WC5016 5020 Service

Work Center 5016, 5020
Service Documentation
701P48365
June 2008
CAUTION
Certain components in the Work Center 5016/ 5020
are susceptible to damage from electrostatic discharge. Observe all ESD procedures to avoid component damage.
While Xerox has tried to make this documentation accurate, Xerox will have
no liability arising out of any inaccuracies or ommissions. Changes are periodically made to this document. Changes, technical inaccuracies, and typographical errors will be corrected in subsequent editions.
All service documentation is supplied to Xerox external customers for informational purposes only. Xerox service documentation is intended for use by
certified product trained service personal only. Xerox does not warrant or
represent that such documentation is complete, nor does Xerox represent
or warrant that it will notify or provide to such customer any future changes
to this documentation. Customer performed service of equipment, or modules, components or parts of such equipment may affect the warranty
offered by Xerox with respect to such equipment. You should consult the
applicable warranty for its terms regarding customer or third party provided
service. If the customer services such equipment, modules, components or
parts thereof, the customer releases Xerox from any and all liability for the
customer actions, and the customer agrees to indemnify, defend and hold
Xerox harmless from any third party claims which arise directly or indirectly
from such service.
Acknowledgements
Prepared by Global Knowledge & Llanguage Services - North America
800 Phillips Road - Building 0218-01A
Webster, New York 14580-9791
ISO9001 AND ISO27001 Certified
Copyright 2007-2008 by Xerox Corporation. All rights reserved.
Xerox and all product names and number names
are trademarks of Xerox Corporation.
Printed in the USA
WorkCentre 5016, 5020
Printed in the United States of America.
Service Documentation
XEROX and all Xerox product names mentioned in this publication are trademarks of
XEROX CORPORATION. Other company trademarks are also acknowledged.
WorkCentre 5016, 5020 Service Documentation

PANTONE is a registered trademark of Pantone, Inc.
701P48365
Changes are periodically made to this document. Changes, technical inaccuracies, and typographic errors will be corrected in subsequent editions.
Reissue
June, 2008
CAUTION
***Xerox Private Data***

All service documentation is supplied to Xerox external customers for informational purposes
only. Xerox service documentation is intended for use by certified, product-trained service personnel only. Xerox does not warrant or represent that it will notify or provide to such customer
any future change to this documentation. Customer performed service of equipment, or modules, components, or parts of such equipment may affect whether Xerox is responsible to fix
machine defects under the warranty offered by Xerox with respect to such equipment. You
should consult the applicable warranty for its terms regarding customer or third-party provided
service.
This equipment generates, uses and can radiate radio frequency energy, and if not installed
and used in accordance with the instructions documentation, may cause interference to radio
communications. It has been tested and found to comply with the limits for a Class A computing device pursuant to subpart B of part 15 of FCC rules, which are designed to provide reasonable protection against such interference when operated in a commercial environment.
Operation of this equipment in a residential area is likely to cause interference in which case
the user, at his own expense, will be required to correct the interference.
If the customer services such equipment, modules, components or parts thereof, the customer
releases Xerox from any and all liability for the customer actions, and the customer agrees to
indemnify, defend and hold xerox harmless from any third party claims which arise directly or
indirectly for such service.
While Xerox has tried to make the documentation accurate, Xerox will have no liability arising
out of any inaccuracies or omissions. Changes are periodically made to this document.
Changes, technical inaccuracies, and typographical errors will be corrected in subsequent editions.
Prepared by:
Xerox Corporation
Global Knowledge and Language Services
800 Phillips Road, Bldg. 0218-01A
Webster, New York 14580-9791
USA
2007 - 2008 by Xerox Corporation. All rights reserved.
Copyright protection claimed includes all forms and matters of copyrightable material and information now allowed by statutory judicial law or hereinafter granted, including without limitation,
material generated from the software programs which are displayed on the screen such as
icons, screen displays, looks, etc.
Front Matter
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Front Matter
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Introduction
How To Use This Manual................................................................................................
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Introduction
Introduction
June, 2008
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How To Use This Manual
Chain 1 Standby Power

Chain 2 Mode Selection
Chain 3 Machine Run Control
This manual is used as the standard service manual for the WorkCentre 5016, 5020.
Chain 4 Start Print Power

Chain 6 Imaging
Enter any comments and/or corrections regarding the WorkCentre 5016, 5020 Service Documentationl on the Publication Comment Sheet, and send it to the Technical Support Center
SDEG.
Chain 7 Paper Supplying

Chain 8 Paper Transportation
Chain 9 Marking
This manual describes the standard procedures for servicing the WorkCentre 5016, 5020.
Refer to Section 1 Service Call Procedure for efficient and effective servicing during maintenance calls.
Chain 10 Fusing and Copy Transportation
Contents of Manual
Description of Terminology and Symbols
This manual is divided into nine sections as described below.
The terminology and symbols used throughout this service manual are described as follows:
WARNING
Section 1 Service Call Procedures

This section describes the structured process for determining the type and sequence of actions
that are performed during a service call.
A Warning statement indicates an operating or maintenance procedure, practice, or

condition that, if not strictly observed, could result in personal injury or loss of life.
CAUTION
Section 2 Status Indicator RAPs
A Caution statement indicates an operating or maintenance procedure, practice, or condition

that, if not strictly observed, could result in damage to, or destruction of, equipment.
This section contains the Repair Analysis Procedures (RAPs) necessary to repair all faults
other than image quality faults.
NOTE: A Note statement indicates an operating or maintenance procedure, practice, or condition that is necessary to accomplish a task efficiently.
Section 3 Image Quality RAPs
Reference:
Used when other explanations are given.
This section contains the Repair Analysis Procedures (RAPs) that are used to diagnose image
quality defect problems.
Purpose:
Used to describe the purposes of adjustment and troubleshooting.
Section 4 Removal/Replacement and Adjustment Procedures

REP:
This section contains the removal, replacement, and adjustment procedures for components of
WorkCentre 5016, 5020.
Indicates the removal/replacement procedure for reference.

ADJ:
Section 5 Parts List
Indicates the adjustment procedure for reference.
This section contains a list of spare parts list for the WorkCentre 5016, 5020.
PL:
Section 6 General Procedures/Information
Indicates the parts list for reference.
This section contains frequently used procedures that relate to the diagnosis, setup, or operation of the machine. It also contains pertinent information that will not be found in any other part
of the service documentation.
ASSY:
Means Assembly.
Safety Critical Components (SCC):
Section 7 Wiring Data

This section contains the wiring information for the WorkCentre 5016, 5020. It contains a connector list/locator, wirenet diagrams, and Block Schematic Diagrams (BSDs) for the following
chains:
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These are components, such as electrostatic-sensitive IC chips, which could be damaged if not
handled properly. Follow the regulations regarding Safety Critical Components set by XEROX
Corp.
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Introduction
Introduction
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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
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Service Call Procedures
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1.1 Before Starting Service
1.1.2Things to Note When Handling Customer Data
1.1.1Safety
1.
Before you bring back any sample for the purpose of investigation/analysis, always obtain
permission from the customer. Make sure you assure them that the data will not be used
for any other purpose.
To prevent any accident that may occur during maintenance service, any warning or any caution regarding the service must be strictly observed. Do not perform any hazardous operation.
1.
2.
Power Supply
To prevent electrical shocks, burns, or injury, etc., be sure to switch OFF the machine and
disconnect the plug before starting the maintenance service. If the machine has to be
switched ON, such as when measuring a voltage, take extra care to avoid an electrical
shock.
2.
3.
3.
IOT (Platen): 31.5kg (requires 3 persons)
Follow the safety guidelines established within the OpCo and ensure that customer data
do not get compromised during service.
1.1.3 Other Precautions

To avoid performing wrong or unnecessary service, observe the following:
1.
Reference Materials
2.
Disassembling
Read all relevant service documentation, so that you can take a systematic approach.
2 Tray Modules: 8.6kg (requires 2 persons)
Make sure to note the assembled condition of the machine before removing parts or disassembling it.
Take extra care of your working posture to prevent backache.

Safety Devices
3.
See that safety devices for preventing accidents, such as fuses, circuit breakers, interlock
switches, etc., and those for protecting customers from injury, such as panels and covers,
function properly. Modifications that hinder the function of any safety devices are strictly
prohibited.
5.
7.
Installation and Adjustment

After the installation or adjustment is complete, check that no parts or tools are left inside
the machine.
4.
Handling of replaced parts and consumables

Make sure that any replaced parts or consumables, as well as the packaging materials,
are taken back to the Service Center.
Installing and Removing Parts

The edges of parts and covers may be sharp, so take care not to touch them. Be careful
not to touch those parts, and wipe off any oil that may have adhered to your fingers or
hands before servicing. When pulling out parts, cables, etc., do it gently. Do not use
excessive force.
6.
Other things to note when handling customer data.
Heavy Parts
When removing or installing heavy parts, keep your back straight and lift with your legs.
Some parts should not be lifted by one person:
4.
Security-related NVM values that were changed during diagnostics.

If any security-related NVM values, such as polling, were set for test purposes, make sure
you restore them to their original values after the test.
Drive Area
Never inspect, clear or lubricate the drive components, such as chain belts, chain wheels
or gears, when the machine is in operation.
Handling of copied/printed customer data.
WARNING
Never discard the Drum/Toner Cartridges into a fire. Always keep them away from
open flames to prevent them from igniting and causing a fire.
Specified Tools
Follow the instructions when a particular tool is specified.
NOTE: For separation and processing methods for replaced parts or consumables, refer
to Common Technical Information No. 2-138 for all machines.
Cleaning Up Toner Spills
Since toner can be explosive, sweep or brush any spilled toner into a container to collect
it. To clean away the remaining toner using a vacuum cleaner, always use an FX standard
vacuum cleaner that is toner-tolerant. Never use the customer's vacuum cleaner.
8.
Earthquake Preparedness Measures
If the customer requests earthquake proofing, an earthquake preparedness kit is available.
5.
Check the Service Guide for more information on the earthquake preparedness kit.
9.
Modifications to the Machine

Before altering the machine, submit an irregular use license application.
10. Other Safety Precautions

Follow the recommendations in WORKING PRACTICES FOR ENGINEERS issued by
FXAP EH&S (Environmental Health and Safety).
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If you have replaced the following consumables, affix the "U-TAG" so that the recyclable parts will be handled appropriately.
a.
Drum Cartridge
b.
Toner Cartridge
For recyclable parts, fill in the necessary items on the "U-TAG."
General Precautions
Take care not to disturb the customer's daily work.
Place any service-related trash into a trash bag and bring it to the service office.
Clearly record the following information in the Machine Service Log:
Details of the service call
Parts and consumables replaced
1.1
1.2 Service Call Procedure
1.3 Service Call Details
1.2.1 Initial Actions
1.3.1 Initial Actions
1.
Ask the operator(s) about the machines condition.
1.
2.
Record the billing meter readings.
Frequency and location of recent paper jams
3.
Inspect any faulty copies, then check the machine.
Copy quality
4.
Check the Service Log.
2.
Ask the operator(s) about the machines condition.
Record the billing meter readings.
1.2.2 Actions to Take During UM (Unscheduled Maintenance)
3.
Inspect any faulty copies, then check the machine.
1.
Perform the service flow in Section 2 Status Indicator RAPs.
4.
Check the copy sample and the Service Log from the last call.
2.
Perform the applicable RAP in Section 2 Status Indicator RAPs.
1.3.2 Checking Reproducibility of Problem
If there are no applicable RAPs, troubleshoot by referring to the BSD in Section 7 Wiring
Data.
1.
Perform the service flow in Section 2 Status Indicator RAPs.
2.
Perform the applicable RAP in Section 2 Status Indicator RAPs.
Check the copy quality.
3.
If there are no applicable RAPs, troubleshoot by referring to the BSD in Section 7 Wiring
Data.
3.
Make several copies using the Test Pattern (499T247), then check the quality.
4.
Look at the last 20 error codes in order to understand the machine status.
1.3.3 Checking Copy Quality
1.
2.
If there is a problem in copy quality, perform the applicable RAP in Section 3 Image Quality.
Enter Diagnostic Mode. Enter [40-01] (Display Error History How to Enter the Diagnostic Mode).
When the last error code is displayed, press the [Start] key to return to the Function
input screen.
Pressing the [Stop] key during the display will stop it and return you to the Function
input screen.
5.
Repair all the secondary problems.
6.
Perform TRIM servicing.
1.3.4 TRIM Servicing

Perform TRIM servicing during the maintenance call.
1.
Perform the necessary TRIM items using the TRIM Checklist.
2.
Check for parts that require periodic cleaning/replacement by referring to the TRIM
Checklist and the Periodic Replacement Parts/Consumables List. Clean them if necessary. If replaced, always clear the counters of the corresponding items in the Chain Function.
1.2.3 Actions to Take During SM (Scheduled Maintenance)

1.
Check the copy quality.
2.
Look at the last 20 error codes in order to understand the machine status.
3.
Enter Diagnostic Mode. Enter [40-01] (Display Error History How to Enter the Diagnostic Mode).
When the last error code is displayed, press the [Start] key to return to the Function
input screen.
Pressing the [Stop] key during the display will stop it and return you to the Function
input screen.
Perform TRIM servicing.
1.2.4 Final Actions

1.
Check overall machine operation/features.
2.
Check the machine exterior and consumables.
3.
Train the operator as required.
4.
Complete the Service Log and Service Report.
5.
Keep the copy samples with the Service Log.
1.2, 1.3
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1.4 TRIM Checklist
1.5 Periodic Replacement Parts/Consumables List
A: Check. Clean, replace, or replenish if necessary.
When servicing the machine, check the number of copies and the replacement interval for the
consumables and parts that require periodical cleaning/replacement. Clean or replace them if
necessary. The IOT history can be checked at Chain-Function > NVRAM R/W, while the IIT
history can be checked in the Counters (refer to Diagnostic Mode in Section 2 Status Indicator
RAPs). For items that cannot be checked in the Diagnostic Mode, clean or replace them
according to the replacement intervals (standard PV).
B: Always check and clean.

*: Always replace at the specified interval.
Table 1
CAUTION
Every
time Service Details
No.
Service Items
1.1
Check before servicing

A
(check machine operation)
Do not keep toner and drum cartridges in your car for long periods of time.
Turn on the machine, and make sure that there are

no abnormal sounds.
Table 1
Parts/Consumables
Name/PL No.
Replacement
Interval (copies) Counters Check
1.2
Check before Servicing

(copy the Test Pattern)
Make several copies using the Test Pattern

(499T247), then check the image quality.
Clean the interior of the

machine (paper transport
system)
Clean the paper dust and toner residue in the paper

path and on the jam sensor.
Tray 1 Feed Roll/

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

Count up 1 for every feed. Replace both at the
same time.
Clean the IIT
Clean the Platen Glass surface and the Platen

Cushion with the optical cleaning cloth.
Tray 2 Feed Roll/

Retard Roll
100,000
Clean the Reflector, back of the Platen Glass,

mirrors and lens with the optical cleaning cloth.
[29/25] [29/15] [29/5]

same time.
MSI Feed Roll/

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

same time.
Fuser Unit
100,000
[21/39] [21/29] [21/19] [21/9]

Count up 1 for every feed.
Toner Cartridge
6,000
Drum Cartridge
36,000
Safety Precautions
Make sure that the power cord is plugged in

properly.
Make sure that there are no cracks in the

power plug and no holes or cuts in the power
cord insulation.
If an extension cord or power strip is used,

make sure it is of sufficient capacity to handle
the power requirements of the machine.
Make sure that no more than one power plug

is connected to a single socket.
6.1
Check after servicing

(copy quality check)
6.2

A
(check machine operation)
Check the paper feed.
Make sure that there are no abnormal sounds.

(check the meter)
Create the Service Log and Service Report.
6.3
No
31,000 (Warning)
36,000 (Machine Stops)
Make several copies using the Test Pattern

(499T247), then check the image quality.
CAUTION
Do not touch the Drum of the Drum Cartridge.
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1.4, 1.5
1.4, 1.5
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2 Status Indicator RAPS

Error Codes
Fault Repair Overview and List of Error Codes...............................................................
2-3
RAPs
U0-1 Main Motor Stop Error ............................................................................................
U1-1 Main Motor Rotation Error ......................................................................................
U2-1 Carriage Module Fail ..............................................................................................
U3-5 Laser Power Or ROS Motor Fail ...........................................................................
U4-1 Fuser On Time Fail................................................................................................
U4-2 Over Heat Temp Fail .............................................................................................
U4-3 FS1 Thermistor Defect ..........................................................................................
U4-9 Fuser Fan Defect...................................................................................................
U6-2 RAM Read/Write Check Error ...............................................................................
U6-3 NVM Data Defect ..................................................................................................
U6-4 NVM Read/Write Cannot Be Executed .................................................................
U6-5 CPU Power To Access NVM Is Not Enough .........................................................
U7-0 UI Communication TimeOut ..................................................................................
U7-1 UI Communication Error........................................................................................
U8-1 Billing Counter Defect............................................................................................
U9-0 HVPS Fail..............................................................................................................
062-300 Platen Interlock Open .......................................................................................
062-345 IISS EEPROM Failure.......................................................................................
062-360 Carriage Position Fail........................................................................................
062-371 Lamp Illumination Fail .......................................................................................
062-380 AGC Failure ......................................................................................................
062-386 AOC Failure ......................................................................................................
062-392 IPS PWB Memory Fail ......................................................................................
062-393 IPS PWB Fail ....................................................................................................
005-170 DADF Feed Failure ...........................................................................................
005-171 DADF Regi / Exit Failure..................................................................................
005-172 DADF Inverted Document Jam .........................................................................
005-198 Short Scan Jam ................................................................................................
005-199 Long Scan Jam .................................................................................................
005-305 Feeder Top Cover Open ...................................................................................
005-920 Static Jam .........................................................................................................
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2-25
2-25
2-26
2-26
2-27
2-27
2-28
2-28
2-29
2-29
2-30
2-30
2-31
2-31
2-32
2-32
2-33
2-33
2-34
2-34
2-35
2-35
2-36
2-36
2-37
2-38
2-39
2-40
2-40
2-41
2-41
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Status Indicator RAPS
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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
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2-3
Check the Status of Installation
Descriptions related to connectors are expressed as follows: P/J12" -> The connector (P/
J12) is in the connected state. "P12" -> The plug side when the connector (P/J12) is in the
disconnected state (except when it is directly connected to a board). "J12" -> The jack
side when the connector (P/J12) is in the disconnected state (except when it is directly
connected to a board).
In a RAP, "P/J1 <=> P/J2" means that all the opposing pins between "P/J1" and "P/J12"
(refer to Section 7, Wiring Data) should be measured.
The voltages on small connectors are measured using a special tool. Handle the tool
carefully because it has a sharp tip.
The numerical values described in the RAPs are for reference only. Approximate values
are considered to be the same.
Note that for the checks specified in the RAP, you must check the references for the parts
that must be removed and their procedures.
"Replacement" in the RAPs indicates the parts that are considered to be the cause of the
problem. Check by replacing the parts and, if necessary, the assembly that contains those
parts.
In the RAPs, the highest level paper supply is called "Tray 1," and the one below it is
called "Tray 2."
In the RAPs, some procedures are described separately for each specification. Follow the
instructions for your model to repair the faults.
Before starting to troubleshoot, always check the following items:
The voltage of the power supply (measure the voltage at the power outlet to see if it is
within specification).
The power cord for damage, short circuits, open circuits, and wrong internal connections.
The machine for proper grounding.
The machine is not installed in a place with high temperature, high humidity, low temperature, low humidity, or a place with drastic changes in temperature.
The machine is not installed near a water outlet, humidifier, heater or fire source, dusty
areas, or under the direct draft of an air conditioner.
The machine is not installed in a place where volatile or flammable gas is generated.
The machine is not installed in a place exposed to direct sunlight.
The machine is installed in a well-ventilated place.
The machine is installed on a stable level surface.
The paper is within specification (standard paper is recommended).
The machine for any improper handling.
The Periodic Replacement Parts are replaced at the proper intervals.
Safety Considerations
Before servicing, always unplug the power cord unless required otherwise. When the
power is turned ON, never touch a current-carrying part unless required otherwise. Also,
since current is carried in the LVPS power switch/inlet even when the power is turned
OFF, never touch this area.
When turning the power ON to perform a check while the Interlock Switch or Security
Switch is also turned ON and the covers are removed, always disconnect the connector
( P/J140) that is connected to the ROS, unless required otherwise, because a laser beam
might be emitted from the ROS.
When connecting the connector ( P/J520) on the HVPS according to the instructions in
the RAP, never touch the HVPS and high-voltage output parts.
When performing a high voltage output check using the Input Diagnostics or Output Diagnostics in Diagnostic Mode, make sure that all covers are installed unless specified otherwise. Also, never touch any high voltage output section when performing the high voltage
output check.
When operating the Drive Section using the Input Diagnostics or Output Diagnostics in
Diagnostic Mode, make sure that all covers are installed unless specified otherwise. Also,
never touch the Drive Section while operating it.
Be careful not to burn yourself when touching parts that can get very hot.
When servicing, use a grounded wrist band to remove static electricity from your body.
RAP Flow
RAPs are a good place to start in diagnosing a failure. RAPs guide you through the troubleshooting process by checking for the presence of error codes and other types of problematic
symptoms. To troubleshoot problems related to image quality, refer to Section 3 Image Quality
Troubleshooting.
Things to Note When Using RAPs
When troubleshooting using RAPs, prepare normally working parts such as the AIOC
PWB, LVPS, HVPS and Fuser in advance because they might be required to identify a
failure. In addition, if the fault cannot be repaired, replace the "parts considered to be the
cause" and related parts in sequence and check the operation.
When servicing, always disconnect the power cord unless required otherwise. When the
power cord is connected, never touch any current-carrying part unless absolutely necessary.
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Ask the operator about the problem

Did the operator operate the machine correctly? No
Yes
Explain how to operate the

machine
Turn the Power Switch OFF then ON
Does the error recur when operating the

machine in the same way as before (when
the problem originally occurred)?
No
Procedure is complete
Yes
Refer to the Error Code List and perform the

relevant troubleshooting
Yes
Does the Control Panel display an Error

Code?
Figure 2 RAP Flow
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2-5
Error Code List

NOTE: In the Record in Error Log column, O = yes and X = no.
Error
Code
Error Name/Explanation/I/O Diagnostic Codes/Check Items
Record in
Error Log
RAP
BSD
CH8.1
Figure 1
Error Name
Tray1 F/O#1 SNR on JAM
Explanation
Timeout between Tray1 Feed Clutch ON and Tray1 Feed Sensor ON.
I/O Diagnostic Codes (How to Enter the Diagnostic Mode)
[08-07] Tray1 Feed Sensor
[08-12] Tray1 Feed Clutch
Check Items
Feed Roll or Retard Pad dirty, contaminated with paper dust, worn, or faulty
C1-1
Tray1 Feed Sensor dirty and Sensor Actuator deformed or damaged
Paper damaged, not within specification, or not loaded correctly
Foreign matter, burrs, or paper in the paper path
Drive gear worn or damaged
Tray1 Feed Clutch faulty
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Tray 1 Feed Sensor
(PL 2.5)(REP 2.5.1).
Wire between Tray 1 Feed Sensor J158-3 ( P/J158) and LVPS J501-6 ( P/J501)
Wire between Tray 1 Feed Sensor J158-2 and LVPS J501-7
Replace the Tray1 Feed Clutch (PL 2.2) (REP 2.2.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
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Error
Code
Record in
Error Log
RAP
BSD
CH8.1
Figure 1
CH8.4
Figure 4
Error Name
Tray1 Regi SNR on JAM
Explanation
Timeout between Tray1 Feed Sensor ON and IOT Registration Sensor ON.
[08-05] IOT Registration Sensor
[08-10] IOT Registration Clutch
Check Items
Take Away Roll 1 dirty, contaminated with paper dust, worn, or faulty
C1-2
IOT Registration Clutch faulty
(PL 2.5) (REP 2.5.1).
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.
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2-7
Error
Code
Record in
Error Log
RAP
BSD
CH8.2
Figure 2
Error Name
STM F/O#2 SNR on JAM
Explanation
Timeout between STM Feed Motor ON and STM Feed Sensor ON.
[08-06] STM Feed Sensor
[08-11] STM Feed Clutch
[08-13] STM Feed Motor
Check Items
Tray2 Feed Roll or Tray2 Retard Roll dirty, contaminated with paper dust, worn, or faulty
C2-1
STM Feed Sensor dirty and Sensor Actuator deformed or damaged
STM Feed Clutch faulty
STM Feed Motor faulty
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the STM Feed Sensor (PL
11.5) (REP 11.5.1 ).
- Wire between STM Feed Sensor J172-3 ( P/J172) and STM PWB J542-6 ( P/J542)
- Wire between STM Feed Sensor J172-2 and STM PWB J542-7
- Wire between STM Feed Sensor J172-1 and STM PWB J542-8
Replace the STM Feed Clutch (PL 11.6) (REP 11.6.1), the STM Feed Motor (PL 11.6) (REP 11.6.2), and the STM PWB (PL 11.5) (REP
11.5.2 ) in that order.
June, 2008
2-8
Reissue
Error
Code
Record in
Error Log
RAP
BSD
CH8.1
Figure 1
CH8.2
Figure 2
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.
[08-11] STM Feed Clutch
[08-13] STM Feed Motor
Check Items
C2-2
STM Feed Clutch faulty
STM Feed Motor faulty
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
(PL 2.5) (REP 2.5.1).
Wire between Tray 1 Feed Sensor J158-3 ( P/J158) and STM PWB J501-6 ( P/J501)
Wire between Tray 1 Feed Sensor J158-2 and STM PWB J501-7
Replace the STM Feed Clutch (PL 11.6) (REP 11.6.1), the STM Feed Motor (PL 11.6) (REP 11.6.2), and the STM PWB (PL 11.5) (REP
11.5.2) in that order.
Reissue
June, 2008
2-9
Error
Code
Record in
Error Log
RAP
BSD
CH8.1
Figure 1
CH8.4
Figure 4
CH7.1
Figure 1
Error Name
STM Regi SNR on JAM
Explanation
When feeding paper from the STM, timeout between Tray1 Feed Sensor ON and IOT Registration Sensor ON.
Check Items
C2-3
IOT Registration Sensor dirty and Sensor Actuator deformed or damaged
(PL 2.5) (REP 2.5.1).
Replace the IOT Registration Clutch (PL 2.9) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Error Name
No paper in the selected paper tray (Tray1)
Explanation
No paper is detected in Tray1 when ATS function is disabled and Tray1 is selected during a copy job.
No paper is detected in Tray1 when Tray1 is selected during a print job (the paper size setting matches the one specified for the job).
I/O Diagnostic Codes

[07-07] Tray1 No Paper Sensor
C5-0
Check Items
Press the [Stop] button on the Control Panel.
Check the tray to see if it is empty; if it is, add paper specified by the job.
Tray1 No Paper Sensor dirty and Sensor Actuator deformed or damaged
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Tray 1 No Paper Sensor (PL 2.7) (REP 2.7.1).
Wire between Tray1 No Paper Sensor J157-3 ( P/J157) and LVPS J501-3 ( P/J501)
Wire between Tray1 No Paper Sensor J157-2 and LVPS J501-4
Wire between Tray1 No Paper Sensor J157-1 and LVPS J501-5
Replace the AIOC PWB (PL 8.1) (REP 8.1.1).
June, 2008
2-10
Reissue
Error
Code
Record in
Error Log
RAP
BSD
CH7.2
Figure 2
Error Name
Tray1 Paper Size Mismatch
C5-1
Explanation
Paper that is different from the one in the Tray Settings is detected when feeding.
Or, paper size setting in Tray1 is different from the paper size specification of the job when Tray1 is selected during a print job.
Check Items
Change the paper size of Tray 1 to the one specified by the job.
Error Name
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).

[07-08] STM No Paper Sensor
C6-0
Check Items
Load the correct paper into the STM.
STM No Paper Sensor dirty and Sensor Actuator deformed or damaged.
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the STM No Paper Sensor (PL 11.7) (REP 11.7.1).
Wire between STM No Paper Sensor J171-3 ( P/J171) and STM PWB J542-3 ( P/J542)
Wire between STM No Paper Sensor J171-2 and STM PWB J542-4
Wire between STM No Paper Sensor J171-1 and STM PWB J542-5
Replace the STM PWB (PL 11.5) (REP 11.5.2) and the AIOC PWB (PL 8.1) (REP 8.1.1).
Error Name
C6-1
Explanation
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
Change the paper size of STM to the one specified by the job.
Error Name
MSI Paper Size Mismatch
C7-1
Explanation
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
Change the paper size of Bypass to the one specified by the job.
Reissue
June, 2008
2-11
Error
Code
Record in
Error Log
RAP
BSD
CH3.2
Figure 2
CH8.3
Figure 3
CH8.4
Figure 4
Error Name
APS NG Unselected
Explanation
Either Tray 1 or STM is in one of the "paper settings is of a size that causes missing image" states when APS is selected during a copy job.
C0-1
Or, either Tray 1 or STM is "set with paper size that is different from the one specified for the job" when Auto Tray is selected during a print
job.
Check Items
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.
[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
Bypass Solenoid faulty
Check that the Bypass Solenoid and the LVPS J502-1/3 ( P/J502) pins are connected securely with good electrical contact. If there is no
problem, replace the Bypass Solenoid (PL 7.5).
June, 2008
2-12
Reissue
Error
Code
Record in
Error Log
RAP
BSD
CH8.1
Figure 1
CH8.2
Figure 2
Error Name
F/O#1 SNR Static JAM
Explanation
Tray1 Feed Sensor ON is detected during standby.
C8-1
Check Items
(PL 2.5) (REP 2.5.1).
Wire between Tray 1 Feed Sensor J158-3 ( P/J158) and STM PWB J501-6 ( P/J501)
Error Name
Explanation
STM Feed Sensor ON is detected during standby.
C8-2
Check Items
11.5) (REP 11.5.1).
Wire between STM Feed Sensor J172-3 ( P/J172) and STM PWB J542-6 ( P/J542)
Replace the STM PWB (PL 11.5) (REP 11.5.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Error Name
CPM Image Lost
E0-1
Explanation
During a copy job in CMP Priority Mode, it is detected that the paper containing an image cannot be output after the image is deleted.
Check Items
Reissue
June, 2008
2-13
Error
Code
Record in
Error Log
RAP
BSD
CH8.4
Figure 4
CH10.2
Figure 2
Error Name
Regi SNR Static JAM
Explanation
IOT Registration Sensor ON is detected during standby.
E1-6
Check Items
Sensor dirty
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.
[10-23] Fuser Exit Sensor
E3-6
Check Items
Fuser Exit Sensor dirty and Sensor Actuator deformed or damaged
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Fuser Exit Sensor (PL
6.2).
Wire between Fuser Exit Sensor J153-3 ( P/J153) and LVPS J505-1 ( P/J505)
Wire between Fuser Exit Sensor J153-2 and LVPS J505-2
June, 2008
2-14
Reissue
Error
Code
Record in
Error Log
RAP
BSD
CH1.2
Figure 2
CH1.2
Figure 2
CH7.1
Figure 1
Error Name
IOT L/H Cover open
Explanation
The Left Hand Cover is open.
[01-01] LH Cover Interlock Switch
E5-1
Check Items
Check that the Left Hand Cover closes correctly.
Check that the LH Cover Interlock Switch is correctly installed and that the electrical connection is good.
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the LH Cover Interlock
Switch (PL 8.2).
Wire between LH Cover Interlock Switch FS151 ( FS151) and LVPS J506-4 ( P/J506)
Wire between LH Cover Interlock Switch FS152 ( FS152) and LVPS J506-3
Replace the LVPS (PL 8.1) (REP 8.1.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Error Name
IOT Front Cover open
Explanation
The Front Cover is open.
[01-12] Front Cover Interlock Switch
E5-2
Check Items
Check that the Front Cover closes correctly.
Check that the Front Cover Interlock Switch is correctly installed and that the electrical connection is good.
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Front Cover Interlock
Switch (PL 8.2).
Wire between Front Cover Interlock Switch FS153 ( FS153) and LVPS J506-2 ( P/J506)
Wire between Front Cover Interlock Switch FS154 ( FS154) and LVPS J506-1
Error Name
L/H Low Cover open
Explanation
Access Cover 1 is open.
[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
Reissue
June, 2008
2-15
Error
Code
Record in
Error Log
RAP
BSD
CH7.2
Figure 2
CH3.2
Figure 2
CH3.2
Figure 2
Error Name
STM L/H Cover open
Explanation
Access Cover 2 is open.
[01-10] STM Interlock Switch
E6-2
Check Items
Check that Access Cover 2 closes correctly.
Check that the STM Interlock Switch is correctly installed and that the electrical connection is good.
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the STM Interlock Switch
(PL 11.5).
Wire between STM Interlock Switch J173-2 ( P/J173) and STM PWB J542-9 ( P/J542)
Wire between STM Interlock Switch J173-1 and STM PWB J542-10
Replace the STM PWB (PL 11.5) (REP 11.5.2), the LVPS (PL 8.1) (REP 8.1.2), and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Error Name
Nup NG Out Of Range
Explanation
The magnification is not within the range of 50 to 200% during Nup.
E8-1
Check Items
Press the [Paper Supply] button on the Control Panel.
Press the [Special Copy] button on the Control Panel.
Press the [Original Size Input] button on the Control Panel.
Press the [Clear All] button on the Control Panel.
Error Name
Nup Paper direction mismatch
Explanation
The paper orientation of the document and the tray are not aligned during Nup.
E8-2
Check Items
Press the [Paper Supply] button on the Control Panel.
Press the [Special Copy] button on the Control Panel.
Press the [Original Size Input] button on the Control Panel.
Press the [Clear All] button on the Control Panel.
June, 2008
2-16
Reissue
Error
Code
Record in
Error Log
RAP
BSD
CH10.2
Figure 2
CH10.2
Figure 2
Error Name
Exit SNR on JAM
Explanation
Timeout between IOT Registration Clutch ON and Fuser Exit Sensor ON.
Check Items
Registration Roll dirty, contaminated with paper dust, worn, or faulty
E1-2
Paper damaged or not within specification
Check that the IOT Registration Clutch and the LVPS J503-4/5 ( P/J503) pins are connected securely with good electrical contact. If there is
no problem, replace the IOT Registration Clutch (PL 2.9).
6.2).
Error Name
Exit SNR off JAM
Explanation
Timeout between Fuser Exit Sensor ON and Fuser Exit Sensor OFF.
Check Items

E3-1
Paper damaged or not within specification
6.2).
Reissue
June, 2008
2-17
Error
Code
Record in
Error Log
RAP
BSD
CH3.1
Figure 1
CH3.2
Figure 2
CH9.2
Figure 2
Error Name
MCU-STM comm. error
H9-7
Explanation
A communication failure has occurred between the MCU and the Tray Module.
Check Items
Turn the power OFF then ON.
Check for any open circuit or short circuit between the STM connectors.
Replace the STM PWB (PL 11.5) (REP 11.5.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Error Name
Copy Counter Full
L9-0
Explanation
The user that is logged in has reached the allotted copy limit in the Account Mode.
Check Items
Error Name
Toner Cartridge was PRENEAR empty
Explanation
The toner cartridge is low.
J1-0
Check Items
Refill the toner.
Foreign matter on the sensor.
Check that the Toner Empty Sensor and the LVPS J509-1-4 ( P/J509) pins are connected securely with good electrical contact. If there is no
problem, replace the Toner Empty Sensor (PL 4.2).
Error Name
Toner Empty
Explanation
The Toner Cartridge is empty.
J1-2

[09-07] Toner Empty Sensor
Check Items
Refill the toner.
Foreign matter on the sensor.
Check that the Toner Empty Sensor and the LVPS J509 ( P/J509) 1-4 pins are connected securely with good electrical contact. If there is
no problem, replace the Toner Empty Sensor (PL 4.2).
June, 2008
2-18
Reissue
Error
Code
Record in
Error Log
RAP
BSD
CH9.2
Figure 2
Error Name
No Drum Cartridge
Explanation
Unable to detect the Drum Cartridge.
[09-02] Drum Cartridge
Check Items

J3-1
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Drum Cartridge (PL
4.1) (REP 4.1.1).
Wire between Drum Cartridge P610-7 ( P610) and AIOC PWB J402-1 ( P/J402)
Wire between Drum Cartridge P610-3 and AIOC PWB J402-4
Replace the Drum Cartridge (PL 4.1) (REP 4.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Error Name
Drum near end of life
J6-0
Explanation
The Drum Cartridge is near the end of its life.
Check Items
Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).
Error Name
Drum cartridge life end
J6-1
Explanation
The Drum Cartridge has reached the end of its life.
Check Items
Reissue
June, 2008
2-19
Error
Code
Record in
Error Log
RAP
BSD
CH9.2
Figure 2
CH9.2
Figure 2
CH9.2
Figure 2
Error Name
Drum CRUM comm. Error
Explanation
The AIOC PWB is unable to communicate with the Drum Cartridge.
[09-02] Drum Cartridge

Check Items

J7-1
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Drum Cartridge (PL
4.1) (REP 4.1.1).
Wire between Drum Cartridge P610-7 ( P610) and AIOC PWB J402-1 ( P/J402)
Replace the Drum Cartridge (PL 4.1) (REP 4.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Error Name
Drum CRUM Market Identity Mismatch
J7-2
Explanation
The AIOC PWB has detected that the Drum CRUM destination does not match.
Check Items
Error Name
Drum CRUM ID error
J7-3
Explanation
The AIOC PWB has detected that the Drum CRUM ID is incorrect.
Check Items
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
June, 2008
2-20
Reissue
Error
Code
Record in
Error Log
RAP
BSD
CH3.2
Figure 2
CH3.2
Figure 2
Error Name
No Response from USB-Host
N4-0
Explanation
Either "USB disconnected" or "Communication timed-out" is detected during a print job.
Or, either "USB disconnected" or "Communication timed-out" is detected during a scan job.
Check Items
Cancel the print job.
Reconnect the USB cable correctly.
Error Name
HBPL or XPJL Syntax Error
N4-1
Explanation
An abnormal command that cannot be ignored is received from the USB-Host during a print job.
Check Items
Cancel the print job.
Reconnect the USB cable correctly.
Error Name
Download File Error
N4-2
Explanation
There is an abnormal Product ID or there is a checksum error in the download file.
Check Items
Error Name
Download Flash Write Error
N4-3
Explanation
Unable to write the downloaded file into flash memory.
Check Items
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
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.
Reissue
June, 2008
2-21
Error
Code
Record in
Error Log
RAP
BSD
CH3.2
Figure 2
CH3.2
Figure 2
U0-1
CH4.1
Figure 1
U1-1
CH4.1
Figure 1
U2-1
CH6.2
Figure 2
U3-5
CH6.3
Figure 3
U4-1
CH10.1
Figure 1
U4-2
CH10.1
Figure 1
U4-3
CH10.1
Figure 1
Error Name
Controller Logic fail
N9-0
Explanation
A software defect that cannot be ignored is found in the Controller software.
Check Items
Error Name
IOT Communication Error
N9-1
Explanation
The AIOC PWB has detected a Type-Di communication error.
Check Items
U0-1
U1-1
U2-1
Error Name
Main Motor stop error
Explanation
The motor runs for over 120 seconds without any paper being fed.
Error Name
Main Motor rotation error
Explanation
500ms after the IOT has started, the Main Motor Lock signal is "Low."
Error Name
Carriage Module Fail
Explanation
An abnormality was detected in the Carriage Module.
Error Name
Laser Power or ROS Motor Fail
U3-5
Explanation
The ROS Motor is unable to rotate.
Or, the laser output is not normal.
Error Name
Fuser On Time Fail
U4-1
Explanation
The lamp did not turn OFF within the specified time after turning ON.
U4-2
U4-3
Or, Warm Up was not completed within the specified time after power ON.
Error Name
Over Heat Temp Fail
Explanation
A temperature above 250C is continuously detected for 480ms.
Error Name
FS1 thermistor defect
Explanation
FS1 cannot be monitored any more.
June, 2008
2-22
Reissue
Error
Code
U4-9
U6-2

