 3 4 5 6 7 8 9 10 11 Part 019K07086 809E54170 Description 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)
WorkCentre 5020
07/26/2007 5-11
Parts List
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 110E11580 130E87090 120E29540 Description 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 List
PL 2.5
07/26/2007 5-12
WorkCentre 5020
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 005E18630 006K25750 807E19460 059K48200 413W77559 809E54180 013E90840 013E32690 807E19450 Description 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)
WorkCentre 5020
07/26/2007 5-13
Parts List
PL 2.6
PL 2.7 No Paper Sensor Housing

Item 1 2 3 4 5 Part 120E23791 130E87090 Description 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 List
PL 2.7
07/26/2007 5-14
WorkCentre 5020
PL 2.8 Registration
Item 1 Part 059K48250 Description Registration Roll Assembly (REP 2.8.1)
WorkCentre 5020
07/26/2007 5-15
Parts List
PL 2.8
PL 2.9 Registration Component

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Part 130K71230 121K39710 059K53230 Description 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 List
PL 2.9
07/26/2007 5-16
WorkCentre 5020
PL 3.1 ROS
Item 1 2 3 4 5 Part 062K18161 Description ROS Assembly (REP 3.1.1) Laser Housing (Not Spared) Label (Not Spared) ROS Wire Harness Ground Harness (Not Spared)
WorkCentre 5020
07/26/2007 5-17
Parts List
PL 3.1
PL 4.1 Drum Cartridge

Item 1 2 3 4 5 Part 101R00432 106R01277 604K43850 Description Drum Cartridge (REP 4.1.1) Spring (P/O Item 5) CRU Block (P/O Item 5) Toner Bottle CRU Blocker Kit
Parts List
PL 4.1
07/26/2007 5-18
WorkCentre 5020
PL 4.2 Toner Empty Sensor and Erase Lamp

Item 1 2 Part 130K71400 122K94091 Description Toner Empty Sensor (REP 4.2.1) Erase Lamp (REP 4.2.2)
WorkCentre 5020
07/26/2007 5-19
Parts List
PL 4.2
PL 4.3 Transfer
Item 1 2 3 Part 125K93751 014K83122 Description Transfer Module (Not Spared) (REP 4.3.1) Transfer Corotron Housing Corotron Block Assembly
Parts List
PL 4.3
07/26/2007 5-20
WorkCentre 5020
PL 4.4 Transfer Corotron Housing Component

Item 1 2 3 4 5 6 Part 125K93751 604K43810 Description 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)
WorkCentre 5020
07/26/2007 5-21
Parts List
PL 4.4
PL 5.1 Fuser
Item 1 2 3 4 5 6 7 8 9 Part 126K23581 126K24411 122E92530 122E92550 022E30121 022K74110 130K71361 Description 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 List
PL 5.1
07/26/2007 5-22
WorkCentre 5020
PL 6.1 Exit Transport

Item 1 Part 059K48230 Description Exit Transport (Simplex) (REP 6.1.1)
WorkCentre 5020
07/26/2007 5-23
Parts List
PL 6.1
PL 6.2 Exit Transport Component (Simplex)

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Part 059K43000 059E99331 809E76520 013E30050 130E87090 604K43840 Description 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 List
PL 6.2
07/26/2007 5-24
WorkCentre 5020
PL 7.1 Simplex Module

Item 1 Part 802K99450 Description Simplex Module (REP 7.1.1)
WorkCentre 5020
07/26/2007 5-25
Parts List
PL 7.1
PL 7.2 Left Hand Cover Assembly

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part 604K43860 604K43870 Description 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 Label (Not Spared)
Parts List
PL 7.2
07/26/2007 5-26
WorkCentre 5020
PL 7.5 Bypass Tray Accessory

Item 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 27 28 29 Part 807E17870 121E20950 059K54730 059K48260 604K43820 022E29860 604K45750 604K45770 604K45780 604K45790 Description 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 (P/O Item 22) 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
WorkCentre 5020
07/26/2007 5-27
Parts List
PL 7.5
PL 7.6 Bypass Tray Component

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part 050K58051 019K08890 604K43830 604K45740 604K45760 Description 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
Parts List
PL 7.6
07/26/2007 5-28
WorkCentre 5020
PL 8.1 AIOC PWB, LVPS, Power Switch

Item 1 2 3 4 5 6 7 8 9 10 11 12 Part 110E11320 960K31862 960K31863 105E17391 105E17411 Description 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 AIOC PWB (110V) (REP 8.1.1) AIOC PWB (220V) (REP 8.1.1) LVPS (220V) (REP 8.1.2) LVPS (110V) Choke Coil (Not Spared) Power Cord (Not Spared)
WorkCentre 5020
07/26/2007 5-29
Parts List
PL 8.1
PL 8.2 HVPS, Interlock Switch, Duplex PWB

Item 1 2 3 4 5 6 7 8 9 10 11 Part 014K83141 105E17401 801K25570 Description 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)
Parts List
PL 8.2
07/26/2007 5-30
WorkCentre 5020
PL 8.3 Control Panel Accessory

Item 1 2 3 4 5 Part 962K66150 848K04903 Description Support Bracket (Not Spared) Control Panel Cover (Not Spared) Control Panel Wire Harness Control Panel (110V, 220V) (REP 8.3.1) Label (Not Spared) (WorkCentre 5020)
WorkCentre 5020
07/26/2007 5-31
Parts List
PL 8.3
PL 8.4 Control Panel Component

Item 1 2 3 4 Part 960K32601 Description Control Panel Panel Case (With Key) (P/O PL8.4 Item 1) UI Platen PWB Assembly (REP 8.4.1) Middle Panel (P/O PL8.4 Item 1) Label (P/O PL8.4 Item 1)
Parts List
PL 8.4
07/26/2007 5-32
WorkCentre 5020
PL 9.1 Front / Top Cover

Item 1 2 3 4 5 6 7 8 9 10 11 Part 848E04480 604K46510 848E04511 801E04660 105E12210 Description Exit Cover Front Cover Plate Kit 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
WorkCentre 5020
07/26/2007 5-33
Parts List
PL 9.1
PL 9.2 Rear / Right Cover and NOHAD Fan

Item 1 Part 848E04501 Description 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)
2 3 4 5
848E04451 127K51631 053E93650
Parts List
PL 9.2
07/26/2007 5-34
WorkCentre 5020
PL 10.1 IIT Accessory

Item 1 2 3 4 5 6 7 8 Part 004E17510 604K46500 Description IIT Right Bracket (Not Spared) IIT (Not Spared) Label (Not Spared) Platen Cover (P/O Item 8) Platen Cushion Cap (Not Spared) Label (Not Spared) (Error Code) Platen Cover Kit (REP 10.1.1)
WorkCentre 5020
07/26/2007 5-35
Parts List
PL 10.1
PL 10.2 IIT Component (1 OF 2)

Item 1 2 3 4 Part 848K07410 604K44330 Description IIT Upper Cover (REP 10.2.1) Hinge Kit Blind Cover (Not Spared) Plate Spring (P/O Item 2)
Parts List
PL 10.2
07/26/2007 5-36
WorkCentre 5020
PL 10.3 IIT Component (2 OF 2)

Item 1 2 3 4 5 6 7 Part 041K95870 962K59950 809E79910 809E79920 Description 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)
WorkCentre 5020
07/26/2007 5-37
Parts List
PL 10.3
PL 10.4 IIT Upper Cover Cover Component

Item 1 2 3 4 5 6 7 Part 848E18960 090E02380 090E91720 815E08650 815E42250 Description IIT Upper Cover Small Platen Glass Platen Glass White Referance Sheet (Black and White) Label (Not Spared) Label (Not Spared)
Parts List
PL 10.4
07/26/2007 5-38
WorkCentre 5020
PL 10.5 IIT Under Cover Component

Item 1 2 3 4 5 6 7 8 Part 801K30780 801E05970 110E11551 Description 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
WorkCentre 5020
07/26/2007 5-39
Parts List
PL 10.5
PL 10.6 IIT Carriage Component

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Part 868E12730 121K41690 122E92570 127K57140 Description 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)
Parts List
PL 10.6
07/26/2007 5-40
WorkCentre 5020
PL 10.7 Center Plate Component

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Part 140E88751 Description 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)
WorkCentre 5020
07/26/2007 5-41
Parts List
PL 10.7
PL 11.1 Single Tray Module

Item 1 2 3 4 5 Part 050K57701 Description Tray 2 (REP 11.1.1) Single Tray Frame (Not Spared) Label (End Guide) (Not Spared) Label (Caution) (Not Spared) Label (Instructon) (Not Spared)
Parts List
PL 11.1
07/26/2007 5-42
WorkCentre 5020
PL 11.2 Tray 2 Component (1 OF 3)

Item 1 2 3 4 5 6 7 8 9 10 Part Description 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)
WorkCentre 5020
07/26/2007 5-43
Parts List
PL 11.2

Item 1 2 3 4 5 6 7 8 Part 038K89761 038K89821 Description 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)
Parts List
PL 11.3
07/26/2007 5-44
WorkCentre 5020

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Part 059K48430 059K48660 013E90840 003K15530 019K09250 003K15540 Description 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)
WorkCentre 5020
07/26/2007 5-45
Parts List
PL 11.4
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 110E11580 130E87090 120E28091 055K31090 960K28562 809E74030 Description 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 Feed Sensor Spring Access Cover 2 Sensor Wire Harness (Not Spared)
Parts List
PL 11.5
07/26/2007 5-46
WorkCentre 5020
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 807E18360 059K48440 848K02140 013E32180 013E90840 807E18410 068K53590 127K52180 807E18380 807E18390 807E18400 Description 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)
WorkCentre 5020
07/26/2007 5-47
Parts List
PL 11.6
PL 11.7 STM No Paper Sensor

Item 1 2 3 4 Part 120E29630 130E87090 Description 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)
Parts List
PL 11.7
07/26/2007 5-48
WorkCentre 5020
PL 12.1 Stand Component

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part 017K93121 017K93132 017E12010 121E93360 017E98760 Description 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)
WorkCentre 5020
07/26/2007 5-49
Parts List
PL 12.1
Common Hardware
Item 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 Part 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 Description 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)
Parts List
Common Hardware
07/26/2007 5-50
WorkCentre 5020
Part Number Index