Error Name
Fuser Fan defect
Explanation
After the start of Fan Fail Signal monitoring, the signal level was Low not more than 30 times.
Error Name
RAM read/write check error
Explanation
When the MCU runs the overall Read/Write check for RAM during startup, the Read Data and Write Data do not match.
Record in
Error Log
RAP
BSD
U4-9
CH10.3
Figure 3
U6-2
CH3.2
Figure 2
U6-3
CH3.2
Figure 2
U6-4
CH3.2
Figure 2
U6-5
CH3.2
Figure 2
U7-0
CH2.1
Figure 1
U7-1
CH2.1
Figure 1
U8-1
CH3.2
Figure 2
U9-0
CH9.1
Figure 1
Error Name
NVM data defect
U6-3
Explanation
The NVM Header data ERROR and NVM 3 page data do not match.
Or, unable to find the NVM Write & Read area.
The NVM or Counter areas are full.
Error Name
NVM read/write cannot be executed
U6-4
Explanation
An NVM Ack NG is detected during NVM Read.
U6-5
U7-0
U7-1
An NVM Write Error is detected 5 times during NVM Recovery.
Error Name
CPU Power to access NVM is not enough
Explanation
NVM queue full is detected during NVM Write.
Error Name
UI Communication TimeOut
Explanation
At the Power On Sequence, the AIOC PWB did not communicate with the User Interface PWB.
Error Name
UI Communication Error
Explanation
The User Interface PWB has detected a communication failure.
Error Name
Billing Counter Defect
U8-1
Explanation
It is detected that the Billing Counter Value is incorrect.
U9-0
Or, the AOIC PWB has failed to read the Billing Counter.
Error Name
HVPS fail
Explanation
A 500 msec cycle of the signal HVPS#ERR=High was detected twice in a row.
Reissue
June, 2008
2-23
Display Priority in Case of Multiple Errors

When multiple errors occur simultaneously, they will be shown on the Control Panel display in
the following priority order. Always begin troubleshooting with the highest-priority error.
Priority
Order
Error
Code
Error Name
Error Characteristic
1
(Highest)
U7-0
UI Communication TimeOut
U7-1
UI Communication Error
Unable to control the

display at the Controller
H9-7
MCU-STM comm. error
N9-1
N9-0
Controller Logic fail
U0-1
Main Motor stop error
U1-1
Main Motor rotation error
U2-1
U3-5
Laser Power or ROS Motor Fail
10
U4-1
Fuser On Time Fail
11
U4-2
Over Heat Temp Fail
12
U4-3
13
U4-9
Fuser Fan defect
14
U6-2
15
U6-3
NVM data defect
16
U6-4
NVM read/write cannot be executed
17
U6-5
18
U8-1
19
U9-0
HVPS fail
20
E9-1
AMS NG Out Of Range
21
E9-2
Paper direction mismatch
22
E8-1
Nup NG Out Of Range
23
E8-2
Nup Paper direction mismatch
24
L9-0
Copy Counter Full
25
N4-0
26
N4-1
27
N4-2
Download File Error
27
N4-3
Download Flash Write Error
29
N5-0
Push Scan TimeOut
30
A5-1
Platen Cover Open
32
E5-1
IOT L/H Cover open
33
E5-2
IOT Front Cover open
34
E6-1
L/H Low Cover open
35
E6-2
STM L/H Cover open
Fatal Error
Dynamic Error
(Job Cancel)
Priority
Order
Error
Code
Error Name
36
A1-1
Doc Misfeed Jam
37
A2-2
No Supported Doc Size
38
A4-1
Short Length Detect
39
A4-2
Long Length Detect
40
C1-1
Tray1 F/O#1 SNR on JAM
41
C1-2
Tray1 Regi SNR on JAM
42
C2-1
STM F/O#2 SNR on JAM
43
C2-2
Tray1 F/O#1 SNR on JAM from STM feed
44
C2-3
STM Regi SNR on JAM
46
C9-3
MSI Regi SNR on JAM
47
E1-2
Exit SNR on JAM
48
E3-1
Exit SNR off JAM
49
C8-1
50
C8-2
51
E1-6
Regi SNR Static JAM
52
E3-6
Exit SNR JAM
53
E0-1
CPM Image Lost
54
C0-1
APS NG Unselected
56
C5-1
57
C6-1
58
C7-1
MSI Paper Size Mismatch
59
C5-0
No paper in the select paper tray (Tray1)
60
C6-0
No paper in the select paper tray (Tray2)
61
J1-2
Toner Empty
62
J3-1
No Drum cartridge
63
J6-1
64
J7-1
Drum CRUM comm. Error
65
J7-2
Drum CRUM Market Identity Mismatch
66
J7-3
Drum CRUM ID error
67
N1-1
EPC Memory Full
Error Characteristic
Document Jam
Paper Jam
Tray-related errors
Resolvable by replacing parts
An error that only

stops scanning
Document Cover
Open
Paper Cover Open
June, 2008
2-24
Reissue
U0-1 Main Motor Stop Error
U1-1 Main Motor Rotation Error
BSD-Reference:
BSD-Reference:
CH4.1 (Figure 1)
CH4.1 (Figure 1)
Explanation
Explanation
The motor runs for over 120 seconds without any paper being fed.
500 ms after the IOT Motor starts, the IOT Motor Lock signal is Low.
Procedure
Procedure
The problem can be solved according to RAP U1- 1 Main Motor Rotation Error (U1-1).
Y
N
Execute diagnostics [29-49] (How to Enter the Diagnostic Mode) to check the ROM version. The ROM is the latest version.
Y
N
Upgrade the ROM to the latest version.
Close the Left Hand Cover and the Front Cover. Execute diagnostics [04--01 Main Motor On].
(How to Enter the Diagnostic Mode) The IOT Motor can be heard rotating.
Y
N
Check P/J504 and P/J201. Both P/J504 and P/J201 are connected securely.
Y
N
Connect P/J504 and P/J201 securely.
Replace the IOT Motor (PL 1.1) (REP 1.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in
that order.
Measure the voltage between LVPS PWB P504-1 ( P/J504) (+) and GND (-). The
age is approximately +24VDC.
Y
N
Replace the LVPS (PL 8.1) (REP 8.1.2).
Completed
Check the wire between J504-3 ( P/J504) and J201-3

shorted or open.
Y
N
Repair the wire.
volt-
( P/J201). The wire is not
Replace the IOT Motor (PL 1.1) (REP 1.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in
that order.
Check the installation of the IOT Motor (PL 1.1 ) (REP 1.1.1). The IOT Motor is installed
properly.
Y
N
Install the IOT Motor (PL 1.1 ) (REP 1.1.1) properly.
Turn the rotor of the IOT Motor (PL 1.1 ) counterclockwise by hand. It rotates smoothly,
without any abnormal load.
Y
N
Check for any foreign substances that obstruct the drive and for any incorrectly installed
parts. There are foreign substances or incorrectly installed parts.
Y
N
Replace the IOT Motor (PL 1.1) (REP 1.1.1).
Remove any foreign substances and fix any installation errors.
Check the wire between J504-3 ( P/J504) and J201-3 ( P/J201).
or open.
Y
N
Repair the wire.
The wire is not shorted
Replace the IOT Motor (PL 1.1) (REP 1.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that
order.
Reissue
June, 2008
2-25
U0-1, U1-1
U2-1 Carriage Module Fail
U3-5 Laser Power Or ROS Motor Fail
BSD-Reference:
BSD-Reference:
CH6.2 (Figure 2)
CH6.3 (Figure 3)
Explanation
Explanation
A carriage fault was detected.
The ROS Motor does not turn, or the laser output is not normal.
Procedure
Procedure
Execute diagnostics [05-22 Move scanner to home position] and [05-23 Move scanner to maintenance position]. (How to Enter the Diagnostic Mode) The carriage moves.
Y
N
Check each IIT Carriage connector. Each connector is connected securely.
Y
N
Connect each connector securely.
Execute diagnostics [6-15 ROS Motor ON]. (How to Enter the Diagnostic Mode) The ROS
Motor can be heard rotating.
Y
N
Measure the voltage between the AIOC PWB P403-7 ( P/J403) (+) and GND (-). The
voltage is approximately +24VDC.
Y
N
Replace the AIOC PWB (PL 8.1) (REP 8.1.1) and the LVPS (PL 8.1) (REP 8.1.2) in
that order.
Check for foreign substances and deformed parts in the carriage. None is found.
Y
N
Remove the foreign substances and repair the deformed parts.
Replace the ROS (PL 3.1) (REP 3.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that
order.
Replace the IIT Carriage (PL 10.3)(REP 10.3.1).

Execute diagnostics [05-23 Move scanner to maintenance position]. When the IIT Carriage
has moved to the leftmost position, press the [Stop] button to put the Carriage Sensor into the
blocked state. Execute diagnostics [5-11 Home Sensor], and "H" is displayed.
Y
N
Check each IIT Carriage and Carriage Sensor connector. Each connector is connected securely.
Y
N
Replace the Carriage Sensor (PL 10.6) and the IIT Carriage (PL 10.3) (REP 10.3.1) in
that order.
Check the Carriage Sensor (PL 10.6 ). The Carriage Sensor is installed properly.
Y
N
Install the Carriage Sensor (PL 10.6) properly.
Measure the voltage between the AIOC PWB P403-1 ( P/J403) (+) and GND (-).
age is approximately +5VDC.
Y
N
The
volt-
Check the AIOC PWB P/J403 ( P/J403), LD PWB P/J140 ( P/J140), and P/J130 ( P/J130) connectors. The P/J403, P/J140, and P/J130 connectors are connected securely.
Y
N
Connect the AIOC PWB P/J403 ( P/J403), LD PWB P/J140 ( P/J140), and P/J130 ( P/
J130) connectors securely.
Check the wires between J403 ( P/J403) and J140 ( P/J140) and between J403 and J130 ( P/
J130) The wires are not shorted or open.
Y
N
Repair the wire(s).
Replace the ROS (PL 3.1) (REP 3.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Replace the IIT Carriage (PL 10.3) (REP 10.3.1).
U2-1, U3-5
June, 2008
2-26
Reissue
U4-1 Fuser On Time Fail
U4-2 Over Heat Temp Fail
BSD-Reference:
BSD-Reference:
CH10.1 (Figure 1)
CH10.1 (Figure 1)
Explanation
Explanation
The lamp did not turn OFF within the specified time after turning ON.
A temperature of 250C or higher was detected continuously for 480 ms.
Or, Warm Up was not completed within the specified time after power ON.
Procedure
Procedure
When U4-1 occurs, [NVM 50-20 FSR Reset FuserOverTemp] becomes "3." Run [NVM 50-20
FSR Reset FuserOverTemp] using "0" to reset it. (How to Enter the Diagnostic Mode) Check
to see if there is paper in the Fuser. The Fuser is normal and there is no paper in it.
Y
N
Remove the paper.
Check the condition of the Fuser. The Fuser is installed properly.
Y
N
Install the Fuser properly.
Remove the Fuser. Check the conductivity between the Thermostat contacts. The
are conductive.
Y
N
Replace the Fuser (PL 5.1) (REP 5.1.1).
contacts
When U4-2 occurs, [NVM 50-20 FSR Reset FuserOverTemp] becomes "1." Run [NVM 50-20
FSR Reset FuserOverTemp] using "0" to reset it. (How to Enter the Diagnostic Mode) Check
( P/J601) and
the resistance of the Thermistor. There is no open circuit between J601-1
J601-2, and the resistance is a minimum of 228k ohms (cold).
Y
N
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
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
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.
Reissue
June, 2008
2-27
U4-1, U4-2
U4-3 FS1 Thermistor Defect
U4-9 Fuser Fan Defect
BSD-Reference:
BSD-Reference:
CH10.1 (Figure 1)
CH10.3 (Figure 3)
Explanation
Explanation
Thermistor FS1 cannot be monitored any more.
After the start of Fan Fail Signal monitoring, the signal level was Low not more than 30 times.
Procedure
Procedure
Check the condition of the Fuser. The Fuser is installed properly.

Y
N
Install the Fuser properly.
Turn the power ON. Visually check the NOHAD Fan (PL 9.2). The NOHAD Fan is rotating.
Y
N
Measure the voltage between the AIOC PWB P405-3 ( P/J405) (+) and GND (-). The
voltage is approximately +24VDC.
Y
N
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 NOHAD Fan (PL 9.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Check the wire between J408 ( P/J408) and P601 ( P/J601). The wire is not shorted or
open.
Y
N
Repair the wire.
Measure the voltage between the AIOC PWB P405-2 P/J405 (+) and GND (-). The voltage
is 0.
Y
N
Replace the NOHAD Fan (PL 9.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Replace the Fuser (PL 5.1) (REP 5.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
U4-3, U4-9
June, 2008
2-28
Reissue
U6-2 RAM Read/Write Check Error
U6-3 NVM Data Defect
BSD-Reference:
BSD-Reference:
CH3.2 (Figure 2)
CH3.2 (Figure 2)
Explanation
Explanation
When the AIOC PWB checked RAM read/write at activation, a mismatch of read and write data
was detected.
NVM Header data and NVM 3 page data are mismatched.
Or, the NVM Write & Read area is not found.
Or, the NVM or Counter area is full.
Procedure
Check each AIOC PWB connector. Each connector is connected securely
Y
N
Turn the power OFF and ON. U6-2 recurs.
Y
N
Completed
Reissue
Procedure
Check each AIOC PWB connector. Each connector is connected securely.
Y
N
Y
N
Completed
June, 2008
2-29
U6-2, U6-3
U6-4 NVM Read/Write Cannot Be Executed
U6-5 CPU Power To Access NVM Is Not Enough
BSD-Reference:
BSD-Reference:
CH3.2 (Figure 2)
CH3.2 (Figure 2)
Explanation
Explanation
During NVM read/write, the NVM Ack NG state was detected.
At NVM write, the NVM queue full state was detected.
Or, during NVM repairs, an NVM write error was detected five times.
Procedure
Check each AIOC PWB connector. Each connector is connected securely.
Y
N
Y
N
Completed
Procedure
Execute diagnostics [29-49] to check the ROM version.
Mode) The ROM is the latest version.
Y
N
Upgrade the ROM to the latest version.
(How to Enter the Diagnostic
U6-4, U6-5
June, 2008
2-30
Reissue
U7-0 UI Communication TimeOut
U7-1 UI Communication Error
BSD-Reference:
BSD-Reference:
CH2.1 (Figure 1)
CH2.1 (Figure 1)
Explanation
Explanation
At Power ON, the AIOC PWB does not communicate with the User Interface PWB.
The User Interface PWB detected a communication failure.
Procedure
Procedure
Measure each voltage between AIOC PWB J401-1 ( P/J401) (+), J401-2 (+), and GND (-).
The voltages are approximately +5VDC.
Y
N
Check each User Inferface PWB connector. Each connector is connected securely.
Y
N
Check the wire between J401 ( P/J401) and J710 ( P/J710). The wire is neither shorted nor
open.
Y
N
Repair the wire.

Y
N
Completed
Replace the User Interface PWB (PL 8.4) (REP 8.4.1).
Replace the User Interface PWB (PL 8.4) (REP 8.4.1) and the AIOC PWB (PL 8.1) (REP 8.1.1)
in that order.
Reissue
June, 2008
2-31
U7-0, U7-1
U8-1 Billing Counter Defect
U9-0 HVPS Fail
BSD-Reference:
BSD-Reference:
CH3.2 (Figure 2)
CH9.1 (Figure 1)
Explanation
Explanation
An illegal Billing Counter value was detected.
A 500 ms cycle of HVPS#ERR=High was detected twice in a row.
Or, the AIOC PWB failed to read the Billing Counter.
Procedure
TBD
Procedure
Close the Left Hand Cover and the Front Cover. Make sure that the Drum Cartridge and the
Transfer Corotron are properly seated. Measure the voltages between P406-2 ( P/J406) (+)/
P406-4(+)/P406-5(+) on the AIOC PWB and ground (-). The voltages are approximately
+5VDC.
Y
N
Replace the AIOC PWB (PL 8.1) (REP 8.1.1) and the HVPS (PL 8.2) (REP 8.2.1) in that
order.
Execute diagnostics [09-04 HVPS ON (Low Voltage)]. (How to Enter the Diagnostic Mode)
The voltages at P406-2 ( P/J406) (+)/P406-4 (+)/P406-5 (+) become 0.
Y
N
Replace the 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).
Completed
U8-1, U9-0
June, 2008
2-32
Reissue
062-300 Platen Interlock Open
062-345 IISS EEPROM Failure
BSD-Reference:
BSD-Reference:
CH 5.6
CH 3.1
Explanation
Explanation
Detected the opened Platen Interlock.
Error in writing on or communicatiing with the EEPROM.
Procedure
Procedure
Ensure that the DADF can be closed normally. The DADF can be closed normally.
Y
N
Remove obstructions or repair the DADF Counter Balances. (REP 13.3.2, REP 13.3.3)
Switch off the machine power then switch on the power. The problem is solved.
Y
N
Replace the SLCC PWB (AIOC/Network PWB). (REP 8.1.3) (PL 8.1)
Check that the Platen Interlock is functioning properly. The Platen Interlock is functioning
properly.
Y
N
Replace the Platen Interlock Sensor.
Problem is resolved.
Replace the SLCC PWB (AIOC/Network PWB). (REP 8.1.3) (PL 8.1)
Reissue
June, 2008
2-33
062-300, 062-345
062-360 Carriage Position Fail
062-371 Lamp Illumination Fail
BSD-Reference:
BSD-Reference:
CH 6.2
CH 6.1
Explanation
Explanation
Detected no input of Regi Sensor when carriage was working or detected the failure of the
Regi Sensor position, or detected the failure of the IIT Regi Sensor level.
Detected incufficient light provided from the Lamp to the CCD.
Procedure
Procedure
Check that the Lamp Carriage can move freely and has no loose cables. The Lamp Carriage
and cables are good.
Y
N
Repair the Lamp Carriage. (REP 10.3.1)
Enter the Diagnostic Mode. Enter Component Control Code [62-212]. Check the operation of
the IIT Regi Sensor. The Regi Sensor is good.
Y
N
Reseat the Regi Sensor connector. Check the wiring for proper operation and repair if
necessary. Replace the Regi Sensor. (PL 10.6)
Enter the Diagnostic Mode. Enter Component Control Code [05-22]. The Carriage moves in
the scan direction.
Y
N
Check the connector of the Carriage Motor and repair if necessary. Replace the Carriage
Motor. (PL 10.6)
Check for any obstructions in the optical path between the lamp, the lens or the mirror. The
optical path is clear of any obstructions.
Y
N
Remove the obstuctions.
Check that the White Color Correction Plate (Reflector) is in place and not deterioarated. (PL
10.6) The White Color Correction Tape is good.
Y
N
Clean or replace the White Color Correction Plate. (PL 10.6)
Enter the Diagnostic Mode. Enter Component Control Code [62-02]. The Illumination Lamp
is good.
Y
N
Check that the Lamp harness is properly connected and repair if necessary. Replace the
Illumination Lamp. (REP 10.6.1)
Replace the SLCC PWB (AIOC/Network PWB). (PL 8.1) (REP 8.1.3)
Replace the SLCC PWB (AIOC/Network PWB). (PL 8.1) (REP 8.1.3)
062-360, 062-371
June, 2008
2-34
Reissue
062-380 AGC Failure
062-386 AOC Failure
BSD-Reference:
BSD-Reference:
CH 6.2
CH 6.1
Explanation
Explanation
Control logic has detected insufficient light from the Illumination Lamp during AGC (Automatic
Gain Congrol) of the auto IIT Calibration at Start.
Control logic has detected an output defect of the CCD at AOC (Automatic Offset Control) of
the auto IIT Calibration at Start.
Procedure
Procedure
Check for any obstructions in the optical path. Clean the Mirror, lens and the white balance
strip. Switch off the power then switch it on again. The problem has been resolved.
Y
N
Enter the Diagnostic Mode. Enter Component Control Code [62-02]. The lamp is good.
Y
N
Check that the Lamp harness is properly connected and repair if necessary. Replace
the Illumination Lamp. (REP 10.6.1)
Check the connector P/J410 for proper connection. The problem has been resolved.
Y
N
Replace the SLCC PWB and (3) EEPROMS (AIOC/Network PWB). (PL 8.1) (REP 8.1.3)
POPO the machine and retry.
Replace the SLCC PWB and (3) EEPROMS (AIOC/Network PWB). (PL 8.1) (REP 8.1.3)
POPO the machine and retry.
Reissue
June, 2008
2-35
062-380, 062-386
062-392 IPS PWB Memory Fail
062-393 IPS PWB Fail
BSD-Reference:
BSD-Reference:
CH 3.1
CH 3.1
Explanation
Explanation
Control logic has detected RAM malfunction of IISS PWB.
Control logic has detected a test error or a writing error to the SLCC EEPROMs.
Procedure
Procedure
Switch off the power then switch it on again. If the problem is not solved, replace the SLCC
PWB (AIOC/Network) and the 3 EEPROMs. (REP 8.1.3)
Switch off the power then switch it on again. If the problem is not solved, replace the SLCC
PWB (AIOC/Network) and the 3 EEPROMs. (REP 8.1.3)
062-392, 062-393
June, 2008
2-36
Reissue
005-170 DADF Feed Failure

BSD-Reference:
CH 5.2
C
Replace the Document Feed Clutch (PL 13.9)
Replace the Pick Up Roller and Feed Roller. (REP 13.9.1)
Explanation
Replace the Document Feed Sensor (PL 13.9).
The control logic has detected the failure of paper to reach the Document Feed Sensor after
the Feed Clutch has energized.
Procedure
Check for obstructions in the Document Tray. Clean the Feed Roll. Confirm that a document is
feeding into the document handler. The Feed Roller feeds paper into the document handler.
Y
N
The Document Drive Motor operates.
Y
N
Enter the Diagnostic Mode. Enter Component Control Code [05-01]. The
Document Drive Motor operates.
Y
N
There is +24 VDC at connector CN2 pin 1 and pin 4 on the DADF PWB.
Y
N
Check the following in order:
1. Check the connectors CN1 and CN2 on the DADF PWB for proper
connections
2.
Check the connector J414 on the SLCC PWB (AIOC) for proper connection.
3.
Check the harness from the DADF PWB to the SLCC PWB for an
open circuit.
If the harness and the connectors are good, replace the DADF PWB (REP
13.2.4)
Replace the Document Drive Motor (PL 13.5)
The Feed Roller rotates.
Y
N
Enter the Diagnostic Mode. Enter Component Control Code [05-62]. The Document Feed Clutch operates.
Y
N
Check the connector of the Document Feed Clutch (PL 13.9) If the connector is good, replace the Document Feed Clutch (PL 13.9).
Y
N
Document Feed Clutch operates.
Y
N
Check the connector of the Document Feed Clutch (PL 13.9) If the connector is
good, replace the Document Feed Clutch (PL 13.9).
A
B
C
Reissue
June, 2008
2-37
005-170
005-171 DADF Regi / Exit Failure

BSD-Reference:
CH 5.8
C
Explanation
Enter the Diagnostic Mode. Enter Component Control Code [05-206]. Actuate the Document
Registration Sensor acutator. The display changes from High to Low.
Y
N
Replace the Document Registration Sensor. (PL 13.7)
Control logic has detected no paper at the Registration Sensor after turning on the Registration
Clutch or detected no paper at the Exit/Invert Sensor after turning on the Registration Clutch.
Procedure
Enter the Diagnostic Mode. Enter Component Control Code [05-205]. Actuate the Exit/Invert
Sensor actuator. The display changes from High to Low.
Y
N
Replace the Exit/Invert Sensor. (PL 13.7)
Y
N
Y
N
Y
N
Y
N
connections
2.
3.
open circuit.
Replace the DADF PWB (REP 13.2.4), or replace the SLCC PWB (AIOC/Network) (REP 8.1.3)
13.2.4)
Y
N
Y
N
Y
N
Document Feed Clutch operates.
Y
N
A
B
C
June, 2008
005-171
2-38
Reissue
005-172 DADF Inverted Document Jam

BSD-Reference:
B
Y
CH 5.8
Explanation
N
When inverting documents, the control logic detected a failure of a document at the Feed Sensor after turning off the Feedout Forward or document failure at the Exit/Invert Sensor after
turning on the Document Registration Sensor.
Procedure
Y
N
Y
N
Y
N
Y
N
connections
2.
3.
open circuit.

Enter the Diagnostic Mode. Enter Component Control Code [05-204]. Actuate the Document
Feed Sensor acutator. The display changes from High to Low.
Y
N
Replace the Document Feed Sensor. (PL 13.9)
Enter the Diagnostic Mode. Enter Component Control Code [05-205]. Actuate the Exit/Invert
Sensor actuator. The display changes from High to Low.
Y
N
Replace the Exit/Invert Sensor. (PL 13.7)
Replace the DADF PWB (REP 13.2.4), or replace the SLCC PWB (AIOC/Network) (REP 8.1.3)
13.2.4)
Y
N
Y
N
Y
N
ment Feed Clutch operates.
A
B
Reissue
Docu-
June, 2008
2-39
005-172
005-198 Short Scan Jam
005-199 Long Scan Jam
BSD-Reference:
BSD-Reference:
CH 6.2
CH 6.2
Explanation
Explanation
The control logic has found that the length of slow scan is less than 80mm.
The control logic has detected that the length of slow scan is 450mm or more.
Procedure
Procedure
Choose a document size equal to or larger than A4 paper or 208mm SEF or larger, in the Document Tray. The problem is solved.
Y
N
Choose a document size equal to or less than A3 paper or 294mm SEF or less in the Document Tray. The problem is solved.
Y
N
Inform the customer of the minimum size limitation of documents used in the DADF Document
Tray.
Inform the customer of the maximum size limitation of documents used in the DADF Document
Tray.
005-198, 005-199
June, 2008
2-40
Reissue
005-305 Feeder Top Cover Open
005-920 Static Jam
BSD-Reference:
BSD-Reference:
CH 5.6
CH 5.6
Explanation
Explanation
The control logic has detected that the Feeder Top Cover is open.
At power on, the control logic detected either the Platen Interlock is close when the Feeder
Cover is open or the Feeder Cover Interlock is close when the Platen Interlock is open.
Procedure
Close the Feeder Top Cover. The problem continues.
Y
N
Adjust or repair the Feeder Top Cover latch. (REP 13.4.1)
Replave the Feeder Top Cover Switch. (PL 13.9)
Reissue
Procedure
If this occurs frequently, confirm if there is any interferance with the Feed Sensor (PL 13.9),
the Document Registration Sensor (PL 13.7) or the Exit/Invert Sensor (PL 13.7). Check the
sensor connectors for prober connection. Replace one sensor at a time until the problem is
solved.
June, 2008
2-41
005-305, 005-920
005-305, 005-920
June, 2008
2-42
Reissue
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..................................................................................
Reissue
3-3
3-3
3-4
3-4
3-5
3-5
3-6
3-6
3-7
3-7
3-8
3-8
3-9
3-9
3-10
3-10
3-16
June, 2008
3-1
Image Quality
Image Quality
June, 2008
3-2
Reissue
IQ1 IOT Image Quality Entry RAP
IQ2 IIT Image Quality Entry RAP
Initial Actions
Initial Actions
Determine whether the image quality problem occurs in Copy Mode or Print Mode. If the problem occurs in Copy Mode, go to IQ2.
Clean the IIT Upper Cover (PL 10.2) (REP 10.2.1).

Clean the mirrors and lens with a lint-free cloth.
Procedure
Determine the image quality problem and go to the relevant RAP.
Determine the image quality problem and go to the relevant RAP.
Table 1 IIT Image Quality Problems
Table 1 IOT Image Quality Problems

Image Quality Problem
Symptom
RAP
Image Quality Problem
Symptom
RAP
Low image density
Overall low density of images.
IQ3
Low image density
Wrinkled images
The printed paper is creased, folded or torn.
IQ4
Background contamination
Ghost images
Ghost images appear on the paper. Parts of the IQ5

previous page or current page appear as ghost
images on the paper.
The whole page or part of the page is contamiIQ6

nated by toner. The contamination appears as a
very light grayish color.
IQ3
Background contamination
The whole page or part of the page is contami- IQ6

nated by toner. The contamination appears as a
Black lines, blank areas, or

Black lines or white streaks running parallel to
smears in the process direction. the direction of paper transport.
IQ9

smears at right angles to the
process direction.
Black lines or white streaks running at right

angles to the direction of paper transport.
IQ11
Deletion
Part of the image is missing.
IQ7
Skew/Misregistration
Printed images are not parallel to the edges of

the paper.
IQ8
Spotted blanks
Toner spots and blank areas are spread irregularly over the whole page.
IQ13

Black lines or white streaks running parallel to
smears in the process direction the direction of paper transport.
IQ9
Solid black copy
The output is completely black.
IQ14
Improper fusing, offset
Printed images are not properly fused onto the

paper.
When rubbed, the image comes off easily.
IQ10

smears at right angles to the
process direction.
Black lines or white streaks running at right

angles to the direction of paper transport.
IQ11
Mottle
Uneven printed image density.
IQ12
Spotted blanks
Toner spots and blank areas are spread irregu- IQ13

larly over the whole page.
Solid black copy
The output is completely black.
IQ14
Blank copy
The output is completely white.
IQ15
Reissue
June, 2008
3-3
Image Quality
IQ1, IQ2
IQ3 Low Image Density RAP
IQ4 Wrinkled Image RAP
The output is creased, folded or torn.
Procedure
Procedure
Check for dirt on the Platen Glass. The Platen Glass is clean.
Y
N
Clean any dirt on the Platen.
If unable to clean the dirt, replace the IIT Upper Cover (PL 10.2) (REP 10.2.1).
Check the paper type. The paper used is within specifications.

Y
N
Use paper that is within specifications.
Use paper from a freshly opened packet. The problem recurs.
Y
N
Completed
Check the drum ground contact. The drum ground contact is clean and not damaged.
Y
N
Clean the drum ground contact. If necessary, restore it to its proper shape.
Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF
then ON and make a print. The problem recurs.
Y
N
Completed
Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a
print. The problem recurs.
Y
N
Completed
Remove the Fuser (PL 5.1) (REP 5.1.1) and reinstall it properly. Turn the power OFF then ON
and make a print. The problem recurs.
Y
N
Completed
Check for foreign substances and damaged components in the paper transport path. No foreign substances or damaged components are found in the paper transport path.
Y
N
Remove the foreign substances. Reshape or replace any damaged components.
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 Transfer Corotron (PL 4.3) (REP 4.3.1), followed by the HVPS (PL 8.2) (REP
8.2.1), and finally the AIOC PWB (PL 8.1) (REP 8.1.1).
Image Quality
IQ3, IQ4
June, 2008
3-4
Reissue
IQ5 Residual Image (Ghosting) RAP
IQ6 Background RAP
Ghost images appear on the paper. Parts of the previous page or current page appear as ghost
images on the paper.
The whole page or part of the page is contaminated by toner. The contamination appears as a
Procedure
Procedure
Y
N
Completed
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).
Y
N
Completed
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).
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).
Reissue
June, 2008
3-5
Image Quality
IQ5, IQ6
IQ7 Deletion RAP
IQ8 Skew/Misregistration RAP
Part of the image is missing.
Printed images are not parallel to the edges of the paper.
Procedure
Procedure

Y
N
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.

Y
N
Completed
Y
N
Completed
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).
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.
Image Quality
IQ7, IQ8
June, 2008
3-6
Reissue
IQ9 Process Direction Bands, Streaks, and Smears RAP
IQ10 Unfused Copy/Toner Offset RAP
Black lines or white streaks running parallel to the direction of paper transport.
Printed images are not properly fused onto the paper. When rubbed, the image comes off easily.
Procedure
Check the IIT Carriage Mirrors. The mirrors are not dirty, scratched, or damaged.
Y
N
Clean the mirrors. If the mirrors cant be cleaned, have scratches, or are damaged,
replace the IIT Carriage (PL 10.3) (REP 10.3.1).
Y
N
Completed
Y
N
Completed
Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron is clean and not
damaged.
Y
N
Check for dirt in the paper transport path. The paper transport path is clean.
Y
N
Clean away the dirt.
Procedure
Y
N
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
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.
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).
damaged.
Y
N
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).
Reissue
June, 2008
3-7
Image Quality
IQ9, IQ10
IQ11 Repeating Bands, Streaks, Spots, and Smears RAP
IQ12 Mottle RAP
Black lines or white streaks running at right angles to the direction of paper transport.
Procedure
Procedure

Y
N
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.
Y
N
Completed
Y
N
Completed
damaged.
Y
N
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).

Y
N
Completed
Y
N
Completed
Y
N
Completed
damaged.
Y
N
Y
N
Completed
Image Quality
IQ11, IQ12
June, 2008
3-8
Reissue
IQ13 Spots RAP
IQ14 Black Prints RAP
Toner spots and blank areas are spread irregularly over the whole page.
The paper is printed completely black.
Procedure
Procedure
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).
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.
Y
N
Completed
Y
N
Completed
damaged.
Y
N
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).
Y
N
Y
N
Completed
Reissue
Y
N
Completed
Y
N
Completed
Y
N
Completed
Check the connectors of the HVPS (P/J520) and AIOC PWB (P/J406). The connectors are
connected securely.
Y
N
Connect the connectors securely.
Check the wire between J460-4 and J520-2. The wire between J460-4 and J520-2 is not
shorted or open.
Y
N
Repair the wire.
Check the wires between the ROS (PL 3.1) (REP 3.1.1) and the AIOC PWB (PL 8.1) (REP
8.1.1). The wires between J140 (ROS) and J403 (AIOC PWB), as well as between J130
(ROS) and J403 (AIOC PCB), are not shorted or open.
Y
N
Repair the wire(s).
Replace the ROS (PL 3.1) (REP 3.1.1), followed by the HVPS (PL 8.2) (REP 8.2.1), and finally
the AIOC PWB (PL 8.1) (REP 8.1.1).
June, 2008
3-9
Image Quality
IQ13, IQ14
IQ15 Blank Image RAP
Copy Quality Specification
The paper is printed completely white.
1. Copy Alignment
How to measure
Procedure
Make a copy of the Test Pattern STP3600 (A3) (Figure 1) and measure.
Check the ROS (PL 3.1) (REP 3.1.1). The ROS is installed correctly.
Y
N
Install the ROS (PL 3.1) (REP 3.1.1) correctly.
Table 1 Copy Alignment: Measurement
Check the drum ground contact. The drum ground contact is clean and not damaged.
Y
N
Clean the drum ground contact. If it is damaged, reshape or replace it.
Y
N
Completed
Y
N
Completed
Print a page that is entirely black. During the print cycle, turn OFF the power after you hear the
paper feed (to force a stop during the image transfer) and check the surface of the Drum.
There is a considerable amount of toner left on the surface of the Drum.
Y
N
Check the P/J140, P/J406, J403, and J140 connectors. The connectors are connected
securely.
Y
N
Connect the connectors securely.
Check the ROS (PL 3.1) (REP 3.1.1). The ROS is installed correctly.
Y
N
Install the ROS (PL 3.1) (REP 3.1.1) correctly.
Item
How to measure (Refer to Figure 1)
Lead Edge Registration (mm)
(P1~P2) Standard Value *1
Side Edge Registration (mm)
(P7~P19) Standard Value *1: A3S
Lead Skew (mm)
(P5~P6) (P3~P4)
Vertical Ratio (%)
((P2~P14) - 200) / 200 x 100: A3S
Horizontal Ratio (%)
((P8~P13) - 280) / 280 x 100
Perpendicularity (mm)
Difference between the perpendicular line of the intersection

point between the line that connects P4 and P6, and P14.
Linearity (Vertical) (mm)

400mm
Maximum difference between the [Intersection point of the

vertical line A and each vertical line] and the line that connects P2 and P14.
Linearity (Horizontal) (mm)

280mm

horizontal line C and each horizontal line] and the line that
connects P10 and P15.
Linearity (Skew) (mm) 280mm

skew line D and each line] and the line that connects P17
and P13.
Or
skew line E and each line] and the line that connects P8 and
P18.
Parallelism (mm)
(P10~P12) (P15~P16)
*1: Measure the length of the position of FX STP#3600 and use it as the Standard Value
in the table.
Measure the voltage between pin 1 and pin 2 of connector P403 on the AIOC PWB (PL
8.1) (REP 8.1.1). The voltage is +5VDC.
Y
N
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 Transfer Corotron (PL 4.3) (REP 4.3.1), followed by the HVPS (PL 8.2) (REP
8.2.1), and finally the AIOC PWB (PL 8.1) (REP 8.1.1).
Image Quality
IQ15,
June, 2008
3-10
Reissue
Specification
[System] IOT + IIT
Table 2 Copy Alignment: Specification
Item
Specification
SYSTEM
+/- 2.90
+/- 3.40
Lead Skew (mm)
+/- 2.30
280 mm
Vertical Ratio (%) 100%
+/- 1.40
400 mm
Horizontal Ratio (%) 100%
+/- 1.40
280 mm
Perpendicularity (mm)
+/- 3.40
400 mm
Linearity (Vertical) (mm)
+/- 2.00
400 mm
Linearity (Horizontal) (mm)
+/- 1.40
280 mm
Linearity (Skew) (mm)
+/- 1.42
280 mm
Parallelism
+/- 3.70
400 mm
Application
[DC] IOT + IIT

Item
Specification
Measurement Length
Simplex
MSI
Skew H
+/-1.9
+/-2.2
200mm
Perpendicularity
+/-2.8
+/-3.0
400mm
Linearity: V
1.4
--
400mm
Linearity: H
1.4
--
280mm
Linearity: D
1.4
--
283mm
Registration: Lead
+/-2.4
+/-3.1
Registration: Side
+/-3.0
+/-3.2
Magnification: V (%)
+/-0.95 (100%)
+/-1.16 (50%-99%)
+/-1.47 (101%-200%)
--
400mm
Magnification: H (%)
+/-0.95 (100%)
+/-1.16 (50%-99%)
+/-1.47 (101%-200%)
--
280mm
Reissue
June, 2008
3-11
Image Quality
Figure 1 Copy Alignment Measurement Positions (Test Pattern STP3600)
2. Image Quality
Make a copy of the Test Pattern 499T247 (A3) and measure. See Table 5 for specifications.
How to measure
Table 4
Item
Text/Image Density
Measure the 0.7G line image (10) at 3 locations.
(100%/Normal mode only) Determine the maximum and minimum mean value measured
(within the same copy).
Image Quality
June, 2008
3-12
Reissue
Table 4
Item
Low Contrast
(100% only)
Normal mode: Check that the 0.2G line image 13 can be read.
Darker mode: Measure the 0.2G line image 13 at 3 locations.
Determine the maximum and minimum mean value measured
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)
Solid Density Reproduc- Measure the 1.0G solid 16 at 3 locations.
ibility
(100%/Normal mode only) (within the same copy).
Background
Measure the margin.
Resolution
70.7, 100%: Measure the resolution target 17 at 3 locations.

141.4%: Measure the resolution target 17 at 2 locations.
Skip and Smear
100%: Check that the 2.5lp/mm ladder 18 is resolving across the

entire page.
70.7~99%: Check that the 1.8lp/mm ladder 19 is resolving across
the entire page.
Reissue
June, 2008
3-13
Image Quality
Figure 2 Image Quality Measurement Positions (Test Pattern 499T247)

Image Quality Specification
Total System
Image Quality
June, 2008
3-14
Reissue
Table 5
Reissue
Item
Reduce/
Enlarge
(%)
INPUT
OUTPUT
(Density
Settings
Button)
Lighter 3
Text/Image Density
100
0.7 Gray
>=1.08
>=1.08
Text/Image Density Evenness
100
0.7 Gray
=<0.2
=<0.2
Low Contrast Reproducibility
100
0.2 Gray
>=0.17
>=0.46
>=0.22
Low Contrast Evenness
100
0.2 Gray
=<0.4
Low Contrast Reproducibility
100
0.1 Gray
Does not
reproduce
Reproducibility of the blue color density
100
0.2 Blue
>=0.17
>=0.57
>=0.22
Blue Color Density Evenness
100
0.2 Blue
0.4 (Max)
Reproducibility of the blue color density
100
0.1 Blue
Does not
reproduce
Solid Density Reproducibility
100
1.0 Solid
>=1.0
>=1.0
Solid Density Evenness
100
1.0 Solid
=<0.3
=<0.3
Background (SIR#302)
100
=<1.2
=<1.2
Resolution
(Excluding Skip/Smear)
100
NBS Target
4.3 Lo/mm
(Min)
Resolution
70
NBS Target
2.5 Lo/mm
(Min)
Resolution
141
NBS Target
3.5 Lo/mm
(Min)
Resolution
200
NBS Target
3.5 Lo/mm
Depth of Focus
100
NBS Target
3 Lo/mm
(Min)*1
Skip/Smear
100
Ladder A3 Entire
Page
2.5 Lo/mm
(Min)*1
Skip/Smear
70
Ladder A3 Entire
Page
1.8 Lo/mm
(Min)
Skip/Smear
141
Ladder A3 Entire
Page
2.5 Lo/mm
(Min)
Skip/Smear
200
Ladder A3 Entire
Page
2.5 Lo/mm
(Min)*1
June, 2008
3-15
OUTPUT
(Density
Settings
Button)
Normal
OUTPUT
(Density
Settings
Button)
Darker 3
OUTPUT
(Density
Settings
Button)
Auto
Image Quality
Samples of Image Quality Defects

IOT Image Quality Defects
These are samples of image quality defects due to IOT problems and their corresponding solutions.
Auger Marks (Figure 1)
Strobing (28mm or 14mm Pitch Density) (Figure 2)
White Streaks (Process Direction) (Figure 3)
Black Bands (Figure 4)
Toner Contamination (Figure 5)
Toner Splattering (Figure 6)
White Spots (Irregular) (Figure 7)
Regular Blanks in the Process Direction (Spots, Streaks, Bands etc.) (Figure 8)
Regular Toner Contamination in the Process Direction (Spots, Streaks, Bands etc.) (Figure 9)
IIT Image Quality Defects

These are samples of image quality defects due to IIT problems and their corresponding solutions.
Moire Due to Interference with Copy Original
Fluctuation in Background Suppression Values for Copies of Originals
Defects Related to Scan Print
Light Background Due to Background Suppression in Copies of Originals with Frames

(Figure 10)
Image Quality
June, 2008
3-16
Reissue
Auger Marks
Figure 1 Auger Marks

Cause
Action
1.
Magnetic field failure in the Developer Magnetic Roll.
1.
2.
There was a drop in the level of developer material.
Reissue
June, 2008
3-17
Replace the Drum Cartridge (PL 4.1) (REP 4.1.1). The problem may occur immediately
after you install a new Drum Cartridge. This can be corrected by feeding a few sheets of
paper.
Image Quality
Strobing (28mm or 14mm Pitch Density)
Figure 2 Strobing (28mm or 14mm Pitch Density)

Cause
1.
Developer Magnetic Roll bias.
Action
1.
Image Quality
June, 2008
3-18
Reissue
White Streaks (Process Direction)
Figure 3 White Streaks (Process Direction)

Cause
Action
1.
Foreign substances are blocking the ROS Laser.
1.
2.
Developer material clogging on the Developer Magnetic Roll due to foreign substances.
Clean the optical path between the ROS (PL 3.1) (REP 3.1.1) and the Drum Cartridge (PL
4.1) (REP 4.1.1), and clean the seal glass.
2.
Reissue
June, 2008
3-19
Image Quality
Black Bands
Figure 4 Black Bands

Cause
1.
The developer material is not well mixed.
Action
1.
Mix the developer material by processing blank paper.
Image Quality
June, 2008
3-20
Reissue
Toner Contamination
Figure 5 Toner Contamination

Cause
1.
2.
Cloud of toner falling from the Drum Cartridge (PL 4.1) (REP 4.1.1).
Action
1.
Mix the developer material by processing blank paper.
Reissue
June, 2008
3-21
Image Quality
Toner Splattering
Figure 6 Toner Splattering

Cause
Action
1.
Paper size mismatch (tray settings and paper size are different).
1.
Check the tray settings.
2.
Increased paper resistance due to dry conditions.
2.
Use paper from a freshly opened packet.
Image Quality
June, 2008
3-22
Reissue
White Spots (Irregular)
Figure 7 White Spots

Cause
1.
Increased paper resistance due to dry conditions.
Action
1.
Use paper from a freshly opened packet.
Reissue
June, 2008
3-23
Image Quality
Regular Deletions in the Process Direction (Spots, Streaks, Bands,

etc.)
Figure 8 Regular Deletions in the Process Direction (Spots, Streaks, Bands, etc.)
Cause
4.
1.
94mm Pitch (Drum): Scratches or foreign substances.
Action
2.
57mm Pitch (Developer Roll): Developer material clogging on the Magnetic Roll.
1.
3.
44mm Pitch (Charger): Scratches or foreign substances.
1,4: Clean or replace the Drum Cartridge (PL 4.1) (REP 4.1.1)/Fuser (PL 5.1) (REP
5.1.1).
2.
2,3: Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).
Image Quality
June, 2008
3-24
80mm Pitch (Fuser Heat Roll): Scratches or foreign substances.
Reissue
Regular Toner Contamination In the Process Direction (Spots, Streaks,

Bands, etc.)
Figure 9 Regular Toner Contamination In the Process Direction (Spots, Streaks, Bands, etc.)
Cause
Action
1.
94mm Pitch (Drum): Scratches or foreign substances.
1.
2.
57mm Pitch (Magnetic Roll): Developer material clogging on the Magnetic Roll.
1,4,5,6: Clean or replace the Drum Cartridge (PL 4.1) (REP 4.1.1)/Fuser (PL 5.1) (REP
5.1.1).
3.
44mm Pitch (Charger): Scratches or foreign substances.
2.
2,3: Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).
4.
80mm Pitch (Heat Roll): Scratches or foreign substances.
5.
19mm Pitch (Fuser Roll-Exit): Dirt.
6.
44mm Pitch (Registration): Dirt.
Reissue
June, 2008
3-25
Image Quality
Moire Due to Interference with Copy Original

Cause
Copying originals with certain line patterns may cause moire (wavy lines) on the copy. Combinations of certain angles of screen ruling near 150dpi and certain Reduce/Enlarge ratios may
also cause moire.
Action
1.
Reduce sharpness.
2.
Make copies at a different Reduce/Enlarge ratio.
3.
Change the orientation of the original.
Secondary defect: Text is blurred.
Fluctuation in Background Suppression Values for Copies of Originals

of Medium Density
When [Auto] is selected for originals with a background of medium density (0.5G), the effectiveness of Automatic Exposure fluctuates for each job.
Cause
Since medium density (0.5G) is near the upper limit value for background detection, the Background Suppression value fluctuates according to the result of background detection, which
responds to variations in the original density and how the original is positioned.
Action
Select [Off] for [Auto].
Defects Related to Scan Print

Moire may occur when scanned images are printed.
Cause
This could be due to the resolution conversion process between the original and the printer
driver.
Action
Reduce sharpness.
Secondary defect: Text is blurred.
Image Quality
June, 2008
3-26
Reissue
Light Background in Copies of Originals with Frames

When [Auto] is selected for originals with dark frames along the Lead Registration Edge, the
background suppression value is set so large that areas of medium density appear extremely
light.
Figure 10 Light Background in Copies of Originals with Frames

Cause
Action
[Auto] performs background detection of images at a distance of up to 10mm from the Lead
Registration Edge. If there are dark frames along the Lead Registration Edge, Automatic Exposure cannot detect the original background density. Therefore, Background Suppression is calculated based on the density of the frames.
Select [Off] for [Auto].
Reissue
June, 2008
3-27
Image Quality
Image Quality
June, 2008
3-28
Reissue
4 Repairs and Adjustments

Introduction
Introduction .....................................................................................................................
4-3
Repairs
1. Drive
REP 1.1.1 IOT Motor (SCC)............................................................................................
4-7
4-9
4-10
4-12
4-13
4-17
4. CRU
REP 4.1.1 Drum Cartridge ..............................................................................................
REP 4.2.1 Toner Empty Sensor......................................................................................
REP 4.2.2 Erase Lamp ...................................................................................................
REP 4.3.1 Transfer Module.............................................................................................
REP 4.4.1 Corotron Wire ................................................................................................
4-19
4-20
4-21
4-23
4-27
5. Fuser
REP 5.1.1 Fuser (SCC)...................................................................................................
REP 5.1.2 Temperature Control Sensor Assembly.........................................................
REP 5.1.3 Fuser Lamp....................................................................................................
REP 5.1.4 Fuser Roll ......................................................................................................
REP 5.1.5 Fuser Pressure Roll .......................................................................................
4-29
4-31
4-32
4-35
4-38
6. Exit
REP 6.1.1 Exit Transport (Simplex) ................................................................................
REP 6.1.2 Exit Transport (Duplex)..................................................................................
4-39
4-42
7. Simplex Module and Bypass Tray

REP 7.1.1 Simplex, Duplex Module ................................................................................
REP 7.5.1 Bypass Feed Roll...........................................................................................
4-45
4-47
8. Electrical
REP 8.1.1 AIOC PWB (SCC)..........................................................................................
REP 8.1.2 LVPS (SCC)...................................................................................................
REP 8.1.3 AIOC/Network PWB (DADF/Network Only)...................................................
REP 8.2.1 HVPS (SCC) ..................................................................................................
REP 8.2.2 Duplex PWB (SCC) .......................................................................................
REP 8.3.1 Control Panel (SCC) ......................................................................................
REP 8.4.1 User Interface PWB (SCC) ............................................................................
9. Cover
Reissue
REP 10.1.1 IIT Platen Cover ...........................................................................................

REP 10.2.1 IIT Upper Cover (SCC) ................................................................................
REP 10.3.1 IIT Carriage (SCC) .......................................................................................
REP 10.3.2 Flexible Print Cable (SCC)...........................................................................
REP 10.6.1 Exposure Lamp............................................................................................
REP 10.7.1 Carriage Cable and Drum ............................................................................
REP 10.7.2 Inverter PWB................................................................................................
4-71
4-72
4-73
4-79
4-81
4-82
4-85
11. Single Tray Module
3. ROS
REP 3.1.1 ROS (SCC) ....................................................................................................
4-67
4-68
4-69
4-70
10. IIT
4-5
2. Paper Transport
REP 2.2.1 Tray 1 Feed Clutch (SCC) .............................................................................
REP 2.3.1 Tray 1 Feed Roll (SCC) .................................................................................
REP 2.5.1 Tray 1 Feed Sensor ......................................................................................
REP 2.7.1 Tray 1 No Paper Sensor ...............................................................................
REP 2.8.1 Registration (SCC).........................................................................................
REP 9.1.1 Output Tray ....................................................................................................

REP 9.1.2 Front Left Cover .............................................................................................
REP 9.2.1 Rear Cover.....................................................................................................
REP 9.2.2 Right Cover ....................................................................................................
4-49
4-52
4-55
4-58
4-61
4-62
4-64
REP 11.1.1 Tray 2...........................................................................................................

REP 11.1.2 Single Tray Module (Separation from IOT) ..................................................
REP 11.4.1 Tray 2 Feed Roll ..........................................................................................
REP 11.4.2 Tray 2 Retard Roll........................................................................................
REP 11.5.1 STM Feed Sensor........................................................................................
REP 11.5.2 STM PWB (SCC) .........................................................................................
REP 11.6.1 STM Feed Clutch .........................................................................................
REP 11.6.2 STM Feed Motor ..........................................................................................
REP 11.7.1 STM No Paper Sensor.................................................................................
4-89
4-89
4-91
4-93
4-96
4-97
4-98
4-99
4-100
13. ADF
REP 13.1.1 ADF Assembly .............................................................................................
REP 13.1.2 ADF/DADF Platen Cushion..........................................................................
REP 13.2.1 Document Tray Assembly (ADF) .................................................................
REP 13.2.2 ADF Feeder Assembly.................................................................................
REP 13.2.3 Front Cover ..................................................................................................
REP 13.2.4 Rear Cover...................................................................................................
REP 13.2.5 DADF Eject Roller Solenoid.........................................................................
REP 13.2.6 DADF Assembly...........................................................................................
REP 13.2.7 Document Tray Assembly (DADF)...............................................................
REP 13.2.8 DADF Feeder Assembly ..............................................................................
REP 13.3.1 ADF Control PWB ........................................................................................
REP 13.3.2 Left Counter Balance (SCC) ........................................................................
REP 13.3.3 Right Counter Balance (SCC)......................................................................
REP 13.3.4 DADF PWB ..................................................................................................
REP 13.4.1 Top Cover ....................................................................................................
REP 13.8.1 Retard Roll ...................................................................................................
REP 13.9.1 Pickup Roll, Feed Roll..................................................................................
4-101
4-102
4-104
4-106
4-109
4-110
4-111
4-112
4-113
4-116
4-119
4-121
4-122
4-124
4-125
4-126
4-128
Adjustments
ADJ 8.1.1 Edge Erase Adjustment..................................................................................
ADJ 8.1.2 Controller Firmware Version Upgrade ............................................................
ADJ 10.3.1 IIT Lead Edge/Side Edge Registration .........................................................
June, 2008
4-1
4-131
4-131
4-132
Repairs and Adjustments
ADJ 11.1.1 Carriage Assembly Alignment (Parallelism) .................................................

ADJ 13.1.1 ADF/DADF Positional Adjustment ................................................................
4-133
4-134
June, 2008
4-2
Reissue
Introduction
Terms and Symbols
This section contains procedures required for parts replacement and adjustment.
Terms and symbols used throughout this section are explained here.
WARNING
How to Use the Replacement and Adjustment Section

For installation procedures, only NOTEs are described here since installation procedures are
the reverse of removal ones.
A Warning statement indicates an operating or maintenance procedure, practice, or

condition that, if not strictly observed, could result in personal injury or loss of life.
1.
(Figure X) at the beginning of a procedure indicates that its detailed steps are shown in
the illustration. Numbers in the illustration indicate the sequence of the steps.
A Caution statement indicates an operating or maintenance procedure, practice, or condition

that, if not strictly observed, could result in damage to, or destruction of, equipment.
2.
(REP X.X.X) at the end of a procedure indicates the replacement procedure to be referred
to.
3.
Item numbers of replacement and adjustment procedures (i.e. REP/ADJ No.) correlate to
the PL No. in Section 5 Parts List. Therefore, an appropriate replacement or adjustment
procedure can easily be referred to a PL No. and vice versa. For example, the replacement or adjustment procedure of Component PL 1.1 is REP 1.1.X or ADJ 1.1.X.
CAUTION
4.
NOTE: A Note statement indicates an operating or maintenance procedure, practice, or condition that is necessary to accomplish a task efficiently.
Reference: Used when other explanations are given.
Purpose: Used to describe the purpose of the Adjustment.
Safety Critical Components (SCC):
When replacement/adjustment procedures or title items vary by modification or model,

the modification number or the model is indicated at the beginning or the end of the
respective titles or procedures.
Safety Critical Components are components, such as static-sensitive integrated circuit chips,
that require special precautions to prevent them from being damaged. Follow the regulations
regarding Safety Critical Components set by FUJI XEROX Co., Ltd.
Example 1: REP X.X.X Main PWB [Models with 1V] indicates that the entire procedure
under this title applies to machines with Tag 1V.
Important Information Stored Component (ISC):
Example 2: See Table 1.
This component stores all the important customer information that is input after the installation.
When replacing this component, follow the procedures in Section 4 Repairs and Adjustments.
Make absolutely sure that no customer information gets revealed.
Table 1
Symbol
Description
Illustration 1: Indicates that a specific part has been modified by the
tag number within the circle.
Figure 1 Illustration 1
Illustration 2: Indicates that the configuration of the part shown is the
configuration before the part was modified by the number within the
circle.
Figure 2 Illustration 2
5.
Positions or directions are defined as follows:

a.
Front: Front of the machine.
b.
Right: Right-hand side facing the machine.
c.
Left: Left-hand side facing the machine.
d.
Rear: Rear of the machine.
Reissue
June, 2008
4-29
June, 2008
4-30
Reissue
REP 1.1.1 IOT Motor (SCC)

Parts List on PL 1.1
Removal
WARNING
To avoid personal injury or electrical shock, ensure that the machine is completely off
before disassembling or adjusting. Turn OFF the power and unplug the machine.
1.
Remove the Drum Cartridge (REP 4.1.1).
2.
Remove the Rear Cover (REP 9.2.1).
3.
Disconnect the connector (Figure 1).

1 Remove the screw that secures the Ground Wires (2).
2 Disconnect P/J 504.
3 Release the wire harness of the IOT Motor from the hook.
4 Remove the wire harness of the IOT Motor from the slot in the frame.
Figure 1
Reissue
June, 2008
4-31
REP 1.1.1
4.
Remove the IOT Motor (Figure 2).

1 Remove the Tapping Screws (4).
2 Remove the IOT Motor.
Figure 2
Replacement
1.
To install, do the removal steps in reverse order.
REP 1.1.1
June, 2008
4-32
Reissue
REP 2.2.1 Tray 1 Feed Clutch (SCC)
3.
Remove the screws (3) that secure the Clutch Bracket (Figure 2).
1 Remove the screws (3).

Removal
WARNING
1.
2.

1 Disconnect the connector.
2 Release the wire harness from the clamp.
Figure 2
Figure 1
Reissue
June, 2008
4-33
REP 2.2.1
4.
Remove the Tray 1 Feed Clutch (Figure 3).
Replacement
1 Remove the Clutch Bracket.
1.
2 Remove the bearing.
2.
When installing the Tray 1 Feed Clutch, place the tab of Clutch Bracket in the notch of
Tray 1 Feed Clutch (Figure 4).
3 Remove the Tray 1 Feed Clutch.

4 Pull out the wire harness through the hole.
Figure 4
Figure 3
REP 2.2.1
June, 2008
4-34
Reissue
REP 2.3.1 Tray 1 Feed Roll (SCC)
4.
Remove the Tray 1 Feed Roll (Figure 2).

1 Gently lift up the tab to remove the Tray 1 Feed Roll.

Removal
WARNING
1.
Remove all paper from Tray 1.
2.
Remove Tray 1.
3.
Remove the Feed Shaft (Figure 1).

1 Lower the Bottom Plate.
2 Release the Feed Shaft from the bearing by pressing down on the white tab.
3 Remove the Feed Shaft by pulling it in the direction of the arrow.
Figure 2
Figure 1
Reissue
June, 2008
4-35
REP 2.3.1
Replacement
REP 2.5.1 Tray 1 Feed Sensor
1.
2.
When installing the Tray 1 Feed Roll, align the pin of the Feed Shaft with the slot in the
Tray 1 Feed Roll (Figure 3).

Removal
WARNING
1.
Remove Tray 1.
2.
Remove Tray 2 (REP 11.1.1).
3.
Remove the Sensor Housing of the Tray 1 No Paper Sensor (REP 2.7.1).
4.
Open the Tray 1 Access Cover on the left side of the machine.
Figure 3
REP 2.3.1, REP 2.5.1
June, 2008
4-36
Reissue
5.
Remove the Tray 1 Feed Sensor (Figure 1).
Replacement
1 Remove the Tapping Screw.
1.
2 Remove the cable bands (2).
2.
3 Release the wire harness from the clamps (2).
Insert the Connector Housing of the Tray 1 Interlock Switch into the square hole of the
frame (Figure 2).
4 Move the wire harness toward you and disconnect the connector.
A Square hole
5 Remove the Tray 1 Feed Sensor.
Figure 2
Figure 1
Reissue
June, 2008
4-37
REP 2.5.1
REP 2.7.1 Tray 1 No Paper Sensor
4.
Remove the Tray 1 No Paper Sensor (Figure 2).

1 Remove the Actuator.

Removal
2 Release the tabs to remove the Tray 1 No Paper Sensor.
WARNING
1.
Remove Tray 1.
2.
3.
Remove the Sensor Housing (Figure 1).

2 Release the tabs (2) to remove the Sensor Housing.
Figure 2
Replacement
1.
Figure 1
REP 2.7.1
June, 2008
4-38
Reissue
REP 2.8.1 Registration (SCC)

Removal
WARNING
1.
2.
3.
Remove the Transfer Corotron Housing (REP 4.3.1).
4.

1 Remove the screw to remove the Ground Wire.
2 Remove the screw to remove the Ground Wires (2).
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
Reissue
June, 2008
4-39
REP 2.8.1
5.
Remove the Connector Housing (Figure 2).
6.
1 Remove the wire harness from the guide.
Remove the Front Stopper (Figure 3).

1 Remove the Front Stopper.
2 Slide the Connector Housing through the hole.
Figure 3
Figure 2
REP 2.8.1
June, 2008
4-40
Reissue
7.
Remove the Registration (Figure 4).

1 Press the tab in the direction of the arrow to remove the boss of the Registration from
the frame.
Figure 4
Replacement
1.
Reissue
June, 2008
4-41
REP 2.8.1
REP 2.8.1
June, 2008
4-42
Reissue
REP 3.1.1 ROS (SCC)
1.
Open the Front Cover.

Removal
2.
Remove the Output Tray (REP 9.1.1).
3.
4.
Remove the HVPS and Contact Block (REP 8.2.1).
5.
Remove the Laser Housing (Figure 2).
WARNING

2 Remove the Laser Housing.
NOTE: Attach the attachment in the ROS Replacement Kit to a Stubby Driver to remove the
screws (Figure 1).
Figure 2
Figure 1
Reissue
June, 2008
4-43
REP 3.1.1
6.
Disconnect the ROS connectors (Figure 3).
7.
Remove the ROS (Figure 4).
1 Disconnect the Ground connectors (2).
2 Disconnect the connectors (2).
2 Remove the ROS.

4 Remove the wire harness from the hook.
Figure 4
Figure 3
Replacement
1.

NOTE: When powering up to perform operations with the ROS installed, read the warning
label pasted on the ROS before proceeding with the operation.
REP 3.1.1
June, 2008
4-44
Reissue
REP 4.1.1 Drum Cartridge
2.

Removal
When installing the Drum Cartridge, align the protruding end of the Drum Cartridge with
the cavity in the frame (Figure 2).
WARNING
1.
Open the Simplex/Duplex Module.
2.
3.
Remove the Drum Cartridge (Figure 1).

1 Release the tab.
2 Remove the Drum Cartridge.
Figure 2
Figure 1
Replacement
1.
Reissue
June, 2008
4-45
REP 4.1.1
REP 4.2.1 Toner Empty Sensor
5.
Remove the Toner Empty Sensor (Figure 2).

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

Removal
WARNING
1.
2.
Remove Tray 1.
3.
4.

Figure 2
Figure 1
REP 4.2.1
June, 2008
4-46
Reissue
Replacement
REP 4.2.2 Erase Lamp
1.
2.
Insert the Connector Housing of the Toner Empty Sensor into the square hole of the frame
(Figure 3).

Removal
WARNING
A Square hole
1.
2.
3.
4.
5.
Remove the HVPS and Contact Block (REP 8.2.1).
Figure 3
Reissue
June, 2008
4-47
REP 4.2.1, REP 4.2.2
6.
Release the Erase Lamp tabs (7) (Figure 1).
7.
1 Release the tabs (upper: 3).
Remove the Erase Lamp (Figure 2).

1 Remove the Erase Lamp.
2 Release the tabs (lower: 4).
Figure 2
Figure 1
REP 4.2.2
June, 2008
4-48
Reissue
Replacement
REP 4.3.1 Transfer Module
1.
2.
Insert the Connector Housing of the Erase Lamp into the square hole in the frame (Figure
3).

Removal
WARNING
A Square hole
1.
2.
3.
4.
Remove the Exit Transport (REP 6.1.1).
5.
Remove the Fuser (REP 5.1.1).
Figure 3
Reissue
June, 2008
4-49
REP 4.2.2, REP 4.3.1
6.
Remove the Transfer Corotron Housing (Figure 1).
7.
Remove the Tapping Screws that secure the Corotron Block (Figure 2).
1 Release the hooks (2).
2 Remove the Transfer Corotron Housing by pulling its front side in the direction of the
2 Move the Fuser Connector Bracket.
arrow.
Figure 1
REP 4.3.1
Figure 2
June, 2008
4-50
Reissue
8.
Remove the Corotron Block (Figure 3).
9.
Disconnect the Corotron Block cables (Ground/Detack/Transfer) (Figure 4).
1 Press the Spring Plate.
1 Disconnect the Ground Cable (white).
2 Remove the Corotron Block by pulling it in the direction of arrow.
2 Remove the Ground Cable (white) from the guides (2).

3 Remove the Detack Cable (black).
4 Remove the Detack Cable (black) from the guides (2).
5 Disconnect the Transfer Cable (white).
6 Remove the Transfer Cable (white) from the guides (3).
Figure 3
Figure 4
Reissue
June, 2008
4-51
REP 4.3.1
Replacement
3.
1.
2.
Perform the following steps to install the Corotron Block (Figure 5).
Attach the cables (Ground/Detack/Transfer) to the Corotron Block hooks as shown in Figure 6.
1 Press the Spring Plate.

2 Install the Corotron Block.
Figure 6
Figure 5
REP 4.3.1
June, 2008
4-52
Reissue
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

Removal
WARNING
1.
2.
3.
Remove the Inboard/Outboard Cover (Figure 1).

1 Remove the Inboard Cover in the direction of the arrow.
2 Release the tabs (2) to remove the Outboard Cover.
Figure 7
Figure 1
Reissue
June, 2008
4-53
REP 4.3.1, REP 4.4.1
4.
Attach the Corotron Wire (Figure 2).
5.
1 Attach the Corotron Wire.
Attach the spring (Figure 3).

1 Attach the spring to the Corotron Wire.
2 Attach the spring.
Figure 2
Figure 3
Replacement
1.
REP 4.4.1
June, 2008
4-54
Reissue
REP 5.1.1 Fuser (SCC)
3.
Disconnect the connectors (Figure 2).


Removal
WARNING
WARNING
The Fuser and Exit Transport are hot. Do not work on them until they are cool enough.
1.
Open the Left Side Cover.
2.
Remove the Connector Cover (Figure 1).

2 Remove the Connector Cover.
Figure 2
Figure 1
Reissue
June, 2008
4-55
REP 5.1.1
4.
Remove the Fuser (Figure 3).
Replacement
1.
2 Remove the Fuser by shifting it in the direction of the arrow.
2.

When installing the Connector Cover, do the following (Figure 4):
1 Insert the wire harness into the U-groove of the Fuser Frame.
2 Insert the stud of the Connector Cover into the hole in the frame.
Figure 3
Figure 4
REP 5.1.1
June, 2008
4-56
Reissue
REP 5.1.2 Temperature Control Sensor Assembly
3.
Remove the Temperature Control Sensor Assembly (Figure 2).

1 Remove the Screw.

Removal
2 Remove the Harness.
WARNING
WARNING
1.
2.
Slide the Cover to the left and remove (Figure 1).
Harness
Screw
Cover
Figure 2 Removing the Temperature Control Sensor Assembly
Figure 1 Removing the Cover
Reissue
June, 2008
4-57
REP 5.1.2
Replacement
REP 5.1.3 Fuser Lamp
1.

Removal

NOTE: Before tightening the Screw, make sure that the Tab on the Sensor Block is
inserted in the notch of the Frame (Figure 3).
WARNING
WARNING
1.
2.
Slide the Cover to the left and remove (Figure 1).
Screw
Sensor Block
Tab
Notch
Figure 3 Installing the Temperature Control Sensor Assembly
Cover
Figure 1 Removing the Cover
REP 5.1.2, REP 5.1.3
June, 2008
4-58
Reissue
3.
Disconnect the hot side of the Fuser Lamp (Figure 2).
4.
Disconnect the neutral side of the Fuser Lamp (Figure 3).
1 Disconnect the Terminal.
1 Disconnect the white wire from theTerminal.
2 Remove the Screw.
2 Remove the Screw.
White Wire
Screw
Terminal
Screw
Terminal
Figure 2 Disconnecting the hot side of the Fuser Lamp

Figure 3 Disconnecting the neutral side of the Fuser Lamp
Reissue
June, 2008
4-59
REP 5.1.3
5.
Remove the Fuser Lamp Housing (Figure 4).
6.
1 Remove 2 Screws.
Remove the Fuser Lamp by pulling it through the Fuser Roll (Figure 5).
NOTE: Do not lose the Fuser Lamp Mount.
2 Carefully remove the Fuser Lamp Housing.

Fuser Roll
Screws
Fuser Lamp Mount
Fuser Lamp
Fuser Lamp Housing
Figure 5 Removing the Fuser Lamp
Replacement
Figure 4 Removing the Fuser Lamp Housing
CAUTION
Do not touch the glass part of the Fuser Lamp unless you are are wearing gloves.
1.
REP 5.1.3
June, 2008
4-60
Reissue
REP 5.1.4 Fuser Roll
3.
Remove the Stripper Finger Assembly (Figure 2 and Figure 3).

1 Remove the Screw.

Removal
2 Remove the Stripper Finger Assembly.
WARNING
Cover Mount
Stripper Finger Assembly
WARNING
CAUTION
1.
Remove the Fuser Lamp (REP 5.1.3).
2.
Remove the Fuser Cover (Figure 1).

1 Remove the 2 Screws.
2 Remove the Fuser Cover.
NOTE: Do not lose the Cover Mount (Figure 2).
Fuser Cover
Figure 2 Fuser Cover Removed
Fuser Cover
Stripper Finger Assembly
Screw
Screws
Figure 1 Removing the Fuser Cover
Figure 3 Removing the Stripper Finger Assembly
Reissue
June, 2008
4-61
REP 5.1.4
4.
Remove the Fuser Roll Retaining Rings and Drive Gear (Figure 4).
5.
Remove the Fuser Roll by pulling it through the Bushings in the Frame (Figure 5).
1 Remove the Retaining Ring.

2 Remove the Drive Gear.
3 Remove the Retaining Ring from the other end of the Fuser Roll.
Bushing
Fuser Roll
Frame
Fuser Roll
Drive Gear
Figure 5 Removing the Fuser Roll
Retaining Ring
Figure 4 Removing the Retaining Rings and Drive Gear
REP 5.1.4
June, 2008
4-62
Reissue
Replacement
CAUTION
Make sure the stripper fingers are oriented correctly when reinstalling the Stripper Finger
Assembly, as shown in Figure 7.
CAUTION
Do not touch the glass part of the Fuser Lamp unless you are wearing gloves.
1.

NOTE: When installing the Drive Gear, make sure that the Locating Key is oriented as
shown in Figure 6.
Figure 7 Setting the Stripper Fingers

Locating Key
Figure 6 Installing the Drive Gear
Reissue
June, 2008
4-63
REP 5.1.4
REP 5.1.5 Fuser Pressure Roll
3.
Remove the Fuser Pressure Roll (Figure 2).

1 Remove the Levers.

Removal
2 Remove the Spring Mount Assemblies.

3 Remove the Fuser Pressure Roll.
WARNING
WARNING
CAUTION
Levers
1.
Remove the Fuser Roll (REP 5.1.4).
2.
Remove the Bushings (Figure 1).
Fuser Pressure Roll
Spring Mount Assemblies

Bushings
Figure 2 Removing the Fuser Pressure Roll
Replacement
CAUTION
Do not touch the glass part of the Fuser Lamp unless you are wearing gloves.
NOTE: When installing the Fuser Roll, see REP 5.1.4.
1.
Figure 1 Removing the Bushings
REP 5.1.5
June, 2008
4-64
Reissue
REP 6.1.1 Exit Transport (Simplex)
3.


Removal

WARNING
4 Release the wire harness from the clamps (2).
WARNING
1.
2.
Figure 1
Reissue
June, 2008
4-65
REP 6.1.1
4.
5.
Lower the Fuser levers (2) (Figure 3).

1 Lower the levers (2).
Figure 3
Figure 2
REP 6.1.1
June, 2008
4-66
Reissue
6.
Remove the Exit Transport (Figure 4).
Replacement
1.
2 Remove the Exit Transport.
2.
When installing the Connector Cover, insert the stud of the Connector Cover into the hole
in the frame (Figure 5).
3 Remove the Belt from the Exit Transport Drive Gear, and disconnect J153 from the
Fuser Exit Sensor.
4 Remove the J153 wire harness from the Exit Transport.
J153
Figure 5
Figure 4
Reissue
June, 2008
4-67
REP 6.1.1
REP 6.1.2 Exit Transport (Duplex)
3.


Removal
2. Disconnect P/J 551.

WARNING
WARNING
1.
Open the Duplex Module.
2.
Figure 1
REP 6.1.2
June, 2008
4-68
Reissue
4.
5.
Lower the Fuser levers (2) (Figure 3).

1 Lower the levers (2).
Figure 3
Figure 2
Reissue
June, 2008
4-69
REP 6.1.2
6.
Remove the Exit Transport (Figure 4).
Replacement
1.
2 Remove the Exit Transport.
2.
When installing the Connector Cover, insert the stud of the Connector Cover into the hole
in the frame (Figure 5).
3 Remove the Wire Harness through the hole.
Figure 4
REP 6.1.2
June, 2008
4-70
Reissue
REP 7.1.1 Simplex, Duplex Module
3.
Parts List on PL 7.1, PL 7.3

Removal
4.

WARNING
3 Remove the wire harness from the groove in the frame.
1.
2.
Tape the Bypass Tray so that it cannot open by itself (Figure 1).

5 Remove the wire harness from the groove in the frame.
6 Remove the wire harness from the hooks (3).
1 Apply 2 pieces of tape as shown.
Figure 2
Figure 1
Reissue
June, 2008
4-71
REP 7.1.1
5.
Remove the Front Stopper (Figure 3).
6.
1 Remove the Front Stopper from the Registration.
Remove the Rear Stopper (Figure 4).

1 Release the tab to remove the Rear Stopper.
2 Release the tab to remove the Front Stopper.
Figure 4
Figure 3
REP 7.1.1
June, 2008
4-72
Reissue
7.
Remove the Simplex Module (Figure 5).
REP 7.5.1 Bypass Feed Roll
1 Loosen the Tapping Screws (2).

Removal
2 Move the Pivot Retainers (2) in the direction of the arrow.

3 Remove the Simplex Module.
WARNING
1.
Open the Bypass Tray.
2.
Remove the Feed Roll Cap (Figure 1).

1 Release the tab to remove the Feed Roll Cap.
Figure 5 Removing the Left Hand Cover Assembly
Replacement
1.
Figure 1
Reissue
June, 2008
4-73
REP 7.1.1, REP 7.5.1
3.
Remove the Bypass Feed Roll (Figure 2).

1 Release the hook to remove the Bypass Feed Roll.
Figure 2
Replacement
1.
REP 7.5.1
June, 2008
4-74
Reissue
REP 8.1.1 AIOC PWB (SCC)
3.
Remove the Core Clip (Figure 2).

1 Remove the Core Clip.

Removal
WARNING
CAUTION
Static electricity may damage electrical parts. Always wear an anti-static wrist band during service. If a wrist band is not available, touch a metallic section to discharge the static electricity.
1.
2.
Disconnect the AIOC PWB connectors (9) (Figure 1).
Figure 2 Removing the Core Clip
Figure 1
Reissue
June, 2008
4-75
REP 8.1.1
4.
Disconnect the Flexible Print Cables (2) from the AIOC PWB (Figure 3).
5.
1 Disconnect the Flexible Print Cables (2).
Remove the screw of the USB connector (Figure 4).

1 Remove the screw.
2 Remove the Cores (2).
Figure 4
Figure 3
REP 8.1.1
June, 2008
4-76
Reissue
6.
Remove the AIOC PWB (Figure 5)
Replacement
1.
2.
When replacing the AIOC PWB, transfer the EP ROM (U2) from the old board to the new
one (Figure 6).
3 Slide the the AIOC PWB up and out of P/J 407.
A EP ROM (U2)
Figure 5
Figure 6
Reissue
June, 2008
4-77
REP 8.1.1
REP 8.1.2 LVPS (SCC)
5.
Remove the IIT Ground Plate (Figure 2).

1 Remove the Screws (4).

Removal
2 Remove the IIT Ground Plate.
WARNING
1.
2.
Remove the Right Cover (REP 9.2.2).
3.
Remove the AIOC PWB (REP 8.1.1).
4.
Remove the PWB Bracket (Figure 1).

2 Remove the PWB Bracket.
Figure 2 Removing the IIT Ground Plate
Figure 1
REP 8.1.2
June, 2008
4-78
Reissue
6.
Move the Inlet Bracket (Figure 3).
7.
1 Disconnect the connector (wire: blue).

2 Disconnect the connector (wire: brown).

5 Move the Power Inlet Bracket.
Figure 4
Figure 3
Reissue
June, 2008
4-79
REP 8.1.2
8.
Disconnect the connectors (7) (Figure 5).
9.
Remove the LVPS (Figure 6).

1 Remove the screw to remove the Ground Wire.
3 Remove the LVPS.
Figure 5
Figure 6
Replacement
1.
REP 8.1.2
June, 2008
4-80
Reissue
REP 8.1.3 AIOC/Network PWB (DADF/Network Only)
3.
Remove the EMI Cover (Figure 2).


Removal
2 Remove the EMI Cover.

3 Remove the Cable Clip from the EMI Cover.
NOTE: The following procedure is for the WorkCentre 5020 (DADF/Network) only. If you have
a WorkCentre 5016, or 5020 with Platen only, see REP 8.1.1.
Screw (10)
WARNING
EMI Cover
Cable Clip
CAUTION
Static electricity may damage electrical parts. Always wear an anti-static wrist band during service. If a wrist band is not available, touch a metallic section to discharge the static electricity.
1.
2.
On the right of the machine, remove the Screws holding the USB Connectors (Figure 1).
Figure 1 Removing the Screws Holding the USB Connectors

Figure 2 Removing the EMI Cover
Reissue
June, 2008
4-81
REP 8.1.3
4.
Remove the SLCC PWB (Figure 3).

a.
b.
Disconnect all the Connectors from the right side of the SLCC PWB.
c.
Remove 6 Screws and disconnect the SLCC PWB from the LVPS.
AIOC PWB
Flexible Print Cables
Connectors
Figure 4 Disconnecting the Flexible Print Cables
Screw (6)
Connectors
LVPS
Figure 3 SLCC PWB for DADF/Network
REP 8.1.3
June, 2008
4-82
Reissue
Replacement
NOTE: If you do not transfer the EPROMs, the existing NVM values for skew, copy quality, etc. will be lost.
1.
2.
When replacing the SLCC PWB, transfer the EPROMs (3) from the old PWB to the new
one (Figure 5).
NOTE: If one or more of the EPROMs are damaged during replacement or the information is courpt after replacement, refer to the Reprogaming the EPROMS on the SLCC
PWB Table 1 in Section 6, to reprogram the EPROMs. Customer settings must be reprogramed manually.
EPROM
EPROM
EPROM
Figure 5 Transferring the EPROMs
Reissue
June, 2008
4-83
REP 8.1.3
REP 8.2.1 HVPS (SCC)
NOTE: When removing the HVPS, use a Stubby Driver (499T00353).

Removal
5.
Remove the Tapping Screws that secure the Contact Block (Figure 2).
1 Release the hook to remove the Harness Block.
WARNING
1.
2.
Disconnect the AIOC PWB connector (Figure 1).

2 Remove the wire harness from the clamp.
3 Slide the Connector Housing that was removed in step 1 through the square hole.
Figure 2
Figure 1
3.
4.
REP 8.2.1
June, 2008
4-84
Reissue
6.
Remove the HVPS and Contact Block (Figure 3).
7.
Separate the HVPS from the Contact Block (Figure 4).

1 Remove the Contact Block in the direction of the arrow.
2 Disconnect the connector at the inner side of the HVPS.

3 Remove the HVPS and Contact Block.
Figure 4
Figure 3
Reissue
June, 2008
4-85
REP 8.2.1
Replacement
3.
1.
2.
Insert the wire harness of the HVPS into the slot of the Laser Housing (Figure 5).
When installing the HVPS and Contact Block, insert the slot of the Contact Block into the
guide of the frame (Figure 6).
A Slot
Figure 6
Figure 5
REP 8.2.1
June, 2008
4-86
Reissue
REP 8.2.2 Duplex PWB (SCC)
3.
Remove the Duplex PWB (Figure 2).


Removal
2 Remove the Guide.