Part Number Table 1 Part Number Index Part Number 003K15530 003K15540 004E17510 005E18630 006K25750 007K94880 007K97780 007K97790 013E25881 013E25920 013E30050 013E32180 013E32690 013E90840 013E90840 013E90840 014K83122 014K83141 017E12010 017K93121 017K93132 017E98760 019K07086 019K08890 019K09250 022E29860 022E30121 022K74110 038K89761 038K89821 041K95870 050K57460 050K57701 050K58051 053E93650 055K31090 059K32773 059K33051 059K43000 Part List PL 11.4 PL 11.4 PL 10.1 PL 2.6 PL 2.6 PL 1.1 PL 2.2 PL 2.2 PL 2.3 PL 2.2 PL 6.2 PL 11.6 PL 2.6 PL 11.4 PL 11.6 PL 2.6 PL 4.3 PL 8.2 PL 12.1 PL 12.1 PL 12.1 PL 12.1 PL 2.4 PL 7.6 PL 11.4 PL 7.5 PL 5.1 PL 5.1 PL 11.3 PL 11.3 PL 10.3 PL 2.1 PL 11.1 PL 7.6 PL 9.2 PL 11.5 PL 2.3 PL 2.3 PL 6.2 059K48200 059K48230 059K48250 059K48260 059K48430 059K48440 059K48660 059K53230 059K54730 059E99331 062K18161 068K53590 090E02380 090E91720 101R00432 105E12210 105E17391 105E17401 105E17411 106R01277 110E11320 110E11551 110E11580 110E11580 120E22470 120E23791 120E28091 120E29540 120E29630 121E20950 121K39710 121K40770 121K41690 121E93360 122E92530 122E92550 122E92570 122K94091 125K93751 125K93751 126K23581
Table 1 Part Number Index Part List PL 2.6 PL 6.1 PL 2.8 PL 7.5 PL 11.4 PL 11.6 PL 11.4 PL 2.9 PL 7.5 PL 6.2 PL 3.1 PL 11.6 PL 10.4 PL 10.4 PL 4.1 PL 9.1 PL 8.1 PL 8.2 PL 8.1 PL 4.1 PL 8.1 PL 10.5 PL 11.5 PL 2.5 PL 1.1 PL 2.7 PL 11.5 PL 2.5 PL 11.7 PL 7.5 PL 2.9 PL 2.2 PL 10.6 PL 12.1 PL 5.1 PL 5.1 PL 10.6 PL 4.2 PL 4.3 PL 4.4 PL 5.1 Parts List
WorkCentre 5020
07/26/2007 5-51
Part Number Index
Table 1 Part Number Index Part Number 126K24411 127K51631 127K52180 127K57140 130K71230 130K71361 130K71400 130E87090 130E87090 130E87090 130E87090 130E87090 140E88751 413W77559 604K43810 604K43820 604K43830 604K43840 604K43850 604K43860 604K43870 604K44330 604K45740 604K45750 604K45760 604K45770 604K45780 604K45790 604K46500 604K46510 801E04660 801E05970 801K25570 801K25580 801K30780 802K99450 807E17870 807E18360 807E18380 807E18390 807E18400 Parts List Part List PL 5.1 PL 9.2 PL 11.6 PL 10.6 PL 2.9 PL 5.1 PL 4.2 PL 11.5 PL 6.2 PL 11.7 PL 2.7 PL 2.5 PL 10.7 PL 2.6 PL 4.4 PL 7.5 PL 7.6 PL 6.2 PL 4.1 PL 7.2 PL 7.2 PL 10.2 PL 7.6 PL 7.5 PL 7.6 PL 7.5 PL 7.5 PL 7.5 PL 10.1 PL 9.1 PL 9.1 PL 10.5 PL 8.2 PL 2.2 PL 10.5 PL 7.1 PL 7.5 PL 11.6 PL 11.6 PL 11.6 PL 11.6 Part Number 807E18410 807E19430 807E19440 807E19450 807E19460 809E54170 809E54180 809E73520 809E74030 809E76520 809E79910 809E79920 815E08650 815E42250 848K01660 848K02140 848E04451 848E04480 848E04501 848E04511 848K04903 848K07410 848E18960 868E12730 960K28562 960K31862 960K31863 960K32601 962K59950 962K66150
Table 1 Part Number Index Part List PL 11.6 PL 2.2 PL 2.2 PL 2.6 PL 2.6 PL 2.4 PL 2.6 PL 2.2 PL 11.5 PL 6.2 PL 10.3 PL 10.3 PL 10.4 PL 10.4 PL 2.2 PL 11.6 PL 9.2 PL 9.1 PL 9.2 PL 9.1 PL 8.3 PL 10.2 PL 10.4 PL 10.6 PL 11.5 PL 8.1 PL 8.1 PL 8.4 PL 10.3 PL 8.3
Part Number Index
07/26/2007 5-52
WorkCentre 5020
6 General Procedures
Diagnostics
Diagnostic Mode ............................................................................................................. Basic Operations of the Diagnostic Mode ....................................................................... IOT Diagnostics............................................................................................................... 6-3 6-4 6-5 6-31 6-33 6-38 6-39 6-39
General Procedures
GP1 Serial Number Locations.........................................................................................
General Information
Specifications .................................................................................................................. Tools ............................................................................................................................... Consumables .................................................................................................................. Glossary of Terms...........................................................................................................
July, 2007 6-1
General Procedures
General Procedures
July, 2007 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 Overview
Parts Diagnostics
Input Diagnostics Output 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. 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. This can be used to initialize the NVM, Counters, and Error Histories. Refer to Program Function for the items that can be initialized. This can be used to generate an independent test print from the MCU or through the Controller. Refer to Program Function. This can be used to check the total print counter, serial/product number, SW version, Error Histories, etc. Refer to Program Function. This is used to check and change the values of the various parameters in NVM.
Program Function
Initialization Test Print Check
NVM Check and Change of Settings
Checking the NVM value and changing the settings
July, 2007 6-3
General Procedures
Diagnostic Mode
Basic Operations of the Diagnostic Mode
How to Input the Chain and Function

The following shows the Chain and Function input method in the Diagnostic Mode. 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. 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. Enter the Diagnostic Mode and check that the "C_ " (Chain Code input screen) is shown on the display. The "_" should be blinking.
Display: Displays the menus and their results. Keypad: Inputs Chain Function Codes. [Start] button: Displays the Diagnostics Menu. [Stop] button: Pauses/Stops the diagnostic. 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 _
How to Enter 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. Once in the Diagnostic Mode, "C_ " (Chain Code input screen) is shown on the display. The "_" is blinking. Input the next number, and it will appear in the second digit space.
C 1 _
C _
C 1 2
How to Exit the Diagnostic Mode