3 Disconnect the Connector.
WARNING
1.
2.
Disconnect the Connector (Figure 1).
5 Remove the Duplex PWB.

2 Remove the Wire Harness from the Hook.
3 Remove the Wire Harness from the Guides (3).
Replacement
1.
Reissue
June, 2008
4-87
REP 8.2.2
REP 8.3.1 Control Panel (SCC)
3.
Remove the screws that secure the Control Panel (Figure 2).

Removal
WARNING
1.
Remove the Front Left Cover (REP 9.1.2).
2.
Remove the Control Panel Cover (Figure 1).

2 Press the tabs (2) to release them.
3 Remove the Control Panel Cover towards the front.
Figure 2
Figure 1
REP 8.3.1
June, 2008
4-88
Reissue
4.
Remove the Control Panel (Figure 3).
Replacement
1 Slide the rear of the Control Panel in the direction of the arrow.
1.
2.
When installing the Control Panel, attach the Control Panel hooks (3) to the IIT Frame
(Figure 4).
3 Remove the Cable Band from the Control Panel Hook (Figure 4, B).
A Spring - On top
B Hook - Below
Figure 3
Figure 4
Reissue
June, 2008
4-89
REP 8.3.1
3.
Thread the wire harness of the Control Panel as shown (Figure 5).
REP 8.4.1 User Interface PWB (SCC)

Removal
WARNING
1.
Remove the Control Panel (REP 8.3.1).
2.
Turn the Control Panel upside down.
3.
Remove the Support Brackets (Figure 1).

2 Remove the Support Brackets (3).
Figure 5
Figure 1
REP 8.3.1, REP 8.4.1
June, 2008
4-90
Reissue
4.
Remove the User Interface PWB (Figure 2).

2 Remove the User Interface PWB.
Figure 2
Replacement
1.
Reissue
June, 2008
4-91
REP 8.4.1
REP 8.4.1
June, 2008
4-92
Reissue
REP 9.1.1 Output Tray
Replacement

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

2 Remove the Output Tray by pulling it in the direction of the arrow.
Figure 2
Figure 1
Reissue
June, 2008
4-93
REP 9.1.1
REP 9.1.2 Front Left Cover
Replacement

Removal
1.
2.

When installing the Front Left Cover, attach the hooks (Figure 2).
A Hooks (3)
WARNING
1.
2.
Remove the Front Left Cover (Figure 1).

2 Remove the Front Left Cover by pulling in the direction of the arrow.
Figure 2
Figure 1
REP 9.1.2
June, 2008
4-94
Reissue
REP 9.2.1 Rear Cover
2.
Remove the Rear Cover (Figure 2).


Removal
2 Remove the Rear Cover.
WARNING
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.

2 Remove the cable band.
Figure 2
Replacement
1.
Figure 1
Reissue
June, 2008
4-95
REP 9.2.1
REP 9.2.2 Right Cover
Replacement

Removal
1.
2.

When installing the Right Cover, insert the tabs (Figure 2).
A Tabs (5)
WARNING
1.
2.
3.
Remove the Right Cover (Figure 1).

1 Unplug the Power Cord.
2 Unplug the USB connector.
4 Remove the Right Cover by pulling it in the direction of the arrow.
Figure 2
Figure 1
REP 9.2.2
June, 2008
4-96
Reissue
REP 10.1.1 IIT Platen Cover
Replacement

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

Cushion, place it against this
corner
Figure 1
Reissue
June, 2008
4-97
REP 10.1.1
REP 10.2.1 IIT Upper Cover (SCC)
3.
1 Press the tabs (2) to release them.

Removal
NOTE: The tabs are visible through the Platen Glass.
WARNING
2 Open the right side of the IIT Upper Cover.

3 Press the tabs (2) to release them, and remove the IIT Upper Cover.
1.
2.
Remove the IIT Upper Cover (Figure 2).
Remove the following parts:
Platen Cover (PL 10.1)
Control Panel (REP 8.3.1)
Remove the screws that secure the IIT Upper Cover (Figure 1).
3 Remove the cap.
Figure 2
Replacement
1.
Figure 1
REP 10.2.1
June, 2008
4-98
Reissue
REP 10.3.1 IIT Carriage (SCC)
4.

Removal
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.
WARNING
1.
2.
Remove the IIT Upper Cover (REP 10.2.1).
3.
At the left side of the IIT Carriage, secure the Carriage Cable with tape so that it does not
come loose (Figure 1).
1 Move the IIT Carriage to the rear notch of the IIT Frame.
2 Secure the Carriage Cable with 2 pieces of tape.
Figure 2
Figure 1
Reissue
June, 2008
4-99
REP 10.3.1
5.
While maintaining tension on the Carriage Cable (silver) at the front left side, disconnect it
(Figure 3).
6.
Use pieces of tape to secure the Carriage Cable (silver) that was disconnected in step 5
so that it does not get separated from the pulley of the IIT Carriage (Figure 4).
1 Disconnect the Carriage Cable.
A Secure the Carriage Cable with tape
2 Remove the Cable Spring.
1 Pulley
3 Remove the Carriage Cable from the pulley.

4 Remove the Carriage Cable from the guide.
Figure 4
Figure 3
REP 10.3.1
June, 2008
4-100
Reissue
7.
While maintaining tension on the Carriage Cable (black) at the front right side, disconnect
it (Figure 5).
8.
Use pieces of tape to secure the Carriage Cable (black) that was disconnected in step 7
so that it does not get separated from the pulley of the IIT Carriage (Figure 6).
1 Disconnect the Carriage Cable (black).
A Pulley
2 Remove the Carriage Cable (black) from the guide.
1 Secure the Carriage Cable with tape
3 Remove the Carriage Cable (black) from the guide.
Figure 6
Figure 5
Reissue
June, 2008
4-101
REP 10.3.1
9.
While maintaining tension on the Carriage Cable (black) at the rear left side, disconnect it
(Figure 7).
10. Use tape to secure the Carriage Cable (black) that was disconnected in step 9 so that it
does not get separated from the Cable Supply Drum (Figure 8).
1 Remove the Cable Spring.
1 Secure the Carriage Cable with tape.

3 Remove the Carriage Cable from the pulley.
Figure 8
Figure 7
REP 10.3.1
June, 2008
4-102
Reissue
11. While maintaining tension on the Carriage Cable (silver) at the rear right side, disconnect
it (Figure 9).
12. Use tape to secure the Carriage Cable (silver) that was disconnected in step 11 so that it
does not get separated from the Cable Supply Drum (Figure 10).
1 Secure the Carriage Cable with tape.
Figure 9
Reissue
Figure 10
June, 2008
4-103
REP 10.3.1
13. Turn the left side of the IIT Carriage face up.
Replacement
14. Disconnect the Flexible Print Cable connectors (2) (Figure 11).
1.
2.
Do not allow the Rail Contact of the IIT Carriage to bend in the direction of the arrow
(Figure 12).
A Rail Contact
Figure 11
Figure 12
REP 10.3.1
June, 2008
4-104
Reissue
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)

Removal
WARNING
1.
2.
3.
Remove the IIT Carriage (REP 10.3.1).
4.
Remove the Core Clip (Figure 1).

1 Remove the Core Clip.
Figure 13
Figure 1 Removing the Core Clip
Reissue
June, 2008
4-105
REP 10.3.1, REP 10.3.2
5.
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
1.
REP 10.3.2
June, 2008
4-106
Reissue
REP 10.6.1 Exposure Lamp
4.


Removal
WARNING
1.
2.
3.
Remove the Inverter PWB Bracket 2 (Figure 1).

1 Remove the screw.
2 Remove the Inverter PWB Bracket 2.
Figure 2
Figure 1
Reissue
June, 2008
4-107
REP 10.6.1
5.
Remove the Exposure Lamp (Figure 3).
REP 10.7.1 Carriage Cable and Drum
1 Remove the screw.

Removal
2 Remove the Exposure Lamp from the Lamp Holder.
WARNING
1.
2.
3.
Remove the IIT Carriage (REP 10.3.1).
4.
Turn the IIT Carriage upside down.
Figure 3
Replacement
1.
REP 10.6.1, REP 10.7.1
June, 2008
4-108
Reissue
5.
Remove the Carriage Cables (black and silver) (Figure 1).
Replacement
1 Peel off the pieces of tape to remove the Carriage Cables.
1.
2.
Attach the Carriage Cables (black/silver) to the holes in the Drum (Figure 2).
Figure 1
Figure 2
Reissue
June, 2008
4-109
REP 10.7.1
3.
Wind the Carriage Cables around the Drum and secure them with tape (Figure 3).
4.
Wind the Carriage Cables around the pulleys (Figure 4). See also the Cable Winding
Schematic (Figure 5).
5.
Secure the Cables with pieces of tape so that they do not become loose (see Figure 1).
Figure 3
Figure 4
REP 10.7.1
June, 2008
4-110
Reissue
REP 10.7.2 Inverter PWB

Removal
WARNING
1.
2.
3.

1 Remove the screw.
Figure 5 Cable Winding Schematic
Figure 1
Reissue
June, 2008
4-111
REP 10.7.1, REP 10.7.2
4.
5.
1 Remove the screw.
Figure 2
REP 10.7.2
Figure 3
June, 2008
4-112
Reissue
6.
Remove the Inverter PWB (Figure 4).

2 Remove the Inverter PWB.
Figure 4
Replacement
1.
Reissue
June, 2008
4-113
REP 10.7.2
REP 10.7.2
June, 2008
4-114
Reissue
REP 11.1.1 Tray 2
REP 11.1.2 Single Tray Module (Separation from IOT)

Removal

Removal
WARNING
WARNING
WARNING
1.
Remove all paper from Tray 2.
2.
Pull out Tray 2.
The IOT is heavy. Do this procedure with 2 persons.
3.
Lift the front side of Tray 2 and remove the tray (Figure 1).
1.
Disconnect the connector. (Figure 1).

2 Pull out the cable clamp.
Figure 1
Replacement
Figure 1
Reissue
June, 2008
4-115
REP 11.1.1, REP 11.1.2
2.
Remove the Countersunk Head Screws at the rear (Figure 2).
3.
1 Remove the Countersunk Head Screws (2).
Remove the Countersunk Head Screws at the front (Figure 3).

1 Pull out Tray 1.
2 Remove the Countersunk Head Screws (2).
Figure 2
Figure 3
REP 11.1.2
June, 2008
4-116
Reissue
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

Removal
WARNING
1.
2.
Remove the Feed Shaft (Figure 1).

1 Remove the KL-Clip.
2 Remove the bearing.
3 Slide the Feed Shaft towards the rear to remove it.
Figure 4
Replacement
1.
Figure 1
Reissue
June, 2008
4-117
REP 11.1.2, REP 11.4.1
3.
Remove the Tray 2 Feed Roll (Figure 2).
Replacement
1 Remove the KL-Clip.
1.
2 Remove the Tray 2 Feed Roll.
2.
When installing the Tray 2 Feed Roll, align the pin on the Feed Shaft with the groove in
the Tray 2 Feed Roll (Figure 3).
Figure 2
Figure 3
REP 11.4.1
June, 2008
4-118
Reissue
REP 11.4.2 Tray 2 Retard Roll
3.
Remove the Tray 2 Retard Roll Housing (Figure 2).

1 Release the hooks (2).

Removal
2 Remove the Tray 2 Retard Roll Housing from the tabs (2).
WARNING
1.
2.
Remove the Tray 2 Feeder (Figure 1).

2 Remove the Tray 2 Feeder.
Figure 2
Figure 1
Reissue
June, 2008
4-119
REP 11.4.2
4.
Remove the Retard Shaft (Figure 3).
5.
1 Remove the Retard Shaft.
1 Release the tab to remove the Tray 2 Retard Roll.
Figure 3
REP 11.4.2
Remove the Tray 2 Retard Roll (Figure 4).
Figure 4
June, 2008
4-120
Reissue
Replacement
3.
1.
2.
When installing the Tray 2 Retard Roll, align the coupling of the Friction Clutch with the
Tray 2 Retard Roll (Figure 5).
A Holder Arm
B Tray 2 Retard Roll
Figure 6
Figure 5
Reissue
When installing the Tray 2 Retard Roll Housing, check that the Tray 2 Retard Roll rises
when the Holder Arm is pressed (Figure 6).
June, 2008
4-121
REP 11.4.2
REP 11.5.1 STM Feed Sensor
Replacement

Removal
1.
WARNING
1.
Remove the IOT from the Single Tray Module (REP 11.1.2).
2.
3.
Open Access Cover 2.
4.
Remove the STM Feed Sensor (Figure 1).

1 Pull out the cable clamp.
3 Release the tabs, and remove the STM Feed Sensor.
Figure 1
REP 11.5.1
June, 2008
4-122
Reissue
REP 11.5.2 STM PWB (SCC)
Replacement

Removal
1.
WARNING
1.
Remove the STM Rear Cover (PL 11.5).
2.
Remove the STM PWB (Figure 1).

3 Remove the STM PWB.
Figure 1
Reissue
June, 2008
4-123
REP 11.5.2
REP 11.6.1 STM Feed Clutch
3.
Remove the STM Feed Clutch (Figure 2).


Removal

WARNING
4 Release the tab on the gear, and remove the gear together with the STM Feed Clutch.
1.
2.
Remove the gears (Figure 1).
5 Slide the wire harness through the hole.
1 Remove the E-rings.

2 Release the tabs.
Figure 2
Replacement
1.
Figure 1
REP 11.6.1
June, 2008
4-124
Reissue
REP 11.6.2 STM Feed Motor
3.
Remove the STM Feed Motor (Figure 2).


Removal

WARNING
4 Remove the STM Feed Motor.
1.
2.
Remove the gears (Figure 1).

1 Release the tab, and remove the gear.
2 Release the tab, and remove the gear.
Figure 2
Replacement
1.
Figure 1
Reissue
June, 2008
4-125
REP 11.6.2
REP 11.7.1 STM No Paper Sensor

Removal
WARNING
1.
Remove Tray 1.
2.
3.
Remove the STM No Paper Sensor (Figure 1).

2 Release the tabs, and remove the STM No Paper Sensor.
Figure 1
Replacement
1.
REP 11.7.1
June, 2008
4-126
Reissue
REP 13.1.1 ADF Assembly
3.
Remove the Screws (Figure 2).

1.

Removal
Remove the Screws (2).
WARNING
1.
2.

1.
Disconnect the Connector.
2.
Remove the Cable Band.
Figure 2 (j0hu41302)
Figure 1 (johu41301)
Reissue
June, 2008
4-127
REP 13.1.1
2.
Remove the ADF (Figure 3).
REP 13.1.2 ADF/DADF Platen Cushion
1.

Removal
Remove the ADF.
WARNING
1.
Remove the Platen Cushion ([Figure 1]).

1.
Remove the Platen Cushion.
Replacement
1.
REP 13.1.1, REP 13.1.2
June, 2008
4-128
Reissue
Replacement
1.
Paste the Platen Cushion ([Figure 2]).

1.
Place the Platen Cushion on the Platen Glass.
2.
Adjust the Platen Glass for the correct gap between it and the Registration Guide.
3.
Slowly lower the ADF/DADF and press it onto the Platen Cushion.
Reissue
June, 2008
4-129
REP 13.1.2
REP 13.2.1 Document Tray Assembly (ADF)
4.

Removal
Remove the Support Bracket (Figure 2) .

i.
Release the Wire Harness from the Clamp.
ii.
Remove the Tapping Screw.
iii.
WARNING
iv.
Remove the Ground Wire.
v.
Remove the Support Bracket.
1.
Front Cover (REP 13.2.3)
Rear Cover (REP 13.2.4)
2.
Open the Top Cover.
3.
Remove the Tapping Screw (Figure 1) .

i.
Remove the Screw.
REP 13.2.1
June, 2008
4-130
Reissue
5.
Disconnect the Connector (Figure 3) .

i.
ii.
Remove the Cable Tie.
6.
Remove the Ground Wires (Figure 4) .

i.
Remove the Screw to remove the Ground Wires (2).
Reissue
June, 2008
4-131
REP 13.2.1
7.
Remove the Document Tray Assembly (Figure 5) .
REP 13.2.2 ADF Feeder Assembly
1.

Removal
Remove the Document Tray Assembly.
WARNING
1.
Remove the following covers.
2.
Open the Top Cover.
3.
Remove the Document Tray Assembly (REP 13.2.1).
Replacement
1.
REP 13.2.1, REP 13.2.2
June, 2008
4-132
Reissue
4.
Remove the Rear Blind Cover (Figure 1).
3.
Disconnect the ADF PWB Connectors ([Figure 2]):
1.
CN2
2.
Remove the Rear Blind Cover.
CN3
CN5
NOTE: The configuration of the ADF PWB on the WorkCentre 5020 (DADF/Network) is slightly different, but the Connector reference numbers are the same.
i.
Disconnect the Connectors (3).
Reissue
June, 2008
4-133
REP 13.2.2
4.
Remove the Screws at the front ([Figure 3]).
3.
1.
Remove the Screw (short).
1.
2.
Remove the Screw (long).
2.
Remove the Screws at the rear ([Figure 4]).

3.
Remove the Tapping Screw to remove the Ground Wire.

NOTE: There is no Ground Wire on the WorkCentre 5020 (DADF/Network).
REP 13.2.2
June, 2008
4-134
Reissue
4.
Remove the ADF Feeder Assembly ([Figure 5]).
REP 13.2.3 Front Cover
1.

Removal
Remove the ADF Feeder Assembly.
WARNING
1.
Remove the Front Cover while pressing the sections indicated by the arrows ([Figure 1]).
1.
Remove the Screw.
2.
Remove the Tapping Screws (3).
3.
Remove the Front Cover.
Replacement
1.
Reissue
June, 2008
4-135
REP 13.2.2, REP 13.2.3
Replacement
REP 13.2.4 Rear Cover
1.

Removal
WARNING
1.
Remove the Rear Cover while pressing the sections indicated by the arrow ([Figure 1]).
1.
Remove the Screw.
2.
3.
Remove the Rear Cover.
REP 13.2.3, REP 13.2.4
June, 2008
4-136
Reissue
Replacement
REP 13.2.5 DADF Eject Roller Solenoid
1.

Removal
WARNING
1.
Remove the Front Cover. (REP 13.2.3)
2.
Remove the Eject Roller Solenoid. (Figure 1)

a.
Disconnect the connector.
b.
Remove the screws (2).
c.
Remove the wire from the harness clamp.
d.
Remove the Solenoid.
Disconnect the connector
Remove wire clamp
Remove the screws

(2)
Remove the
Solenoid
Figure 1 Removing the Eject Roller Solenoid
Replacement
Reissue
1.
Install the DADF Eject Roller Solenoid and ensure that the Solenoid linkage is properly
install into the Eject Roller control arm.
2.
Perform the remainder of the replacement procedure in reverse order of the removal procedure.
June, 2008
4-137
REP 13.2.4, REP 13.2.5
REP 13.2.6 DADF Assembly
3.
Remove the Screws (Figure 2).

1.

Removal
WARNING
1.
2.
If you have a WorkCentre 5020 (DADF/Network), you must remove the EMI Cover (10
Screws) and then remove the Cable Band from the EMI Cover (REP 8.1.3)
3.

1.
2.
Remove the DADF Cable.

Disconnect the connectors (2)
Figure 1 Disconnecting the DADF Cable
REP 13.2.6
June, 2008
4-138
Reissue
2.
Remove the DADF (Figure 3).
REP 13.2.7 Document Tray Assembly (DADF)
1.

Removal
Remove the DADF.
WARNING
1.
2.
Open the Top Cover.
3.
Loosen the Tapping Screw (Figure 1).

a.
Loosen the Screw.
Loosen the screw
(1)
Replacement
1.
Figure 1 Loosening the screw

4.
Reissue
June, 2008
4-139
Remove the Support Bracket (Figure 2).

i.
Release the Wire Harness from the Clamp.
ii.
iii.
iv.
Remove the Ground Wire.
v.
Remove the Support Bracket.
REP 13.2.6, REP 13.2.7
5.

i.
ii.
Remove the Cable Tie.
Remove cable tie
Figure 3 Disconnecting the connecgor
REP 13.2.7
June, 2008
4-140
Reissue
6.
Remove the Ground Wires (Figure 4).

i.
7.
Remove the Screw to remove the Ground Wires (2).
Remove the Document Tray Assembly (Figure 5).

1.
Remove the Document Tray Assembly.
Replacement
1.
Reissue
June, 2008
4-141
REP 13.2.7
REP 13.2.8 DADF Feeder Assembly
4.

Removal
Remove the Rear Blind Cover (Figure 1).

i.
ii.
Remove the Rear Blind Cover.
WARNING
1.
Remove the following covers.
2.
Open the Top Cover.
3.
Remove the Document Tray Assembly (REP 13.2.7).
REP 13.2.8
June, 2008
4-142
Reissue
5.
Disconnect the ADF PWB Connectors (Figure 2):

CN2
CN3
Remove
the Solenoid
Bracket
CN5
CN7
i.
Remove the screws (3)
Figure 3 Removing the Eject Roller Solenoid Bracket

7.
Remove the Screws at the front ([Figure 3]).

i.
Remove the Screw (short).
ii.
Disconnect the connectors

Figure 2 Disconnect the connectors (4)
6.
Remove the DADF Eject Roller Solenoid.

a.
Disconnect the connector.
b.
c.
Remove the Eject Roller Solenoid.
Reissue
June, 2008
4-143
REP 13.2.8
8.

i.
Remove the Screws at the rear ([Figure 4]).
ii.
iii.
REP 13.2.8
June, 2008
4-144
Reissue
9.
Remove the ADF Feeder Assembly ([Figure 5]).
REP 13.3.1 ADF Control PWB
1.

Removal
Remove the ADF Feeder Assembly.
WARNING
1.
2.
Raise the Document Tray Assembly in the direction of the arrow ([Figure 1]).
1.
Raise the Document Tray Assembly in the direction of the arrow.
Replacement
1.
Reissue
June, 2008
4-145
REP 13.2.8, REP 13.3.1
2.
Disconnect the PWB Connectors ([Figure 2]).

1.
2.
Disconnect the PWB Connectors (5).
Remove the ADF Control PWB ([Figure 3]).

1.
2.
3.
4.
Remove the ADF Control PWB.
Replacement
1.
REP 13.3.1
June, 2008
4-146
Reissue
REP 13.3.2 Left Counter Balance (SCC)

Removal
WARNING
WARNING
The ADF must be removed. There is danger when removing a Counter Balance that is in
closed state because the compressed spring may get released suddenly.
1.
Remove the ADF (REP 13.1.1).
2.
3.
Open the Top Cover.
4.
Remove the Film Cover (Figure 1).

1.
Remove the Film Cover.
Reissue
June, 2008
4-147
REP 13.3.2
2.
Remove the Left Counter Balance (Figure 2).
REP 13.3.3 Right Counter Balance (SCC)
1.
2.
Remove the Left Counter Balance.

Removal
WARNING
WARNING
The ADF/DADF must be removed. There is danger when removing a Counter Balance
that is in closed state because the compressed spring may get released suddenly.
1.
Remove the ADF/DADF (REP 13.1.1).
2.
Remove the Rear Cover (PL 13.2).
Replacement
1.
REP 13.3.2, REP 13.3.3
June, 2008
4-148
Reissue
3.
Remove the Film Cover (Figure 1).

1.
2.
Remove the Film Cover.
Remove the screws that secure the Right Counter Balance (Figure 2).
1.
Use the marking tool and make a marking line.
2.
3.
Remove the Right Counter Balance.
Replacement
Reissue
1.
2.
Check the ADF/DADF Positional Adjustment (ADJ 13.1.1).
June, 2008
4-149
REP 13.3.3
REP 13.3.4 DADF PWB
3.
Disconnect the PWB Connectors (Figure 2).

1.

Removal
Disconnect the PWB Connectors (5).
Disconnect the
connectors
WARNING
1.
2.
Raise the Document Tray Assembly in the direction of the arrow (Figure 1).
i.
Raise the Document Tray Assembly in the direction of the arrow.
Disconnect the
connectors
REP 13.3.4
June, 2008
4-150
Reissue
2.
Remove the DADF Control PWB (Figure 3).
REP 13.4.1 Top Cover
1.
2.

Removal
3.
4.
Remove the DADF Control PWB.
WARNING
1
Remove screws
(2)
Remove the PWB
Remove the screw (1)
Remove the screw

(1)
1.
Open the Upper Feeder Assembly.
2.
Remove the Top Cover (Figure 1).

1.
2.
Release the Hooks (2).
3.
Push in the Hooks (3).
4.
Remove the Top Cover.
Figure 3 Removing the DADF Control PWB
Replacement
1.
Reissue
June, 2008
4-151
REP 13.3.4, REP 13.4.1
Replacement
REP 13.8.1 Retard Roll
1.

Removal
WARNING
1.
Open the Top Cover.
2.
Open the Retard Roll Assembly (Figure 1).

1.
Open the Retard Roll Assembly.
REP 13.4.1, REP 13.8.1
June, 2008
4-152
Reissue
2.
Remove the Plate (Figure 2).
3.
a.
b.
Remove the Plate.
Remove the Retard Roll together with the Bearings (Figure 3).
1.
Remove the Retard Roll.
Reissue
June, 2008
4-153
REP 13.8.1
2.
Remove the Retard Roll (Figure 4).
REP 13.9.1 Pickup Roll, Feed Roll
1.

Removal
Remove the Bearings (2).
WARNING
1.
Open the Upper Feeder Assembly.
2.
Remove the Top Cover (REP 13.4.1).
3.
Remove the Sensor Holder (Figure 1).

1.
2.
Remove the Sensor Holder.
Replacement
1.
2.
After a replacement, enter the Diagnostic Mode How to Enter the Diagnostic Mode and
clear the simplex and duplex feed counters.
REP 13.8.1, REP 13.9.1
June, 2008
4-154
Reissue
3.
Remove the E-Clip and the Bearing.
4.
Remove the Feed Roll Assembly (Figure 3).
a.
Remove the Spring (Figure 2).
1.
Move the Shaft.
b.
Remove the E-Clips (2).
2.
Remove the Feed Roll Assembly.
c.
Remove the Spring.
Reissue
June, 2008
4-155
REP 13.9.1
3.
Remove the Feed Roll (Figure 4).
4.
Remove the Pickup Roll (Figure 5).
1.
Remove the E-Clip.
a.
Remove the Bearing.
2.
Remove the Shaft.
b.
Remove the Pickup Roll.
3.
Remove the Feed Roll.
Replacement
1.
2.
After a replacement, enter the Diagnostic Mode and clear the simplex and duplex feed
counters.
REP 13.9.1
June, 2008
4-156
Reissue
ADJ 8.1.1 Edge Erase Adjustment
ADJ 8.1.2 Controller Firmware Version Upgrade
Purpose
Purpose
To set the right amount of edge erase at the lead edge and trail edge, as well as at both sides
(left/right) of the image.
To upgrade the version of the Controller.
Check
NOTE: Do the IOT Lead Edge/Side Edge Registration adjustment first.
Check the current version:
Check
1.
Specify a tray that contains paper, leave the platen cover open, and make a completely
black copy by not putting any document on the glass.
2.
Check that the white portion at the lead edge, trail edge, and both sides of the copy are all
2mm wide.
Adjustment
1.
Enter the Diagnostic Mode and adjust the following NVM. Increasing the value will
increase the amount of edge erase.
Table 1
Chain Func
Name
Min
Initial
Max
Step
Normal Side Edge Erase Adjustment
16
32
0.254mm
59
60
Normal Lead Edge Erase Adjustment
16
32
0.145mm
63
Normal Trail Edge Erase Adjustment
16
32
0.145mm
Reissue
Enter the Diagnostic Mode and check the Controller Firmware version xxx using Chain-Function [29-50].
Adjustment
[USB Connection]
1.
Download the Firmware from our home page.
2.
Decompress the Firmware.
3.
Connect the PC to the USB connector at the Right Cover.
4.
Turn the power ON, and the Add USB Device window will appear on the PC. Click the
[Cancel] button when the New Hardware Detected Wizard window is displayed.
5.
Double-click the executable file of the decompressed Firmware to run it.
6.
The [Firmware Update Tool (Printer Model And File Selection)] is displayed. Select the
machine model and the downloaded Firmware file, and then click [Next].
7.
The [Firmware Update Tool (Communication Interface Selection)] is displayed. Select

[USB Port] and click [Next].
8.
The [Firmware Update Tool (Updating...)] window is displayed indicating the data transfer
in progress. Once the upgrade is completed, the [Firmware Update Tool (Result)] window
is displayed. Click the [Finish] button.
June, 2008
4-157
ADJ 8.1.1, ADJ 8.1.2
ADJ 10.3.1 IIT Lead Edge/Side Edge Registration
3.
Purpose
Check that the measured values for lead edge (A) and side edge (B) meet the specifications of the corresponding mode.
To obtain the home position in the IIT lead edge (slow scan)/IIT side edge (fast scan) direction.
Check
1.
Set the Test Pattern 499T247 (A3) on the platen, so that there is no gap between it and
the Rear Registration Guide. Make 3 copies using 100% R/E and A3 SEF paper.
2.
Measure the lead edge and side edge of the 3rd copy (Figure 1).
Table 1 Specification
Item
Simplex
MSI
Lead edge (A)
10 1.6mm
10 2.2mm
Side edge (B)
5 2.1mm
5 3.0mm
Lead edge: part A in the figure
Adjustment
Side edge: part B in the figure
1.
Enter the Diagnostic Mode, and use the following Chain Functions to perform adjustments
until the measured values for lead edge (A) and side edge (B) registration are within the
specifications.
When the measured value is short, reduce the setting value.
When the measured value is long, increase the setting value.
Table 2
Chain Func
Sub
Name
System
Value
Initial
Max. Value
1 Count
Min.
20
PH
REGI ADJUSTMENT - ALL
60
30
0.146mm
20
41
PH
TRAY 1 for Normal LEAD REGI 0

ADJ
60
30
0.146mm
20
42
PH
TRAY 2 for Normal LEAD REGI 0

ADJ
60
30
0.146mm
20
43
PH
MSI for Normal LEAD REGI

ADJ
60
30
0.146mm
20
ROS
ALL TRAY - LASER SIDE REGI 1

ADJUSTMENT
99
50
0.254mm
21
ROS
TRAY 1 - LASER SIDE REGI

ADJUSTMENT
99
50
0.254mm
22
ROS
TRAY 2 - LASER SIDE REGI

ADJUSTMENT
99
50
0.254mm
26
ROS
MSI - LASER SIDE REGI

ADJUSTMENT
99
50
0.254mm
2.
After the adjustment, again set the Test Pattern 499T247 (A3) on the platen so that there
is no gap between it and the Rear Registration Guide. Make a copy using 100% R/E and
A3 SEF paper.
3.
Repeat the procedure until the measured values for lead edge (A) and side edge (B) are
within the specifications.
Figure 1 IIT Lead Edge/Side Edge Registration
ADJ 10.3.1
June, 2008
4-158
Reissue
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.
2.
IIT Upper Cover (REP 10.2.1)
Adjust until the Carriage Assembly and the IIT Under Cover are parallel (Figure 1).
1 Loosen the Stop Screw.
2 Move the Carriage Assembly all the way to the right.
3 Turn the Adjustment Screw to adjust.
4 Tighten the Stop Screw.
Reference: Turning the Adjustment Screw counterclockwise moves the front of the Carriage Assembly to the left.
Figure 1 Carriage Assembly Alignment (Parallelism)
Reissue
3.
Return the machine to its original state, and make a copy in Platen Mode.
4.
Check for optical skew, and repeat from step 1 as needed.
June, 2008
4-159
ADJ 11.1.1
ADJ 13.1.1 ADF/DADF Positional Adjustment
Result when the ADF/DADF is moved in direction A (Figure 2):
Purpose
To correct the alignment of the ADF/DADF and correct the movement of the document.
Adjustment
1.
Remove the ADF/DADF Rear Cover (PL 13.2).
2.
Change the position of the Right Counter Balance to adjust the skew amount (Figure 1).
1.
Loosen the Screws (4).
2.
Move the DADF/ADF in direction of A or B.
3.
Tighten the Screws (4).
Figure 2 ADF Adjustment - Direction A (j0hu41335)
Figure 1 ADF Adjustment - 1 (j0hu41334)
ADJ 13.1.1
June, 2008
4-160
Reissue
Result when the ADF/DADF is moved in direction B (Figure 3):
Figure 3 ADF Adjustment - Direction B (j0hu41336)
Reissue
June, 2008
4-161
ADJ 13.1.1
ADJ 13.1.1
June, 2008
4-162
Reissue
5 Parts List
Overview
Introduction .....................................................................................................................
Subsystem Information ...................................................................................................
Symbology ......................................................................................................................
PL 8.4 Control Panel Component....................................................................................

5-3
5-4
5-5
Parts Lists
5-7
Paper Transport
PL 2.1 Tray 1...................................................................................................................
PL 2.2 Tray 1 Frame Accessory......................................................................................
PL 2.3 Tray 1 Components (1 OF 2) ...............................................................................
PL 2.4 Tray 1 Components ( 2 OF 2)..............................................................................
PL 2.5 Tray 1 Frame Components..................................................................................
PL 2.6 Tray 1 Frame Components (2 OF 2) ...................................................................
PL 2.7 No Paper Sensor Housing ...................................................................................
PL 2.8 Registration..........................................................................................................
PL 2.9 Registration Component ......................................................................................
5-8
5-9
5-10
5-11
5-12
5-13
5-14
5-15
5-16
ROS
PL 3.1 ROS .....................................................................................................................
5-17
CRU
PL 4.1 Drum Cartridge ....................................................................................................
PL 4.2 Toner Empty Sensor and Erase Lamp ................................................................
PL 4.3 Transfer ...............................................................................................................
PL 4.4 Transfer Corotron Housing Component...............................................................
5-22
Exit Transport
PL 6.1 Exit Transport ......................................................................................................
PL 6.2 Exit Transport Component (Simplex)...................................................................
PL 6.3 Exit Transport Component (Duplex) ....................................................................
5-23
5-24
5-25
Simplex / Duplex Module and Bypass Tray

PL 7.1 Simplex Module ...................................................................................................
PL 7.2 Left Hand Cover Assembly ..................................................................................
PL 7.3 Duplex Module Component (1 OF 2)...................................................................
PL 7.5 Bypass Tray Accessory .......................................................................................
PL 7.6 Bypass Tray Component .....................................................................................
5-36
5-37
PL 10.1 IIT Accessory .....................................................................................................

PL 10.2 IIT Component (1 OF 2).....................................................................................
PL 10.4 IIT Upper Cover Cover Component ...................................................................
PL 10.5 IIT Under Cover Component..............................................................................
PL 10.6 IIT Carriage Component ....................................................................................
PL 10.7 Center Plate Component ...................................................................................
5-38
5-39
5-40
5-41
5-42
5-43
5-44
Single Tray Module

PL 11.1 Single Tray Module ............................................................................................
PL 11.2 Tray 2 Component (1 OF 3)...............................................................................
PL 11.5 Single Tray Frame Component (1 OF 2) ...........................................................
PL 11.7 STM No Paper Sensor.......................................................................................
5-45
5-46
5-47
5-48
5-49
5-50
5-51
Stand
5-18
5-19
5-20
5-21
Fuser
PL 5.1 Fuser....................................................................................................................
Cover
PL 9.1 Front / Top Cover.................................................................................................
PL 9.2 Rear / Right Cover and NOHAD Fan ...................................................................
IIT
Drive
PL 1.1 IOT Motor.............................................................................................................
5-35
5-26
5-27
5-28
5-29
5-30
5-31
PL 12.1 Stand Component ..............................................................................................
5-52
ADF/DADF
PL 13.1 ADF/DADF Accessory .......................................................................................
PL 13.2 Component, Cover.............................................................................................
PL 13.3 Base Cover Component.....................................................................................
PL 13.4 Feeder Component ............................................................................................
PL 13.5 Lower Feeder Component .................................................................................
PL 13.6 Retard Roll Component .....................................................................................
PL 13.7 Lower Feeder Assembly ....................................................................................
PL 13.8 Retard Roll Assembly ........................................................................................
PL 13.9 Upper Feeder Assembly ....................................................................................
PL 13.10 Document Tray ................................................................................................
5-53
5-54
5-55
5-56
5-57
5-58
5-59
5-60
5-61
5-62
Common Hardware
Common Hardware .........................................................................................................
Part Number Index ..........................................................................................................
5-63
5-64
Electrical
PL 8.1 AIOC PWB, LVPS, Power Switch........................................................................
PL 8.2 HVPS, Interlock Switch, Duplex PWB .................................................................
PL 8.3 Control Panel Accessory .....................................................................................
Reissue
5-32
5-33
5-34
June, 2008
5-1
Parts Lists
Parts Lists
June, 2008
5-2
Reissue
Introduction
Table 1
Overview
Abbreviation
The Parts List section identifies all part numbers and the corresponding location of all spared
subsystem components.
R/E
Reduction/Enlargement
REF:
Refer to
SCSI
Small Computer Systems Interface
Organization
W/
With
Parts Lists
W/O
Without
Each item number in the part number listing corresponds to an item number in the related
illustration. All the parts in a given subsystem of the machine will be located in the same
illustration or in a series of associated illustrations.
Meaning
Table 2
Operating Companies
Electrical Connectors and Fasteners
Abbreviation
This section contains the illustrations and descriptions of the plugs, jacks, and fasteners used
in the machine. A part number listing of the connectors is included.
AO
Americas Operations
NASG - US
North American Solutions Group - US
Common Hardware
NASG Canada
North American Solutions Group Canada
XE
Xerox Europe
The common hardware is listed in alphabetical order by the letter or letters used to identify
each item in the part number listing and in the illustrations. Dimensions are in millimeters
unless otherwise identified.
Meaning
Symbology
Part Number Index
Symbology used in the Parts List section is identified in the Symbology section.
This index lists all the spared parts in the machine in numerical order. Each number is followed
by a reference to the parts list on which the part may be found.
Service Procedure Referencing

If a part or assembly has an associated repair or adjustment procedure, the procedure number
will be listed at the end of the part description in the parts lists e.g. (REP 5.1, ADJ 5.3)
Other Information
Abbreviations
Abbreviations are used in the parts lists and the exploded view illustrations to provide
information in a limited amount of space. The following abbreviations are used in this manual:
Table 1
Abbreviation
Meaning
A3
297 x 594 Millimeters
A4
A5
AD
Auto Duplex
AWG
American Wire Gauge
EMI
Electro Magnetic Induction
GB
Giga Byte
KB
Kilo Byte
MB
Mega Byte
MM
Millimeters
MOD
Magneto Optical Drive
NOHAD
Noise Ozone Heat Air Dirt
PL
Parts List
P/O
Part of
Reissue
June, 2008
5-3
Parts Lists
Introduction
Subsystem Information
Use of the Term Assembly
The term assembly will be used for items in the part number listing that include other itemized
parts in the part number listing. When the word assembly is found in the part number listing,
there will be a corresponding item number on the illustrations followed by a bracket and a
listing of the contents of the assembly.
Brackets
A bracket is used when an assembly or kit is spared, but is not shown in the illustration. The
item number of the assembly or kit precedes the bracket; the item numbers of the piece parts
follow the bracket.
Tag
The notation W/Tag in the parts description indicates that the part configuration has been
updated. Check the change Tag index in the General Information section of the Service Data
for the name and purpose of the modification.
In some cases, a part or assembly may be spared in two versions: with the Tag and without the
Tag. In those cases, use whichever part is appropriate for the configuration of the machine on
which the part is to be installed. If the machine does not have a particular Tag and the only
replacement part available is listed as W/Tag, install the Tag kit or all of the piece parts. The
Change Tag Index tells you which kit or piece parts you need.
Whenever you install a Tag kit or all the piece parts that make up a Tag, mark the appropriate
number on the Tag matrix.
Parts Lists
Subsystem Information
June, 2008
5-4
Reissue
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
Reissue
June, 2008
5-5
Parts Lists
Symbology
A tag number within a circle with no apex shows that the entire drawing has been changed by
the tag number within the circle (Figure 3). Information on the modification is in the Change Tag
Index.
A tag number within a circle with no apex and having a shaded bar shows that the entire
drawing was the configuration before being changed by the tag number within the circle
(Figure 4).
Figure 3 Entire Drawing With Tag Symbol
Figure 4 Entire Drawing Without Tag Symbol
Parts Lists
Symbology
June, 2008
5-6
Reissue
Overview
Introduction .....................................................................................................................
Subsystem Information ...................................................................................................
Symbology ......................................................................................................................
PL 9.2 Rear / Right Cover and NOHAD Fan ...................................................................

5-3
5-4
5-5
Parts Lists
Drive
PL 1.1 IOT Motor.............................................................................................................
5-7
Paper Transport
PL 2.1 Tray 1...................................................................................................................
PL 2.2 Tray 1 Frame Accessory......................................................................................
PL 2.3 Tray 1 Components (1 OF 2) ...............................................................................
PL 2.4 Tray 1 Components ( 2 OF 2)..............................................................................
PL 2.5 Tray 1 Frame Components..................................................................................
PL 2.6 Tray 1 Frame Components (2 OF 2) ...................................................................
PL 2.7 No Paper Sensor Housing ...................................................................................
PL 2.8 Registration..........................................................................................................
PL 2.9 Registration Component ......................................................................................
5-8
5-9
5-10
5-11
5-12
5-13
5-14
5-15
5-16
5-18
5-19
5-20
5-21
5-22
5-23
5-24
5-25
Simplex / Duplex Module and Bypass Tray

PL 7.1 Simplex Module ...................................................................................................
PL 7.2 Left Hand Cover Assembly ..................................................................................
PL 7.5 Bypass Tray Accessory .......................................................................................
PL 7.6 Bypass Tray Component .....................................................................................
5-52
ADF/DADF
Exit Transport
PL 6.1 Exit Transport ......................................................................................................
PL 6.2 Exit Transport Component (Simplex)...................................................................
PL 6.3 Exit Transport Component (Duplex) ....................................................................
5-45
5-46
5-47
5-48
5-49
5-50
5-51
5-17
Fuser
PL 5.1 Fuser....................................................................................................................
5-38
5-39
5-40
5-41
5-42
5-43
5-44
Single Tray Module

PL 11.1 Single Tray Module ............................................................................................
PL 11.7 STM No Paper Sensor.......................................................................................
PL 12.1 Stand Component ..............................................................................................
CRU
PL 4.1 Drum Cartridge ....................................................................................................
PL 4.2 Toner Empty Sensor and Erase Lamp ................................................................
PL 4.3 Transfer ...............................................................................................................
PL 4.4 Transfer Corotron Housing Component...............................................................
IIT
PL 10.1 IIT Accessory .....................................................................................................
PL 10.4 IIT Upper Cover Cover Component ...................................................................
PL 10.5 IIT Under Cover Component..............................................................................
PL 10.6 IIT Carriage Component ....................................................................................
PL 10.7 Center Plate Component ...................................................................................
Stand
ROS
PL 3.1 ROS .....................................................................................................................
5-37
PL 13.1 ADF/DADF Accessory .......................................................................................

PL 13.2 Component, Cover.............................................................................................
PL 13.3 Base Cover Component.....................................................................................
PL 13.4 Feeder Component ............................................................................................
PL 13.5 Lower Feeder Component .................................................................................
PL 13.6 Retard Roll Component .....................................................................................
PL 13.7 Lower Feeder Assembly ....................................................................................
PL 13.8 Retard Roll Assembly ........................................................................................
PL 13.9 Upper Feeder Assembly ....................................................................................
PL 13.10 Document Tray ................................................................................................
5-53
5-54
5-55
5-56
5-57
5-58
5-59
5-60
5-61
5-62
Common Hardware
Common Hardware .........................................................................................................
Part Number Index ..........................................................................................................
5-63
5-64
5-26
5-27
5-28
5-29
5-30
5-31
Electrical
PL 8.1 AIOC PWB, LVPS, Power Switch........................................................................
PL 8.2 HVPS, Interlock Switch, Duplex PWB .................................................................
PL 8.3 Control Panel Accessory .....................................................................................
PL 8.4 Control Panel Component ...................................................................................
5-32
5-33
5-34
5-35
Cover
PL 9.1 Front / Top Cover.................................................................................................
Reissue
5-36
June, 2008
5-1
Parts Lists
Parts Lists
June, 2008
5-2
Reissue
PL 1.1 IOT Motor

Item
1
2
3
4
5
6
Part
Description
007K94880
120E22470
IOT Motor (REP 1.1.1)

Push Tie
Gear Pulley (Not Spared)
Cover (Not Spared)
Belt (Not Spared)
Traceability Label (Not Spared)
Reissue
June, 2008
5-3
Parts Lists
PL 1.1
PL 2.1 Tray 1
Item
1
2
3
4
Part
Description
050K62940
Tray 1 Assembly
Tray Stopper (Not Spared)
Label (P/O Item 1)
Tray 1 (P/O Item 1)
Parts Lists
PL 2.1
June, 2008
5-4
Reissue
PL 2.2 Tray 1 Frame Accessory

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part
Description
848K01660
007K97780
007K97790
807E19430
809E73520
807E19440
013E25920
121K40770
801K25580
Tray 1 Frame (P/O PL2.1 Item 1)

No Paper Sensor
Drive Gear Assembly
Bracket (P/O Item 3)
Gear (37T/23T) (P/O Item 3)
Gear (41T/22T) (P/O Item 3)
Link Gear
Gear (61T)
Link Spring
Clutch Bracket (Not Spared)
Gear (29T/29T)
Bearing
Tray 1 Feed Clutch (REP 2.2.1)
Interlock Switch Frame Assembly
Reissue
June, 2008
5-5
Parts Lists
PL 2.2
PL 2.3 Tray 1 Components (1 OF 2)

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
013E25881
059K33051
059K32773
Tray (Not Spared)

Tray Front Cover (Not Spared)
Bottom Plate Assembly (Not
Spared)
Bottom Plate (P/O Item 3)
Bottom Pad (P/O Item 3)
Bearing
Roll And Shaft Assembly
Feed Shaft (P/O Item 7)
Feed Roll (REP 2.3.1)
Cover (Not Spared)
End Guide (Not Spared)
Pivot (Not Spared)
Spring (Not Spared)
Stopper (Not Spared)
Parts Lists
PL 2.3
June, 2008
5-6
Reissue
PL 2.4 Tray 1 Components ( 2 OF 2)

Item
1
2
3
4
5
6
7
8
9
10
11
Part
Description
019K07086
809E54170
Front Side Guide (Not Spared)

Paper Guide (Not Spared)
Rear Side Guide (Not Spared)
Retard Shaft (Not Spared)
Pad Spring (Not Spared)
Retard Pad
Label (Max) (Not Spared)
Pinion Gear (Not Spared)
Bottom Stopper (Not Spared)
Stopper Spring
Earth Plate (Not Spared)
Reissue
June, 2008
5-7
Parts Lists
PL 2.4
PL 2.5 Tray 1 Frame Components

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part
Description
110E11580
130E87090
120E29540
Sensor Block (Not Spared)

Tray 1 Interlock Switch
Tray 1 Feed Sensor (REP 2.5.1)
Actuator
Feed Chute (Not Spared)
Upper Baffle (Not Spared)
Plate Spring (P/O Item 6)
Shaft (P/O Item 6)
Roll (P/O Item 6)
Upper Baffle (P/O Item 6)
Eliminator (Not Spared)
Sensor Bracket (Not Spared)
Feed Sensor Spring (Not Spared)
Access Cover 1 (Not Spared)
Parts Lists
PL 2.5
June, 2008
5-8
Reissue
PL 2.6 Tray 1 Frame Components (2

OF 2)
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
Part
Description
005E26740
006K25751
807E19460
059K48200
413W77559
809E54180
013E90840
013E32690
807E19450
Tray Spacer (Not Spared)

Enclosure Plate (Not Spared)
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)
Reissue
June, 2008
5-9
Parts Lists
PL 2.6
PL 2.7 No Paper Sensor Housing

Item
Part
Description
1
2
3
120E23791
130E87090
4
5
No Paper Actuator
Sensor Housing (Not Spared)
Tray 1 No Paper Sensor (REP
2.7.1)
Bracket (Not Spared)
Parts Lists
PL 2.7
June, 2008
5-10
Reissue
PL 2.8 Registration
Item
1
Part
Description
059K48250
Registration Roll Assembly (REP

2.8.1)
Reissue
June, 2008
5-11
Parts Lists
PL 2.8
PL 2.9 Registration Component

Item
Part
Description
3
4
5
6
130K71230
7
8
9
121K39710
10
11
12
13
14
15
16
17
18
059K53230
Corotron Bracket (P/O PL2.8 Item

1)
Registration Frame (P/O PL2.8
Item 1)
Sensor Plate (P/O PL2.8 Item 1)
Registration Sensor Assembly
Wire Harness (P/O PL2.8 Item 1)
Registration Press Spring (P/O
PL2.8 Item 1)
Ground Spring (P/O PL2.8 Item 1)
Registration Clutch Assembly
Press Level Arm (P/O PL2.8 Item
1)
Corotron Press Spring (P/O PL2.8
Item 1)
Transfer Corotron Spring (P/O
PL2.8 Item 1)
Ground Sleeve (P/O PL2.8 Item 1)
Washer (P/O PL2.8 Item 1)
Press Roll (P/O PL2.8 Item 1)
Closing Roll (P/O PL2.8 Item 1)
Bearing (P/O PL2.8 Item 1)
Registration Roll
Clamp (P/O PL2.8 Item 1)
Parts Lists
PL 2.9
June, 2008
5-12
Reissue
PL 3.1 ROS
Item
1
2
3
4
5
Part
Description
062K18161
ROS Assembly (REP 3.1.1)

Laser Housing (Not Spared)
Label (Not Spared)
ROS Wire Harness (Not Spared)
Ground Harness (Not Spared)
Reissue
June, 2008
5-13
Parts Lists
PL 3.1
PL 4.1 Drum Cartridge

Item
1
2
3
4
5
Part
Description
101R00432
106R01277
604K43851
Drum Cartridge (REP 4.1.1)

Spring (P/O Item 5)
CRU Block (P/O Item 5)
Toner Bottle
CRU Blocker Kit
Parts Lists
PL 4.1
June, 2008
5-14
Reissue
PL 4.2 Toner Empty Sensor and Erase

Lamp
Item
1
2
Part
Description
130K71400
122K94091
Toner Empty Sensor (REP 4.2.1)

Erase Lamp (REP 4.2.2)
Reissue
June, 2008
5-15
Parts Lists
PL 4.2
PL 4.3 Transfer
Item
Part
Description
2
3
125K93751
014K83123
Transfer Module (Not Spared) (REP

4.3.1)
Transfer Corotron Housing
Corotron Block Assembly
Parts Lists
PL 4.3
June, 2008
5-16
Reissue
PL 4.4 Transfer Corotron Housing

Component
Item
1
2
3
4
5
6
Part
Description
125K93751
604K43810
Transfer Corotron Housing

Corotron Wire Kit (REP 4.4.1)
Spring (P/O Item 2)
Outboard Cover (Not Spared)
Latch (Not Spared)
Corotron Wire (P/O Item 2)
Reissue
June, 2008
5-17
Parts Lists
PL 4.4
PL 5.1 Fuser
Item
Part
Description
1
2
126K23581
126K24411
3
4
5
6
7
8
122E92530
122E92550
022E30121
022K74110
130K71361
Connector Cover (Not Spared)

Fuser Assembly (220V) (REP
5.1.1)
Fuser Assembly (110V) (REP
5.1.1)
AC Fuser Harness (Not Spared)
DC Fuser Harness (Not Spared)
Baffle Clip (Not Spared)
Fuser Lamp (220V) (REP 5.1.3)
Fuser Lamp (110V) (REP 5.1.3)
Fuser Roll (REP 5.1.4)
Pressure Roll Assembly (REP
5.1.5)
Temperature Control Sensor (REP
5.1.2)
Parts Lists
PL 5.1
June, 2008
5-18
Reissue
PL 6.1 Exit Transport

Item
Part
Description
059K48230
059K48240
Exit Transport Assembly (Simplex)

(REP 6.1.1)
Exit Transport Assembly (Duplex)
(REP 6.1.2)
Label (Not Spared)
Reissue
June, 2008
5-19
Parts Lists
PL 6.1
PL 6.2 Exit Transport Component

(Simplex)
Item
Part
Description
1
2
3
4
059K43000
059E99331
5
6
7
809E76520
013E30050
8
9
10
11
12
13
14
15
16
17
18
130E87090
604K43840
Lower Chute (P/O PL6.1 Item 1)

Exit Roll
Pinch Roll
Pinch Roll Support (P/O PL6.1 Item
1)
Pinch Spring
Bearing
Sensor Wire Harness (P/O PL6.1
Item 1)
Earth Plate (P/O PL6.1 Item 1)
Gear (19T) (P/O PL6.1 Item 1)
Gear Pulley (P/O PL6.1 Item 1)
Cap (P/O PL6.1 Item 1)
Sensor Support (P/O Item 18)
Fuser Exit Sensor
Actuator (P/O Item 18)
Actuator Spring (P/O Item 18)
Insulator (P/O Item 18)
Exit Sensor Kit
Parts Lists
PL 6.2
June, 2008
5-20
Reissue
PL 6.3 Exit Transport Component

(Duplex)
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Part
Description
059K43000
059E99331
809E76520
013E30050
130E87090
127K51590
423W06555
604K43840
Lower Chute (Not Spared)

Exit Roll
Pinch Roll
Pinch Roll Support (Not Spared)
Pinch Spring
Bearing
Bearing (Not Spared)
Gear Pulley
Gear (24T) (Not Spared)
Sensor Support (P/O Item 19)
Fuser Exit Sensor
Actuator Spring (P/O Item 19)
Motor Frame (Not Spared)
Exit Motor
Belt
Insulator (P/O Item 20)
Exit Sensor Kit
Reissue
June, 2008
5-21
Parts Lists
PL 6.3
PL 7.1 Simplex Module

Item
1
Part
Description
802K99450
Simplex Module (REP 7.1.1)
Parts Lists
PL 7.1
June, 2008
5-22
Reissue
PL 7.2 Left Hand Cover Assembly

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
604K43860
604K43870
Left Hand Cover (Not Spared)

Left Hand Upper Chute (Not
Spared)
Left Hand Chute (Not Spared)
Front Stopper (P/O Item 12)
Pivot Retainer (P/O Item 12)
Latch Handle (P/O Item 13)
Latch (P/O Item 13)
Latch Shaft (P/O Item 13)
Main Baffle (Not Spared)
Rear Stopper (P/O Item 12)
Latch Spring (P/O Item 13)
Left Hand Door Kit
Left Hand Door Latch Kit
Jam Clear Label (P/O Item 1)
Reissue
June, 2008
5-23
Parts Lists
PL 7.2
PL 7.3 Duplex Module Component (1

OF 2)
Item
Part
Description
802K97500
2
3
4
5
059E03090
6
7
8
9
10
11
12
13
14
013E33260
023E26660
604K43860
Left Hand Cover Assembly (REP

7.1.1)
Pinch Roll
Pinch Spring (P/O Item 1)
Left Hand Chute (P/O Item 1)
Left Hand Upper Chute (P/O Item
1)
Front Stopper (P/O Item 1)
Duplex Roll 1 (P/O Item 1)
Bearing
Pulley (P/O Item 1)
Belt
Pivot Retainer (P/O Item 13)
Rear Stopper (P/O Item 13)
Left Hand Door Kit
Left Hand Cover (P/O Item 1)
Parts Lists
PL 7.3
June, 2008
5-24
Reissue
PL 7.4 Duplex Module Component (2

OF 2)
Item
Part
Description
2
3
4
5
6
7
8
9
10
11
12
13
14
809E76630
059E03650
013E33260
807E21180
006K86440
604K43870
Duplex Main Baffle (P/O PL7.3 Item

1)
Duplex in Chute (P/O PL7.3 Item 1)
Idler Spring
Idler Shaft (P/O PL7.3 Item 1)
Idler Roll
Latch Spring (P/O Item 14)
Latch Handle (P/O Item 14)
Latch (P/O Item 14)
Bearing
Latch Shaft (P/O Item 14)
Gear (18T)
Duplex Roll 2
Label (Jam Clear) (Not Spared)
Left Hand Door Latch Kit
Reissue
June, 2008
5-25
Parts Lists
PL 7.4
PL 7.5 Bypass Tray Accessory

Item
Part
Description
1
2
3
4
5
8
9
10
11
12
13
14
15
16
17
18
19
20
807E17870
121E20950
059K54730
21
22
23
24
25
26
27
28
29
059K48260
604K43820
022E29860
604K45750
604K45770
604K45780
604K45790
Bypass Feed Shaft (P/O Item 22)

Bearing (P/O Item 22, Item 27)
Idler Roll (P/O Item 22, Item 28)
Idler Shaft (P/O Item 22, Item 28)
Bypass Idler Spring (P/O Item 22,
Item 24, Item 28)
Drive Support Bracket (P/O Item
22, Item 26)
Gear (42/30T) (P/O Item 22, Item
26)
Shaft (P/O Item 22, Item 26)
Idler Arm (P/O Item 22, Item 26)
Gear (49T) (P/O Item 22, Item 26)
Sector Gear Spring (P/O Item 22,
Item 24, Item 26)
Idler Arm Spring (P/O Item 22, Item
24, Item 26)
Gear Pulley
Sector Gear (P/O Item 22, Item 27)
Cam (P/O Item 22, Item 27)
Bypass Solenoid
Bypass Feed Roll (REP 7.5.1)
Feed Roll Cap (P/O Item 22, Item
29)
Bypass Tray (P/O Item 22)
Bypass Feeder Assembly
Label (Not Spared)
MSI Spring Kit
Nudge Roller
MSI Assembly No. 2 Repair Kit
Parts Lists
PL 7.5
June, 2008
5-26
Reissue
PL 7.6 Bypass Tray Component

Item
Part
Description
1
2
3
050K58051
4
5
6
7
8
9
10
11
12
13
14
15
019K08890
604K43830
604K45740
604K45760
Bypass Tray Assembly

Bearing (P/O Item 15)
Bypass Take Away Roll (P/O Item
15)
Lower Baffle (P/O Item 15)
Nudger Plate (P/O Item 14)
Nudger Pad (P/O Item 13, Item 14)
Nudger Spring (P/O Item 13, PL7.5
Item 29)
Gear (18T) (P/O Item 15)
Roll (Not Spared)
Retard Spring (P/O PL7.5 Item 24)
Retard Pad Assembly
Pre Shingler Bracket (P/O Item 15)
Bypass Retard Kit
Reissue
June, 2008
5-27
Parts Lists
PL 7.6
PL 8.1 AIOC PWB, LVPS, Power

Switch
Item
Part
Description
1
2
3
4
5
6
7
8
110E11320
960K43421
960K44250
10
11
12
13
105E17391
105E17411
105E18010
105E18020
960K28611
Power Switch
Screw (With Washer) (Not Spared)
Inlet Bracket (Not Spared)
PWB Bracket (Not Spared)
Inlet (Not Spared)
CRUM ID Harness (Not Spared)
Inlet Wire Harness (Not Spared)
Billing Counter Harness (Not
Spared)
AIOC PWB (REP 8.1.1)
AIOC/Network PWB ((DADF Only))
(REP 8.1.3)
LVPS (220V) (REP 8.1.2)
LVPS (110V) (REP 8.1.2)
DADF LVPS (220V) (REP 8.1.2)
DADF LVPS (110V) (REP 8.1.2)
Choke Coil (Not Spared)
Power Cord (Not Spared)
Exit PWB
Parts Lists
PL 8.1
June, 2008
5-28
Reissue
PL 8.2 HVPS, Interlock Switch, Duplex

PWB
Item
Part
Description
1
2
3
4
014K83141
105E17401
801K25570
5
6
7
8
9
10
11
HV Contact Block
HVPS (REP 8.2.1)
Left Hand Interlock Switch
Interlock Switch Wire Harness (Not
Spared)
Core (Not Spared)
Front Cover Interlock Switch (Not
Spared)
Harness Block (Not Spared)
Harness Block (Not Spared)
Core Clip (Not Spared)
Reissue
June, 2008
5-29
Parts Lists
PL 8.2
PL 8.3 Control Panel Accessory

Item
Part
Description
1
2
3
4
962K66150
802K97694
848K04904
896E58070
Support Bracket (Not Spared)

Control Panel Cover (Not Spared)
Control Panel Wire Harness
Control Panel (ADF, DADF Only)
(REP 8.3.1)
Control Panel (110V, 220V) (REP
8.3.1)
Label (WorkCentre 5020)
Parts Lists
PL 8.3
June, 2008
5-30
Reissue
PL 8.4 Control Panel Component

Item
Part
Description
960K32602
960K32783
960K38300
3
4
Control Panel Panel Case (With

Key) (P/O PL8.3 Item 4)
UI Platen PWB Assembly (REP
8.4.1)
UI PWB Assembly (ADF Only)
(REP 8.4.1)
UI PWB Assembly (DADF Only)
(REP 8.4.1)
Middle Panel (P/O PL8.3 Item 4)
Label (P/O PL8.3 Item 4)
Reissue
June, 2008
5-31
Parts Lists
PL 8.4
PL 9.1 Front / Top Cover

Item
Part
Description
1
2
3
4
848E04480
848K17300
5
6
7
8
9
10
11
848E04511
801E04660
105E12210
Exit Cover
Front Cover Assembly
Front Left Cover (REP 9.1.2)
Output Tray (Not Spared) (REP
9.1.1)
Right Top Cover (Not Spared)
Xerox Badge Plate (P/O Item 2)
IIT Support Bracket (Not Spared)
Duct (Not Spared)
Front Cover
Strap
Static Eliminator
Parts Lists
PL 9.1
June, 2008
5-32
Reissue
PL 9.2 Rear / Right Cover and NOHAD

Fan
Item
Part
Description
848E04501
2
3
4
5
848E04451
127K51632
053E93650
Rear Cover (Remove Data Plate

and Place on New Rear Cover)
(REP 9.2.1)
Right Cover (REP 9.2.2)
NOHAD Fan
Ozone Filter
Data Plate (Not Spared) (Remove
Data Plate and Place on New Rear
Cover)
Reissue
June, 2008
5-33
Parts Lists
PL 9.2
PL 10.1 IIT Accessory

Item
1
2
3
4
5
6
7
8
Part
Description
604K47130
604K46500
IIT Right Bracket (Not Spared)

IIT (Not Spared)
Label (Not Spared)
Platen Cover (P/O Item 8)
Platen Cushion (P/O Item 8)
Cap (Not Spared)
Error Code Label Kit
Platen Cover Kit (REP 10.1.1)
Parts Lists
PL 10.1
June, 2008
5-34
Reissue
PL 10.2 IIT Component (1 OF 2)

Item
1
2
3
4
Part
Description
848K07410
604K44330
IIT Upper Cover (REP 10.2.1)

Hinge Kit
Blind Cover (Not Spared)
Reissue
June, 2008
5-35
Parts Lists
PL 10.2
PL 10.3 IIT Component (2 OF 2)

Item
1
2
3
4
5
6
7
Part
Description
041K95870
962K59950
809E79910
809E79920
IIT Carriage (REP 10.3.1)

IIT Under Cover (Not Spared)
Flexible Print Cable (REP 10.3.2)
Plate Spring (Not Spared)
Cable Spring (Rear)
Cable Spring (Front)
Pulley (Not Spared)
Parts Lists
PL 10.3
June, 2008
5-36
Reissue
PL 10.4 IIT Upper Cover Cover

Component
Item
1
2
3
4
5
6
7
Part
Description
802K71882
090E02380
090E91720
815E08650
815E42250
IIT Upper Cover

Small Platen Glass
Platen Glass
White Referance
Sheet (Black and White)
Label (Not Spared)
Label (Not Spared)
Reissue
June, 2008
5-37
Parts Lists
PL 10.4
PL 10.5 IIT Under Cover Component

Item
1
2
3
4
5
6
7
8
Part
Description
801K30780
801E05970
110E11551
Under Cover (P/O PL10.3 Item 2)

Front Rail
Rear Frame (P/O PL10.3 Item 2)
Rear Rail
Hinge Sleeve (P/O PL10.3 Item 2)
Pulley (P/O PL10.3 Item 2)
Cable Bracket (P/O PL10.3 Item 2)
Platen Open Switch
Parts Lists
PL 10.5
June, 2008
5-38
Reissue
PL 10.6 IIT Carriage Component

Item
Part
Description
1
2
4
5
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
868E12730
121K41690
122E92570
127K57140
Center Plate (P/O PL10.3 Item 1)

Front Mirror Frame (P/O PL10.3
Item 1)
Rear Mirror Frame (P/O PL10.3
Item 1)
Mirror Clip (P/O PL10.3 Item 1)
Mirror 2 Damper (P/O PL10.3 Item
1)
Mirror 3 Damper (P/O PL10.3 Item
1)
Rear Mirror Stopper (P/O PL10.3
Item 1)
Rear Mirror Stopper (P/O PL10.3
Item 1)
Mirror Weight (P/O PL10.3 Item 1)
Front Lamp Holder (P/O PL10.3
Item 1)
Rear Lamp Holder (P/O PL10.3
Item 1)
Sensor Plate (P/O PL10.3 Item 1)
Reflector (P/O PL10.3 Item 1)
IIT Carriage Cover (P/O PL10.3
Item 1)
Reflector Cover (P/O PL10.3 Item
1)
Sensor Plate Spring
Rail Contact (P/O PL10.3 Item 1)
Mirror Weight (P/O PL10.3 Item 1)
Carriage Sensor
Exposure Lamp (REP 10.6.1)
Carriage Motor
Mirror 1 (P/O PL10.3 Item 1)
Reissue
June, 2008
5-39
Parts Lists
PL 10.6
PL 10.7 Center Plate Component

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
140E88751
22
23
Len Assembly (P/O PL10.3 Item 1)

Drum and Carriage Cable (P/O
PL10.3 Item 1) (ACO) (REP 10.7.1)
Pulley (P/O PL10.3 Item 1)
Mirror Clip (P/O PL10.3 Item 1)
Mirror Frame (P/O PL10.3 Item 1)
Side Slider (P/O PL10.3 Item 1)
Rail Contact (P/O PL10.3 Item 1)
Rail Slider (P/O PL10.3 Item 1)
Front Slider (P/O PL10.3 Item 1)
Gear (P/O PL10.3 Item 1)
Gear (P/O PL10.3 Item 1)
Mirror Frame Bracket (P/O PL10.3
Item 1)
CCD Support (P/O PL10.3 Item 1)
Lock Plate (P/O PL10.3 Item 1)
Inverter PWB Bracket 1 (P/O
PL10.3 Item 1)
Inverter PWB Bracket 2 (Not
Spared)
Bracket (P/O PL10.3 Item 1)
Inverter PWB (REP 10.7.2)
Carriage Cable (Black) (Not
Spared)
Carriage Cable (Silver) (P/O
PL10.3 Item 1)
Drum (P/O PL10.3 Item 1)
Parts Lists
PL 10.7
June, 2008
5-40
Reissue
PL 11.1 Single Tray Module

Item
1
2
3
4
Part
Description
050K57701
896E41981
896E42140
Tray 2 (REP 11.1.1)

Single Tray Frame (Not Spared)
End Guide Label
Install Label
Reissue
June, 2008
5-41
Parts Lists
PL 11.1
PL 11.2 Tray 2 Component (1 OF 3)

Item
Part
Description
1
2
3
5
6
7
9
10
End Guide (P/O PL11.1 Item 1)

Tray (P/O PL11.1 Item 1)
Tray Front Cover (P/O PL11.1 Item
1)
End Guide Spring (P/O PL11.1 Item
1)
Cover (P/O PL11.1 Item 1)
End Guide Lock (P/O PL11.1 Item
1)
Mini Bottom Plate (P/O PL11.1 Item
1)
Spring (Side) (P/O PL11.1 Item 1)
Spring (Center) (P/O PL11.1 Item 1)
Parts Lists
PL 11.2
June, 2008
5-42
Reissue

Item
1
2
3
4
5
6
7
8
Part
Description
038K89761
038K89821
Front Side Guide

Rear Side Guide
Tapping Screw (P/O PL11.1 Item 1)
Rack (P/O PL11.1 Item 1)
Latch (P/O PL11.1 Item 1)
Pinion (P/O PL11.1 Item 1)
Latch Spring (P/O PL11.1 Item 1)
Rack (P/O PL11.1 Item 1)
Reissue
June, 2008
5-43
Parts Lists
PL 11.3

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
059K48430
059K48660
013E90840
003K15530
019K09250
18
19
20
21
22
003K15540
Tray 2 Feeder Assembly

Feed Chute (P/O Item 1)
Tray 2 Feed Roll (REP 11.4.1)
Feed Shaft (P/O Item 1)
Bearing
Earth Spring (P/O Item 1)
Core Roll (P/O Item 1)
Holder Seal (P/O Item 1)
Front Latch Assembly
Holder Arm (Not Spared)
Spring (Not Spared)
Retard Roll Housing
Retard Housing (P/O Item 12)
Retard Holder (P/O Item 12)
Retard Shaft (P/O Item 12)
Friction Clutch (P/O Item 12)
Tray 2 Retard Roll (P/O Item 12)
(REP 11.4.2)
Retard Plate (P/O Item 12)
Retard Spring (P/O PL11.1 Item 1)
Latch Cover (P/O PL11.1 Item 1)
Rear Latch Assembly
Spring (P/O PL11.1 Item 1)
Parts Lists
PL 11.4
June, 2008
5-44
Reissue
PL 11.5 Single Tray Frame

Component (1 OF 2)
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Part
Description
110E11580
130E87090
120E28091
055K31090
960K28562
809E74030
STM Rear Cover (Not Spared)

STM Wire Harness (Not Spared)
Earth Cushion (Not Spared)
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)
Shaft (P/O Item 9)
Baffle (P/O Item 9)
Eliminator (P/O Item 9)
STM PWB (REP 11.5.2)
Guide Spring (Not Spared)
Arm Guide (Not Spared)
Tray Stopper (Not Spared)
Upper Feed Chute (Not Spared)
Feed Sensor Spring
Access Cover 2 (Not Spared)
Reissue
June, 2008
5-45
Parts Lists
PL 11.5
PL 11.6 Single Tray Frame

Component (2 OF 2)
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part
Description
807E18360
059K48440
848K02140
013E32180
013E90840
807E18410
068K53590
127K52180
807E18380
807E18390
807E18400
Harness Holder (Not Spared)

Gear (Helical 21T)
Take Away Roll
No Paper Sensor Assembly
Bearing (220v)
Bearing (110V)
Gear (Helical 20T/36T)
STM Feed Clutch (REP 11.6.1)
STM Feed Motor (REP 11.6.2)
Gear (Helical 37T)
Tray Rear Stopper (Not Spared)
Parts Lists
PL 11.6
June, 2008
5-46
Reissue
PL 11.7 STM No Paper Sensor

Item
Part
Description
2
3
4
120E29630
130E87090
Actuator Support (P/O PL11.6 Item

4)
No Paper Sensor Actuator
No Paper Sensor (REP 11.7.1)
Sensor Housing (P/O PL11.6 Item
4)
Reissue
June, 2008
5-47
Parts Lists
PL 11.7
PL 12.1 Stand Component

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Part
Description
017K93121
017K93132
017E12010
121E93360
017E98760
Stand (Not Spared)

Caster
Caster (With Stopper)
Locator Peg
Catch Magnet
Front Door (Not Spared)
Stand Hinge (Not Spared)
Door Hinge (Not Spared)
Guide (Not Spared)
Support
Screw (Not Spared)
Foot Cover (Not Spared)
Adjuster Foot (Not Spared)
Front Foot (Not Spared)
Foot Bracket (Not Spared)
Parts Lists
PL 12.1
June, 2008
5-48
Reissue
PL 13.1 ADF/DADF Accessory

Item
Part
Description
022K74860
2
3
4
004E17510
ADF Assembly (with Item 2) (REP

13.1.1, ADJ 13.1.1)
Platen Cushion (REP 13.1.2)
Screw (Not Spared)
Push Tie (Not Spared)
Reissue
June, 2008
5-49
Parts Lists
PL 13.1
PL 13.2 Component, Cover

Item
Part
Description
022K75730
059K55590
2
3
4
050K60800
5
6
7
8
050K63270
DADF Scanner Assembly

ADF Scanner Assembly (REP
13.2.2)
Rear Cover (Not Spared)
Front Cover (Not Spared)
ADF Document Tray Assembly
(REP 13.2.1)
DADF Document Tray Assembly
Front Blind Cover (Not Spared)
Rear Blind Cover (Not Spared)
Support Bracket (Not Spared)
Base Cover Assembly (Not Spared)
Parts Lists
PL 13.2
June, 2008
5-50
Reissue
PL 13.3 Base Cover Component

Item
Part
Description
2
3
4
5
6
7
8
9
10
11
960K42980
960K32370
962K60840
604K44340
059K55600
016E93560
003K86760
12
003K13560
003K15950
13
14
15
604K44350
16
17
18
19
20
21
22
059K55860
DADF PWB (REP 13.3.4)

ADF PWB (REP 13.3.1)
Bracket (Not Spared)
ADF Cable
Exit Chute (Not Spared)
Stamp Cover (Not Spared)
Lead In Pinch Roller (Not Spared)
Spring Plate Kit (5/Kit)
Exit Pinch Roller
Bush
Base Cover (Not Spared)
Right Counter Balance (REP
13.3.3)
Left Counter Balance (ADF Only)
(REP 13.3.2)
Left Counter Balance (DADF Only)
(REP 13.3.2)
Pinch Roll Bracket (Not Spared)
Read Out Pinch Roller Kit (5/Kit)
Spring Plate (Read Out) (Not
Spared)
Interlock Magnet (Not Spared)
Bottom Plate (Not Spared)
ADF Earth Spring (Not Spared)
Film Cover (Not Spared)
Film Cover (Not Spared)
Earth Wire (Not Spared)
Pinch Roll Assembly
Reissue
June, 2008
5-51
Parts Lists
PL 13.3
PL 13.4 Feeder Component

Item
Part
Description
2
3
4
5
Upper Feeder Assembly (P/O

PL13.2 Item 1)
Top Cover (Not Spared)
ADF Lower Feeder Assembly (P/O
PL13.2 Item 1)
Pin (P/O PL13.2 Item 1)
Stopper Belt (P/O PL13.2 Item 1)
Parts Lists
PL 13.4
June, 2008
5-52
Reissue
PL 13.5 Lower Feeder Component

Item
Part
Description
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
127K58700
127K57120
Document Drive Motor (P/O Item

24) (ADF Only)
Motor Plate (P/O Item 24)
Gear (40T-21T) (P/O Item 24)
Bracket (P/O Item 24)
Gear (39T-26T) (P/O PL13.4 Item
3)
Bush (P/O PL13.4 Item 3)
3)
3)
3)
3)
Registration Clutch (P/O PL13.4
Item 3)
Eject Torque Limiter (P/O PL13.4
Item 3)
Cable Fence (P/O PL13.4 Item 3)
(DADF Only)
Exit/Invert Clutch (P/O PL13.4 Item
3) (DADF Only)
Motor Assembly (DADF Only)
Motor Assembly (ADF Only)
Gear Plate (P/O PL13.4 Item 3)
(DADF Only)
Reissue
June, 2008
5-53
Parts Lists
PL 13.5
PL 13.6 Retard Roll Component

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
Retard Roll Assembly (Not Spared)

Registration Mylar (P/O Item 1)
Retard Mylar (P/O Item 1)
Base Lower Feeder Assembly (Not
Spared)
Arm Pin (Not Spared)
Shaft (Not Spared)
Paper Guide Plate (Not Spared)
Bearing (Oil Less) (Not Spared)
Roll Assembly (P/O Item 1)
Parts Lists
PL 13.6
June, 2008
5-54
Reissue
PL 13.7 Lower Feeder Assembly

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
059K55620
059K55630
059K55610
14
15
16
17
18
19
20
21
22
Bottom Chute (Not Spared)

White Sheet (Not Spared)
Bottom Sheet (Not Spared)
Base Frame (Not Spared)
Lead In Roll
Lead Out Roll
Registration Roll
Front Bracket (Not Spared)
Rear Bracket (Not Spared)
ADF Invert Gate (Not Spared)
Seal (Not Spared)
Exit/Invert Sensor (Not Spared)
(DADF Only)
Sensor Holding Bracket (Not
Spared) (DADF Only)
Registration Sensor (Not Spared)
(DADF Only)
Registration Sensor Actuator (Not
Spared) (DADF Only)
Registratin Sensor Spring (Not
Spared) (DADF Only)
Exit/Invert Sensor Spring (Not
Spared) (DADF Only)
Exit/Invert Sensor Actuator (Not
Spared) (DADF Only)
Exit/Invert Solenoid Bracket (Not
Spared) (DADF Only)
Solenoid Bracket (Not Spared)
(DADF Only)
Exit/Invert Solenoid (Not Spared)
(DADF Only)
Reissue
June, 2008
5-55
Parts Lists
PL 13.7
PL 13.8 Retard Roll Assembly

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
809E56440
14
15
16
17
18
19
059E04080
Plate (Not Spared)

Exit Roller (Not Spared)
Rear Exit Arm (Not Spared)
Spring (Coil)
Front Exit Arm (Not Spared)
Exit Roll Drive Shaft (Not Spared)
Spring Plate (Not Spared)
Spring Plate (Not Spared)
Plate (Not Spared)
Retard Roll Chute (Not Spared)
(REP 13.8.1)
Retard Roll Drive Shaft (Not
Spared)
Bush (Not Spared)
Bush (Not Spared)
Spring (Coil) (Not Spared)
Retard Roll (REP 13.8.1)
Parts Lists
PL 13.8
June, 2008
5-56
Reissue
PL 13.9 Upper Feeder Assembly

Item
Part
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
059K55640
25
26
27
28
29
30
31
32
33
34
35
36
37
121K41670
059E99690
110E11570
121K41650
121K41600
121K41660
Lock Lever (P/O PL13.4 Item 1)

Main Shaft (P/O Item 22)
Bearing (P/O Item 22)
Pickup Roll (P/O Item 22) (REP
13.9.1)
Pickup Roll Shaft (P/O Item 22)
Housing (P/O Item 22)
Feed Roll (P/O Item 22) (REP
13.9.1)
Gear (22T) (P/O Item 22)
Plate (P/O PL13.4 Item 1)
Spring Box (P/O PL13.4 Item 1)
Spring (Coil) (P/O PL13.4 Item 1)
Spring Housing (P/O PL13.4 Item
1)
Front Lock Arm (P/O PL13.4 Item
1)
Top Frame (P/O PL13.4 Item 1)
Rear Lock Arm (P/O PL13.4 Item 1)
Sensor Holder (P/O Item 32)
Document Set Sensor Actuator
(P/O Item 32)
Document Feeder Width Sensor
Document Feeder Width Sensor,
Document Set Sensor (P/O Item
32)
Feeder Assembly
Sensor Holder (P/O Item 37)
Document Feed Sensor (P/O Item
37)
Document Feed Sensor Actuator
(P/O Item 37)
Spring (P/O Item 37)
Clutch (One Way)
Shaft (P/O PL13.4 Item 1)
Registration Pinch Roller
Plate (P/O PL13.4 Item 1)
DADF/ADF Top Cover Switch
Document Set Sensor Assembly
Document Feed Clutch
Adjust Plate (P/O PL13.4 Item 1)
Read Sensor Assembly
Reissue
June, 2008
5-57
Parts Lists
PL 13.9
PL 13.10 Document Tray