Switch the machine OFF and then ON again.
General Procedures
July, 2007 6-4
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.
IOT Diagnostics
Input Diagnostics
F _
Use the keypad to enter the 2-digit Function Code.
The Input Diagnostics can be used to check the status of the various sensors in the engine, IIT, and Trays. Pressing the [Stop] button will stop the monitoring and return you to the Function Code input screen. To resume the monitoring, press the [Start] button again. Chain Func Sub Contents of Data Meaning
01
01 10 11 12 10 11 07 08 05 06 07 47 02
PH TRAY PH PH IIT IIT TRAY TRAY PH TRAY TRAY TRAY XERO
L/H (Left Side) COVER STM (Tray 2) L/H COVER L/H (Tray 1) LOW COVER FRONT COVER Platen COVER Open Carriage Home Sensor Tray1 No Paper Sensor STM No Paper Sensor IOT Regi Sensor STM Feed Sensor Tray1 Feed Sensor FEED READY SIGNAL Drum Cartridge Detected
L: Cover is closed H: Cover is open L: Cover is closed H: Cover is open L: Cover is closed H: FCover is open L: Cover is closed H: Cover is open L: Cover is closed H: Cover is open L: Sensor is exposed H: Sensor is blocked L: Paper present H: No paper L: Paper present H: No paper L: No paper H: Paper present L: No paper H: Paper present L: No paper H: Paper present Level is high Hot-Line Control L: No Drum Cartridge H: Cartridge present
General Procedures
F 2 _
Pressing the [Start] button will then run the specified Diagnostic Code.
01 01 01
F 2 3
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 Function Code input screen. Pressing the [AC] button will return you to the Chain Code input screen (C_).
05 05 07 07 08 08 08 08 09
July, 2007 6-5
Chain
Func
Sub
Contents of Data
Meaning
Chain
Func
Sub
Contents of Data
Meaning
09 10 10
07 23 60
XERO PH FUSER
Toner Empty Sensor Fuser Exit Sensor
L: Toner available H: Toner depleted L: No paper H: Paper present
05
20
IIT
Carriage Motor High Speed scan
Nohad Fan Fail Monitor L: Able to monitor FUSER FAN FAIL H: Unable to monitor FUSER FAN FAIL
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.
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. Move the Carriage toward home position at 80mm/sec. NOTE: See 05-20. Move the Carriage in the scan direction at 40mm/ sec. NOTE: See 05-20. Move the Carriage toward home position at 40mm/sec. NOTE: See 05-20. ROS Motor Start & Stop
05
21
IIT
Carriage Motor High Speed return
r u n
Pressing the [Stop] button will stop the operation of the component and return you to the Function Code input screen.
05
22
IIT
Carriage Motor Low Speed scan Carriage Motor Low Speed return
05
23
IIT
06
15 10 11 12 13 17 04
ROS PH TRAY TRAY TRAY PH XERO
ROS Motor ON IOT Registration Clutch STM Feed Clutch Tray1 Feed Clutch STM Feed Motor Bypass Solenoid HVPS ON (LOW VOLTAGE)
F 2 3
To resume the operation of the specified component, press the [Start] button again. Chain Func Sub Contents of Data Meaning
08 08 08 08 08 Fuser Fan changes from Low to High speed 09
04 04
01 02
PH FUSER
IOT Motor ON Nohad Fan Motor (HIGH SPEED)
General Procedures
July, 2007 6-6
Chain
Func
Sub
Contents of Data
Meaning
Clearing the error will return you to the Function Code input screen.
09 09
05 06
XERO XERO
HVPS ON (HIGH VOLTAGE) Pre-Charge Erase Lamp
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] This will return the NVM settings to their default values. While the NVM is being initialized, "run" is displayed.
Program Function
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
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. 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
When NVM initialization is complete, you will be returned to the Function Code input screen.
r u n
Once the test print starts, an error code will be displayed if an error occurs while printing.
C 1
Initial Issue WorkCentre 5020 July, 2007 6-7 General Procedures
Display Error History [40-01] This can be used to check for the last 20 errors. Pressing the [Start] button will display the error codes, starting with the most recent error.
Display Firmware Version [29-49] This can be used to check the firmware versions of the Controller and the MCU. 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
When the last error is displayed, press the [Start] key to return to the Function Code input screen. Clear Error History [20-59]
F
This can be used to clear the Error History.
1 a 2
F _
Pressing the [Stop] key during the display will stop it and return you to the Function Code input screen. 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. Pressing the [Start] button again will return you to the Function Code input screen.
While the Error History is being cleared, "run" is displayed.
r u n
Once the Error History has been cleared, you will be returned to the Function Code input screen. Display Serial Number [25-20] This can be used to display the serial number of the machine. 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.
7 1 1 6 F 1
2 9 5 8 F 3 1 6 4 7 0
General Procedures
July, 2007 6-8
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 _
July, 2007 6-9
General Procedures
Summary of Program Functions
Chain
Function
Sub
Contents of Data
Meaning
20 20 20
58 59 60
Initialize Initialize Initialize
MCU NVM Initialize Clear Error History MCU NVM Update
Sets the initial value in the MCU's system data. Clears the Error History. Sets the initial value in additional system data between old and new MCU versions. Use "DIAG EXECUTE" command. Executes test pattern printing. 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) Displays the total print count (6 digits). The display is divided into 2 portions: the high-order digits and the low-order digits. 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. 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. Displays the firmware version of the Controller. The display is divided into 3 portions, starting from the highest-order digit. Displays the firmware version of the MCU. The display is divided into 3 portions, starting from the highest-order digit. Displays the Error History, starting with the most recent error code.
23 23
10 01
Test Print Test Print
Test Print Print Controller built-in pattern
25 25 25 29 29 40
01 20 21 50 49 01
Check Check Check Check Check Check
Display total print counter Display machine serial number Display machine product code Display Controller firmware version Display MCU firmware version Display Error History
General Procedures
July, 2007 6-10
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.
July, 2007 6-11
General Procedures
List of NVM Settings 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 Remarks
06 06 06 06 06 06 06 06 06 07
20 21 22 26 28 29 30 34 52 46
ROS ROS ROS ROS ROS ROS ROS ROS ROS TRAY
ALL TRAY-LASER SIDE REGI ADJUSTMENT TRAY1-LASER SIDE REGI ADJUSTMENT TRAY2-LASER SIDE REGI ADJUSTMENT MSI-LASER SIDE REGI ADJUSTMENT DUP ALL TRAY-LASER SIDE REGI ADJUSTMENT DUP TRAY1-LASER SIDE REGI ADJUSTMENT DUP TRAY2-LASER SIDE REGI ADJUSTMENT DUP MSI-LASER SIDE REGI ADJUSTMENT IMAGE AREA Tray1-paper size
1~99 1~99 1~99 1~99 1~99 1~99 1~99 1~99 0~1 0~254
0.254 mm 0.254 mm 0.254 mm 0.254 mm 0.254 mm 0.254 mm 0.254 mm 0.254 mm 1mm
50 50 50 50 50 50 50 50 0 2
O O O O O O O O O O
O O O O O O O O O O
O O O O O O O O O O 0:Normal Image Area 1:Wide Image Area value paper type 1: 11x17 SEF 2: A3 SEF 3: 8K SEF*1 5: B4SEF 6: 8.5x14 SEF(Legal) 7: 8.5x13.4 SEF(Mexico Folio) 8: 8.5x13 (Folio) 10: A4 SEF 11: 8.5x11 SEF(Letter) 12: 16K SEF*1 15: B5 SEF 17: 8.5x11 LEF(Letter)
General Procedures
July, 2007 6-12
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
value paper type 1: 11x17 SEF 2: A3 SEF 3: 8K SEF*1 5: B4SEF 6: 8.5x14 SEF(Legal) 7: 8.5x13.4 SEF(Mexico Folio) 8: 8.5x13 (Folio) 10: A4 SEF 11: 8.5x11 SEF(Letter) 12: 16K SEF*1 15: B5 SEF 17: 8.5x11 LEF(Letter) value paper type 1: 11x17 SEF 2: A3 SEF 3: 8K SEF*1 5: B4SEF 6: 8.5x14 SEF(Legal) 7: 8.5x13.4 SEF(Mexico Folio) 8: 8.5x13 (Folio) 10: A4 SEF 11: 8.5x11 SEF(Letter) 12: 16K SEF*1 15: B5 SEF 17: 8.5x11 LEF(Letter) 18: 5.5x8.5 S 19: A5 S Image input is delayed when Set Value is increased. Min(0)=-4.46mm, Max(66)=4.46mm, Initial(33)=0mm Image input is delayed when Set Value is increased. Image input is delayed when Set Value is increased.
07
48
TRAY
MSI Paper size
0~254
1mm
20
01
PH
LEAD REGI ADJUSTMENT - ALL TRAY
0~60
0.146 mm
30
20 20
41 42
PH PH
TRAY1 for Normal LEAD REGI ADJ TRAY2 for Normal LEAD REGI ADJ
0~60 0~60
0.146 mm 0.146 mm
30 30
O O
O O
O O
July, 2007 6-13
General Procedures
20 20 20 20 20 20 20 21
43 45 46 47 48 49 51 09
PH PH PH PH PH PH PH HFSI
SMH for Normal LEAD REGI ADJ DUP ALL SIZE for Normal LEAD REGI ADJ ALL TRAY - REGI LOOP TIMER TRAY1 for Normal Paper REGI LOOP TIMER TRAY2 for Normal Paper REGI LOOP TIMER SMH for Normal Paper - REGI LOOP TIMER DUP for Normal Paper - REGI LOOP TIMER Last 2 of Fuser discharging Number
0~60 0~60 0~66 0~66 0~66 0~66 0~66 0~99
0.146 mm 0.146 mm 0.438 mm 0.438 mm 0.438 mm 0.438 mm 0.438 mm 1
30 30 33 33 33 11 33 0
O O O O O O O O
O O O O O O O O
O O O O O O O X
Image input is delayed when Set Value is increased. Image input is delayed when Set Value is increased. Loop increases when Set Value is increased. Loop increases when Set Value is increased. Loop increases when Set Value is increased. Loop increases when Set Value is increased. Loop increases when Set Value is increased. Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.) Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.) Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.) Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.) 0: Simplex 1: Duplex
21
19
HFSI
5th & 6th Fuser discharging Number
0~99
21
29
HFSI
3rd & 4th Fuser discharging Number
0~99
21
39
HFSI
1st 2 of Fuser discharging Number
0~3
23
20
PH
Simplex/Duplex
0~1
General Procedures
July, 2007 6-14
23 23
21 22
PH PH
Feed Tray Output Tray
1~6 0~4
1 0
O O
O O
O O
1: Tray1. 2: Tray2. 3: Tray3. 4: Tray4. 5: HCF. 6: MSI 0: FACE DOWN TRAY#1. 1: FACE DOWN TRAY#2. 2: FACE UP TRAY. 3: FINISHER Bin1. 4: FINISHER Top Tray Number of Test Prints Number of Test Prints
23 23 29 29 29 29
26 27 01 11 21 04
PH PH Billing Billing Billing HFSI
Test Print Run Length Low Byte Test Print Run Length High Byte Last 2 Dig Total Copy Counter(8 Digits) 3rd & 4th Dig Total Copy Counter(8 Digits) 1st 2 Dig Total Copy Counter(8 Digits) Tray1 Last 2 Digits of Feed Capacity (8 Digits)
0~99 0~99 0~99 0~99 0~99 0~99 1
1 0 0 0 0 0
O O O O O O
O O X X X O
O O X X X X
Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.) Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.) Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.) Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.)
29
14
HFSI
Tray1 5th & 6th Digits of Feed Capacity (8 Digits)
0~99
29
24
HFSI
Tray1 3rd & 4th Digits of Feed Capacity (8 Digits)
0~99
29
34
HFSI
Tray1 1st 2 Digits of Feed Capacity (8 Digits)
0~3
July, 2007 6-15
General Procedures
29
05
HFSI
Tray2 Last 2 Digits of Feed Capacity (6 Digits)
0~99
Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.) Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.) Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.) Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.) Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.) Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.) Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.)
29
15
HFSI
Tray2 5th & 6th Digits of Feed Capacity (6 Digits)
0~99
29
25
HFSI
Tray2 3rd & 4th Digits of Feed Capacity (6 Digits)
0~99
29
09
HFSI
MSI Last 2 Digits of Feed Capacity (8 Digits)
0~99
29
19
HFSI
MSI 5th & 6th Digits of Feed Capacity (8 Digits)
0~99
29
29
HFSI
MSI 3rd & 4th Digits of Feed Capacity (8 Digits)
0~99
29
39
HFSI
MSI 1st 2 Digits of Feed Capacity (8 Digits)
0~3
30 30 30
04 14 24
Recycle Recycle Recycle
Last 2 Digits of MSI Feed Capacity (8 Digits) 5th & 6th Digits of MSI Feed Capacity (8 Digits) 3rd & 4th Digits of MSI Feed Capacity (8 Digits)
0~99 0~99 0~99
1 1 1
0 0 0
O O O
X X X
X X X
General Procedures
July, 2007 6-16
30 30 30 30 30 30 30 30 30 30 30 30 30
34 05 15 25 06 16 26 36 07 17 27 37 41
Recycle Recycle Recycle Recycle Recycle Recycle Recycle Recycle Recycle Recycle Recycle Recycle HFSI
1st 2 Digits of MSI Feed Capacity (8 Digits) Last 2 of IOT Starting Number 3rd & 4th IOT Starting Number 1st 2 of IOT Starting Number Tray1 Last 2 Digits of Feed Capacity (8 Digits) Tray1 5th & 6th Digits of Feed Capacity (8 Digits) Tray1 3rd & 4th Digits of Feed Capacity (8 Digits) Tray1 1st 2 Digits of Feed Capacity (8 Digits) Tray2 Last 2 Digits of Feed Capacity (6 Digits) Tray2 5th & 6th Digits of Feed Capacity (6 Digits) Tray2 3rd & 4th Digits of Feed Capacity (6 Digits) Tray2 1st 2 Digits of Feed Capacity (8 Digits) Last 2 Digits of the number of Sheets Reaching BIAS transfer Roll (8 Digits) 5th & 6th Digits of the number of Sheets Reaching BIAS transfer Roll (8 Digits)
0~3 0~99 0~99 0~99 0~99 0~99 0~99 0~3 0~99 0~99 0~99 0~3 0~99
1 1 1 1 1 1 1 1 1 1 1 1 1
0 0 0 0 0 0 0 0 0 0 0 0 0
O O O O O O O O O O O O O
X X X X X X X X X X X X O
X X X X X X X X X X X X X Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.) Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.)
30
42
HFSI
0~99
July, 2007 6-17
General Procedures
30
43
HFSI
3rd & 4th Digits of the number of Sheets Reaching BIAS transfer Roll (8 Digits) 1st Two Digits of the number of Sheets Reaching BIAS transfer Roll (8 Digits) Tray Feed Capacity MAX Over
0~99
Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.) Only 0 clearance is possible in the write mode. ("0 clearance" means all bytes change to 0 at the same time.) It is shown whether the Recycle Tray Feed Capacity NVM was written more than 4000000 times. 0: not exceed 1: exceeded. It is shown whether the IOT Starting Number NVM was written more than 1000000 times. 0: not exceed 1: exceeded. CRU Remain percentage 0=OFF(Disabled), 1=20sec 2=30sec, 3=60sec, 4=90sec 1=Tray1 2=Tray2 3=MSI 1=Text 2=Text & Photo 3=Photo 0=Lightest 1=Light 2=Normal 3=Dark 4=Darkest
30
44
HFSI
0~3
30
61
Recycle
0~1
30
62
Recycle
IOT Starting Number MAX Over
0~1
33 33 33
04 05 06
CRU ESS IF ESS IF
CRU Remain UI Auto Clear Time Priority Paper Tray
0~100 0~4 1~3
1% -
100 3 1
O O O
X O O
X O O
33
07
ESS IF
Document Type
1~3
33
08
ESS IF
Density Adjustment
0~4
General Procedures
July, 2007 6-18
33
09
ESS IF
Default Reduction / Enlargement
0~4
0=100% 1=50% 2=70%(Metic),78%(Inch13&14) 3=129%(Metic),141%(Inch13&14) 4=200% 0=Disable 1=Enable 0=Disable 1=Enable China 82=82%(=82) XC 64=64%(=64) 0=Weakest 1=Weaker 2=Normal 3=Stronger 4=Strongest 0=Weakest 1=Weaker 2=Normal 3=Stronger 5=Strongest 0=0min(Shift immediately) 1=5min 2=20min 3=60min 4=120min 5=240min 254=OFF(Disable) 0=0min(Shift immediately) 1=5min 2=20min 3=60min 4=120min 5=240min 254=OFF(Disable)
General Procedures
33 33 33 33
11 12 13 14
ESS IF ESS IF ESS IF ESS IF
Auto Tray Switch Auto Paper Selection Default Customizing Reduction / Enlargement Sharpness Adjustment for Copy Job
0~1 0~1 50~200 0~4
1 1 82 2
O O O O
O O O O
O O O O
33
15
ESS IF
Sharpness Adjustment for Scan Job
0~4
33
16
ESS IF
MCU Low Power Mode
1~254
33
17
ESS IF
MCU Sleep Mode
0~254
July, 2007 6-19
33
18
ESS IF
Device Power Off Mode
0~254
0=0min(Shift immediately) 1=5min 2=20min 3=60min 4=120min 5=240min 254=OFF(Disable) 0=OFF 1=Level1 2=Level2 3=Level3 4=Level4 5=Level5 0=OFF 1=Level1 2=Level2 3=Level3 4=Level4 5=Level5 0=Disable 1=Single User Password Mode 2=Multi User Password Mode 0=Metric 1=Inch13 2=Inch14 0=OFF(Disabled) 1=20sec 2=30sec 3=60sec 4=90sec 0- 60sec 0- 60sec
33
19
ESS IF
Background removal for COPY
0~5
33
20
ESS IF
Background removal for SCAN
0~5
33
21
ESS IF
Account Mode
0~2
33
22
ESS IF
Paper Class
0~2
33
23
ESS IF
Add Original Auto Clear Time 0~4
33 33
24 25
ESS IF ESS IF
Wait Time After MSI Jam Clear Carriage Return Default Position
0~60 0~60
1sec 1sec
8 7
O O
O O
O O
General Procedures
July, 2007 6-20
33
26
ESS IF
Platen Fast Scan REGI Adjustment Platen Slow scan REGI Adjustment ADF Fast Scan REGI Adjustment ADF Slow scan REGI Adjustment Shading Offset for ADF
0~144
1dot (600dpi) 1dot (600dpi) 1dot (600dpi) 0.1mm
72
0-71=-72 to -1dot 72=0dot 73-144=1 to 72dot 0-23=-24 to -1dot 24=0dot 25-144=1 to 151dot 0-71=-72 to -1dot 72=0dot 73-144=1 to 72dot 0-39=-4.0 to -0.1mm 40=0mm 41-80=0.1 to 4.0mm complement 100=x1 1-99=x0.01-x0.99 (dark) 101-254=x1.01-x2.54 (light) complement 100=x1 1-99=x0.01-x0.99 (dark) 101-254=x1.01-x2.54 (light) 0-9=-1.0% to -0.1% 10=0% 11-20=0.1% to 1.0% 0-9=-1.0% to -0.1% 10=0% 11-20=0.1% to 1.0% 0-4=-5 to -1mm 5=0mm 1-5=1 to 5mm 0 : DC 1 : CPS 0 : not installed 1 : installed
33
27
ESS IF
0~151
24
33
28
ESS IF
0~144
72
33
29
ESS IF
0~79
40
33
30
ESS IF
1~254
100
33
31
ESS IF
Shading Offset for ADF
1~254
100
33
33
ESS IF
Platen Slow Scan scale Adjustment ADF Slow Scan scale Adjustment ADF Loop Adjustment
0~20
0.10%
10
33
35
ESS IF
0~20
0.10%
10
33
36
ESS IF
0~10
1mm
33 33
37 38
ESS IF ESS IF
M/C config ADF installation
0~1 0~1
1 0
O O
X O
X X
July, 2007 6-21
General Procedures
34 34 34 34 34 34 34 34 34 34 34 34 34 34 34
01 11 21 02 12 22 03 13 23 04 14 24 05 15 25
ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF
Administrator User Login Password Low byte Administrator User Login Password Mid byte Administrator User Login Password High Byte User1 Login Password Low Byte User1 Login Password Mid byte User1 Login Password High byte User2 Login Password Low Byte User2 Login Password Mid byte User2 Login Password High byte User3 Login Password Low Byte User3 Login Password Mid byte User3 Login Password High byte User4 Login Password Low Byte User4 Login Password Mid byte User4 Login Password High byte
48~57 48~57 48~57 48~57 48~57 48~57 48~57 48~57 48~57 48~57 48~57 48~57 48~57 48~57 48~57
49 49 49 48 48 48 48 48 48 48 48 48 48 48 48
O O O O O O O O O O O O O O O
48-57
General Procedures
July, 2007 6-22
34 34 34 34 34 34 34 34 34 34 34 34 35 35 35
06 16 26 07 17 27 08 18 28 09 19 29 01 11 21
ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF
User5 Login Password Low Byte User5 Login Password Mid byte User5 Login Password High byte User6 Login Password Low Byte User6 Login Password Mid byte User6 Login Password High byte User7 Login Password Low Byte User7 Login Password Mid byte User7 Login Password High byte User8 Login Password Low Byte User8 Login Password Mid byte User8 Login Password High byte User9 Login Password Low Byte User9 Login Password Mid byte User9 Login Password High byte
48~57 48~57 48~57 48~57 48~57 48~57 48~57 48~57 48~57 48~57 48~57 48~57 48~57 48~57 48~57
48 48 48 48 48 48 48 48 48 48 48 48 48 48 48
July, 2007 6-23
General Procedures
35 35 35 35 35 35 35 35 35 35 35 35 35 36 36 36 36 36 36 36 36 36 36 36
02 12 22 23 24 25 26 27 28 29 30 31 32 01 11 21 02 12 22 03 13 23 04 14
ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF
User10 Login Password Low Byte User10 Login Password Mid byte User10 Login Password High byte User1 Copy Credit User2 Copy Credit User3 Copy Credit User4 Copy Credit User5 Copy Credit User6 Copy Credit User7 Copy Credit User8 Copy Credit User9 Copy Credit User10 Copy Credit User1 Copy Count Low byte User1 Copy Count Mid byte User1 Copy Count High byte User2 Copy Count Low byte User2 Copy Count Mid byte User2 Copy Count High byte User3 Copy Count Low byte User3 Copy Count Mid byte User3 Copy Count High byte User4 Copy Count Low byte User4 Copy Count Mid byte
48~57 48~57 48~57 0~60 0~60 0~60 0~60 0~60 0~60 0~60 0~60 0~60 0~60 0~99 0~99 0~99 0~99 0~99 0~99 0~99 0~99 0~99 0~99 0~99
1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 July, 2007 6-24
48 48 48 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
O O O O O O O O O O O O O O O O O O O O O O O O
General Procedures
36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 36 42 42 42 42 42 42 42
Initial Issue
24 05 15 25 06 16 26 07 17 27 08 18 28 09 19 29 10 20 30 01 11 21 02 12 22 03
ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF ESS IF
User4 Copy Count High byte User5 Copy Count Low byte User5 Copy Count Mid byte User5 Copy Count High byte User6 Copy Count Low byte User6 Copy Count Mid byte User6 Copy Count High byte User7 Copy Count Low byte User7 Copy Count Mid byte User7 Copy Count High byte User8 Copy Count Low byte User8 Copy Count Mid byte User8 Copy Count High byte User9 Copy Count Low byte User9 Copy Count Mid byte User9 Copy Count High byte User10 Copy Count Low byte User10 Copy Count Mid Byte
0~99 0~99 0~99 0~99 0~99 0~99 0~99 0~99 0~99 0~99 0~99 0~99 0~99 0~99 0~99 0~99 0~99 0~99
July, 2007 6-25
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 48 48 48 48 48 48 48
O O O O O O O O O O O O O O O O O O O O O O O O O O
General Procedures
User10 Copy Count High Byte 0~99 Last 20 Fault History 1st Last Last 20 Fault History 1st 2nd Last 20 Fault History 1st 1st Last 20 Fault History 2nd Last Last 20 Fault History 2nd 2nd Last 20 Fault History 2nd 1st Last 20 Fault History 3rd Last 48~122 48~122 48~122 48~122 48~122 48~122 48~122
WorkCentre 5020
42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 43 43 43
13 23 04 14 24 05 15 25 06 16 26 07 17 27 08 18 28 09 19 29 10 20 30 01 11 21
Last 20 Fault History 3rd 2nd Last 20 Fault History 3rd 1st Last 20 Fault History 4th Last Last 20 Fault History 4th 2nd Last 20 Fault History 4th 1st Last 20 Fault History 5th Last Last 20 Fault History 5th 2nd Last 20 Fault History 5th 1st Last 20 Fault History 6th Last Last 20 Fault History 6th 2nd Last 20 Fault History 6th 1st Last 20 Fault History 7th Last Last 20 Fault History 7th 2nd Last 20 Fault History 7th 1st Last 20 Fault History 8th Last Last 20 Fault History 8th 2nd Last 20 Fault History 8th 1st Last 20 Fault History 9th Last Last 20 Fault History 9th 2nd Last 20 Fault History 9th 1st
48~122 48~122 48~122 48~122 48~122 48~122 48~122 48~122 48~122 48~122 48~122 48~122 48~122 48~122 48~122 48~122 48~122 48~122 48~122 48~122
48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48
Last 20 Fault History 10th Last 48~122 Last 20 Fault History 10th 2nd 48~122 Last 20 Fault History 10th 1st 48~122
Last 20 Fault History 11th Last 48~122 Last 20 Fault History 11th 2nd Last 20 Fault History 11th 1st 48~122 48~122
General Procedures
July, 2007 6-26
43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43 43
Initial Issue
02 12 22 03 13 23 04 14 24 05 15 25 06 16 26 07 17 27 08 18 28 09 19 29 10 20
July, 2007 6-27
48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48 48
General Procedures
Last 20 Fault History 20th Last 48~122 Last 20 Fault History 20th 2nd 48~122
WorkCentre 5020
43 43 50
30 40 15
ESS IF ESS IF EXIT
Last 20 Fault History 20th 1st Offset to the latest error Enable OCT & Inverter
48~122 0~19 0~2
48 0 2
O O O
O O O
O O O 0:Disable 1:Inverter+OCT 2:Inverter Only 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.)
50
20
FUSER
FSR Reset FuserOverTemp
0~3
60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60
01 02 03 06 07 18 19 26 27 28 29 30 31 32 33 34
ESS IF ESS IF ESS IF ESS IF ESS IF General General MC Code MC Code MC Code MC Code MC Code MC Code MC Code MC Code MC Code
MCU VERSION MCU Release Number MCU Patch Level STM Version STM Release Number CPM Market Identity Serial Code1 Serial Code2 Serial Code3 Serial Code4 Serial Code5 Serial Code6 Serial Code7 Serial Code8 Serial Code9
0~1 0~99 0~99 0~99 0~99 0~99 0~254 0~254 0~254 0~254 0~254 0~254 0~254 0~254 0~254 0~254
1 1 1 1 1 1 1 1 1
0 0 0 0 0 0 0 0 0
O O O O O O O O O O O O O O O O
X X X X X X X X X X X X X X X X
X X X X X X X X X X X X X X X X 20:20PPM Other:PPM NG 22: DMO
General Procedures
July, 2007 6-28
60 60 60 60 60 60 60 60 60
35 36 37 38 39 40 41 42 43
MC Code Product Product Product Product Product Product Product Product
Serial Code10 Product code 1 Product code 2 Product code 3 Product code 4 Product code 5 Product code 6 Product code 7 Product code 8
0~254 0~254 0~254 0~254 0~254 0~254 0~254 0~254 0~254
1 1 1 1 1 1 1 1 1
0 0 0 0 0 0 0 0 0
O O O O O O O O O
X X X X X X X X X
X X X X X X X X X
July, 2007 6-29
General Procedures
General Procedures
July, 2007 6-30
GP1 Serial Number Locations