Item
Part
Description
1
2
5
6
7
8
10
11
12
13

Front Side Guide (P/O PL13.2 Item
4)
Rear Side Guide (P/O PL13.2 Item
4)
Width Sensor Actuator (P/O PL13.2
Item 4)
Eliminator (P/O PL13.2 Item 4)
Pinion Gear (P/O PL13.2 Item 4)
Pinion Spring (P/O PL13.2 Item 4)
Lower Document Tray (P/O PL13.2
Item 4)
Document Tray Width Sensor 1,
Document Tray Width Sensor 2
(P/O PL13.2 Item 4)
Actuator (P/O PL13.2 Item 4)
Document Tray Length Sensor 1,
Document Tray Length Sensor 2
(P/O PL13.2 Item 4)
Upper Document Tray (P/O PL13.2
Item 4)
Parts Lists
PL 13.10
June, 2008
5-58
Reissue
Common Hardware
Item
Part
Description
AA
AB
AC
AD
AE
AF
AG
AH
AJ
AK
AL
AM
AN
AP
AQ
AR
AS
AT
AU
AV
AW
AX
AY
AZ
BA
BB
BC
BD
BE
BF
102W37178
102W38278
112W27898
113W20878
113W21478
113W27688
114W27678
114W27878
153W16088
153W16288
153W17688
153W17888
153W18088
153W18288
153W18488
153W27678
153W27878
153W28078
158W27678
158W27878
252W27450
354W15278
354W18278
354W19278
354W21278
354W24278
354W27254
354W27278
158W36878
158W36078
Countersunk Head Screw (M4x25)

Countersunk Head Screw (M4x45)
Pan Head Screw (M3x8)
Screw (M3x8)
Screw (M3x14)
Pan Head Screw (M3x6)
Bind Head Tapping Screw (M3x6)
Tapping Screw (M4x10)
Tapping Screw (4Mx12)
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)
Reissue
June, 2008
5-59
Parts Lists
Common Hardware
Part Number Index
Table 1 Part Number Index

Part Number
Part List
038K89761
PL 11.3
Part Number
Part List
038K89821
PL 11.3
003K13560
PL 13.3
041K95870
PL 10.3
003K15530
PL 11.4
050K57701
PL 11.1
003K15540
PL 11.4
050K58051
PL 7.6
003K15950
PL 13.3
050K60800
PL 13.2
003K86760
PL 13.3
050K62940
PL 2.1
004E17510
PL 13.1
050K63270
PL 13.2
005E26740
PL 2.6
053E93650
PL 9.2
006K25751
PL 2.6
055K31090
PL 11.5
006K86440
PL 7.4
059E03090
PL 7.3
007K94880
PL 1.1
059E03650
PL 7.4
007K97780
PL 2.2
059E04080
PL 13.8
007K97790
PL 2.2
059K32773
PL 2.3
013E25881
PL 2.3
059K33051
PL 2.3
013E25920
PL 2.2
059K43000
PL 6.2
013E30050
PL 6.2
059K43000
PL 6.3
013E30050
PL 6.3
059K48200
PL 2.6
013E32180
PL 11.6
059K48230
PL 6.1
013E32690
PL 2.6
059K48240
PL 6.1
013E33260
PL 7.3
059K48250
PL 2.8
013E33260
PL 7.4
059K48260
PL 7.5
013E90840
PL 11.4
059K48430
PL 11.4
013E90840
PL 2.6
059K48440
PL 11.6
013E90840
PL 11.6
059K48660
PL 11.4
014K83123
PL 4.3
059K53230
PL 2.9
014K83141
PL 8.2
059K54730
PL 7.5
016E93560
PL 13.3
059K55590
PL 13.2
017E12010
PL 12.1
059K55600
PL 13.3
017K93121
PL 12.1
059K55610
PL 13.7
017K93132
PL 12.1
059K55620
PL 13.7
017E98760
PL 12.1
059K55630
PL 13.7
019K07086
PL 2.4
059K55640
PL 13.9
019K08890
PL 7.6
059K55860
PL 13.3
019K09250
PL 11.4
059E99331
PL 6.2
022E29860
PL 7.5
059E99331
PL 6.3
022E30121
PL 5.1
059E99690
PL 13.9
022K74110
PL 5.1
062K18161
PL 3.1
022K74860
PL 13.1
068K53590
PL 11.6
022K75730
PL 13.2
090E02380
PL 10.4
023E26660
PL 7.3
090E91720
PL 10.4
Parts Lists
Part Number Index
June, 2008
5-60
Reissue
Part Number
Part List
Part Number
Part List
101R00432
PL 4.1
130K71230
PL 2.9
105E12210
PL 9.1
130K71361
PL 5.1
105E17391
PL 8.1
130K71400
PL 4.2
105E17401
PL 8.2
130E87090
PL 11.5
105E17411
PL 8.1
130E87090
PL 11.7
105E18010
PL 8.1
130E87090
PL 6.3
105E18020
PL 8.1
130E87090
PL 6.2
106R01277
PL 4.1
130E87090
PL 2.7
110E11320
PL 8.1
130E87090
PL 2.5
110E11551
PL 10.5
140E88751
PL 10.7
110E11570
PL 13.9
413W77559
PL 2.6
110E11580
PL 11.5
423W06555
PL 6.3
110E11580
PL 2.5
604K43810
PL 4.4
120E22470
PL 1.1
604K43820
PL 7.5
120E23791
PL 2.7
604K43830
PL 7.6
120E28091
PL 11.5
604K43840
PL 6.2
120E29540
PL 2.5
604K43840
PL 6.3
120E29630
PL 11.7
604K43851
PL 4.1
121E20950
PL 7.5
604K43860
PL 7.2
121K39710
PL 2.9
604K43860
PL 7.3
121K40770
PL 2.2
604K43870
PL 7.2
121K41600
PL 13.9
604K43870
PL 7.4
121K41650
PL 13.9
604K44330
PL 10.2
121K41660
PL 13.9
604K44340
PL 13.3
121K41670
PL 13.9
604K44350
PL 13.3
121K41690
PL 10.6
604K45740
PL 7.6
121E93360
PL 12.1
604K45750
PL 7.5
122E92530
PL 5.1
604K45760
PL 7.6
122E92550
PL 5.1
604K45770
PL 7.5
122E92570
PL 10.6
604K45780
PL 7.5
122K94091
PL 4.2
604K45790
PL 7.5
125K93751
PL 4.3
604K46500
PL 10.1
125K93751
PL 4.4
604K47130
PL 10.1
126K23581
PL 5.1
801E04660
PL 9.1
126K24411
PL 5.1
801E05970
PL 10.5
127K51590
PL 6.3
801K25570
PL 8.2
127K51632
PL 9.2
801K25580
PL 2.2
127K52180
PL 11.6
801K30780
PL 10.5
127K57120
PL 13.5
802K71882
PL 10.4
127K57140
PL 10.6
802K97500
PL 7.3
127K58700
PL 13.5
802K97694
PL 8.3
Reissue
June, 2008
5-61
Parts Lists
Part Number Index
Part Number
Part List
Part Number
Part List
802K99450
PL 7.1
960K32783
PL 8.4
807E17870
PL 7.5
960K38300
PL 8.4
807E18360
PL 11.6
960K42980
PL 13.3
807E18380
PL 11.6
960K43421
PL 8.1
807E18390
PL 11.6
960K44250
PL 8.1
807E18400
PL 11.6
962K59950
PL 10.3
807E18410
PL 11.6
962K60840
PL 13.3
807E19430
PL 2.2
962K66150
PL 8.3
807E19440
PL 2.2
807E19450
PL 2.6
807E19460
PL 2.6
807E21180
PL 7.4
809E54170
PL 2.4
809E54180
PL 2.6
809E56440
PL 13.8
809E73520
PL 2.2
809E74030
PL 11.5
809E76520
PL 6.2
809E76520
PL 6.3
809E76630
PL 7.4
809E79910
PL 10.3
809E79920
PL 10.3
815E08650
PL 10.4
815E42250
PL 10.4
848K01660
PL 2.2
848K02140
PL 11.6
848E04451
PL 9.2
848E04480
PL 9.1
848E04501
PL 9.2
848E04511
PL 9.1
848K04904
PL 8.3
848K07410
PL 10.2
848K17300
PL 9.1
868E12730
PL 10.6
896E41981
PL 11.1
896E42140
PL 11.1
896E58070
PL 8.3
960K28562
PL 11.5
960K28611
PL 8.1
960K32370
PL 13.3
960K32602
PL 8.4
Parts Lists
Part Number Index
June, 2008
5-62
Reissue
6 General Procedures
Diagnostics
Diagnostic Mode .............................................................................................................
Basic Operations of the Diagnostic Mode .......................................................................
IOT Diagnostics...............................................................................................................
6-3
6-4
6-7
General Procedures
GP1 Serial Number Locations.........................................................................................
GP 2 Viewing the Six Digit Error Code............................................................................
6-43
6-43
General Information
Specifications ..................................................................................................................
Tools ...............................................................................................................................
Consumables ..................................................................................................................
Glossary of Terms...........................................................................................................
Reissue
6-45
6-52
6-52
6-53
June, 2008
6-1
General Procedures
General Procedures
June, 2008
6-2
Reissue
Diagnostic Mode
This mode is used by service engineers to solve problems in the field and is intended to identify the fault areas in terms of replaceable components. In the Diagnostic Mode, the following
diagnostic functions can be run from the Control Panel:
Function
Parts Diagnostics
Program Function
NVM Check and Change of Settings
Reissue
Overview
Input Diagnostics
This can be used to check the status of the various sensors in the engine, IIT, and Trays. Refer to
Input Diagnostics for the sensors that can be checked and their Chain Function Codes.
Output Diagnostics
This can be used to operate the various motors, solenoids and clutches in the engine, IIT, and
Trays. Refer to Output Diagnostics for the components that can be operated and their Chain
Function Codes.
Initialization
This can be used to initialize the NVM, Counters, and Error Histories. Refer to Program Function
for the items that can be initialized.
Test Print
This can be used to generate an independent test print from the MCU or through the Controller.
Refer to Program Function.
Check
This can be used to check the total print counter, serial/product number, SW version, Error
Histories, etc. Refer to Program Function.
Checking the NVM value

and changing the settings
This is used to check and change the values of the various parameters in NVM.
June, 2008
6-3
General Procedures
Diagnostic Mode
Basic Operations of the Diagnostic Mode
Once in the Diagnostic Mode, "C_ " (Chain Code input screen) is shown on the display.
The "_" is blinking.
C _
How to Exit the Diagnostic Mode
Switch the machine OFF and then ON again.
How to Input the Chain and Function (WC 5016, 5020 w/Platen, ADF)
Display: Displays the menus and their results.
The following shows the Chain and Function input method in the Diagnostic Mode.
Keypad: Inputs Chain Function Codes.
A Chain/Function Code must be input as 2 digits. If the Chain/Function Code is "1,"

it must be input as "01." Any input value that goes beyond the 2nd digit will be ignored.
[Start] button: Displays the Diagnostics Menu.

[Stop] button: Pauses/Stops the diagnostic.
To clear the Chain/Function Code that was input, press the "C" button.
Both digits will be cleared, and you will be returned to the Code input screen.
When inputting the Function Code, pressing the [Start] button after inputting a Function Code
that is out of the specified range will transfer you to the initial screen of Function input.
How to Enter the Diagnostic Mode
Enter the Diagnostic Mode and check that the "C_ " (Chain Code input screen) is shown on the
display. The "_" should be blinking.
There are 2 ways to enter the diagnostic mode depending on the model of the IOT.
The procedure below entitled WC 5016, 5020 (with platen or ADF) Entering the Diagnostic
Mode is for IOT models with a platen, or with an ADF.
The procedure following entitled WC 5020 is for IOT models with a DADF.
C _
WC 5016, 5020 (with Platen or ADF) Entering the Diagnostic Mode

Press and hold down the [0] button on the keypad for 4 seconds or longer, and then press (and
quickly release) the [Start] button while still keeping the [0] button pressed.
Use the keypad to enter the 2-digit Chain Code.

The first number will appear in the first digit space, and the "_" will move to the right.
C 1 _
General Procedures
June, 2008
6-4
Reissue
Input the next number, and it will appear in the second digit space.
Once in the Diagnostic Mode, "C_ " (Chain Code input screen) is shown on the display.
The "_" is blinking.
C 1 2
Pressing the [Start] button will show the "F_ " (Function Code input screen) on the display.
An "F" and the blinking "_" are shown on the Function Code input screen.
How to Exit the Diagnostic Mode

Switch the machine OFF and then ON again.
How to Input the Chain and Link (WC 5020 w/DADF)
F _
The following shows the Chain and Link input method in the Diagnostic Mode.
A Chain/Link Code can be up to 3 digits. If the Chain/Function Code is "1,"
it must be input as "1." Do necessary to 0 fill. Any input value that goes beyond the 3rd digits
will be ignored.
Use the keypad to enter the 2-digit Function Code.
To clear the Chain/Link Code that was input, press the "AC" button.
Both digits will be cleared, and you will be returned to the Chain Code input screen.
When inputting the Link Code, pressing the [Start] button after inputting a Link Code that is out
of the specified range will transfer you to the initial screen of Link input.
F 2 _
Enter the Diagnostic Mode and check that the "C_ " (Chain Code input screen) is shown on the
display. The "_" should be blinking.
Pressing the [Start] button will then run the specified Diagnostic Code.
F 2 3
WC 5020 Entering the Diagnostic Mode
Press and hold down the [0] button on the keypad for 4 seconds or longer, and then press (and
quickly release) the [Start] button while still keeping the [0] button pressed.
Use the keypad to enter the Chain Code.

The first number will appear in the right hand digit space, and the "_" will move to the left and
the C will disappear.
Enter 6, 7, 8, and 9 then press the Start button.
Reissue
June, 2008
6-5
General Procedures
Input the next number, and it will appear in the right hand digit space.
Input the next number and it will appear in the right hand digit space.
Pressing the [Start] button will then run the specified Diagnostic Code.
NOTE: If in NVM, the value of that NVM location will flash waiting for a new input. After inputing
a new NVM code press the START button and the Link Code input screen will appear on the
display waiting for a new Lind Code.
How to Interrupt a Diagnostic

Press the [Stop] button when the diagnostic is still running.
Stopping a diagnostic that is running will return you to the Link Code input screen.
Pressing the [Start] button will show the "L_ " (Link Code input screen) on the display.
An "L" and the blinking "_" are shown on the Link Code input screen.
Pressing the [AC] button will return you to the Chain Code input screen (C_).
Use the keypad to enter the Link Code first digit.
General Procedures
June, 2008
6-6
Reissue
Input Component Control Codes
IOT Diagnostics
Input Diagnostics
The Input Diagnostics can be used to check the status of the various sensors in the engine, IIT,
and Trays.
For Platen and ADF model machines; Pressing the [Stop] button will stop the operation of the
component and return you to the Function Code input screen.
For DADF model machines; Pressing the [Stop] button will stop the operation of the component
and return to the Link Code inpit screen.
Chain
Func
or
Link
Sub
Contents of Data
Meaning
05
33
ADF
Document Tray Width

Sensor 2
L: No document
H: Document present
05
34
ADF
Document Tray Length

Sensor 1
L: No document
H: Document present
05
35
ADF
Document Tray Length

Sensor 2
L: No document
H: Document present
05
36
ADF
Document Feed Sensor
L: No document
H: Document present
07
07
TRAY
Tray1 No Paper Sensor
L: Paper present
H: No paper
07
08
TRAY
STM No Paper Sensor
L: Paper present
H: No paper
08
05
PH
IOT Regi Sensor
L: No paper
H: Paper present
08
06
TRAY
STM Feed Sensor
L: No paper
H: Paper present
08
07
TRAY
Tray1 Feed Sensor
L: No paper
H: Paper present
08
47
TRAY
FEED READY
SIGNAL
Level is high
Hot-Line Control
09
02
XERO
Drum Cartridge
Detected
L: No Drum Cartridge
H: Cartridge present
09
07
XERO
Toner Empty Sensor
L: Toner available
H: Toner depleted
10
23
PH
Fuser Exit Sensor
L: No paper
H: Paper present
10
60
FUSER
Nohad Fan Fail Monitor L: Able to monitor FUSER

FAN FAIL
H: Unable to monitor
FUSER FAN FAIL
Chain
Func
or
Link
Sub
Contents of Data
Meaning
01
01
PH
L/H (Left Side)

COVER
L: Cover is closed
H: Cover is open
01
10
TRAY
STM (Tray 2) L/H

COVER
L: Cover is closed
H: Cover is open
01
11
PH
L/H (Tray 1) LOW

COVER
L: Cover is closed
H: FCover is open
01
12
PH
FRONT COVER
L: Cover is closed
H: Cover is open
05
10
IIT
Platen COVER Open
L: Cover is closed
H: Cover is open
05
11
IIT
Carriage Home Sensor
L: Sensor is exposed
H: Sensor is blocked
05
29
ADF
ADF Top Cover Open
L: Cover is open
H: Cover is closed
05
30
ADF
Document Set Sensor
L: No document
H: Document present
05
31
ADF
Document Feeder
Width Sensor
L: No document
H: Document present
05
32
ADF
Document Tray Width

Sensor 1
L: No document
H: Document present
Reissue
June, 2008
6-7
General Procedures
Chain
Func
or
Link
Sub
Contents of Data
Meaning
05
217
DADF
Document Width Sensor
L:
H:
62
212
IIT
Regi Sensor
L:
H:
62
272
IIT
Scan Start
L:
H:
62
300
IIT
Platen I/L Switch
L:
H:
212
DADF
Feeder Cover Switch
L:
H:
102
DADF
Document Set Sensor
L:
H:
215
DADF
Doc Feeder Width Sensor
L:
H:
216
DADF
Doc Tray Width Sensor

1
L:
H:
217
DADF
Doc Tray Width Sensor

2
L:
H:
218
DADF
Doc Tray Length Sensor 1
L:
H:
219
DADF
Doc Tray Length Sensor 2
L:
H:
204
ADF/
DADF
Document Feed Sensor
L:
H:
206
ADF/
DADF
Doc Regi Sensor
L:
H:
205
ADF/
DADF
Doc Feedout Sen sor/

Exit Invert Sensor
L:
H:
General Procedures
Output Diagnostics
The Output Diagnostics can be used to operate and check the status of the various motors,
solenoids and clutches in the engine, IIT, and Trays. The operation can be enabled for every
component, and whether or not the component is operating properly can be determined by
checking the operation from outside.
When a component is operating, "run" is displayed.
r u n
For Platen and ADF model machines; Pressing the [Stop] button will stop the operation of the
component and return you to the Function Code input screen.
F 2 3
For DADF model machines; Pressing the [Stop] button will stop the operation of the component
and return to the Link Code inpit screen.
To resume the operation of the specified component, press the [Start] button again.
Output Component Control Codes

Chain
Func
Sub
Contents of Data
04
01
PH
IOT Motor ON
04
02
FUSER
Nohad Fan Motor

(HIGH SPEED)
June, 2008
6-8
Meaning
Fuser Fan changes from

Low to High speed
Reissue
Chain
Func
Sub
Contents of Data
Meaning
Chain
Func
Sub
Contents of Data
05
20
IIT
Carriage Motor High

Speed scan
Move the Carriage in the

scan direction at 80mm/
sec. NOTE: After the
scan, the Carriage stops
beyond the end position.
Pressing the [Start] button again returns the Carriage to the home
position. After another
scan, the Carriage stops
beyond the end position.
Turn the power off and on
to return the Carriage to
the home position.
08
11
TRAY
STM Feed Clutch
08
12
TRAY
Tray1 Feed Clutch
08
13
TRAY
STM Feed Motor
08
17
PH
Bypass Solenoid
09
04
XERO
HVPS ON (LOW
VOLTAGE)
09
05
XERO
HVPS ON (HIGH
VOLTAGE)
09
06
XERO
Pre-Charge Erase
Lamp
10
08
PH
Exit Motor Forward
10
09
PH
Exit Motor Reverse
05
62
DADF
Paper Feed Clutch
05
63
DADF
Registration Clutch
05
64
DADF
Output Inverting
Clutch
05
65
DADF
Output Spacing Solenoid
62
05
IIT
Scan Motor, Scan

Direction
Used with locking position

Used with locking position
05
05
05
05
05
21
22
23
40
41
IIT
IIT
IIT
ADF
ADF
Carriage Motor High

Speed return
Move the Carriage

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

Speed scan
Move the Carriage in the

scan direction at 40mm/
sec. NOTE: See 05-20.
Carriage Motor Low

Speed return
Move the Carriage

toward home position at
40mm/sec. NOTE: See
05-20.
Document Drive Motor

High Speed
Run the Document Drive

Motor at 80 mm/sec.
62
06
IIT
Scan Motor Return

Direction
Document Drive Motor

Low Speed
Run the Document Drive

Motor at 40 mm/sec.
62
07
IIT
Scan Locking Position
05
01
DADF
DADF Motor
62
IIT
Exposure Lamp
62
86
IIT
Image Area H8_PS
05
42
ADF
Turn the Document Feed

Clutch on.
06
15
ROS
ROS Motor ON
ROS Motor Start & Stop.
08
10
PH
IOT Registration
Clutch
Reissue
June, 2008
6-9
Meaning
NOTE: Ejects paper.
General Procedures
Program Function
Clearing the error will return you to the Function Code input screen.
The Program Function can access the NVM (the EEPROM on the AIOC PWB) to perform the
following functions:
Test Print
Initialize NVM
Check Error History
Check Print Count
Display Version
Clear Error History
Display Serial Number, Product Number
F _
To resume the test print, press the [Start] button again.
Pressing the [Stop] button in the middle of a test print will stop the feeding of additional paper,
output any paper that was already fed, and return you to the Function Code input screen.
Initialize NVM [20-58]
Test Print [23-10], [23-01]

There are two test print modes: one that outputs the Controller built-in pattern, and another that
outputs the MCU built-in pattern.
This will return the NVM settings to their default values.

While the NVM is being initialized, "run" is displayed.
NOTE: Before running either of these test prints, you must check and make sure that the applicable NVM settings are correct. See Summary of Program Functions.
During a test print, "run" is displayed.
r u n
r u n
When NVM initialization is complete, you will be returned to the Function Code input screen.
Once the test print starts, an error code will be displayed if an error occurs while printing.
C 1
General Procedures
June, 2008
6-10
Reissue
Display Error History [40-01]
Display Firmware Version [29-49]
This can be used to check for the last 20 errors.
This can be used to check the firmware versions of the Controller and the MCU.
Pressing the [Start] button will display the error codes, starting with the most recent error.
Pressing the [Start] button will display the firmware version, starting from the highest order (leftmost) digit.
Once everything has been displayed, you will be returned to the Function Code input screen.
E 1
J
6 6
1
F
When the last error is displayed, press the [Start] key to return to the Function Code input
screen.
1
a
2
Clear Error History [20-59]

This can be used to clear the Error History.
F _
While the Error History is being cleared, "run" is displayed.
Pressing the [Stop] key during the display will stop it and return you to the Function Code input
screen.
r u n
Check Print Count [25-01]

This can be used to check the total print count. The display is in decimal numbers.
The initial display shows the first 3 digits of the print count. Pressing the [Start] button will show
you the next 3 digits.
Once the Error History has been cleared, you will be returned to the Function Code input
screen.
Display Serial Number [25-20]
Pressing the [Start] button again will return you to the Function Code input screen.
This can be used to display the serial number of the machine.
7 1 1
6
F
Reissue
Pressing the [Start] button will display the serial number, starting from the highest order (leftmost) digit.
Once the whole serial number has been displayed, you will be returned to the Function Code
input screen.
2 9
5
8
F
3 1
6
4
7
0
June, 2008
6-11
General Procedures
Display Product Code [25-21]

This can be used to display the product code of the machine.
Pressing the [Start] button will display the product code, starting from the highest order (leftmost) digit.
Once the whole product code has been displayed, you will be returned to the Function Code
input screen.
F _
General Procedures
June, 2008
6-12
Reissue
Summary of Program Functions
Chain
Function
Sub
Contents of Data
Meaning
05
22
IIT
Move Scanner
Moves the Scanner to the home position.
05
23
IIT
Move Scanner
Moves the Scanner to the maintenance position.
20
58
Initialize
MCU NVM Initialize
Sets the initial value in the MCU's system data.
20
59
Initialize
Clear Error History
Clears the Error History.
20
60
Initialize
MCU NVM Update
Sets the initial value in additional system data between old and new MCU
versions.
Use "DIAG EXECUTE" command.
23
10
Test Print
Test Print
Executes test pattern printing.
23
01
Test Print
Print Controller built-in pattern
Prints the Controller built-in grid, using the following NVM settings:
1-Sided or 2-Sided: 23-20
Paper Source: 23-21
Number of prints: 23-27 (high-order digits) and
23-26 (low-order digits)
25
01
Check
Display total print counter
Displays the total print count (6 digits). The display is divided into 2
portions: the high-order digits and the low-order digits.
25
20
Check
Display machine serial number
Displays the machine serial number (10 digits). The display is divided into 4
portions: the highest-order digit, followed by 3 sets of 3 digits.
25
21
Check
Display machine product code
Displays the machine product code (8 digits). The display is divided into 3
portions: the 2 highest-order digits, followed by 2 sets of 3 digits.
29
50
Check
Display Controller firmware version
Displays the firmware version of the Controller. The display is divided into
3 portions, starting from the highest-order digit.
29
49
Check
Display MCU firmware version
Displays the firmware version of the MCU. The display is divided into 3
portions, starting from the highest-order digit.
40
01
Check
Display Error History
Displays the Error History, starting with the most recent error code.
Reissue
June, 2008
6-13
General Procedures
NVM Settings Mode

Basic Operations of the NVM Settings Mode
The NVM Settings Mode allows you to check or change the value of each NVM setting.
Initially, the current value of the specified NVM item is shown as blinking.
3
Using the keypad to input a value shows the value as blinking.
3 1
3
Pressing the [C] button clears the value that was input and leaves the current value as blinking.
3
Pressing the [Start] button sets the value that was input, stops the blinking, and returns you to
the Function Code input screen after 2 seconds has passed.
3
If the [Start] button is pressed when "_" is displayed, or when the input value is outside the
range of possible settings, the input value is treated as invalid while the current value is shown
as blinking. You will then be returned to the Function Code input screen after 4 seconds has
passed.
See List of NVM Settings (WC 5016, 5020 ADF).
General Procedures
June, 2008
6-14
Reissue
List of NVM Settings (WC 5016, 5020 ADF)

NOTE: In the CE Access columns, O = yes and X = no.
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Unit
Initial
Value
Init
06
20
ROS
ALL TRAY-LASER SIDE

REGI ADJUSTMENT
1~99
0.254
mm
50
06
21
ROS
TRAY1-LASER SIDE REGI

ADJUSTMENT
1~99
0.254
mm
50
06
22
ROS
TRAY2-LASER SIDE REGI

ADJUSTMENT
1~99
0.254
mm
50
06
26
ROS
MSI-LASER SIDE REGI

ADJUSTMENT
1~99
0.254
mm
50
06
28
ROS
DUP ALL TRAY-LASER

SIDE REGI ADJUSTMENT
1~99
0.254
mm
50
06
29
ROS
DUP TRAY1-LASER SIDE

REGI ADJUSTMENT
1~99
0.254
mm
50
06
30
ROS
DUP TRAY2-LASER SIDE

REGI ADJUSTMENT
1~99
0.254
mm
50
06
34
ROS
DUP MSI-LASER SIDE

REGI ADJUSTMENT
1~99
0.254
mm
50
06
52
ROS
IMAGE AREA
0~1
0:Normal Image Area

1:Wide Image Area
07
46
TRAY
Tray1-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)
Reissue
June, 2008
6-15
Remarks
General Procedures
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Unit
Initial
Value
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
8: 8.5x13 (Folio)
10: A4 SEF
12: 16K SEF*1
15: B5 SEF
07
48
TRAY
MSI Paper size
0~254
1mm
value paper type

1: 11x17 SEF
2: A3 SEF
3: 8K SEF*1
5: B4SEF
8: 8.5x13 (Folio)
10: A4 SEF
12: 16K SEF*1
15: B5 SEF
18: 5.5x8.5 S
19: A5 S
20
01
PH
LEAD REGI ADJUSTMENT

- ALL TRAY
0~60
0.146
mm
30
Image input is delayed when Set Value is

increased.
Min(0)=-4.46mm, Max(66)=4.46mm,
Initial(33)=0mm
20
41
PH
TRAY1 for Normal LEAD

REGI ADJ
0~60
0.146
mm
30

increased.
20
42
PH
TRAY2 for Normal LEAD

REGI ADJ
0~60
0.146
mm
30

increased.
General Procedures
June, 2008
6-16
Reissue
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Unit
Initial
Value
Init
Remarks
20
43
PH
SMH for Normal LEAD REGI

ADJ
0~60
0.146
mm
30

increased.
20
45
PH
DUP ALL SIZE for Normal

LEAD REGI ADJ
0~60
0.146
mm
30

increased.
20
46
PH
ALL TRAY - REGI LOOP

TIMER
0~66
0.438
mm
33
Loop increases when Set Value is

increased.
20
47
PH
TRAY1 for Normal Paper REGI LOOP TIMER
0~66
0.438
mm
33

increased.
20
48
PH
TRAY2 for Normal Paper REGI LOOP TIMER
0~66
0.438
mm
33

increased.
20
49
PH
SMH for Normal Paper - REGI

LOOP TIMER
0~66
0.438
mm
11

increased.
20
51
PH
DUP for Normal Paper - REGI

LOOP TIMER
0~66
0.438
mm
33

increased.
21
09
HFSI
Last 2 of Fuser discharging

Number
0~99
Only 0 clearance is possible in the write

mode.
("0 clearance" means all bytes change to 0
at the same time.)
21
19
HFSI
5th & 6th Fuser discharging

Number
0~99

mode.
at the same time.)
21
29
HFSI
3rd & 4th Fuser discharging

Number
0~99

mode.
at the same time.)
21
39
HFSI
1st 2 of Fuser discharging

Number
0~3

mode.
at the same time.)
23
20
PH
Simplex/Duplex
0~1
0: Simplex
1: Duplex
Reissue
June, 2008
6-17
General Procedures
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Initial
Value
Init
Remarks
23
21
PH
Feed Tray
1~6
1: Tray1. 2: Tray2. 3: Tray3. 4: Tray4.

5: HCF. 6: MSI
23
22
PH
Output Tray
0~4
0: FACE DOWN TRAY#1.

1: FACE DOWN TRAY#2.
2: FACE UP TRAY.
3: FINISHER Bin1.
4: FINISHER Top Tray
23
26
PH
Test Print Run Length Low

Byte
0~99
Number of Test Prints
23
27
PH
Test Print Run Length High

Byte
0~99
Number of Test Prints
29
01
Billing
Last 2 Dig Total Copy

Counter(8 Digits)
0~99
29
11
Billing
3rd & 4th Dig Total Copy

Counter(8 Digits)
0~99
29
21
Billing
1st 2 Dig Total Copy

Counter(8 Digits)
0~99
29
04
HFSI
Tray1 Last 2 Digits of Feed

Capacity (8 Digits)
0~99

mode.
at the same time.)
29
14
HFSI
Tray1 5th & 6th Digits of Feed

Capacity (8 Digits)
0~99

mode.
at the same time.)
29
24
HFSI
Tray1 3rd & 4th Digits of

Feed Capacity (8 Digits)
0~99

mode.
at the same time.)
29
34
HFSI
Tray1 1st 2 Digits of Feed

Capacity (8 Digits)
0~3

mode.
at the same time.)
General Procedures
Unit
June, 2008
6-18
Reissue
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Unit
Initial
Value
Init
Remarks
29
05
HFSI

Capacity (6 Digits)
0~99

mode.
at the same time.)
29
15
HFSI

Capacity (6 Digits)
0~99

mode.
at the same time.)
29
25
HFSI

0~99

mode.
at the same time.)
29
09
HFSI
MSI Last 2 Digits of Feed

Capacity (8 Digits)
0~99

mode.
at the same time.)
29
19
HFSI
MSI 5th & 6th Digits of Feed

Capacity (8 Digits)
0~99

mode.
at the same time.)
29
29
HFSI
MSI 3rd & 4th Digits of Feed

Capacity (8 Digits)
0~99

mode.
at the same time.)
29
39
HFSI
MSI 1st 2 Digits of Feed

Capacity (8 Digits)
0~3

mode.
at the same time.)
30
04
Recycle
Last 2 Digits of MSI Feed

Capacity (8 Digits)
0~99
30
14
Recycle
5th & 6th Digits of MSI Feed

Capacity (8 Digits)
0~99
30
24
Recycle
3rd & 4th Digits of MSI Feed

Capacity (8 Digits)
0~99
Reissue
June, 2008
6-19
General Procedures
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Unit
Initial
Value
Init
30
34
Recycle
1st 2 Digits of MSI Feed

Capacity (8 Digits)
0~3
30
05
Recycle
Last 2 of IOT Starting Number
0~99
30
15
Recycle
3rd & 4th IOT Starting

Number
0~99
30
25
Recycle
1st 2 of IOT Starting Number
0~99
30
06
Recycle

Capacity (8 Digits)
0~99
30
16
Recycle

Capacity (8 Digits)
0~99
30
26
Recycle

0~99
30
36
Recycle

Capacity (8 Digits)
0~3
30
07
Recycle

Capacity (6 Digits)
0~99
30
17
Recycle

Capacity (6 Digits)
0~99
30
27
Recycle

0~99
30
37
Recycle

Capacity (8 Digits)
0~3
30
41
HFSI
Last 2 Digits of the number of

Sheets Reaching BIAS transfer
Roll (8 Digits)
0~99

mode.
at the same time.)
30
42
HFSI
5th & 6th Digits of the number

of Sheets Reaching BIAS
transfer Roll (8 Digits)
0~99

mode.
at the same time.)
General Procedures
June, 2008
6-20
Remarks
Reissue
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Unit
Initial
Value
Init
Remarks
30
43
HFSI
3rd & 4th Digits of the number

0~99

mode.
at the same time.)
30
44
HFSI
1st Two Digits of the number

0~3

mode.
at the same time.)
30
61
Recycle
Tray Feed Capacity MAX

Over
0~1
It is shown whether the Recycle Tray

Feed Capacity NVM was written more
than 4000000 times.
0: not exceed
1: exceeded.
30
62
Recycle
IOT Starting Number MAX

Over
0~1
It is shown whether the IOT Starting

Number NVM was written more than
1000000 times.
0: not exceed
1: exceeded.
33
04
CRU
CRU Remain
0~100
1%
100
CRU Remain percentage
33
05
ESS IF
UI Auto Clear Time
0~4
0=OFF(Disabled), 1=20sec
2=30sec, 3=60sec, 4=90sec
33
06
ESS IF
Priority Paper Tray
1~3
1=Tray1
2=Tray2
3=MSI
33
07
ESS IF
Document Type
1~3
1=Text
2=Text & Photo
3=Photo
33
08
ESS IF
Density Adjustment
0~4
0=Lightest
1=Light
2=Normal
3=Dark
4=Darkest
Reissue
June, 2008
6-21
General Procedures
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Unit
Initial
Value
Init
Remarks
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%
33
11
ESS IF
Auto Tray Switch
0~1
0=Disable
1=Enable
33
12
ESS IF
Auto Paper Selection
0~1
0=Disable
1=Enable
33
13
ESS IF
Default Customizing
Reduction / Enlargement
50~200
82
China 82=82%(=82)
XC 64=64%(=64)
33
14
ESS IF
Sharpness Adjustment for

Copy Job
0~4
0=Weakest
1=Weaker
2=Normal
3=Stronger
4=Strongest
33
15
ESS IF
Sharpness Adjustment for

Scan Job
0~4
0=Weakest
1=Weaker
2=Normal
3=Stronger
5=Strongest
33
16
ESS IF
MCU Low Power Mode
1~254
0=0min(Shift immediately)
1=5min
2=20min
3=60min
4=120min
5=240min
254=OFF(Disable)
33
17
ESS IF
MCU Sleep Mode
0~254
1=5min
2=20min
3=60min
4=120min
5=240min
254=OFF(Disable)
General Procedures
June, 2008
6-22
Reissue
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Unit
Initial
Value
Init
Remarks
33
18
ESS IF
Device Power Off Mode
0~254
1=5min
2=20min
3=60min
4=120min
5=240min
254=OFF(Disable)
33
19
ESS IF
Background removal for

COPY
0~5
0=OFF
1=Level1
2=Level2
3=Level3
4=Level4
5=Level5
33
20
ESS IF
Background removal for

SCAN
0~5
0=OFF
1=Level1
2=Level2
3=Level3
4=Level4
5=Level5
33
21
ESS IF
Account Mode
0~2
0=Disable
1=Single User Password Mode
2=Multi User Password Mode
33
22
ESS IF
Paper Class
0~2
0=Metric
1=Inch13
2=Inch14
33
23
ESS IF
Add Original Auto Clear Time 0~4
0=OFF(Disabled)
1=20sec
2=30sec
3=60sec
4=90sec
33
24
ESS IF
Wait Time After MSI Jam

Clear
0~60
1sec
0- 60sec
33
25
ESS IF
Carriage Return Default

Position
0~60
1sec
0- 60sec
Reissue
June, 2008
6-23
General Procedures
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Unit
Initial
Value
Init
Remarks
33
26
ESS IF
Platen Fast Scan REGI

Adjustment
0~144
1dot
(600dpi)
72
0-71=-72 to -1dot
72=0dot
73-144=1 to 72dot
33
27
ESS IF
Platen Slow scan REGI

Adjustment
0~151
1dot
(600dpi)
24
0-23=-24 to -1dot
24=0dot
25-144=1 to 151dot
33
28
ESS IF
ADF Fast Scan REGI

Adjustment
0~144
1dot
(600dpi)
72
0-71=-72 to -1dot
72=0dot
73-144=1 to 72dot
33
29
ESS IF
ADF Slow scan REGI

Adjustment
0~79
0.1mm
40
0-39=-4.0 to -0.1mm
40=0mm
41-80=0.1 to 4.0mm
33
30
ESS IF
Shading Offset for ADF
1~254
100
complement
100=x1
1-99=x0.01-x0.99 (dark)
101-254=x1.01-x2.54 (light)
33
31
ESS IF
Shading Offset for ADF
1~254
100
complement
100=x1
1-99=x0.01-x0.99 (dark)
101-254=x1.01-x2.54 (light)
33
33
ESS IF
Platen Slow Scan scale

Adjustment
0~20
0.10%
10
0-9=-1.0% to -0.1%
10=0%
11-20=0.1% to 1.0%
33
35
ESS IF
ADF Slow Scan scale

Adjustment
0~20
0.10%
10
0-9=-1.0% to -0.1%
10=0%
11-20=0.1% to 1.0%
33
36
ESS IF
ADF Loop Adjustment
0~10
1mm
0-4=-5 to -1mm
5=0mm
1-5=1 to 5mm
33
37
ESS IF
M/C config
0~1
0 : DC
1 : CPS
33
38
ESS IF
ADF installation
0~1
0 : not installed
1 : installed
General Procedures
June, 2008
6-24
Reissue
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Unit
Initial
Value
Init
Remarks
34
01
ESS IF
Administrator User Login

Password Low byte
48~57
49
48-57
34
11
ESS IF

Password Mid byte
48~57
49
34
21
ESS IF

Password High Byte
48~57
49
34
02
ESS IF
User1 Login Password Low

Byte
48~57
48
34
12
ESS IF
User1 Login Password Mid

byte
48~57
48
34
22
ESS IF
User1 Login Password High

byte
48~57
48
34
03
ESS IF

Byte
48~57
48
34
13
ESS IF

byte
48~57
48
34
23
ESS IF

byte
48~57
48
34
04
ESS IF

Byte
48~57
48
34
14
ESS IF

byte
48~57
48
34
24
ESS IF

byte
48~57
48
34
05
ESS IF

Byte
48~57
48
34
15
ESS IF

byte
48~57
48
34
25
ESS IF

byte
48~57
48
Reissue
June, 2008
6-25
General Procedures
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Unit
Initial
Value
Init
34
06
ESS IF

Byte
48~57
48
34
16
ESS IF

byte
48~57
48
34
26
ESS IF

byte
48~57
48
34
07
ESS IF

Byte
48~57
48
34
17
ESS IF

byte
48~57
48
34
27
ESS IF

byte
48~57
48
34
08
ESS IF

Byte
48~57
48
34
18
ESS IF

byte
48~57
48
34
28
ESS IF

byte
48~57
48
34
09
ESS IF

Byte
48~57
48
34
19
ESS IF

byte
48~57
48
34
29
ESS IF

byte
48~57
48
35
01
ESS IF

Byte
48~57
48
35
11
ESS IF

byte
48~57
48
35
21
ESS IF

byte
48~57
48
General Procedures
June, 2008
6-26
Remarks
Reissue
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Unit
Initial
Value
Init
35
02
ESS IF

Byte
48~57
48
35
12
ESS IF

byte
48~57
48
35
22
ESS IF

byte
48~57
48
35
23
ESS IF
User1 Copy Credit
0~60
1000
35
24
ESS IF
User2 Copy Credit
0~60
1000
35
25
ESS IF
User3 Copy Credit
0~60
1000
35
26
ESS IF
User4 Copy Credit
0~60
1000
35
27
ESS IF
User5 Copy Credit
0~60
1000
35
28
ESS IF
User6 Copy Credit
0~60
1000
35
29
ESS IF
User7 Copy Credit
0~60
1000
35
30
ESS IF
User8 Copy Credit
0~60
1000
35
31
ESS IF
User9 Copy Credit
0~60
1000
35
32
ESS IF
User10 Copy Credit
0~60
1000
36
01
ESS IF
User1 Copy Count Low byte
0~99
36
11
ESS IF
User1 Copy Count Mid byte
0~99
36
21
ESS IF
User1 Copy Count High byte
0~99
36
02
ESS IF
0~99
36
12
ESS IF
0~99
36
22
ESS IF
0~99
36
03
ESS IF
0~99
36
13
ESS IF
0~99
36
23
ESS IF
0~99
36
04
ESS IF
0~99
36
14
ESS IF
0~99
Reissue
June, 2008
6-27
Remarks
General Procedures
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Unit
Initial
Value
Init
36
24
ESS IF
0~99
36
05
ESS IF
0~99
36
15
ESS IF
0~99
36
25
ESS IF
0~99
36
06
ESS IF
0~99
36
16
ESS IF
0~99
36
26
ESS IF
0~99
36
07
ESS IF
0~99
36
17
ESS IF
0~99
36
27
ESS IF
0~99
36
08
ESS IF
0~99
36
18
ESS IF
0~99
36
28
ESS IF
0~99
36
09
ESS IF
0~99
36
19
ESS IF
0~99
36
29
ESS IF
0~99
36
10
ESS IF
0~99
36
20
ESS IF
User10 Copy Count Mid Byte
0~99
36
30
ESS IF
User10 Copy Count High Byte 0~99
42
01
ESS IF
Last 20 Fault History 1st Last
48~122
48
42
11
ESS IF
Last 20 Fault History 1st 2nd
48~122
48
42
21
ESS IF
Last 20 Fault History 1st 1st
48~122
48
42
02
ESS IF
Last 20 Fault History 2nd Last
48~122
48
42
12
ESS IF
Last 20 Fault History 2nd 2nd
48~122
48
42
22
ESS IF
Last 20 Fault History 2nd 1st
48~122
48
42
03
ESS IF
Last 20 Fault History 3rd Last
48~122
48
General Procedures
June, 2008
6-28
Remarks
Reissue
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Unit
Initial
Value
Init
42
13
ESS IF
Last 20 Fault History 3rd 2nd
48~122
48
42
23
ESS IF
Last 20 Fault History 3rd 1st
48~122
48
42
04
ESS IF
Last 20 Fault History 4th Last
48~122
48
42
14
ESS IF
Last 20 Fault History 4th 2nd
48~122
48
42
24
ESS IF
Last 20 Fault History 4th 1st
48~122
48
42
05
ESS IF
48~122
48
42
15
ESS IF
48~122
48
42
25
ESS IF
48~122
48
42
06
ESS IF
48~122
48
42
16
ESS IF
48~122
48
42
26
ESS IF
48~122
48
42
07
ESS IF
48~122
48
42
17
ESS IF
48~122
48
42
27
ESS IF
48~122
48
42
08
ESS IF
48~122
48
42
18
ESS IF
48~122
48
42
28
ESS IF
48~122
48
42
09
ESS IF
48~122
48
42
19
ESS IF
48~122
48
42
29
ESS IF
48~122
48
42
10
ESS IF
Last 20 Fault History 10th Last 48~122
48
42
20
ESS IF
Last 20 Fault History 10th 2nd 48~122
48
42
30
ESS IF
48~122
48
43
01
ESS IF
48
43
11
ESS IF
48~122
48
43
21
ESS IF
48~122
48
Reissue
June, 2008
6-29
Remarks
General Procedures
CE
Access
Chain
Func
tion
Sub
Contents of Data
Unit
Initial
Value
Init
43
02
ESS IF
48
43
12
ESS IF
48
43
22
ESS IF
48~122
48
43
03
ESS IF
48
43
13
ESS IF
48
43
23
ESS IF
48~122
48
43
04
ESS IF
48
43
14
ESS IF
48
43
24
ESS IF
48~122
48
43
05
ESS IF
48
43
15
ESS IF
48
43
25
ESS IF
48~122
48
43
06
ESS IF
48
43
16
ESS IF
48
43
26
ESS IF
48~122
48
43
07
ESS IF
48
43
17
ESS IF
48
43
27
ESS IF
48~122
48
43
08
ESS IF
48
43
18
ESS IF
48
43
28
ESS IF
48~122
48
43
09
ESS IF
48
43
19
ESS IF
48
43
29
ESS IF
48~122
48
43
10
ESS IF
48
43
20
ESS IF
48
General Procedures
Range
June, 2008
6-30
Remarks
Reissue
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Unit
Initial
Value
Init
43
30
ESS IF
48~122
48
43
40
ESS IF
Offset to the latest error
0~19
50
15
EXIT
Enable OCT & Inverter
0~2
0:Disable
1:Inverter+OCT
2:Inverter Only
50
20
FUSER
FSR Reset FuserOverTemp
0~3
0:reset
1:FS1 Detected over temp
2:FS2 Detected over temp
3:On time Fail
5:Cold Sagging Fail(Only reset is possible
in the diagnostics mode.)
60
01
ESS IF
MCU VERSION
0~1
60
02
ESS IF
MCU Release Number
0~99
60
03
ESS IF
MCU Patch Level
0~99
60
06
ESS IF
STM Version
0~99
60
07
ESS IF
STM Release Number
0~99
60
18
General
CPM
0~99
20:20PPM
Other:PPM NG
60
19
General
Market Identity
0~254
22: DMO
60
26
MC Code
Serial Code1
0~254
60
27
MC Code
Serial Code2
0~254
60
28
MC Code
Serial Code3
0~254
60
29
MC Code
Serial Code4
0~254
60
30
MC Code
Serial Code5
0~254
60
31
MC Code
Serial Code6
0~254
60
32
MC Code
Serial Code7
0~254
60
33
MC Code
Serial Code8
0~254
60
34
MC Code
Serial Code9
0~254
Reissue
June, 2008
6-31
Remarks
General Procedures
CE
Access
Chain
Func
tion
Sub
Contents of Data
Range
Unit
Initial
Value
Init
60
35
MC Code
Serial Code10
0~254
60
36
Product
Product code 1
0~254
60
37
Product
Product code 2
0~254
60
38
Product
Product code 3
0~254
60
39
Product
Product code 4
0~254
60
40
Product
Product code 5
0~254
60
41
Product
Product code 6
0~254
60
42
Product
Product code 7
0~254
60
43
Product
Product code 8
0~254
Remarks
Reprograming the DADF EPROMS on the SLCC PWB when replacing them with new ones.
Table 1 Reprogaming the EPROMS on the SLCC PWB (DADF)
XC(DMO-W)
110 V
100S12656
Serial No.
KMA469001MMA484000
XC(DMO-W)
220 V
100S12657
Serial No.
KMX484001KMX494000
XC(DMO-E)
220 V
100S12655
Serial No.
331494001x331524000x
Chain
Link
700
339
700
340
700
341
700
342
700
343
700
344
700
348
700
349
700
350
700
165
840
840
826
Country Code
840:USA 826:UK
This list
700
402
Paper Size Group
1: Japan, 2:NA, 4:AP, 5:SA
This list
700
337
15
15
15
Device Type
CPFS:15
This list
700
338
Territory
0x01:FX 0x02:XC 0x03:XE

0x04:AP
This list
700
700
Machine serial number format
This list
General Procedures
NVM Destination
Remarks
Reference
Get the information from the latest

soft ware version.
June, 2008
6-32
Reissue
Table 1 Reprogaming the EPROMS on the SLCC PWB (DADF)
Chain
Link
XC(DMO-W)
110 V
100S12656
Serial No.
KMA469001MMA484000
700
329
75
75
75
Product Code #1
700
330
77
77
76
Product Code #2
700
331
65
88
66
Procuct Code #3
700
332
Product Code #4
700
333
Product Code #5
700
334
Product Code #6
700
335
Product Code #7
700
336
Product Code #8
700
701
DMP Indication
709
11
85
85
85
XJ Code #1
709
12
67
67
67
XJ Code #2
709
13
78
80
77
XJ Code #3
709
14
XJ Code #4
700
297
75
75
51
Upper 3Byte Serial No. #1
This list or the Serial Number Plate
700
298
77
77
51
700
299
65
88
49
780
203
1:LEF
1:LEF
1:LEF
Tray 1 Standard paper size-Orientation
780
204
44:8.5 x 11 (Letter) 44:8.5x11 (Letter)
5:A4
Tray 1 Standard paper size-Size
This list
780
205
1:LEF
1:LEF
1:LEF
Tray2 Standard paper size-Orientation
This list
780
206
5:A4
5:A4
5:A4
Tray2 Standard paper size-Size
This list
780
232
2:SEF
2:SEF
2:SEF
MSI Standard paper size-Orientation
This list
780
233
39:11x17
39:11x17
4:A3
MSI Standard paper size-Size
715
21
Platen Fast Scan REGI Adjustment
Initial Value: 120
Refer to the NEC Serial Number

Plate which is on the back of the IIT
715
20
Platen Slow Scan REGI Adjustment
Iniatial Value: 120
Refer to the NEC Serial Number

Plate which is on the back of the IIT
650
15
EXIT
0: Simplex M/C
1: 2: Duplex M/C
This list
606
020
All Tray-Laser Side REGI
Initial Value: 50
620
001
Lead REGI Adjustment-All Tray
606
058
Reissue
14
XC(DMO-W)
220 V
100S12657
Serial No.
KMX484001KMX494000
XC(DMO-E)
220 V
100S12655
Serial No.
331494001x331524000x
NVM Destination
14
14
END Video Enable Timing Adjustment
June, 2008
6-33
Remarks
Reference
Refer to this list or the Serial Number

Plate.
2:DMP5/6 3:DMP7
This list
This list

0:none specified, 1:LEF,
2:SEF
This list
This list
Initial Value: 6
This list
General Procedures
List of NVM Settings (WC 5020 DADF)

NOTE: In the CE Access columns, O = yes and X = no.
Table 2
Chain
Link
Name of data
Range
Unit
Initial
Value
715
IISS Major Version
0 ~ 65535
65535
IISS Major Version number
715
IISS Minor Version
0 ~ 65535
65535
IISS Minor Version number
715
IISS Revision Version
0 ~ 65535
65535
IISS Revision Version number
715
10
Platen/DADF
0~1
Switch Platen model and DADF Model

0: Platen
1: DADF
715
11
Change Size Table
0~3
Switch document size detection table of DADF

0: mm (AP)
1: inch 13-12 (EU/South America)
2: inch 14 (North America)
3: Mexico
715
20
Platen SS Registration Adjustment
80 ~ 260
1 dot
120
Platen SS Registration Correction Value. NVM initial

value is Adjustment Value 0. Adjust by 1 dot. (Not
include the adjustment value from Module Sensor ~
Registration)
715
21
Platen PRadjF
0 ~ 240
1 dot
120
Platen FS Registration Correction Value. NVM value

120 is Adjustment Value 0. Adjust by 1 dot.
715
22
CVT Image Reading Position
0 ~ 500
0.1 mm
100
DADF Reading Position Correction Value
715
23
SS Feed Position Correction (Side 1)
400 ~ 600
0.1 mm
505
SS Feed Position Correction Value (Side 1) Includes

the adjustment value from Doc Regi Sensor (SNS8)
ON~Start of Reading Side 1
715
24
SS Feed Position Correcation (Side 2)
400 ~ 600
0.1 mm
505
SS Feed Position Correction Value (Side 2) Includes

the adjustment value from Doc Regi Sensor (SNS8)
ON~Start of Reading Side 2.
715
25
SS Tail Registration Corerection (Side 1)
400~600
0.1 mm
446
Includes the adjustment value from Doc Regi Sensor

(SNS8) OFF~Finish of Reading Side 1.
715
26
SS Tail Registration Correction (Side 2)
400~600
0.1 mm
446
Includes the adjustment value from Doc Regi Sensor

(SNS8) Off~Finish of Reading Side 2.
715
27
Registration Loop Degree Adjustment A
50~200
0.1 mm
89
Feed Sensor (SNS7) ON~Feed CL (EMC1) OFF after

feeding the document (Adjustment Value A)
715
28
Registration Loop Degree Adjustment B
50~200
0.1 mm
150
Feed Sensor (SNS7) ON~Regi Cl (ENC2) ON when

inverting document. (Adjustment Value B)
715
29
Feed Clutch Timing Adjustment (output)
700~1000
0.1 mm
940
Feedout Sensor OFF~Feedout Clutch OFF when outputting
715
30
Feedout Clutch Timing Adjustment (invert) 0~500
0.1 mm
210
Feedout Sensor) OFF~Feedout Clutch OFF when

inverting
715
31
CVT FS OFFset Side 1
1 dot
120
CVT FS Registration Correction Value for Side 1 (front

side) NVM value 120 is Adjustment Value 0. Adjust by 1
dot.
General Procedures
0~240
June, 2008
6-34
CE Access
W
Init Remarks
Reissue
Table 2
Chain
Link
Name of data
Range
Unit
Initial
Value
715
32
CVT FS OFFset Side 2
0~240
1 dot
120
CVT FS Registration Correction Value for Side 2 (back

side) NVM value 120 is Adjustment Value 0. Adjust by 1
dot.
715
40
FS Magnification Adjustment
0~100
0.1%
50
Fine Adjustment Value of FS magnification. Shows =/5% (by 0.1%) fine adjustment value with 50 for 0%, ) for
-5% and 100 for 5%.
715
41
Platen SS Magnification Adjustment
40~60
0.1%
50
Fine Adjustment Value of Platen SS Magnification.

Shows +/- 1% (by 0.1%) fine adjustment value with 50
for 0%, 40 for -1% and 60 for +1%/
715
42
CVT SS Magnification Adjustment
40~60
0.1%
50
Fine Adjustment Value of CVT SS Magnification.

Shows +/- 1% (by 0.1%) fine adjustment value with 50
for 0%, 40 for -1% and 60 for +1%.
715
90
Fail Bypass
0~1
0: With out Fail Bypass

1: With Fail Bypass
715
91
Error Information
0~65535
Debug information
715
92
Size detection: Sensor Information of Cus- 0~65535

tom Size
Sensor information in the case of the size detection

result being Custom Size. If the result is not Custom
Size, this NVM update will not be done.
bit 0: Sensor 6
bit 1: Sensor 5
bit 2: Sensor 4
bit 3: Sensor 3
bit 4: Sensor 2
bit 5-15: (spare)
Meaning of bit = 0: Sensor OFF, 1: Sensor ON
715
100
WREF ADJ Platen
50~255
111
Correction Factor of Blue W-Fef (for Platen)
715
101
Density Level ADJ RGBK
80~120
100
Highlight Fine Adjustment (x 1/100, dommon to RGBK)
715
102
102WDL STD CL 30 B
0~1023
Standard Data of White Variation Correction.
715
103
WREF ADJ CVT
50~255
78
Correction factor of Blue W-Fef (for CVT)
715
110
AGOC SHD NVM
0~8
0: PROM used
1: NVM of (*1) enabled.
715
111
FBLM
0~1023
984
AGC Maximum Allowable Value (*1)
715
112
FBLI
0~1023
64
AGC Minimum Allowable Value (81)
715
113
PLSnCL
0~255
32
Reading Line Number of Shading RGB. (*1)
715
114
FL CHK NG Count
0~65535
Once
Number of Lamp Check Failure (Reset by lamp

replacement)
715
115
FL CHK NG Data
0~1023
Downloaded Dtaat at Lamp Check Failure (Get data

when white is read, which is compared at the check)
715
120
AGC ADJ BW
1~200
100
AGC BW for Target Value Correction (x1/100: 100=x1)
715
121
Gap (1)
0~1023
128
CCD Ch-1 Gain Value
715
122
Gap (2)
0~1023
128
CCD Ch-2 Gain Value
715
123
AGCP (1)
0~511
128
CCD Ch-1 AGC Setting Value
715
124
AGCP (2)
0~511
128
CCD Ch-2 AGC Setting Value
Reissue
June, 2008
6-35
CE Access
W
Init Remarks
General Procedures
Table 2
Initial
Value
0~1023
CCD Ch-1 AGC Downloaded Data
0~1023
CCD Ch-2 AGC Downloaded Date
Gloop (1)
0~255
CCD CH-1 AGC Loop Number
128
Gloop (2)
0~255
CCD CH-2 AGC Loop Number
715
130
Oadj
0~255
AOC BW Level Correction Value (Complement of 2: 128 +127)
715
131
AOCP (1)
0~1023
128
CCD Ch-1 AOC Setting Value
715
132
AOCP (2)
0~1023
128
CCD Ch-2 AOC Setting Value
715
133
Osmp (1)
0~1023
CCD Ch-1 AOC Downloaded Average Data
715
134
Osmp (2)
0~1023
CCD Ch-2 AOC Downloaded Average Data
715
135
Osmpx (1)
0~1023
CCD Ch-1 AOC Max Value Downloaded Average Data
715
136
Osmpx (2)
0~1023
715
137
Osmpn (1)
0~1023
715
138
Osmpn (2)
0~1023
715
139
AOCerr
0~255
Number of AOC Plow Abnormal End
715
150
BWPG Density
0~255
128
PG Density of Entire Solid Imagae (0: white)
715
161
PreIPS_Through 1
0~65535
bit 0: ALLCBTF
bit 1: ALLKTF
bit 2: ALLCTF
bit 3: SSFCTF
bit 4: MRCTF
bit 5: WDVCTF0
bit 6: WDVCTF1
bit 7: DKCTF
bit 8: FSFTF0
bit 9: FSFTF1
bit 10: DCBCTF
bit 11: DCACTF
bit 12: GPCTF
bit 13: (SPARE)
bit 14: (SPARE)
bit 15: (SPARE)
meaning of Bit
0: Through (Skip) Val;id. 1: Through (Skip) Invalid
Chain
Link
Name of data
Range
715
125
Gsmp (1)
715
126
Gsmp (2)
715
127
715
General Procedures
Unit
June, 2008
6-36
CE Access
W
Init Remarks
Reissue
Table 2
Link
Name of data
Range
715
162
PreIPS_Through2
0~65535
715
163
PreIPS_Through3
0~65535
Reissue
Unit
Initial
Value
Chain
June, 2008
6-37
CE Access
W
Init Remarks
bit 0: FMTF
bit 1: IPCTF
bit 2: EBTF
bit 3: EATF
bit 4: MKATF
bit 5: GFATF
bit 6: BFATF
bit 7: (Spare)
bit 8: (Spare)
bit 9: WDVTF0
bit 10: WDVTF1
bit 11: DKBTF
bit 12: DCBKTF
bit 13: DCAKTF
bit 14: GPBTF
bit 15: (spare)
Meaning of Bit
0: Through Valid, 1: Through Invalid
bit 0: BWTF
bit 1: IPKTF
bit 2: EETF
bit 3: EDTF
bit 4: MKKTF
bit 5: GFBTF
bit 6: BTBTF
bit 7: MWTF
bit 8: ECTF
bit 9: MKBTF
bit 10: FOBTF
bit 11: SSRTF
bit 12: (spare)
bit 13: (spare)
bit 14: (spare)
bit 15: (spare)
Meaning of Bit
0: Through Valid, 1: Through Invalid
General Procedures
Table 2
Initial
Value
0~65535
Make each function of image process block forcibly

through (sk;ipped).
Change values at S/W & H/W DEBUG.
Should be 0 for usual use without fail. (Careful handling required). Through setting of each function is
allocated by bit and multiple bit can be specified at
once.
D0: AES
D1: DF39
D2: SSR
D3: FSRE
D4: NSP
D5: 4DLUT
D6: 5AER
D7: 5MUL
D8: 5MWA
D9: 4AER
D10: 4MIL
D11: TRC
D12: ED
D13: DIRECT *
D14: AMAOSEL
D15: (SPARE)
Meaning of Bit
0: Forcible Through Invalid, 1: Forcible Through Valid.
*If D13 is 1, release all Masks.
S2X_OUT CONTROL
0~7
Specify the intake of image for scanning jig.

0: AMAO intake (Lab)*
1: AMAO intake (Shipping Inspection)*
2: DAIMAJIN intake
3: PRIDE intake
4: TOTODB intake (CMY)
5: WOZDB intake
6: FLC intake
7: TOTODB intake (YMC)
*If NVM value is 0 or 1, release athe Mask for
AMAO.
202
VIPOUT Select
0~255
255
Switch the image path of VIPOUT. If this value is 255,

nothing should be done. (Keep current SET VIP)
VDO-MASK release will be carried out according to thie
setting. Related register: SETVIP
715
205
AE FS External Area
0~65535
1dot
255
AE-FS Undetected Area INSTV For AES parameter

calculation Related Register: SMPST, SMPED
715
206
0~65535
0.16mm
60
AE-SS Variation Fix Line-NCON AE detected amount

of SS lead edge Sep number of NCON register=0.16mm
Chain
Link
Name of data
Range
715
200
Post IPS Bypass Setting
715
201
715
General Procedures
Unit
June, 2008
6-38
CE Access
W
Init Remarks
Reissue
Table 2
Initial
Value
0~1
LIM Control Mode

0: Variaable Mode
1: Fixed Mode (NCON preferred mode)
Related register: AESMOD
AE Control of FS Length
0~1
0: Minimum lenmgth of FS detection size will FS detection length

1: Input the document size or regard the result of automatic size detection as FS detected length. For AES
parameter calculation Related registaer: SMPST,
SMPED
209
Minimum FS Length for AE
0~65535
0.1mm
500
Minimum FS detection lengath (1 step=0.1mm)

For AES parameter calculation
715
210
AE Upper Limit of SS Magnification adjust- 0~4000

ing
0.1%
4000
Maximum SS detection length (1 step=0.1%) For RAE.
715
211
SS Not Detect Area for Platen Job
0~65535
SS Dead Zone Setting Value at REal-Time AE for

Platen Job
Related registaer: BASE
715
212
SS Not Detect Area for ADF Job
0~65535
SS Dead Zone Setting Value at REal-Time AE for

DADF Job
Related register: BASE
715
213
Background removal for COPY
0~4
AE Remval Level for Copy Job

0: Standare
1: High +1
2: High +2
3: High +3
4: High +4
Since this NVM is written by Controller, direct modification of this value will be invalid. (Overwritten later) Refer
to the procedire of Cont. side of Removal Level change.
715
219
Background removal for SCAN
0~4
AE Removal Level for Copy Job

0: Standard
1: High +1
2: High +2
3: High +3
4: High +4
Since the NVM is written by Conroller, direct modification of this value will be invalid. (Overwritten Later)
Refer to the procedure of Cont. Side of Removal Level
change.
715
230
AE Detection Level (Copy Platen)
0~4
Parameter Level of Detecxted Background Amount.

(For Platen copy Job)
1: Low ~4: High
0: Ruby 1 Compatible Mode (not fully correspond)
Chain
Link
Name of data
Range
715
207
AE Detect Variation Control
715
208
715
Reissue
Unit
June, 2008
6-39
CE Access
W
Init Remarks
General Procedures
Table 2
Initial
Value
0~4
Parameter Level of Detected Background Amount

(For ADF copy job)
1: Low ~4: High
0: Ruby 1 Compatible Mode (Not fully correspond)
AE Detection Level (SCAN Platen)
0~4
Parameter Level of Detected Background Amount

(For Platen scanning job)
0: Low ~4: High
233
AE Detection Level (SCAN ADF)
0~4
Parameter Lelel of Detected Background Amount

(For ADF scanning job)
0: Low ~4: High
715
240
Density Correction LUT enaabling flag for

Job Type
0~3
Select the job type applying the corrective LUT of

A*X+B.
0(0x00)~3(0x03)
Bit assign
0 bit: Copy Job
1 bit: Scan Job
2 - 7 bit: Not use.
(0=disable, 1=enable)
715
241
Density Corrective LUT enabling flag for

Org Type
0~7
Select the document mode applying the corrective LUT

of A*X+B.
0(0x00)~7(0x07)
Bit assign
0bit: TX Mode
1bit: T/P Mode
2bit: Photo Mode
3-7bit: Not use.
(0=disable 1=enable)
715
242
Density Corrective LUT enabling flag for

Density
0~31
Select the density level applying the corrective LUT of

A*X+B.
0(0x00)~31(0x1f)
Bit assign
0bit: Lighter2
1bit: Lighter1
2bit: Nomal Density
3bit: Darker1
4bit: Darker2
5-7bit: Not use.
(0=disable, 1=enable)
715
243
Density Corrective LUT Parameter A
0~255
64
Paramaeeter A to create the corrective LUT of A*X+B.

Settable range of A is 0~3.984375.
0(0x00)~3.984375(0xff)
Bit assign
7-6bit: Interger number area.
5-0bit: decimal number area.
Chain
Link
Name of data
Range
715
231
AE Detection Level (Copy ADF)
715
232
715
General Procedures
Unit
June, 2008
6-40
CE Access
W
Init Remarks
Reissue
Table 2
Chain
Link
Name of data
Range
715
244
Density Corrective LUT Parameter B
0~255
Reissue
Unit
Initial
Value
June, 2008
6-41
CE Access
W
Init Remarks
O
Parameter B to create the corrective LUT of A*X+B.

Settable range of B is -128~+127.Minus value shows
complement number of 2.
-128(0x80)~+127(0x7f)
General Procedures
General Procedures
June, 2008
6-42
Reissue
GP1 Serial Number Locations
GP 2 Viewing the Six Digit Error Code
The Serial Number is located in three places on the machine:
If an error occurs, the two-digit error code, such as C1 and E2, appears in the display on the
Control Panel. To view the six digit error code in the display, use the following procedudre.
NOTE: If the Rear cover has to be replaced, do not worry about saving the data plate (which
has the machine serial number), since the serial number can be found in two other locations.
1.
When the two digit error code appears in the Display, press the Display Button.
2.
Press the Display Button.
3.
Press the Display Button.
a.
On the Data Plate on the Rear Cover.
In software on the machine. The serial number can be displayed by accessing Diagnostics (How to Enter the Diagnostic Mode) and entering NVM code [25-20].
On a bar code sticker at the left rear of the machine, which can be seen by opening the
Left Side Cover and looking toward the back.
Reissue
a.
June, 2008
6-43
a.
The first three digits of the six digit error code appears in the display.
The second half of the six digit error code appears in the display.
The display switches back to the two digit error codes.
General Procedures
GP1, GP 2
General Procedures
GP1, GP 2
June, 2008
6-44
Reissue
Specifications
Standard Specification of IIT, IOT, and Control UI
This subsection contains the performance specifications of the WorkCentre 5020, the multifunctional machine that has copier, printer, and scanner functions.
Table 1
IIT
CCD Image Sensor capable of scanning

at multi-level 600 dpi
IOT
20 PPM
600 dpi
Paper Feeding:
1 tray 250 sheets
MSI 50 sheets
Paper Output:
Face down tray (250 sheet capacity)
Writes video data on paper for copying and printing. A laser xerography system is applied.
Images can be written at 600dpi on paper up to 11"x17"/ A3 size.
PANEL
LED
UI (User Interface)
Standard Specification of Controller
System Overview
The WorkCentre 5020 consists of IIT, IOT, PANEL, Controller, and Printer I/F. The summary of
each system is as follows:
1.
IIT (Image Input Terminal)
2.
IOT (Image Output Terminal)
Scans documents for copying and scanning. The IIT resolution is 600 dpi at multi-level.
3.
Displays various settings, errors.

4.
5.
6.
Controller
Table 2
Controls the whole machine. Processes and stores input from IIT, printer I/F, and images
to be output to IOT. Controls UI as well.
Item
GDI Controller
NW Controller
Notes
Printer I/F (GDI)
CPU
OTI4110
MPC8311E
--
Receives data from the computer and passes it to the IOT (printer). In scan mode, outputs
image data to the computer.
Standard memory
SDRAM 64M
--
Serial EEPROM 4Mbit
--
I/F (NetWork)
Extended slot
Not supported
--
Network I/F receives data from the computer and passes the data to IOT (printer).
Standard Specification of Host
For scanning, Network I/F outputs image data to the network.

7.
User Registration and Department Management

Table 3
Administrators can register users who can use a machine, so that only limited users can
use the machine and that each users operation history can be managed and recorded.
Item
Description
GDI
Host I/F
USB (2.0) x 1
Yes
GDI
Number of Account: 10 users
Password: 3 digits, Numerical only
Product Codes
Network
Number of Account: 99
Table 4
Password: 4-12 columns digits, Numerical only, ommissible

8.
Product
Code
Code
Duplex Copy
XJ
IOT
Prt/
CODE Model speed Scan Dup IIT
Platen ADF FINAL ASSY
Duplex copies can be made using simplex documents or duplex documents. Simplex copies can be made using duplex documents.
Side images (input:output): Simp:simp, *Dup:Simp, Simp:Dup, *Dup:Dup.
*Dup (DADF needed)
Reissue
June, 2008
6-45
General Procedures
Options
FCOT shall be 7.5 sec or less. FCOT (Warm Start) is measured from the time the Start button
is pressed (when the engine receives a START command in the "STAND-BY" state) till the trail
edge of the first sheet is fed out, under the following conditions:
Table 5
Product name
Installation
User
Code
STM (500sheets)
EL200735
Stand
EL200736
Documents are placed on Platen
Power is on
Engine motor is not running
Fuser is ready
Laser scanner motor (ROS: Raster Output Scanner) is ready
Paper size and feeding orientation: A4 or 8.5x11 LEF
In an ambient environment of 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.
Paper tray: Tray 1
Low Power Mode
FPOT
When the machine is not operated for a certain period of time, the machine enters Low Power
Mode automatically.
FPOT: First Print Output Time
Warm-up Time
FPOT shall be 12sec or less

Control Panel: LED: ON
Resolution
Device Control: The fuser reduces its temperature.
Copy print: 600 X 600 dpi. Printer print: 600 X 600 dpi.
Printer I/F: Activated status.
Software Download
After a certain amount of time in Standby Mode, the machine enters Low Power Mode. This
time can be changed by a software program (setting range: 0-240 minutes). The factory default
is 5 minutes.
Controller Part: User can upgrade the software by downloading the object from the PC.
IOT Engine Part

MCU: Replacing the board. Optional Tray: Replacing the board.
Low Power Mode is cancelled when a button is pressed on the Control Panel or when a printer
job is received.
Sleep Mode (Off Mode)

The machine operates as follows to save power when the machine is in Low Power Mode for a
specified time:
Control Panel: LED: OFF, Power Save Button: ON
Device Control: Power is turned off (except for warm-up).
After a certain amount of time in Low Power Mode, the machine enters Sleep Mode. This time
can be changed by a software program (setting range: 0-240 minutes). The factory default is 5
minutes.
Sleep mode is cancelled when a button is pressed on the Control Panel or when a printer job is
received. When Sleep Mode is cancelled, the machine returns to Standby Mode.
Time to transfer to Standby Mode shall be 45 seconds or less (on standard configuration).
FCOT (Warm Start)

FCOT: First Copy Output Time
General Procedures
June, 2008
6-46
Reissue
Count-up for Print/Copy jobs: GDI
Electrical/Mechanical Characteristics
The purpose of the Count-up Meter is to categorize the number of sheets of print output by
print job, copy job, and test prints (Diagnostic Mode). The NLM Count-up Meter is not guaranteed as a meter for billing purposes. The Count-up Meter is managed by the device unit and
can be confirmed with device UI.
Electrical Characteristics
Table 8
Input Voltage Frequency
(VAC)
(Hz)
Rated input cur- Power Conrent Max (A)

sumption*
Spec (VA)
220 - 240V
240+10%
220-10%
50/60+/-3 Hz
6A
110 - 127V
110+10%
110-10%
50/60 +/-3 Hz 12A
The Count-up Meter has only one total counter.

Table 6
Job type
Counter type
Description
Copy
Total Counter
Counter of copy job
Print
Counter of print job
Diag
Test print in Diag mode

(It doesn't contain the Diag test print with Type-Di.)
Sleep Mode
(Off Mode)
Reference
1320VA (Max) 6 W (Max)

1320VA (Max) 6 W (Max)
*Power consumption is specified assuming full configuration.
Rated Power Consumption

Report: One (Printer).
[GDI]
GDI: not supported.
Table 9 GDI
Timing of Count-up
MCU increments the billing counter when the trail edge of the paper passes the Exit Sensor.
The number of counter increments is as follows:
Table 7
Paper size
Number of counter increments

Billing
Life
A3, B4, 8K, 11x17, Non-fixed
A4 or less (A4, Letter, ....)
Mode
Power consumption
Configuration
In Low Power Mode
CP: 107W or less

91W or less
20cpm
16cpm
In Sleep Mode (Off Mode)
DC: 6W or less
CP: 20W or less
At operation
(During printing operation)
110V
12A, 1320VA (Max)
220/240V
6A, 1320VA (Max)
Full configuration
Network
Table 10 NetWork
Reissue
Mode
Power consumption
In Low Power Mode
CP: 107W or less
In Sleep Mode (Off Mode)
CP: 20W or less
At operation
(During printing operation)
110V
12A, 1320VA (Max)
220/240V
6A, 1320VA (Max)
June, 2008
6-47
Configuration
Full configuration
General Procedures
TEC Method (New E-Star)
Machine Size/Weight
The machine specified below does not include a drum and toner cartridge.
Table 11
Config
DC20
CP20
TEC
GDI
Network
3.0Kwh
6.0Kwh
1.
Size
Table 12
Type
Width (mm)
Depth (mm)
Height (mm)
IOT
595+/-5
532+/-5
505+/-5
IOT+IIT (Platen Glass)
595+/-5
532+/-5
528+/-5
IOT+IIT+ADF/DADF/DUP
595+/-5
532+/-5
605+/-5
[Optional Devices]
Table 13
Width (mm)
Depth (mm)
Height (mm)
STM (500 Sheets)
551+/-5
522+/-5
130+/-5
Stand
551+/-5
506+/-5
385+/-5
Size of Package:
2.
DC: 710x660x716 (mm)
IBG ADF, DADF: 710x660x840 (mm)
Weight
Table 14
General Procedures
Main body
Configuration
Platen model: Net weight

(including toner cartridge)
33.02 Kg
Platen/IIT/MSI/Std Tray (250sheets) including

toner cartridge
STM
8.8 Kg
Optional tray: 500sheets
Toner cartridge
1.2 Kg
ADF Model
37.88 Kg
ADF/IIT/MSI/Std tray/Dup including Consumables
DADF Model
39 Kg
DADF/IIT/MSI/Std tray/Dup including Consumables
Net weight (full configuration)
38.0 Kg TBD IIT/MSI/Std Tray (250sheets) including toner cartridge
Stand
18 Kg TBD
June, 2008
6-48
Reissue
Storage Environment (According to Egret)
Copy Speed
A machine (without CRU and Toner Cartridge)which has been stored in the following environment shall attain the specified performance when installed in the environment specified.
Continuous copy speed at 100% magnification.
1.
In operation (guaranteed copy quality environment): 10 - 32 degrees C @ 15 - 85% RH
2.
Shipping and storage conditions:
Measurement method: Make 11 continuous copies. Measure the time (T, in seconds) from the
output of the trail edge of the first sheet of paper to the output of the trail edge of 11th sheet of
paper, and convert into copies per 60 seconds: CPM = T/60 (normal paper mode).
Table 18
Table 15
Type
Temperature
Transit (48 hrs)
Storage (18 mo)
Comments
-29 to 66 degrees C
-29 to 66 degrees C
After storage or transit,
(-20 to 150 degrees F) (-20 to 150 degrees F) the machine must normalize to the operating environment before power is
applied (this could take up
to 4 hours maximum at
extreme values).
Humidity
10 - 95% RH
20 - 80% RH
Altitude
Up to 12,000 m
Up to 3,000 m
Noise (Sound Power Level: LWAd)

Unit: B
Paper Size
and
Paper Orientation
Tray 1
STM (Add 1 Tray)
Paper Tray
Plain Paper
Plain Paper
MSI
Fixed Mode
A4 LEF
20
20
10
15
15
10
8.5"x13"SEF 8.5"x14" 12
SEF
12
10
10
10
Not supported
10
8.5" x 11" LEF

16K LEF
B5 LEF
A4 SEF
8.5" x 11" SEF
16K SEF
B5 SEF
Mexico Folio
(8.5" x13.4")
Table 16
Standby Mode
Operation Mode
A3 SEF
11" x 17" SEF
Base Machine
4.0
6.8
Full System
4.0
6.8
8K SEF
B4 SEF
Impulse Sound Power (FX) Impulse Sound Power Level (LWAI)

LWAI B(A)
A5 SEF
5.5" ( 8.5" SEF)
A5 LEF
10
10
Not supported
5.5" x 8.5" LEF

Table 17
Base Machine
6.6
Full system
7.1
Chemical Substances
1.
Levels of Ozone:
Ozone formed from this product: less than 0.02 mg/m3 (according to C11-705)
Eco-Mark Requirement: 0.02 mg/m3
2004 Version Green Target A Limit: 0.015 mg/m3
2.
Airborne Dust Concentration:

Inhaled airborne dust from this product: less than 0.08 mg/m3 (according to C11-705)
Eco-Mark Requirement: 0.075 mg/m3
2004 Version Green Target A Limit: 0.04 mg/m3
Reissue
June, 2008
6-49
General Procedures
Alignment
Paper Supply
1.
All paper trays (excluding MSI) are universal trays, which are front-loading trays.
[Full System] IOT + IIT + ADF + DADF

1.
Specification
SYSTEM
2 Sided
+/- 2.90
+/- 3.80
+/- 3.40
+/- 3.90
Lead Skew (mm)
+/- 2.30
+/- 2.70
280 mm
Vertical Ratio (%)

100%
+/- 1.40
-1.72
400 mm
Horizontal Ratio (%)

100%
+/- 1.40
-1.72
280 mm
Perpendicularity (mm) +/- 3.40
+/- 4.00
400 mm
Linearity (Vertical)
(mm)
+/- 2.00
400 mm
Linearity (Horizontal)
(mm)
+/- 1.40
280 mm
Item
The height of a stack of paper shall be 27mm or less.

Application
STM (optional): 500 sheets (Busines 70gsm/sheet).

450 sheets (Business 80gsm/sheet).
The height of a stack of paper shall be 54mm or less.
2.
Standard paper
3.
Weight
Standard paper is indicated by "Standard Paper" on "Paper List."

Tray 1: 60gsm to 90gsm
STM: 60gsm to 90gsm
4.
Size
Standard paper sizes: A4L/S, A3, B5L/S, B4, 8K, 16KL/S, 8.5 x11L/S, 8.5 x 13, 8.5 x 13.4
(Mexico Folio), 8.5 x 14, 11 x 17
5.
Usage rate
Tray 1: 60%
Linearity (Skew) (mm) +/- 1.42
280 mm
Parallelism
-4.00
400 mm
2.
Capacity
Tray 1: 250 sheets (Business 80gsm/sheet).
Specification
SYSTEM
1 Sided
+/- 3.70
STM: 30%
[DC] IOT+IIT
Item
Specification
SYSTEM
Measurement
Length
Simplex
Duplex
Skew H
+/-2.3
+/-2.7
200mm
Perpendicularity
+/-3.7
+/-4.0
400mm
Linearity: V
2.3
--
400mm
Linearity: H
2.3
--
280mm
Linearity: D
2.3
--
283mm
Registration: Lead
+/-2.9
+/-3.8
Registration: Side
+/-3.4
+/-3.9
Magnification: V (%)
+/-1.4 (100%)
+/-1.72 (100%)
+/-1.56 (50%-99%) +/-1.89 (50%-99%)
+/-1.8 (101%-200%) +/-2.42 (101%200%)
400mm
Magnification: H (%)
+/-1.4 (100%)
+/-1.72 (100%)
+/-1.56 (50%-99%) +/-1.89 (50%-99%)
+/-1.8 (101%-200%) +/-2.42 (101%200%)
280mm
General Procedures
June, 2008
6-50
Reissue
Bypass Tray(MSI)
1.
Paper List
Capacity
Table 21
50 sheets of paper (70 gsm)

2.
Media Type
Paper size and paper orientation

Size and orientation of paper set on MSI shall be as follows: A4L/S, A3, B5L/S, B4, 8K,
16KL/S, 8.5 x11L/S, 8.5 x 13, 8.5 x 13.4 (Mexico Folio), 8.5 x 14, 11 x 17, 5.5 x 8.5"S, A5S
3.
Paper weight
Baseline Paper
Weight of paper that can be supplied from MSI is 60g/m2 to 110g/m2.