The Serial Number is located in three places on the machine: 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. 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.
July, 2007 6-31
General Procedures
GP1
General Procedures
GP1
July, 2007 6-32
Specifications
This subsection contains the performance specifications of the WorkCentre 5020, the multifunctional machine that has copier, printer, and scanner functions.
Standard Specification of IIT, IOT, and Control UI

Table 1 IIT CCD Image Sensor capable of scanning at multi-level 600 dpi 20 PPM 600 dpi Paper Feeding: 1 tray 250 sheets MSI 50 sheets Paper Output: Face down tray (250 sheet capacity) LED
System Overview
The WorkCentre 5020 consists of IIT, IOT, PANEL, Controller, and Printer I/F. The summary of each system is as follows: 1. 2. IIT (Image Input Ternimal) Scans documents for copying and scanning. The IIT resolution is 600 dpi at multi-level. IOT (Image Output Terminal) 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. 3. 4. UI (User Interface) Displays various settings, errors. Controller Controls the whole machine. Processes and stores input from IIT, printer I/F, and images to be output to IOT. Controls UI as well. 5. Printer I/F (GDI) Receives data from the computer and passes it to the IOT (printer). In scan mode, outputs image data to the computer. Item CPU PANEL IOT
Standard Specification of Controller

Table 2 GDI Controller OTI4110 SDRAM 64M Serial EEPROM 4Mbit Extended slot Not supported NW Controller MPC8311E TBD TBD TBD Notes -----
Standard memory
Standard Specification of Host

Table 3 Item Host I/F Description USB (2.0) x 1 GDI Yes
Product Codes
Table 4 Product Code Code XJ IOT Prt/ CODE Model speed Scan Dup IIT Platen ADF FINAL ASSY
July, 2007 6-33
General Procedures
Options
Table 5 Product name STM (500sheets) Stand Installation User O O Code EL200735 EL200736
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: 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 Paper tray: Tray 1
Warmup Time
In an ambient environment of 22C 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.
Low Power Mode

When the machine is not operated for a certain period of time, the machine enters Low Power Mode automatically. Control Panel: LED: ON
FPOT
FPOT: First Print Output Time FPOT shall be 12sec or less
Resolution
Device Control: The fuser reduces its temperature. Printer I/F: Activated status. 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. Low Power Mode is cancelled when a button is pressed on the Control Panel or when a printer job is received. Copy print: 600 X 600 dpi. Printer print: 600 X 600 dpi.
Read Rate
TBD
Software Download
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.
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 warmup).
Count-up for Print/Copy jobs: GDI

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. The Count-up Meter has only one total counter. Table 6
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).
Job type Copy Print Diag
Counter type Total Counter
Description Counter of copy job Counter of print job Test print in Diag mode (It doesn't contain the Diag test print with Type-Di.)
FCOT (Warm Start)

FCOT: First Copy Output Time Report: One (Printer).
General Procedures
July, 2007 6-34
GDI: not supported.
TEC Method (New E-Star)

Table 10 Config GDI DC20 CP20 3.0Kwh 6.0Kwh TEC Network -
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 A3, B4, 8K, 11x17, Non-fixed A4 or less (A4, Letter, ....) Number of counter increments Billing 1 1 Life 2 1
Machine Size/Weight
The machine specified below does not include a drum and toner cartridge. 1. Size Table 11 Type IOT Width (mm) 595+/-5 595+/-5 Depth (mm) 532+/-5 532+/-5 Height (mm) 505+/-5 528+/-5
Electrical/Mechanical Characteristics
Electrical Characteristics Table 8 Input Voltage Frequency (VAC) (Hz) 220 - 240V 110 - 120V 240+10% 220-10% TBD 50/60+/-3 Hz TBD Rated input cur- Power Conrent Max (A) sumption* Spec (VA) 6A TBD Sleep Mode (Off Mode) Reference
IOT+IIT (Platen Glass) [Optional Devices]
1320VA (Max) 6 W (Max) TBD TBD STM (500 Sheets) Stand Width (mm) 551+/-5 551+/-5
Table 12 Depth (mm) 522+/-5 506+/-5 Height (mm) 130+/-5 385+/-5
*Power consumption is specified assuming full configuration.
Rated Power Consumption

[GDI] 2. Table 9 Mode In Low Power Mode In Sleep Mode (Off Mode) At operation (During printing operation) Power consumption DC: 43W or less CP: 107W or less DC: 6W or less CP: 20W or less (TBD) 110V 12A, 1320VA (Max) 220/240V 6A, 1320VA (Max)
Size of Package: 710x660x716 (mm) Weight Table 13 Main body Platen: Net weight (including toner cartridge) Gross weight (with Package) STM Toner cartridge Net weight (full configuration) Stand 33.02 Kg 48.5Kg (Reference) 8.8 Kg 1.2 Kg 38.0 Kg TBD IIT/MSI/Std Tray (250sheets) including toner cartridge 18 Kg TBD Optional tray: 500sheets Configuration Platen/IIT/MSI/Std Tray (250sheets) including toner cartridge
July, 2007 6-35
General Procedures
Noise (Sound Power Level: LWAd)

Unit: B Table 14 Standby Mode Base Machine Full System 4.0 4.0 Operation Mode 6.8 6.8 8.5"x13"SEF 8.5"x14" 12 SEF Mexico Folio (8.5" x13.4") A3 SEF 11" x 17" SEF 8K SEF B4 SEF A5 SEF 5.5" ( 8.5" SEF) A5 LEF 5.5" x 8.5" LEF Table 15 Base Machine Full system 6.6 7.1 10
Table 16 12 10
10
10
Not supported
10 10 Not supported
Impulse Sound Power (FX) Impulse Sound Power Level (LWAI)

LWAI B(A)
Alignment
1. Full system] IOT+IIT+ADF Table 17 Item Specification Measurement Length
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 Skew H [mm] Perpendicularity [mm] Linearity: V [mm] Linearity: H [mm] Linearity: D [mm] Registration: Lead [mm] Registration: Side [mm] 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 16 Paper Size and Paper Orientation A4 LEF 8.5" x 11" LEF 16K LEF B5 LEF A4 SEF 8.5" x 11" SEF 16K SEF B5 SEF General Procedures 15 15 10 Skew H Perpendicularity Linearity: V Simplex +/-2.0 +/-3.1 1.6 MSI +/-2.3 +/-3.3 -200mm 400mm 400mm Item Paper Tray Tray 1 Plain Paper 20 STM (Add 1 Tray) Plain Paper 20 MSI Fixed Mode 10 Table 18 Specification Measurement Length 2. [DC] IOT+IIT (TBD) Magnification: V (%) +/-2.3 +/-3.7 2.3 2.3 2.3 +/-2.9 +/-3.4 +/-1.4 (100%) +/-1.56 (50%-99%) +/-1.8 (101%-200%) +/-1.4 (100%) +/-1.56 (50%-99%) +/-1.8 (101%-200%) 400mm 200mm 400mm 400mm 280mm 280mm
Copy Speed
Continuous copy speed at 100% magnification.
280mm
July, 2007 6-36
Table 18 Linearity: H Linearity: D Registration: Lead Registration: Side Magnification: V (%) 1.6 1.6 +/-2.5 +/-3.1 +/-1.0 (100%) +/-1.2 (50%-99%) +/-1.5 (101%200%) +/-1.0 (100%) +/-1.2 (50%-99%) +/-1.5 (101%200%) --+/-3.2 +/-3.3 -400mm 280mm 280mm
Bypass Tray(MSI)
1. 2. Capacity 50 sheets of paper (70 gsm) 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. 4. Paper weight Weight of paper that can be supplied from MSI is 60g/m2 to 110g/m2. -280mm Usage rate 10%
Paper Supply
All paper trays (excluding MSI) are universal trays, which are front-loading trays. 1. Capacity Tray 1: 250 sheets (Business 80gsm/sheet). The height of a stack of paper shall be 27mm or less. 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. 3. Standard paper Standard paper is indicated by "Standard Paper" on "Paper List." Weight 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% STM: 30%
July, 2007 6-37
General Procedures
Paper List
Table 19 Media Type Paper Flag Ship (80 gsm) Baseline Paper Xerox Business Multipurpose 4200 20 lb Xerox Xcite (80 gsm) Xerox Xplore (70 gsm) Xerox Premier (80 gsm) Xerox Business (80 gsm) Flag Ship (70/80 gsm) Standard Paper Canary (70/80 gsm) Transmate (70/80 gsm) Jetset (70/80 gsm) HOOPOE(70/80 gsm) [APP Co] Colotec+ 90 gsm Colotec+ 100 gsm Topgun (70/80 gsm) Plain Transparency Removable Bar Stripe Xerox Label Recycle Paper Business 80 gsm-4 Hole (Hole on TE) 3R91823 Other Primier A4 80 gsm-4 Hole (Hole on TE) 3- Hole (hole on TE) Paperbacked OHP is out of quality assurance. 3R91723 3R2193 3R96002 3R96023 3R12050 (TBD) O O O O Code CIM O O O O O O O O O O O O Bypass O O O O O O O O O O O O O O O O O O O O O O
Tools
Most maintenance procedures can be done with the following standard tools: Table 1 No. 1 2 3 4 5 6 7 TOOL NO. /TOOL NAME 499T 1423 BOX DRIVER 5.5 499T 355 SCREWDRIVER (+) 499T 2004 ROUND NOSE PLIERS 499T 2320 S/E TESTER SET 499T 2601 SILVER SCALE (ISO M/N) 12 499T 8104 FLASHLIGHT (UM-2) 499T 8902 BRUSH 13 14 499T 9507 TESTER LEAD WIRE (Red) 499T 9508 TESTER LEAD WIRE (Black) 499T 353 * STUBBY DRIVER No. 8 9 10 TOOL NO. /TOOL NAME 499T 247 TEST PATTERN (A3) 499T 301 MINI DRIVER 499T 1901 SIDE CUTTING NIPPER
* 499T 353 STUBBY DRIVER should be used when replacing the ROS ASSEMBLY.
Paper Selection
User selects the paper tray that contains the required type of paper (size and orientation).
General Procedures
July, 2007 6-38
Consumables
Machine CRU Strategy
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.
Glossary of Terms
Table 1 Term A3 A4 AC ACT A/D ADF Table 1 ADJ STRATEGY/REPLACEMENT Warning/Hard Stop - Warning with approximately 100 copies of toner remaining. End of life Warning/Hard Stop - Warning at 16K Hard Stop at 22K (XC) Bit CCD CD CF CP CPF Chip CRU CVT DADF DC DC DMM Description Paper size 297 millimeters (11.69 inches) x 420 millimeters (16.54 inches). Paper size 210 millimeters (8.27 inches) x 297 millimeters (11.69 inches). Alternating Current is type of current available at power source for machine. Advanced Customer Training: teaches customers to perform some of service that is normally performed by Xerox Service Representative. Analog to Digital refers to conversion of signal Automatic Document Feeder Adjustment Procedure Binary digit, either 1 or 0, representing an electrical state. Charge Coupled Device (Photoelectric Converter) 1: Circuit Diagram; 2: Compact Disc Copier Fax Copier Printer Copier Printer Fax Integrated Circuit (IC) Customer Replaceable Unit Constant Velocity Transport Duplexing Automatic Document Feeder Direct Current is type of power for machine components. Machine converts AC power from power source to DC power. Digital Copier Digital Multimeter is generic name for meter that measures voltage, current, or electrical resistance. Electromagnetic Emissions are emitted from machine during normal operation and power of these emissions are reduced by machine design features. Engineer Replaceable Unit Electrostatic Discharge. A transfer of charge between bodies at different electrostatic potential. Fax Scanner Fast Scan (direction) - Inboard - to - Outboard Electronic Sub-System English Two Tray Module Facsimile Final Integration Center Ground High Frequency Service Item High Voltage Power Supply
Consumable Replacement Intervals (TBD)
ITEM Toner
YIELD/LIFE 6K @ 5% area coverage of A4 size Test pattern Hard Stop: 22K @ 5% A4 area coverage for XC Job Size = 4 pages
Drum Cartridge
This specification is applied when the machine is operated under the following conditions: Paper: A4 LEF Paper Tray: Tray 1 Copy Mode (not Print Mode)
Duplex 2-sided printing or copying EME ERU ESD FS FS ESS ENG 2TM FAX FIC GND HFSI HVPS
July, 2007 6-39
General Procedures
Glossary of Terms
Table 1 Term Hz IIT IOT IQ KC LCD LE LED LEF LTR LUT LVPS MF MN MPT NBCR NIC NSC NVM OEM OGM PC PL PO PS PSW PWB PWS PJ RAM RAP R/E REP RIS ROM ROS SAD Description Hertz (Cycles per second) Image Input Terminal - the Scanner/CCD portion of the machine Image Output Terminal - the ROS/Xero/paper handling/ fusing portion of the machine Image Quality 1000 copies Liquid Crystal Display Lead Edge of copy or print paper, with reference to definition of term TE Light Emitting Diode Long Edge Feed Letter size paper (8.5 x 11 inches) Look Up Table - array of NVM locations that store process control data Low Voltage Power Supply Multi-Function Multinational Multi Purpose Tray New Book Scanner Control Relay Network Interface Card New Scanner Controller Non Volatile Memory Original equipment manufacturer On-going Maintenance Personal Computer Parts List Part of (Assembly Name) Post Script Portable Standard Workstation Printed Wiring Board Portable Workstation for Service Plug Jack (electrical connections) Random Access Memory Repair Analysis Procedure for diagnosis of machine status codes and abnormal conditions Reduction/Enlargement refers to features selection or components that enable reduction or enlargement Repair Procedure for disassembly and reassembly of component on machine Raster Input Scanner Read Only Memory Raster Output Scanner - Device that transfers digitally processed image, using laser light, to photoreceptor. Solid Area Density Term SCP SEF Selftest SIMM FS TE UM UI USB W/ W/O XBRA XC XE XLA XMEX Description Service Call Procedure Short Edge Feed
Table 1
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. Single Inline Memory Module used to increase printing capacity Fast Scan (direction) - LE - to - TE Trail Edge of copy or print paper, with reference to definition of term LE Unscheduled Maintenance User Interface Universal Serial Bus With - indicates machine condition where specified condition is present Without - indicates machine condition where specified condition is not present Xerox Brazil Xerox Corporation Xerox Europe - also referred to as ESG (European Solutions Group) Xerox Latin America Xerox Mexico
Simplex Single sided copies
General Procedures
Glossary of Terms
July, 2007 6-40
7 Wiring Data
BSDs
Chain 1 Standby Power ................................................................................................. Chain 2 Mode Selection ................................................................................................. Chain 3 Machine Run Control ........................................................................................ Chain 4 Start Power ....................................................................................................... Chain 6 Imaging ............................................................................................................. Chain 7 Paper Supplying ............................................................................................... Chain 8 Paper Transportation ........................................................................................ Chain 9 Marking ............................................................................................................. Chain 10 Fusing and Copy Transportation .................................................................... 7-3 7-6 7-8 7-11 7-13 7-17 7-20 7-26 7-30 7-35 7-45
Wirenets
Wirenets ..........................................................................................................................
P/J Locations
7.1 P/J Locations............................................................................................................
July, 2007 7-1
Wiring Data
Wiring Data
July, 2007 7-2
Chain 1 Standby Power
July, 2007 7-3
Wiring Data
F
AIOC PWB PL8.1
1.1 MAIN POWER GENERATION

ALL B6 J414
B5
B3,B4
2
CHOKE COIL PL8.1 J5 BLK 2
LVPS PL8.1
B1,B2
A11,A12 DC POWER GENERATION J416 3 BLK 1 4 LENS ASSEMBLY PL10.7 IIT PWB J409 4,5 J410 DC COM ALL +5VDC ALL DC COM P/J407 B18 1.2 ON/ OFF +24VDC F1 DC COM ALL ALL A7,A8, B7,B8 A9,A10, B9,B10 9,10,11 +24VDC 13,12,11 ALL 20,21 DC COM STM PWB PL11.5 J508 1 GRY DC COM VIO 24VRTN VIO +24V ORN ORN VIO VIO +5VDC J540 GRY 1 ALL 3 2 ALL 2,1 A12,A13,B 12,B13 6,7 +5VDC 16,15 ALL A11,B11 1,2 A14,A15,B 14,B15 1,6,11,15,17, 19,21,23,25,27 ,29,31,34 J409 DC COM +3.3VDC J721 18,17 J720 34,29,24,20,1 8,16,14,12,10 ,8,6,4,1 J721 21,20 ALL ALL ALL
3
POWER CORD PL8.1 FS11 BLK FS60 GN/YL FS12 ACN FS33 ACH FS31
POWER SWITCH PL8.1 FS32 BLK BRN FS34 WHT BLU
AC H
1
10.1 +3.3VDC ACH 10.1
P/J407 A16,A17,B 16,B17
T21
WHT
AC N
2
4
AIOC PWB PL8.1
ALL
DC COM
5
1 Wire Color BLK:100V M/C, BRN:200V M/C Wire Color WHT:100V M/C, BLU:200V M/C
ALL
5 ALL
10
Figure 1 1.1 Main Power Generation Wiring Data Initial Issue WorkCentre 5020
July, 2007 7-4
1.2 INTERLOCK SWITCHING

1
LVPS PL8.1
LH COVER INTERLOCK SWITCH PL8.2 J506 FS151 4 ORN
LVPS PL8.1 1-1 1 LH COVER INTERLOCK SWITCH FS152 COVER OPEN(L) +24VDC
FRONT COVER INTERLOCK SWITCH PL8.2 J506 FS153
LVPS PL8.1 1-12 1 4.1 J506 ORN 1 F2 10.1 FRONT COVER INTERLOCK SWITCH FS154 COVER OPEN(L) +24VDC
AIOC PWB PL8.1
J506 ORN 3 2
J416 1
ORN
+24VDC (1.1)
2
AIOC PWB PL8.1 P/J407 A1 E5-2
P/J407 A2
B1 E5-1 INTLK +24VDC INTLK +24VDC
E5-1
LH Cover Open Front Cover Open
E5-2
5
LH COVER INTERLOCK SWITCH
Fail Code
The H/L level is displayed on the UI display.
FRONT COVER INTERLOCK SWITCH
Figure 2 1.2 Interlock Switching Initial Issue WorkCentre 5020 Wiring Data
July, 2007 7-5
Chain 2 Mode Selection
Wiring Data
July, 2007 7-6
2.1 CONTROL PANEL

Fail Code
AIOC PWB PL8.1
USER INTERFACE PWB PL8.4
U7-0
UI Communication Timeout UI Communication Error
J401 8 BLU
WAKE UP
J710 BLU 1 AIOC PWB PL8.1
U7-1
BLU
UI RESET
BLU
2 U7-0 6 U7-1
2
5 BLU UI TXD J710 BLU 4 3 BLU UI RXD J401 BLU
BLU
BLU
5 6.1
BLU
BLU
6 DC COM
DC COM (1.1) 2 BLU BLU 7
1 +5VDC (1.1)
BLU
BLU
8 +5VDC
1 4 7
6
1 2
2 5 8 0
3 6 9
Figure 1 2.1 Control Panel Initial Issue WorkCentre 5020 Wiring Data
July, 2007 7-7
Chain 3 Machine Run Control
Wiring Data
July, 2007 7-8
3.1 PWB COMMUNICATION (STM PWB)

1
AIOC PWB PL8.1 LVPS PL8.1 STM PWB PL11.5 LVPS PL8.1 P/J407 B19 J508 9 YEL STM IIC SCL J540 YEL 6 P/J407 B21 AIOC PWB PL8.1
B20
STM IIC SDA YEL YEL
J540 4 3 YEL
STM REQ
J508 YEL 6
H9-7
Fail Code
H9-7
MCU (AIOC PWB) - STM PWB Communication Error
Figure 1 3.1 PWB Communication (STM PWB) Initial Issue WorkCentre 5020 Wiring Data
July, 2007 7-9
G
Fail Code U8-1
3.2 BILLING AND MACHINE CONTROL

1
AIOC PWB PL8.1
Billing Counter Defect RAM Read/Write Check Error NVM Data Defect NVM Read/Write Cannot be Excuted CPU Power to access NVM is not enough Controller Logic Fail IOT Communication Error AMS NG Out Of Range Paper Direction Mismatch Nup NG Out Of Range Paper Direction Mismatch Copy Counter Full No Response from USBHost HBPL or XPJL Syntax Error CPM Image Lost APS NG Unselected
U6-2 U6-3 9.2 BILLING COUNTER PL8.1 U6-4 U6-5 N9-0
J401 9 BLU
U8-1
BILL ID
J630 BLU 2 1
P630
2
U6-2 RAM DC COM (1.1) U6-3 U6-4 NVM 10 BLU BLU 1 2 N9-1 E9-1 E9-2 E8-1 E8-2 N9-0 N9-1 E9-1 E9-2 N4-2 E8-1 C0-1 E8-2 L9-0 N4-0 P/J411 1,2,3, 4,5 L9-0 USB 2.0 N4-0 N4-1
U6-5
N4-1 N4-2 C0-1 C0-2
Figure 2 3.2 Billing and Machine Control Wiring Data Initial Issue WorkCentre 5020
July, 2007 7-10
Chain 4 Start Power
July, 2007 7-11
Wiring Data
4.1 MAIN DRIVE

1
AIOC PWB PL8.1
LVPS PL8.1 4-1 P/J407 B2 J504 4 BLU IOT MOTOR ON(H) +5VDC J201 BLU 4
IOT MOTOR PL1.1
Fuser
CRU
F3 1 RED RED 1 MOT 3
J201 YEL
IOT MOTOR LOCK(H) +5VDC
INTLK +24VDC (1.2) DC COM (1.1)
BLK
BLK
GN/YL T82 T81
LVPS PL8.1
AIOC PWB PL8.1
Regi
INLET FRAME
DRV ESD GND J504 GRN YEL F155 3
+5VDC P/J407 B3
U0-1 U1-1
T30
4
DRV ESD GND IOT ESD GND
Dupulex
Fail Code U0-1 IOT Motor Stop Error
U1-1
IOT Motor Rotation Error
Tray
Figure 1 4.1 Main Drive Wiring Data Initial Issue WorkCentre 5020
July, 2007 7-12
Chain 6 Imaging
July, 2007 7-13
Wiring Data
6.1 IMAGE INPUT

1
AIOC PWB PL8.1 LENS ASSEMBLY PL10.7 IIT PWB CCD J410 22 CCD SHFT CLK0 J720 13 2,3,4,5 ,7,8,9, 10, 12,13, 14,16, 18,20 J720 J410 33,32, 31,30, 28,27, 26,25, 23,22, 21,19, 17,15 AIOC PWB PL8.1
24
CCD SHFT CLK1
11
VIDEO DATA
LENS ASSEMBLY
2
26 CCD RST CLK 9
28
CCD CLMP CLK
30
CCD TRNSF CLK
5 PLATEN OPEN SWITCH
PLATEN OPEN SWITCH PL10.5 5-10 PLATEN OPEN SWITCH COVER CLOSED(L) +5VDC J711 BLK 2
4
MAGNET J711 1 DC COM (2.1) BLK
+5VDC A5-1
Fail Code A5-1 Platen Cover Open
Figure 1 6.1 Image Input Wiring Data Initial Issue WorkCentre 5020
July, 2007 7-14
C
5-20
H
CARRIAGE MOTOR
6.2 CARRIAGE SCAN

High speed scan High speed return Low speed scan Low speed return IIT5 1 CARRIAGE MOTOR PL10.6 CARRIAGE SENSOR
AIOC PWB PL8.1
LENS ASSEMBLY PL10.7 IIT PWB J409 CLOCK A CLOCK A CLOCK /A CLOCK /A CLOCK /B CLOCK /B CLOCK B CLOCK B J721 10 9 8 7 6 5 4 3 5 +24VDC (1.1) 4 3 2 1 CN4 YEL
5-21 5-22 5-23
EXPOSURE LAMP
12 13
CARRIAGE MOTOR ON +24V CLOCK
14 15 16 17 18
CARRIAGE MOTOR ON +24V CLOCK ORN
CARRIAGE MOTOR ON +24V CLOCK BRN
MOT
Fail Code U2-1 Carriage Module Fail
CARRIAGE MOTOR ON +24V CLOCK BLK
4 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.
19
RED
INVERTER PWB PL10.7 J410 J720 3 DC COM 1 +24VDC (1.1) DC COM (1.1) GRY 1
32
EXPOSURE CN3 LAMP ON 2 GRY
EXPOSURE LAMP PL10.6 INV CN2
INV CN1 2
GRY
3 CARRIAGE SENSOR PL10.6 IIT4 2 CN3 GRY 4
LENS ASSEMBLY PL10.7 IIT PWB J720 2 5-11 CARRIAGE SENSOR BLOCKED(H) +5VDC 1 J410
AIOC PWB PL8.1
+3.3VDC 33 U2-1
x CAUTION High Voltage
IIT4 6 +5VDC (1.1) DC COM (1.1) GRY 1
GRY
Figure 2 6.2 Carriage Scan Initial Issue WorkCentre 5020 Wiring Data
July, 2007 7-15
6.3 LASER CONTROL AND SCANNING

1
AIOC PWB PL8.1 ROS PL3.1 LD PWB J404 2 RED J160 RED 2 LD INTLK +5VDC 1 BLU BLU 1 DC COM LD INTLK +5VDC J403 6 BLU LASER DIODE ENABLE ON(L) +5VDC J140 BLU 1 LD INTLK +5VDC 4 POWER CONTROL ON(L) +5VDC BLU 6-16 5 9.2 1 BLU BLU 8 LD INTLK +5VDC ROS VREF OUT SIGNAL BLU 6-17 BLU 4 COM Fail Code U3-5 BLU PD 5 INLET FRAME LD ROS GND IIT GND ROS GND LASER DIODE T24 GRN F171 F156 GRN F170 1 3 2 3 J201 J2011 1 SOS PWB SOS SENSOR LD PWB AIOC PWB PL8.1
LD INTLK +5VDC J2011 J201 2 6 J140 SOS SENSED SIGNAL J403 3
+5VDC U3-5
Laser Power or ROS Motor Fail
4
DC COM (1.1)
BLU
BLU
7 LD PWB
6-15 ROS MOTOR ON(L) +5VDC BLU ROS MOTOR CLOCK BLU BLU P620 BLU 2 3 J620 J130 3
ROS MOTOR
10
MOT
7 +24VDC (1.1) 8
BLU
BLU
BLU
BLU
DC COM (1.1)
ROS MOTOR
SOS PWB
Figure 3 6.3 Laser Control and Scanning Wiring Data Initial Issue WorkCentre 5020
July, 2007 7-16
Chain 7 Paper Supplying
July, 2007 7-17
Wiring Data
7.1 TRAY1 PAPER STACKING

1
TRAY1 NO PAPER SENSOR PL2.7 LVPS PL8.1 +5VDC (1.1) J501 3 BLU P203 3 1 J203 J157 BLU 3 J157 1 BLU J203 3 1 P203 7-7 TRAY1 NO PAPER SENSOR PAPER SENSED(L) +5VDC J501 BLU 5 P/J407 A19 LVPS PL8.1 AIOC PWB PL8.1 +5VDC C5-0
4 DC COM (1.1)
BLU
BLU
3
J161 9 DC COM (1.1) BLU BLU 2
TRAY1 INTERLOCK SWITCH PL2.5 J161 1 BLU
1-11 TRAY1 INTERLOCK SWITCH COVER OPEN(H) +5VDC BLU
+5VDC 10 B22 E6-1
4
TRAY1 NO PAPER SENSOR TRAY1 INTERLOCK SWITCH
Fail Code C5-0
No paper in the selected paper tray (Tray1)

L/H Lower Cover open
E6-1
Figure 1 7.1 Tray 1 Paper Stacking Wiring Data Initial Issue WorkCentre 5020
July, 2007 7-18
7.2 STM PAPER STACKING

1
STM NO PAPER SENSOR PL11.7 STM PWB PL11.5 +5VDC (1.1) J542 3 BLU J171 BLU 3 J171 1 BLU 7-8 STM NO PAPER SENSOR PAPER SENSED(L) +5VDC J542 BLU 5 C6-0 STM PWB PL11.5 +5VDC
4 DC COM (1.1)
BLU
BLU
3
J173 9 DC COM (1.1) BLU BLU 2
STM INTERLOCK SWITCH PL11.5 J173 1 BLU
1-10 STM INTERLOCK SWITCH COVER OPEN(H) +5VDC BLU
+5VDC 10 E6-2
Fail Code C6-0
No paper in the selected paper tray (Tray2)

STM L/H Cover open
E6-2 STM NO PAPER SENSOR STM INTERLOCK SWITCH
Figure 2 7.2 STM Paper Stacking Initial Issue WorkCentre 5020 Wiring Data
July, 2007 7-19
Chain 8 Paper Transportation
Wiring Data
July, 2007 7-20
8.1 TRAY1 PAPER FEEDING

LVPS PL8.1 AIOC PWB PL8.1 +5VDC J501 BLU 8
P/J407 A20
TRAY1 FEED SENSOR PL2.5 J158 1 AIOC PWB PL8.1 LVPS PL8.1 +5VDC (1.1) BLU
8-7
TRAY1 FEED SENSOR PAPER SENSED(L) +5VDC
C1-1 C2-2 C8-1
J501 6 BLU
J158 BLU 3
7 DC COM (1.1)
BLU
BLU
8-12
TRAY1 FEED CLUTCH PL2.2 P202 BLU 2 1 J202
P/J407 A18
2 DC COM 1 +24VDC (1.1)
TRAY1 FEED CLUTCH ON(L) +24VDC BLU
BLU
BLU
IOT Motor
Fail Code C1-1 Tray1 Feed Sensor on JAM
The H/L level is displayed on the UI display
TRAY1 FEED CLUTCH
TRAY1 FEED SENSOR C2-2 Tray1 Feed Sensor on JAM from STM Feed Take Away Roll 1 C8-1 Tray1 Feed Sensor Static JAM Tray 1 Feed Roll
Figure 1 8.1 Tray 1 Paper Feeding Initial Issue WorkCentre 5020 Wiring Data
July, 2007 7-21
8.2 STM PAPER FEEDING

STM PWB PL11.5
STM FEED SENSOR PL11.5 J172 1 STM PWB PL11.5 +5VDC (1.1) BLU
8-6
1 J542 BLU 8
+5VDC C2-1 C8-2
STM FEED SENSOR PAPER SENSED(L) +5VDC
J542 6 BLU
J172 BLU 3
7 DC COM (1.1)
BLU
BLU
8-11
STM FEED CLUTCH PL11.6 P212 BLU 2 1 STM FEED CLUTCH 1 2 J212
3
DC COM
STM FEED CLUTCH ON(L) +24VDC BLU
1 +24VDC (1.1)
BLU
BLU
STM FEED MOTOR
8-13 J541 STM FEED MOTOR ON +24V CLOCK STM FEED MOTOR ON +24V CLOCK RED STM FEED MOTOR ON +24V CLOCK ORN STM FEED MOTOR ON +24V CLOCK BRN
STM FEED MOTOR PL11.6
Take Away Roll 2
YEL STM FEED SENSOR MOT
5
Tray 2 Feed Roll
Fail Code C2-1 STM Feed Sensor on JAM
C8-2
STM Feed Sensor Static JAM
Figure 2 8.2 STM Paper Feeding Wiring Data Initial Issue WorkCentre 5020
July, 2007 7-22
8.3 MANUAL BYPASS

1
AIOC PWB PL8.1 LVPS PL8.1
8-17
P/J407 A5
BYPASS SOLENOID PL7.5
J502 3 DC COM 1 +24VDC (1.1) RED RED
BYPASS SOLENOID ON(L) +24VDC
BYPASS SOLENOID
Bypass Feed Roll
Bypass Take Away Roll
Figure 3 8.3 Manual Bypass Initial Issue WorkCentre 5020 Wiring Data
July, 2007 7-23
8.4 PAPER REGISTRATION

LVPS PL8.1 AIOC PWB PL8.1 +5VDC J503 BLU 3
P/J407 A4
IOT REGI. SENSOR PL2.9 J156 1 AIOC PWB PL8.1 LVPS PL8.1 +5VDC (1.1) BLU
8-5
IOT REGI. SENSOR PAPER SENSED(L) +5VDC
C1-2 C2-3 C6-2
J503 1 BLU
J156 BLU 3 C9-3 E1-6
2 DC COM (1.1)
BLU
BLU
8-10
P/J407 A6
IOT REGI. CLUTCH PL2.9 P640 BLU 1 2 J640
4 DC COM 5 +24VDC (1.1)
IOT REGI. CLUTCH ON(L) +24VDC BLU
BLU
BLU
IOT Motor
Fail Code C1-2 Tray1 Regi. Sensor on JAM
IOT REGI. CLUTCH C2-3 STM IOT Regi. Sensor on JAM
C9-3
Manual Bypass IOT Regi. Sensor on JAM
IOT REGI. SENSOR
E1-6
IOT Regi. Sensor Static JAM
Regi. Roll
Figure 4 8.4 Paper Registration Wiring Data Initial Issue WorkCentre 5020
July, 2007 7-24
8.5 PAPER PATH

1
Exit Roll
FUSER EXIT SENSOR
3
Regi. Roll
Fuser IOT MOTOR
IOT REGI. SENSOR
Drum
4
Bypass Feed Roll
TRAY1 FEED SENSOR Bypass Take Away Roll Take Away Roll 1 TRAY1 NO PAPER SENSOR
Tray 1 Feed Roll Take Away Roll 2 STM NO PAPER SENSOR
STM FEED SENSOR
STM FEED MOTOR
Tray 2 Feed Roll
Figure 5 8.5 Paper Path Initial Issue WorkCentre 5020 Wiring Data
July, 2007 7-25
Chain 9 Marking
Wiring Data
July, 2007 7-26
9.1 XEROGRAPHICS
1
AIOC PWB PL8.1 9-4 9-5 J406 2 BLU CHARGE ON(L) +5VDC J520 BLU 2 GND 4 DC COM 5 DC COM 3 TRANSFER S/D ON BLU BLU DETACK 3 9.3 9 INTLK +24VDC 7 BLU BLU 7 BLU BLU 9 INTLK +24VDC Magnet Roll GND TRANSFER TRANSFER ON(L) +5VDC BLU BLU 5 TRANSFER COROTRON HOUSING PL4.3 Transfer Corotron DEVE BIAS AC/DC ON(L) +5VDC BLU BLU 4 DEVE BIAS Detack Saw Grid GRID HVPS PWB PL8.2 DRUM CARTRIDGE PL4.1 CHARGE Paper ChargeCorotron Drum
DC COM
3
DC COM
Deve Bias
4
DC COM (1.1)
BLU
BLU
AIOC PWB PL8.1
+5VDC J520 1 RED HVPS ERROR(L) +5VDC J406 RED 1 U9-0
Fail Code U9-0 HVPS fail
Figure 1 9.1 Xerographics Initial Issue WorkCentre 5020 Wiring Data
July, 2007 7-27
9.2 TONER SENSE AND CRUM

1
TONER EMPTY SENSOR PL4.2 J509 1 +24VDC (1.1) 3 DC COM (1.1) BLU BLU 2 3 BLK GRN 4 1 BLU BLU P110 BLU 4 1 J110 RED J110 WHT 2 3 P110 BLU 9-7 TONER EMPTY SENSOR TONER SENSED(L) +5VDC BLU J509 BLU 2 +5VDC 4
P/J407 B4
LVPS PL8.1
LVPS PL8.1
AIOC PWB PL8.1
J1-2
AIOC PWB PL8.1
DRUM CARTRIDGE PL4.1 CRUM
+12VDC
3.2 1
J402 BLU
CRU ID
P610 BLU 7 1
J610 2
J6-1 J7-1 J7-2 9-2 J610 P610 4 4 BLU 1 J402 BLU 3 6.3 J3-1 +5VDC J7-3
3
4 DC COM (1.1) INTLK +5VDC +24VDC (1.2) 5 BLU BLU 2 6 BLU BLU 3 5 1
DRUM CARTRIDGE SENSED(L) +5VDC
INTLK +5VDC BLU BLU
INTLK +5VDC BLU BLU
6 INTLK +5VDC
DC COM
Fail Code J1-2 Toner Empty
The H/L level is displayed on the UI display.
J3-1
No Drum cartridge
CRUM
J6-1
Drum cartridge life end
J7-1
Drum CRUM communication error
TONER EMPTY SENSOR
J7-2
Drum CRUM Market identity mismatch DRUM CARTRIDGE
J7-3
Drum CRUM ID error
Figure 2 9.2 Toner Sense and CRUM Wiring Data Initial Issue WorkCentre 5020
July, 2007 7-28
9.3 ERASE LAMP

1
AIOC PWB PL8.1 HVPS PWB PL8.2
9-6 J406 6 BLU ERASE LAMP ON(L) +5VDC J520 BLU 6
+24VDC J521 1 DC COM DC COM 3 DC COM 2 INTLK +24VDC (9.1) BLU 2 BLU 3 BLU J210 1
ERASE LAMP PL4.2
ERASE LAMP
Figure 3 9.3 Erase Lamp Initial Issue WorkCentre 5020 Wiring Data
July, 2007 7-29
Chain 10 Fusing and Copy Transportation
Wiring Data
July, 2007 7-30
10.1 FUSER TEMPERATURE CONTROL

1
AIOC PWB PL8.1 LVPS PL8.1 FUSER PL5.1 THERMOSTAT
P/J407 B6
+5VDC
J3 3 BLK
FUSER LAMP ON ACH BLK
J600 2 BLK
F28
F25
DC COM
ACH SWITCHED (1.1) B5 DC COM
FUSER LAMP F26 AIOC PWB PL8.1 F27 1 1 U4-1 THERMISTOR 10-20 J601 2 1 P601 BLU FUSER THERMISTOR SENSED SIGNAL J408 BLU 1 U4-3 +5VDC U4-2
+24VDC INTLK (1.2)
WHT
WHT
ACN (1.1)
J408 2 DC COM (1.1) BLU
P601 BLU 2 1
J601
4
Fail Code U4-1 Fuser On Time Fail
U4-2
Over Heat Temp Fail
5
THERMISTOR
FUSER LAMP
U4-3
FS1 thermistor defect
THERMOSTAT
Figure 1 10.1 Fuser Temperature Control Initial Issue WorkCentre 5020 Wiring Data
July, 2007 7-31
E
LVPS PL8.1
F
AIOC PWB PL8.1 +5VDC J505 BLU 3
P/J407 A3
10.2 EXIT
1
FUSER EXIT SENSOR PL6.3 J153 LVPS PL8.1 +5VDC J505 J153 BLU 3 1 1 BLU 10-23 1
E1-2 E3-1 E3-6
FUSER EXIT SENSOR PAPER SENSED(L) +5VDC
BLU
2 DC COM (1.1)
BLU
BLU
SimplexTransport: Exit Roll is driven by IOT Motor.
Fail Code E1-2 Fuser Exit Sensor on JAM E3-1 Fuser Exit Sensor off JAM E3-6 Fuser Exit Sensor Static JAM
Exit Roll
5
1 The H/L level is displayed on the UI display
IOT Motor
6
FUSER EXIT SENSOR
Figure 2 10.2 Exit Wiring Data Initial Issue WorkCentre 5020
July, 2007 7-32
10.3 MACHINE COOLING

1
AIOC PWB PL8.1 +24VDC J405 3 RED 4-2 1
NOHAD FAN PL9.2
AIOC PWB PL8.1
NOHAD FAN ON(H) +24VDC MOT 10-60 NOHAD FAN FAIL(H) +5VDC J405 BLU 1 U4-9 +5VDC
BLK
DC COM (1.1)
Fail Code
1 Nohad Fan defect
U4-9
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
Figure 3 10.3 Machine Cooling Initial Issue WorkCentre 5020 Wiring Data
July, 2007 7-33
Wiring Data
July, 2007 7-34
Wirenets
7.2.1 WIRE NET AC POWER (HOT)
POWER CORD POWER SWITCH LOW VOLTAGE POWER SUPPLY FS32 1 FS60 GN/YL WHT (SEE WIRE NET AC POWER (NEUT)) FUSER J3 3 BLK P600 2 BLK J600 F28 THERMOSTAT F25 F26 FUSER LAMP 10.1 BLK BLK BRN 1 BLK BLK J5 LOW VOLTAGE POWER SUPPLY J5 2
CHOKE COIL
1.1
FS11
FS31
Wire Color BLK: 100V M/C, BRN: 200V M/C
7.2.2 WIRE NET AC POWER (NEUT)

POWER CORD POWER SWITCH LOW VOLTAGE POWER SUPPLY
FUSER J3 1 WHT P600 1 J600 F27 FUSER LAMP 10.1
FS12 FS60 GN/YL BLK WHT
FS33
FS34 WHT BLU 1
(SEE WIRE NET AC POWER (HOT))
DC POWER GENERATION
Wire Color WHT: 100V M/C, BLU: 200V M/C
July, 2007 7-35
Wiring Data
7.2.3 WIRE NET +3.3VDC

LOW VOLTAGE POWER SUPPLY AIOC PWB IIT PWB +3.3VDC P/J407 A16 A17 B16 B17 J414 B6 J409 4 5 FLAT CABLE J721 18 17 LENS ASSEMBLY
Wiring Data
July, 2007 7-36
7.2.4 WIRE NET +5VDC-1

LOW VOLTAGE POWER SUPPLY J501 3 BLU J158 +5VDC 6 BLU J503 1 BLU J505 1 BLU J153 3 FUSER EXIT SENSOR J156 3 IOT REGISTRATION SENSOR 8.4 3 TRAY1 FEED SENSOR P203 3 1 BLU 8.1 J203 J157 3 TRAY1 NO PAPER SENSOR 7.1
10.2
STM PWB J508 1 GRY J540 1 3 BLU J172 6 BLU 3 STM FEED SENSOR J542 J171 3 STM NO PAPER SENSOR 7.2
8.2
AIOC PWB P/J407 A11 USER INTERFACE PWB 8 BLU
J401 1
J710
2.1
B11
2 BLU
(SEE WIRE NET +5VDC-2)
July, 2007 7-37
Wiring Data

(FROM WIRE NET +5VDC-1)
LENS ASSEMBLY IIT PWB J409 6 J721 16 6 GRY CN3 IIT4 1 CARRIAGE SENSOR 6.2
7 FLAT CABLE J416 3
15
J414 B5
AIOC PWB
Wiring Data
July, 2007 7-38
7.2.6 WIRE NET DC COM (+5V RTN)-1

LOW VOLTAGE POWER SUPPLY J501 4 BLU J158 +5VRTN 7 BLU J161 9 BLU J503 2 BLU J505 2 BLU STM PWB J508 3 VIO J540 2 4 BLU J172 7 BLU J173 9 BLU 2 STM INTERLOCK SWITCH 7.2 2 STM FEED SENSOR J542 J171 2 STM NO PAPER SENSOR J153 2 FUSER EXIT SENSOR J156 2 2 TRAY1 INTERLOCK SWITCH 7.1 2 TRAY1 FEED SENSOR P203 2 2 BLU 8.1 J203 J157 2 TRAY1 NO PAPER SENSOR 7.1
IOT REGISTRATION SENSOR
8.4
10.2
7.2
8.2
J509 3 BLU
P110 2 3
J110 BLK
TONER EMPTY SENSOR
9.2
(SEE WIRE NET DC COM (+5VRTN)-2)
July, 2007 7-39
Wiring Data

(FROM WIRE NET DC COM (+5VRTN)-1)
LOW VOLTAGE POWER SUPPLY
AIOC PWB DRUM CARTRIDGE P/J407 A12 J402 4 BLU 5 A13 BLU 2 6 P610 3 5 J610 1 CRUM 9.2
J416 B12 4
LENS ASSEMBLY B13 J409 1 J721 21 IIT PWB
2 FLAT CABLE J410 +3.3VRTN A14 1 6 A15 11 15 B14 17 B14 19 21 23 25 27 29 31 34 FLAT CABLE (SEE WIRE NET DC COM(+5VRTN)-3) J720
20
CN3 34 29 24 20 18 16 14 12 10 8 6 4 1 5 GRY
IIT4 3 CARRIAGE SENSOR
6.2
Wiring Data
July, 2007 7-40

(FROM WIRE NET DC COM (+5VRTN)-2)
USER INTERFACE PWB J401 3 BLU J710 6 2 BLK J711 PLATEN OPEN SWITCH
6.1
4 BLU J630 10 BLU
P630 1 2 BILLING COUNTER
3.2
ROS J403 2 BLU FUSER J408 2 BLU P601 2 1 J601 THERMISTOR 10.1 J140 7 LD PWB 6.3
J414 B3
B4
AIOC PWB
July, 2007 7-41
Wiring Data

LOW VOLTAGE POWER SUPPLY J506 4 ORN F1 +24VDC LOW VOLTAGE POWER SUPPLY J506 1 ORN F3 1 BLU J504 J201 1 IOT MOTOR 4.1 FS151 3 1 ORN LH COVER INTERLOCK SWITCH FS152 J506 3 2 ORN LOW VOLTAGE POWER SUPPLY J506 FS153 3 1 ORN FRONT COVER INTERLOCK SWITCH FS154
F2 4
J508 N.C
AIOC PWB P/J407 A1 J406 9 BLU P520 9
HIGH VOLTAGE POWER SUPPLY J521 2 BLU J210 2 ERASE LAMP 9.3
J416 B1 1
J501 1 BLU
P202 1 2
J202 TRAY1 FEED CLUTCH
8.1
J502 1 RED BYPASS SOLENOID
8.3
J503 5 BLU
P640 2 1
J640
IOT REGISTRATION CLUTCH
8.4
STM PWB J508 10 ORN J540 7 1 BLU J542 P212 1 2 J212 STM FEED CLUTCH 8.2
(SEE WIRE NET +24VDC-2)
Wiring Data
July, 2007 7-42

(FROM WIRE NET +24VDC-1)
J509 1 BLU AIOC PWB
P110 4 1
J110 RED
TONER EMPTY SENSOR
9.2
ROS P/J407 A7 J403 7 BLU P620 4 1 J620 J130 5 ROS MOTOR 6.3
A8 LENS ASSEMBLY B7 J409 9 B8 10 11 FLAT CABLE 12 CN3 11 1 GRY INV CN1 1 INVERTER PWB 6.2 J721 13 5 RED
IIT PWB CN4 IIT5 5 CARRIAGE MOTOR
6.2
J414 B1
B2 LOW VOLTAGE POWER SUPPLY
July, 2007 7-43
Wiring Data
7.2.11 WIRE NET DC COM (+24V RTN)
LOW VOLTAGE POWER SUPPLY
J504 +24VRTN 2 BLU J508 8 VIO
J201 2 IOT MOTOR
4.1
J540 5
STM PWB
AIOC PWB ROS P/J407 A7 J403 8 BLU J405 A8 2 BLK J406 B1 7 BLU J520 HIGH VOLTAGE 7 POWER SUPPLY 9.1 NOHAD FAN 10.3 P620 3 2 J620 J130 4 ROS MOTOR 6.3
B7
8 BLU
LENS ASSEMBLY B8 IIT PWB J409 20 J721 2 3 GRY CN3 INV CN1 3 INVERTER PWB 6.2
21 FLAT CABLE J416 2
J414 A11
A12
Wiring Data
July, 2007 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.
July, 2007 7-45
Wiring Data
7.1.2 P/J List

Table 1 P/J No. Figure No. Item No. Description P/J No. Figure No. Item No.
Table 1 Description
P/J158 P/J160 P/J161 P/J171 P/J172 P/J173 P/J201 P/J201 P/J2011 P/J202 P/J203 P/J210 P/J212 P/J401 P/J402 P/J403 P/J404 P/J405 P/J406 P/J407 P/J408 P/J409 P/J410 P/J414A/B P/J416 P/J501 P/J502 P/J503 P/J504 P/J505 P/J506 P/J509 P/J520 P/J521 P/J540 P/J541 P/J542 P/J600 P/J601 P/J620 1 4 3 2 4 6 8 7 4 5 7 1 3 2 5 5 6 2 1 1 8 2 7 8 14 16 15 2 15 9 18 17 6 2 5 1 4 7 Fuser Thermostat Fuser Lamp Fuser Lamp Fuser Thermostat Inlet Inlet LH Cover Interlock Switch LH Cover Interlock Switch Front Cover Interlock Switch Front Cover Interlock Switch Power Switch Power Switch Power Switch Power Switch Inlet GND Carriage Sensor Carriage Motor Inverter PWB Inverter PWB AIOC PWB STM CRU NBCR PWB NSC PWB AIOC PWB AIOC PWB AIOC PWB AIOC PWB LVPS CRU Fuser Lamp Choke Coil Toner Empty Sensor ROS MPA ROS Fuser Exit Sensor IOT Regi. Sensor Tray 1 No Paper Sensor
Figure 4 Figure 2 Figure 4 Figure 6 Figure 6 Figure 6 Figure 8 Figure 2 Figure 2 Figure 8 Figure 8 Figure 3 Figure 6 Figure 7 Figure 7 Figure 7 Figure 7 Figure 7 Figure 7 Figure 9 Figure 7 Figure 7 Figure 7 Figure 7 Figure 7 Figure 9 Figure 9 Figure 9 Figure 9 Figure 9 Figure 9 Figure 9 Figure 3 Figure 3 Figure 6 Figure 6 Figure 6 Figure 4 Figure 4 Figure 2
6 6 5 2 1 3 6 4 1 7 8 1 4 6 11 12 5 9 8 16 13 4 3 7 10 13 10 12 9 14 11 8 3 2 7 5 6 2 3 3
Tray 1 Feed Sensor ROS, Video Tray 1 Interlock Sensor STM No Paper Sensor STM Feed Sensor STM Interlock Switch IOT Motor ROS, SOS PWB ROS, SOS PWB Tray 1 Feed Clutch Tray 1 No Paper Sensor Erase Lamp STM Feed Clutch UI CRU ID ROS ROS, Video Nohad Fan HVPS LVPS-AIOC PWB AIOC PWB AIOC PWB AIOC PWB AIOC PWB AIOC PWB LVPS LVPS LVPS LVPS LVPS LVPS LVPS HVPS HVPS STM STM Feed Motor STM (TOTAL CL, SNR, SW) Fuser Lamp Fuser Thermistor ROS MPA
F25 F26 F27 F28 FS11 FS12 FS151 FS152 FS153 FS154 FS31 FS32 FS33 FS34 FS60 IIT4 IIT5 INV CN1 INV CN2 J411 J508 J610 NBCR CN6 NSC CN1 P412 P417 P418 P419 P508 P610 P/J3 P/J5 P/J110 P/J130 P/J140 P/J153 P/J156 P/J157
Figure 5 Figure 5 Figure 5 Figure 5 Figure 9 Figure 9 Figure 4 Figure 4 Figure 3 Figure 3 Figure 9 Figure 9 Figure 9 Figure 9 Figure 9 Figure 1 Figure 1 Figure 1 Figure 1 Figure 7 Figure 6 Figure 8 Figure 1 Figure 1 Figure 7 Figure 7 Figure 7 Figure 7 Figure 9 Figure 8 Figure 9 Figure 9 Figure 3 Figure 2 Figure 2 Figure 4 Figure 4 Figure 3
Wiring Data
July, 2007 7-46
Table 1 P/J No. Figure No. Item No. Description
P/J630 P/J640 P/J710 P/J711 P/J720 P/J721
Figure 8 Figure 8 Figure 1 Figure 1 Figure 1 Figure 1
1 5 9 10 4 3
Billing ID IOT Regi Clutch UI Platen Switch IIT Data IIT Power
July, 2007 7-47
Wiring Data
Figure 1 IIT Wiring Data Initial Issue WorkCentre 5020
July, 2007 7-48
Figure 2 ROS
July, 2007 7-49
Wiring Data
Figure 3 HVPS
Wiring Data
July, 2007 7-50
Figure 4 LH
July, 2007 7-51
Wiring Data
Figure 5 Fuser
Wiring Data
July, 2007 7-52
Figure 6 STM
July, 2007 7-53
Wiring Data
Figure 7 AIOC PWB
Wiring Data
July, 2007 7-54
Figure 8 Rear
July, 2007 7-55
Wiring Data
P/ J503
P/ J505
Figure 9 Inlet & LVPS Wiring Data Initial Issue WorkCentre 5020
July, 2007 7-56

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WorkCentre 5020 Service Documentation WorkCentre 5020 Service Documentation 701P47442 Initial Issue July, 2007 ***Xerox Private

Initial Issue WorkCentre 5020

Initial Issue WorkCentre 5020

How To Use This Manual

Description of Terminology and Symbols

July, 2007 iii

Initial Issue WorkCentre 5020

1 Service Call Procedures

Initial Issue WorkCentre 5020

July, 2007 1-1

Service Call Procedures

Service Call Procedures

July, 2007 1-2

Initial Issue WorkCentre 5020

1.1 Before Starting Service

1.1.2Things to Note When Handling Customer Data

1.1.3 Other Precautions

Initial Issue WorkCentre 5020

July, 2007 1-3

Service Call Procedures

1.2 Service Call Procedure

1.3 Service Call Details

1.2.2 Actions to Take During UM (Unscheduled Maintenance)

1.3.2 Checking Reproducibility of Problem

1.3.3 Checking Copy Quality

1.3.4 TRIM Servicing

1.2.3 Actions to Take During SM (Scheduled Maintenance)

1.2.4 Final Actions

Service Call Procedures

July, 2007 1-4

Initial Issue WorkCentre 5020

1.4 TRIM Checklist

1.5 Periodic Replacement Parts/Consumables List

100,000 6,000 36,000

6.1 6.2 Check after servicing (copy quality check) A

Create the Service Log and Service Report.

CAUTION Do not touch the Drum of the Drum Cartridge.

Initial Issue WorkCentre 5020

July, 2007 1-5

Service Call Procedures

Service Call Procedures

July, 2007 1-6

Initial Issue WorkCentre 5020

2 Status Indicator RAPS

Initial Issue WorkCentre 5020

July, 2007 2-1

Status Indicator RAPS

Status Indicator RAPS

July, 2007 2-2

Initial Issue WorkCentre 5020

Fault Repair Overview and List of Error Codes

Check the status of Installation

Check the problem status

Diagnostic Mode Operating Principles Wiring Data

Reference Information Check if the fault is repaired

Figure 1 Troubleshooting Procedure

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July, 2007 2-3

Status Indicator RAPS

Things to Note When Using RAPs

Status Indicator RAPS

July, 2007 2-4

Initial Issue WorkCentre 5020

Turn the Power Switch OFF then ON