4.
Usage rate
Paper
Code
CIM
Bypass
Flag Ship (80 gsm)
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)
Canary (70/80 gsm)
Transmate (70/80 gsm)
Jetset (70/80 gsm)
HOOPOE(70/80 gsm) [APP Co]
Colotec+ 90 gsm
10%
Standard Paper
Colotec+ 100 gsm
Topgun (70/80 gsm)
Plain
3R96002
Removable Bar Stripe
3R96023
Xerox
3R12050
(TBD)
Label
Recycle Paper
Transparency
Other
Business 80 gsm-4 Hole (Hole on TE) 3R91823
Primier A4 80 gsm-4 Hole (Hole on

TE)
3R91723
3- Hole (hole on TE)
3R2193
Paperbacked OHP is out of quality assurance.
Paper Selection
There are two methods of Paper Tray selection:
1.
Direct selection
User selects the paper tray that contains the required type of paper (size and orientation).
2.
APS (Automatic Paper Selection) (ADF/DADF only)

MC automatically selects the paper that matches the image size.
Reissue
June, 2008
6-51
General Procedures
Tools
Consumables
Most maintenance procedures can be done with the following standard tools:
Machine CRU Strategy
Table 1
No.
TOOL NO. /TOOL NAME
No.
TOOL NO. /TOOL NAME
499T 1423 BOX DRIVER 5.5
499T 247 TEST PATTERN (A3)
499T 355 SCREWDRIVER (+)
499T 301 MINI DRIVER
499T 2004 ROUND NOSE PLIERS
10
499T 1901 SIDE CUTTING NIPPER
499T 2320 S/E TESTER SET
499T 2601 SILVER SCALE (ISO M/N) 12
499T 9507 TESTER LEAD WIRE

(Red)
499T 8104 FLASHLIGHT (UM-2)
13
499T 9508 TESTER LEAD WIRE

(Black)
499T 8902 BRUSH
14
499T 353 * STUBBY DRIVER
Machine LCB is designed to interface with a CRUM and Billing Counter on all configurations.
The CRUM can be used to provide a "hard stop" capability for markets requiring this feature.
The primary uses of the CRUM are to ensure that the CRU being used is correct for the market
& service/warranty agreements, store the number of copies made on the CRU, and enforce the
end-of-life point. The primary uses of the Counter are to indentify the machine's market location, electronically store the machine's serial number, and store the number of copies made on
the machine.
Consumable Replacement Intervals (TBD)

Table 1
ITEM
YIELD/LIFE
STRATEGY/REPLACEMENT
Toner
6K @ 5% area coverage of A4 size

Test pattern
Warning/Hard Stop
- Warning with approximately 100
copies of toner remaining.
Drum Cartridge
Hard Stop: 22K @ 5% A4 area coverage for XC

Job Size = 4 pages
End of life Warning/Hard Stop

- Warning at 16K
Hard Stop at 22K (XC)
* 499T 353 STUBBY DRIVER should be used when replacing the ROS ASSEMBLY.
This specification is applied when the machine is operated under the following conditions:
General Procedures
Paper: A4 LEF
Paper Tray: Tray 1
Copy Mode (not Print Mode)
June, 2008
6-52
Reissue
Glossary of Terms
Table 1
Table 1
Term
Description
Hz
Hertz (Cycles per second)
Term
Description
IIT
Image Input Terminal - the Scanner/CCD portion of the machine
A3
Paper size 297 millimeters (11.69 inches) x 420 millimeters (16.54 inches).
IOT
A4
Paper size 210 millimeters (8.27 inches) x 297 millimeters (11.69 inches).
Image Output Terminal - the ROS/Xero/paper handling/ fusing portion of the

machine
AC
Alternating Current is type of current available at power source for machine.
IQ
Image Quality
ACT
Advanced Customer Training: teaches customers to perform some of service that is

normally performed by Xerox Service Representative.
KC
1000 copies
LCD
Liquid Crystal Display
A/D
Analog to Digital refers to conversion of signal
LE
Lead Edge of copy or print paper, with reference to definition of term TE
ADF
Automatic Document Feeder
LED
Light Emitting Diode
ADJ
Adjustment Procedure
LEF
Long Edge Feed
Bit
Binary digit, either 1 or 0, representing an electrical state.
LTR
Letter size paper (8.5 x 11 inches)
CCD
Charge Coupled Device (Photoelectric Converter)
LUT
Look Up Table - array of NVM locations that store process control data
CD
1: Circuit Diagram; 2: Compact Disc
LVPS
Low Voltage Power Supply
CF
Copier Fax
MF
Multi-Function
CP
Copier Printer
MN
Multinational
CPF
Copier Printer Fax
MPT
Multi Purpose Tray
Chip
Integrated Circuit (IC)
NBCR
New Book Scanner Control Relay
CRU
Customer Replaceable Unit
NIC
Network Interface Card
CVT
Constant Velocity Transport
NSC
New Scanner Controller
DADF
Duplexing Automatic Document Feeder
NVM
Non Volatile Memory
DC
Direct Current is type of power for machine components. Machine converts AC

power from power source to DC power.
OEM
Original equipment manufacturer
OGM
On-going Maintenance
DC
Digital Copier
PC
Personal Computer
DMM
Digital Multimeter is generic name for meter that measures voltage, current, or electrical resistance.
PL
Parts List
PO
Part of (Assembly Name)
Duplex 2-sided printing or copying
PS
Post Script
EME
PSW
Portable Standard Workstation
PWB
Printed Wiring Board
PWS
Portable Workstation for Service
PJ
Plug Jack (electrical connections)
Fax Scanner
RAM
Random Access Memory
FS
Fast Scan (direction) - Inboard - to - Outboard
RAP
ESS
Electronic Sub-System
Repair Analysis Procedure for diagnosis of machine status codes and abnormal conditions
ENG
English
R/E
Reduction/Enlargement refers to features selection or components that enable

reduction or enlargement
2TM
Two Tray Module
REP
Repair Procedure for disassembly and reassembly of component on machine
FAX
Facsimile
RIS
Raster Input Scanner
FIC
Final Integration Center
ROM
Read Only Memory
GND
Ground
ROS
HFSI
High Frequency Service Item
Raster Output Scanner - Device that transfers digitally processed image, using laser
light, to photoreceptor.
HVPS
High Voltage Power Supply
SAD
Solid Area Density
Electromagnetic Emissions are emitted from machine during normal operation and
power of these emissions are reduced by machine design features.
ERU
Engineer Replaceable Unit
ESD
Electrostatic Discharge. A transfer of charge between bodies at different electrostatic

potential.
FS
Reissue
June, 2008
6-53
General Procedures
Glossary of Terms
Table 1
Term
Description
SCP
Service Call Procedure
SEF
Short Edge Feed
Selftest
An automatic process that is used to check Control Logic circuitry. Any fault that is
detected during self-test is displayed by fault code or by LEDs on PWB.
SIMM
Single Inline Memory Module used to increase printing capacity
Simplex Single sided copies

FS
Fast Scan (direction) - LE - to - TE
TE
Trail Edge of copy or print paper, with reference to definition of term LE
UM
Unscheduled Maintenance
UI
User Interface
USB
Universal Serial Bus
W/
With - indicates machine condition where specified condition is present
W/O
Without - indicates machine condition where specified condition is not present
XBRA
Xerox Brazil
XC
Xerox Corporation
XE
Xerox Europe - also referred to as ESG (European Solutions Group)
XLA
Xerox Latin America
XMEX
Xerox Mexico
General Procedures
Glossary of Terms
June, 2008
6-54
Reissue
7 Wiring Data
BSDs
Chain 1 Standby Power .................................................................................................
Chain 2 Mode Selection .................................................................................................
Chain 3 Machine Run Control ........................................................................................
Chain 4 Start Power .......................................................................................................
Chain 5 ADF/DADF ........................................................................................................
Chain 6 Imaging .............................................................................................................
Chain 7 Paper Supplying ...............................................................................................
Chain 8 Paper Transportation ........................................................................................
Chain 9 Marking .............................................................................................................
Chain 10 Fusing and Copy Transportation ....................................................................
7-3
7-5
7-6
7-8
7-9
7-18
7-21
7-23
7-28
7-31
Wirenets
Wirenets ..........................................................................................................................
7-35
P/J Locations
7.1 P/J Locations............................................................................................................
Reissue
7-45
June, 2008
7-1
Wiring Data
Wiring Data
June, 2008
7-2
Reissue
Chain 1 Standby Power

A
1.1 MAIN POWER GENERATION
AIOC PWB
PL8.1
ALL
J414
B6 YEL
B1,B2 YEL
LVPS
PL8.1
2
CHOKE
COIL
PL8.1
J5
BLK
BLK
3
POWER
CORD
PL8.1
POWER
SWITCH
FS11 ACHFS31 PL8.1
BLK
FS60
10.1
FS12 ACNFS33
FS34 ACN
WHT
WHT
BLU
P/J407
A16,A17
,B16,B1
7
A14,A15
,B14,B1
5
+3.3VDC
ACH
10.1
DC COM
ALL
+5VDC
DC COM
P/J407
B18
ON/
OFF
1.2
ALL
+24VDC
F1
DC COM
ALL
1
Wire Color
BLK:100V M/C, BRN:200V M/C
Wire Color
WHT:100V M/C, BLU:200V M/C
YEL
DC COM
YEL
YEL
B8
B10,B
9
ALL
ALL
+24VDC
B12,B11
ALL
DC COM
YEL
J409
4,5
1,6,11,15,1 J410
7,
19,21,23,2
5,27,29,31,
34
J409
1,2
A11,B11
ALL
AIOC PWB
PL8.1
ALL
+5VDC
A2,A1
DUPLEX PWB
PL8.2
ALL
J416 +5VDC J550
3 BLU
7
BLU
ALL
DC COM
4 BLU
6
BLU
DC COM
2 BLU
8
BLU
GN/YL
T21
DC POWER
GENERATION
FS32 ACH
BLK
BRN
A11,A12 YEL
ADF PWB
PL13.3
ALL
J731
B7
YEL
+3.3VDC
B5 YEL
B3,B4 YEL
A12,A13
,B12,B1
3
9,10,1
1
A9,A10,
B9,B10
20,21
1 GRY
3 VIO
8 VIO
10 ORN
DC COM
DC COM
+5VDC
6,7
A7,A8,
B7,B8
J508
+3.3VDC
+5VDC
+24VDC
LENS ASSEMBLY
PL10.7
IIT PWB
ALL
J721 18,1
7
J720 34,29,24,2
ALL
0,18,16,14
,12,10,8,6,
4,1
ALL
J721 21,2
0
ALL
16,1
5
ALL
13,12,11
ALL
DC COM
J540
GRY
2,1
STM PWB
PL11.5
ALL
1
ALL
DC COM
VIO
2
ALL
24VRTN
VIO
5
ALL
+24V
ORN
Figure 1 1.1 Main Power Generation
Reissue
June, 2008
7-3
Wiring Data
1.2 INTERLOCK SWITCHING

1
LVPS
PL8.1
LH COVER
INTERLOCK
SWITCH
PL8.2
J506FS151
4 ORN
1-1
LVPS
PL8.1
LH COVER
INTERLOCK SWITCH
FS152 COVER OPEN(L) +24VDC
J506
3
ORN
FRONT COVER
INTERLOCK
SWITCH
PL8.2
J506FS153
1-12
LVPS
PL8.1
FRONT COVER
INTERLOCK SWITCH
FS154 COVER OPEN(L) +24VDC
2 ORN
J506
1
ORN
+24VDC
(1.1)
AIOC PWB
PL8.1
4.1
10.1
J416
1 BLU
F2
2
AIOC PWB
PL8.1
P/J407
A2
P/J407
A1
E5-2
B1
E5-1
INTLK
+24VDC
INTLK
+24VDC
Fail Code
E5-1
LH Cover Open
E5-2
Front Cover Open
DUPLEX PWB
PL8.2
INTLK +24VDCJ550
BLU
10.2
9
The actual H/L level is displayed inversely on the UI display.
LH COVER INTERLOCK SWITCH

FRONT COVER INTERLOCK SWITCH
Figure 2 1.2 Interlock Switching

Wiring Data
June, 2008
7-4
Reissue
Chain 2 Mode Selection

A
2.1 CONTROL PANEL

Fail
Code
AIOC PWB
PL8.1
USER INTERFACE PWB

PL8.4
J401
8
BLU
BLU
WAKE
UP
UI
RESET
J710
BLU
BLU
U7-0
UI Communication
Timeout
U7-1
UI Communication
Error
AIOC PWB
PL8.1
2
5
BLU
UI
TXD
J710
BLU
BLU
BLU
BLU
BLU
UI RXD
U7-0
J401
BLU
BLU
6
U7-1
5
6.1
DC COM
(1.1)
DC COM
2
BLU
BLU
BLU
BLU
+5VDC
(1.1)
8
+5VDC
1
2
Figure 1 2.1 Control Panel
Reissue
June, 2008
7-5
Wiring Data
Chain 3 Machine Run Control

A
3.1 PWB COMMUNICATION (STM PWB)

1
AIOC PWB
PL8.1
LVPS
PL8.1
STM PWB
PL11.5
LVPS
PL8.1
P/ J407
B19
B20
J508
STM IIC SCL
YEL
J540
YEL
J540
STM IIC SDA

YEL
AIOC PWB
PL8.1
YEL
STM REQ
YEL
J508
YEL
P/ J407
B21
H9-7
Fail Code
H9-7
MCU (AIOC PWB) - STM PWB Communication Error
Figure 1 3.1 PWB Communication (STM PWB)
Wiring Data
June, 2008
7-6
Reissue
3.2 BILLING AND MACHINE CONTROL
AIOC PWB
PL8.1
9.2
J401
9 BLU
BILL ID
J630
BLU
P630
BILLING
COUNTER
PL8.1
2
U6-2
RAM
10 BLU
BLU
DC COM
(1.1)
U6-3
U6-4
3
NVM
U6-5
N9-0
N9-1
E9-1
Fail Code
U8-1
P/J411
1,2,3
,4,5
USB 2.0
E9-2
E8-1
E8-2
L9-0
U8-1
U6-2
RAM Read/Write Check Error
U6-3
NVM Data Defect
U6-4
NVM Read/Write Cannot be Excuted
U6-5
CPU Power to access NVM is not enough
N9-0
Controller Logic Fail
N9-1
E9-1
AMS NG Out Of Range
E9-2
Paper Direction Mismatch
E8-1
Nup NG Out Of Range
E8-2
Paper Direction Mismatch
L9-0
Copy Counter Full
N4-0
N4-1
N4-2
CPM Image Lost
C0-1
APS NG Unselected
C0-2
ADF NG out of range
N4-0
5
N4-1
N4-2
C0-1
C0-2
Figure 2 3.2 Billing and Machine Control

Reissue
June, 2008
7-7
Wiring Data
Chain 4 Start Power

A
4.1 MAIN DRIVE

1
AIOC PWB LVPS

PL8.1
PL8.1
P/J407
B2
J504
4 BLU
F3
IOT MOTOR
PL1.1
4-1
INTLK
+24VDC
(1.2)
IOT MOTOR
ON(H) +5VDC J201
BLU
1 RED
RED
2 BLK
BLK
Fuser
CRU
MOT
J201
3 YEL
IOT MOTOR LOCK(H) +5VDC
DC COM
(1.1)
GN/YL
T82
LVPS
PL8.1
T81
INLET FRAME
DRV ESD GND
+5VDC
J504
YEL
GRN
T30
AIOC PWB
PL8.1
P/J407
B3
Regi
U0-1
U1-1
F155
DRV ESD GND
IOT ESD GND
Duplex
Dupulex
Fail Code
U0-1
IOT Motor Stop Error
U1-1
IOT Motor Rotation Error
Tray
Figure 1 4.1 Main Drive
Wiring Data
June, 2008
7-8
Reissue
Chain 5 ADF/DADF
5.1 DOCUMENT SIZE SENSING

DOCUMENT
TRAY LENGTH
SENSOR 1
PL13.10
5-34
2
BLU
ADF PWB
PL13.3
+5VDC
(1.1)
DOCUMENT
TRAY LENGTH
SENSOR 2
PL13.10
CN4 DF4
5 WHT
6 WHT
DC COM
(1.1)
DF5
WHT
WHT
DOCUMENT
TRAY WIDTH
SENSOR 1
PL13.10
1 WHT
+5VDC
(1.1)
DF3
2 WHT
DC COM
(1.1)
CN5
3 WHT
+5VDC
(1.1)
4 WHT
J731
A3 YEL
B5 YEL
B6 YEL
ADF SEL0 J414

YEL
A10
ADF SEL1
YEL
ADF SEL2
YEL
B8
A2-2
B7
3
1
+3.3VDC
DOCUMENT TRAY
WIDTH SENSOR 1
DOCUMENT SENSED(H) +3.3VDC
DOCUMENT
TRAY WIDTH
SENSOR 2
PL13.10
5-33
2
5-31
2
A2-2
Not Supported Doc Size
+3.3VDC
YEL
DOCUMENT
FEEDER
WIDTH
SENSOR
PL13.9
Fail Code
DOCUMENT TRAY
WIDTH SENSOR 2
DF2
WHT
RED
DF2
+3.3VDC
+3.3VDC
BLK
DF3
WHT
AIOC PWB
PL8.1
DOCUMENT TRAY
LENGTH SENSOR 2
DF5
5-32
2
5-35
ADF PWB
PL13.3
DOCUMENT TRAY
LENGTH SENSOR 1
DOCUMENT SENSED(H) +3.3VDC CN4
DF4
4
DOCUMENT TRAY WIDTH SENSOR 2
DOCUMENT FEEDER
WIDTH SENSOR
DF8 DOCUMENT SENSED(H) +3.3VDC
CN5
YEL
+3.3VDC
DOCUMENT TRAY
LENGTH SENSOR 2
3
DF8
DOCUMENT FEEDER WIDTH SENSOR
DC COM
(1.1)
6
1
A combination of H and L levels of these five sensors determines a document size.

For the relation between H/L of each sensor and document size,
see the marginal table under 5.4 DOCUMENT PATH.

DOCUMENT TRAY LENGTH SENSOR 1
Figure 1 Document Size Sensing
Reissue
June, 2008
7-9
Wiring Data
5.2 DOCUMENT SETTING AND TRANSPORT

1
ADF PWB
PL13.3
ADF PWB
PL13.3
CN5
DF14
2 WHT
WHT
DC COM
(1.1)
ADF TOP
COVER
SWITCH
PL13.9
5-29
DF14
2 WHT
DOCUMENT
SET SENSOR
PL13.9
6 WHT
+5VDC
(1.1)
7 WHT
2 WHT
A5 YEL
J414
YEL
YEL
+3.3VDC
DOCUMENT FEED SENSOR

DOCUMENT SENSED(L) +3.3VDC
WHT
A5-2
A8
+3.3VDC
A4 YEL
A9
+3.3VDC
A1-1
10
A6 YEL
YEL
A7
A4-1
A4-2
3
DF10
WHT
9 WHT
+3.3VDC
J731
+3.3VDC
5-36
DF10
DC COM
(1.1)
WHT
BLU
DOCUMENT
FEED SENSOR
PL13.9
DF9
CN5
5-30
2 BLU
+3.3VDC
ADF TOP COVER SWITCH

COVER OPEN(L) +3.3VDC
DOCUMENT SET SENSOR

DF9
AIOC PWB
PL8.1
WHT
1
3
ADF TOP COVER SWITCH
DC COM
(1.1)

Fail Code
A5-2
ADF Cover Open
A1-1
Doc Misfeed Jam
A4-1
Short Length Detect
A4-2
Long Length Detect
DOCUMENT SET SENSOR
Figure 2 Document Setting and Transport
Wiring Data
June, 2008
7-10
Reissue
5.3 DOCUMENT FEED AND TRANSPORT MECHANISM

1
AIOC PWB
PL8.1
ADF PWB
PL13.3
J414
A6 YEL
5-42
DOCUMENT
FEED CLUTCH
CN3 ON(L) +24VDCDF13
J731
A7
YEL
2 WHT
1 WHT
DOCUMENT
FEED CLUTCH
DF13 PL13.9
DOCUMENT FEED CLUTCH

Feed Roller
DC COM
+24VDC
DOCUMENT
DRIVE MOTOR
5-40
5-41
A1 YEL
B12 YEL
A2 YEL
MOT M1
YEL
MOT M2
A3 YEL
2 ORN
B1
YEL
YEL
MOT CLOCK
A12
DC COM
MOT M3
B11 YEL
CN2
YEL
MOT ON
YEL
A11
3 YEL
DC COM
5 BRN
B2
DC COM
6 BLK
A10
MOT RST
YEL
DOCUMENT SET SENSOR
DOCUMENT FEEDER
WIDTH SENSOR
DOCUMENT DRIVE MOTOR

ON +24V CLOCK
ON +24V CLOCK
ON +24V CLOCK
Exit Roller
MOT
B4
Regi Roll
1 WHT
MOT CURR2
A4 YEL
A9
YEL
B9 YEL

ON +24V CLOCK
DOCUMENT
DRIVE MOTOR
PL13.5
DC COM
MOT CURR1
B10 YEL
B3
YEL
High Speed
Low Speed
Reed Out
Feed
Out Roll
Roll
4 BLK
Reed In
Feed
In Roll
Roll
+24VDC
(1.1)
MOT CW/CCW
A5 YEL
A8
YEL
DOCUMENT LEAD EDGE SENSOR
Figure 3 Document Feed and Transport Mechanism
Reissue
June, 2008
7-11
Wiring Data
5.4 DOCUMENT PATH

Feed Roll
DOCUMENT SET SENSOR

DOCUMENT FEEDER WIDTH SENSOR
Regi Roll
Read In Roll
Read Out Roll
Exit Roller
The table at the right shows the relationship between High/Low

of each document size sensor and document size .
The standard size of a document is sensed at the tim e the
DOCUMENT FEEDER WIDTH SENSOR detects it after it is fed.
Document Size
DOCUMENT
FEEDER WIDTH
SENSOR
DOCUMENT
TRAY WIDTH
SENSOR 1
DOCUMENT
TRAY WIDTH
SENSOR 2
DOCUMENT
TRAY LENGTH
SENSOR 1
DOCUMENT
TRAY LENGTH
SENSOR 2
5.5"x8.5"SEF
A5 SEF
B5 SEF
A4 SEF
A5 LEF
5.5"x8.5"LEF
8.5"x11"SEF (Letter)
8.5"x13"SEF (Legal)
H
H
8.5"x14"SEF (Legal)
B5 LEF
B4 SEF
Executive LEF
16K LEF
8K SEF
8.5"x11"LEF (Letter)
11"x17"SEF(Ledger)
A4 LEF
A3 SEF
Figure 4 Document Path
Wiring Data
June, 2008
7-12
Reissue
Figure 5 BSD 5.5 Document Size Sensing - DADF/Network Configuration

Reissue
June, 2008
7-13
Wiring Data
Figure 6 BSD 5.6 Document Setting & Transport - DADF/Network Configuration
Wiring Data
June, 2008
7-14
Reissue
Figure 7 BSD 5.7 Document Feed & Transport Mechanism- DADF/Network Configuration
Reissue
June, 2008
7-15
Wiring Data
Figure 8 BSD 5.8 Document Inversion - DADF/Network Configuration
Wiring Data
June, 2008
7-16
Reissue
Figure 9 BSD 5.9 Document Path - DADF/Network Configuration

Reissue
June, 2008
7-17
Wiring Data
Chain 6 Imaging
A
6.1 IMAGE INPUT

1
AIOC PWB
PL8.1
LENS ASSEMBLY
PL10.7
AIOC PWB
PL8.1
IIT PWB
CCD
J410
22
CCD SHFT CLK0
CCD SHFT CLK1
24
J720
2,3,4,5
,7,8,9,
10,
12,13,
14,16,
18,20
11
2
CCD RST CLK
26
CCD CLMP CLK
28
CCD TRNSF CLK
30
J410
J720
13
VIDEO DATA
33,32,
31,30,
28,27,
26,25,
23,22,
21,19,
17,15
LENS ASSEMBLY
PLATEN OPEN SWITCH
USER INTERFACE
PWB
PL8.4
PLATEN OPEN
SWITCH
PL10.5
4
MAGNET
J711
1
BLK
USER INTERFACE PWB

PL8.4
5-10
PLATEN OPEN SWITCH
COVER CLOSED(L) +5VDC
+5VDC
J711
BLK
A5-1
DC COM
(2.1)
Fail Code
A5-1
Platen Cover Open
Figure 1 6.1 Image Input
Wiring Data
June, 2008
7-18
Reissue
6.2 CARRIAGE SCAN

1
AIOC PWB
PL8.1
12
J409 CLOCK A
CARRIAGE MOTOR
ON +24V CLOCK
YEL
CARRIAGE
MOTOR
PL10.6
EXPOSURE LAMP
IIT5
1
CARRIAGE MOTOR
ON +24V CLOCK
ORN
CARRIAGE MOTOR
ON +24V CLOCK
BRN
MOT
Fail Code
5
4
CARRIAGE MOTOR
ON +24V CLOCK
BLK
U2-1
CARRIAGE SENSOR turns High with the carriage to the left side.
With the carriage at any location other than the location, sensor level is Low.
When trying to move the carriage, run CARRIAGE MOTOR in diag.
Run DC [5-23] to move the carriage until it reaches the left side,
and then stop it. It can then be detected that CARRIAGE SENSOR turns High.
3
5
RED
4
1
CLOCK B
19
CN4
1
CLOCK B
18
Low speed return
CLOCK /B
17
Low speed scan
5-23
CLOCK /B
16
5-22
IIT PWB
CARRIAGE MOTOR
CARRIAGE SENSOR
CLOCK /A
15
High speed return
10
CLOCK /A
14
High speed scan
5-21
J721
CLOCK A
13
5-20
LENS
ASSEMBLY
PL10.7
+24VDC
(1.1)
INVERTER PWB
PL10.7
J410
32
EXPOSURE
CN3 LAMP ON
2
GRY
J720
3
INV CN1
EXPOSURE
LAMP
PL10.6
INV CN2
DC COM
1
+24VDC
(1.1)
GRY
GRY
1
LENS
ASSEMBLY
PL10.7
DC COM
(1.1)
CARRIAGE
SENSOR
PL10.6
x
CAUTION
High Voltage
AIOC PWB
PL8.1
IIT PWB
IIT4
2
5-11
CN3
GRY
J720
4
CARRIAGE SENSOR
BLOCKED(H) +5VDC
+3.3VDC
J410
33
U2-1
IIT4
6
+5VDC
(1.1)
GRY
GRY
DC COM
(1.1)
Figure 2 6.2 Carriage Scan

Reissue
June, 2008
7-19
Wiring Data
6.3 LASER CONTROL AND SCANNING

1
AIOC PWB
PL8.1
ROS
PL3.1
LD PWB
J404
J160
RED
RED
SOS PWB
J201
J2011
1
LD PWB
SOS
SENSOR
LD INTLK
+5VDC
LD INTLK
+5VDC
1
BLU
BLU
J2011
AIOC PWB
PL8.1
+5VDC
J201
SOS SENSED
SIGNAL
J140
2
J403
3
U3-5
DC COM
LD INTLK
+5VDC
J403
6
LASER DIODE
ENABLE ON(L) +5VDC
J140
BLU
BLU
GRN
LASER DIODE
GRN
T24
LD INTLK
+5VDC
F171
F156
F170
PD
POWER CONTROL
ON(L) +5VDC
BLU
BLU
INLET FRAME
ROS GND
IIT GND
ROS GND
LD
6-16
5
ROS VREF
OUT SIGNAL
6-17
BLU
BLU
BLU
BLU
Fail Code
4
COM
U3-5
Laser Power or ROS Motor

Fail
9.2
1
8
LD INTLK
+5VDC
BLU
BLU
7
LD PWB
DC COM
(1.1)
ROS MOTOR
6-15
10
ROS MOTOR
ON(L) +5VDC
BLU
P620
BLU
ROS MOTOR
CLOCK
BLU
BLU
BLU
BLU
BLU
BLU
J620
J130
MOT
+24VDC
(1.1)
8
DC COM
(1.1)
ROS MOTOR
SOS PWB
Figure 3 6.3 Laser Control and Scanning

Wiring Data
June, 2008
7-20
Reissue
Chain 7 Paper Supplying

A
7.1 TRAY1 PAPER STACKING

LVPS
PL8.1
1
TRAY1 NO PAPER
SENSOR
PL2.7
7-7
J157
LVPS
PL8.1
AIOC PWB
PL8.1
BLU
J203
P203
3
TRAY1 NO PAPER SENSOR

PAPER SENSED(L) +5VDC
+5VDC
J501
BLU
P/ J407
A19
C5-0
+5VDC
(1.1)
J501
3
BLU
BLU
P203
J203
3
J157
BLU
BLU
DC COM
(1.1)
TRAY1
INTERLOCK
SWITCH
PL2.5
1-11
J161
9
BLU
BLU
J161
2
+5VDC
TRAY1 INTERLOCK SWITCH

COVER OPEN(H) +5VDC
BLU
BLU
B22
10
E6-1
DC COM
(1.1)
Fail Code
C5-0
E6-1
L/H Lower Cover open
TRAY1 INTERLOCK SWITCH
Figure 1 7.1 Tray 1 Paper Stacking
Reissue
June, 2008
7-21
Wiring Data
7.2 STM PAPER STACKING

STM PWB
PL11.5
1
STM NO PAPER
SENSOR
PL11.7
7-8
J171
STM PWB
PL11.5
STM NO PAPER SENSOR

BLU
+5VDC
J542
BLU
C6-0
+5VDC
(1.1)
J542
J171
BLU
BLU
BLU
BLU
DC COM
(1.1)
STM INTERLOCK
SWITCH
PL11.5
1-10
J173
9
BLU
BLU
J173
2
+5VDC
STM INTERLOCK SWITCH

COVER OPEN(H) +5VDC
BLU
BLU
10
E6-2
DC COM
(1.1)
Fail Code
C6-0
E6-2
STM L/H Cover open
STM NO PAPER SENSOR

STM INTERLOCK SWITCH
Figure 2 7.2 STM Paper Stacking

Wiring Data
June, 2008
7-22
Reissue
Chain 8 Paper Transportation

A
8.1 TRAY1 PAPER FEEDING

LVPS
PL8.1
TRAY1 FEED
SENSOR
PL2.5
8-7
1 BLU
AIOC PWB LVPS

PL8.1
PL8.1
TRAY1 FEED SENSOR

J158
AIOC PWB
PL8.1
+5VDC
J501
BLU
P/J407
A20
C2-2
+5VDC
(1.1)
C8-1
J501
J158
6 BLU
BLU
7 BLU
BLU
3
2
DC COM
(1.1)
TRAY1 FEED
CLUTCH
PL2.2
8-12
P/J407
A18
C1-1
2 BLU
TRAY1 FEED CLUTCH

ON(L) +24VDC
P202
BLU
J202
DC COM
1 BLU
BLU
IOT Motor
+24VDC
(1.1)
Fail Code
C1-1
Tray1 Feed Sensor on JAM
C2-2
Tray1 Feed Sensor on JAM from STM Feed
C8-1
Tray1 Feed Sensor Static JAM
TRAY1 FEED CLUTCH
TRAY1 FEED SENSOR

Take Away Roll 1
Tray 1 Feed Roll
Figure 1 8.1 Tray 1 Paper Feeding
Reissue
June, 2008
7-23
Wiring Data
8.2 STM PAPER FEEDING

STM PWB
PL11.5
STM FEED
SENSOR
PL11.5
8-6
J172
1 BLU
STM PWB
PL11.5
+5VDC
STM FEED SENSOR

J542
BLU
C2-1
C8-2
+5VDC
(1.1)
J542
6 BLU
J172
BLU
7 BLU
BLU
3
2
DC COM
(1.1)
STM FEED
CLUTCH
PL11.6
8-11
2 BLU
STM FEED CLUTCH

P212
ON(L) +24VDC
BLU
J212
STM FEED CLUTCH
DC COM
1 BLU
BLU
STM FEED MOTOR
+24VDC
(1.1)
8-13
J541
1 YEL
2 RED
3 ORN
4 BRN
STM FEED MOTOR

ON +24V CLOCK
STM FEED
MOTOR
PL11.6
Take Away Roll 2
STM FEED MOTOR

ON +24V CLOCK
STM FEED MOTOR
ON +24V CLOCK
STM FEED SENSOR

MOT
STM FEED MOTOR

ON +24V CLOCK
5
Tray 2 Feed Roll
Fail Code
C2-1
STM Feed Sensor on JAM
C8-2
STM Feed Sensor Static JAM
Figure 2 8.2 STM Paper Feeding

Wiring Data
June, 2008
7-24
Reissue
8.3 MANUAL BYPASS

1
AIOC PWB
PL8.1
LVPS
PL8.1
8-17
P/ J407
A5
J502
3
BYPASS
SOLENOID
PL7.5
BYPASS SOLENOID
ON(L) +24VDC
RED
DC COM
1
RED
+24VDC
(1.1)
BYPASS SOLENOID
Bypass Feed Roll
Bypass Take Away Roll
Figure 3 8.3 Manual Bypass

Reissue
June, 2008
7-25
Wiring Data
8.4 PAPER REGISTRATION

LVPS
PL8.1
IOT REGI.
SENSOR
PL2.9
8-5
1 BLU
AIOC PWB LVPS

PL8.1
PL8.1
IOT REGI. SENSOR

J156
C1-2
C6-2
J156
C9-3
3
BLU
2 BLU
BLU
E1-6
DC COM
(1.1)
IOT REGI.
CLUTCH
PL2.9
8-10
P/J407
A6
P/J407
A4
C2-3
J503
1 BLU
+5VDC
J503
BLU
+5VDC
(1.1)
AIOC PWB
PL8.1
4 BLU
IOT REGI. CLUTCH

ON(L) +24VDC
P640
BLU
J640
DC COM
5 BLU
BLU
+24VDC
(1.1)
IOT Motor
Fail Code
C1-2
Tray1 Regi. Sensor on JAM
C2-3
STM IOT Regi. Sensor on JAM
C6-2
Duplex IOT Regi. Sensor on JAM
C9-3
Manual Bypass IOT Regi. Sensor on JAM
E1-6
IOT Regi. Sensor Static JAM
IOT REGI. CLUTCH
IOT REGI. SENSOR
Regi. Roll
Figure 4 8.4 Paper Registration

Wiring Data
June, 2008
7-26
Reissue
8.5 PAPER PATH

1
ExitExit
RollRoll
EXIT MOTOR
FUSER EXIT SENSOR
Duplex Roll 1
Fuser
IOT MOTOR
Regi. Roll
Duplex Roll 2
IOT REGI. SENSOR
Bypass Feed Roll
Bypass Take Away Roll

Take Away Roll 1
Drum
TRAY1 FEED 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

Reissue
June, 2008
7-27
Wiring Data
Chain 9 Marking
A
9.1 XEROGRAPHICS
ChargeCorotron
Drum
AIOC PWB
PL8.1
HVPS PWB
PL8.2
9-4
DRUM CARTRIDGE
PL4.1
Paper
CHARGE
9-5
J406
2
CHARGE ON(L) +5VDC
BLU
J520
BLU
GRID
2
Detack Saw
GND
DC COM
4
DEVE BIAS AC/DC ON(L) +5VDC

BLU
BLU
Grid
DEVE
BIAS
DC COM
5
TRANSFER ON(L) +5VDC

BLU
BLU
TRANSFER COROTRON
HOUSING
PL4.3
DC COM
3
BLU
BLU
BLU
DC COM
9.3
9
INTLK
+24VDC
BLU
BLU
BLU
BLU
TRANSFER
Deve Bias
INTLK
+24VDC
7
Transfer Corotron
DETACK
TRANSFER S/D ON
BLU
Magnet Roll
GND
AIOC PWB
PL8.1
DC COM
(1.1)
+5VDC
J520
1
HVPS ERROR(L) +5VDC
RED
J406
RED
U9-0
Fail Code
U9-0
HVPS fail
Figure 1 9.1 Xerographics
Wiring Data
June, 2008
7-28
Reissue
9.2 TONER SENSE AND CRUM

1
TONER EMPTY
SENSOR
PL4.2
LVPS
PL8.1
J509
1 BLU
P110
BLU
J110
1 RED
LVPS
PL8.1
J110
WHT
P110
3 BLU
+24VDC
(1.1)
3 BLU
BLU
3 BLK
GRN
1 BLU
J509
BLU
9-7
TONER EMPTY SENSOR

TONER SENSED(L) +5VDC
BLU
AIOC PWB
PL8.1
2
+5VDC
P/J407
B4
J1-2
DC COM
(1.1)
AIOC PWB
PL8.1
DRUM CARTRIDGE
PL4.1
CRUM
+12VDC
3.2
J402
1 BLU
CRU ID
P610
BLU
J610
J6-1
2
J7-1
3
4 BLU
BLU
DC COM
(1.1)
INTLK
+5VDC +24VDC
(1.2)
5 BLU
2 BLU
BLU
INTLK +5VDC
BLU
J7-2
9-2
J610
P610
4 BLU
1 BLU
DRUM CARTRIDGE
SENSED(L) +5VDC
+5VDC
J402
BLU
6.3
INTLK +5VDC
BLU
6
INTLK
+5VDC
J1-2
Toner Empty
J3-1
No Drum cartridge
J6-1
J7-1
Drum CRUM communication error
J7-2
Drum CRUM Market identity mismatch
J7-3
Drum CRUM ID error
J3-1
DC COM
Fail Code
J7-3
CRUM
TONER EMPTY SENSOR
DRUM CARTRIDGE
Figure 2 9.2 Toner Sense and CRUM

Reissue
June, 2008
7-29
Wiring Data
9.3 ERASE LAMP

1
AIOC PWB
PL8.1
HVPS PWB
PL8.2
J406
6
BLU
ERASE LAMP ON(L) +5VDC
ERASE LAMP
PL4.2
+24VDC
9-6
J520
BLU
J521
6
1
DC COM
J210
BLU
DC COM
3
BLU
DC COM
2
BLU
ERASE LAMP
INTLK
+24VDC
(9.1)
Figure 3 9.3 Erase Lamp

Wiring Data
June, 2008
7-30
Reissue
Chain 10 Fusing and Copy Transportation

A
10.1 FUSER TEMPERATURE CONTROL

1
AIOC PWB
PL8.1
+5VDC
LVPS
PL8.1
FUSER
PL5.1
THERMOSTAT
P/ J407
B6
J3
3
BLK
J600
FUSER LAMP ON ACH
BLK
F28
F25
BLK
DC COM
ACH
SWITCHED
(1.1)
FUSER LAMP
F26
B5
AIOC PWB
PL8.1
DC COM
F27
1
+24VDC
INTLK
(1.2)
WHT
WHT
1
U4-1
ACN
(1.1)
10-20
THERMISTOR
2
J408
P601
BLU
BLU
J601
2
J601
P601
2
+5VDC
FUSER THERMISTOR
SENSED SIGNAL
BLU
U4-2
J408
BLU
U4-3
DC COM
(1.1)
4
Fail Code
FUSER LAMP
U4-1
Fuser On Time Fail
U4-2
Over Heat Temp Fail
U4-3
THERMISTOR
THERMOSTAT
Figure 1 10.1 Fuser Temperature Control
Reissue
June, 2008
7-31
Wiring Data
10.2 EXIT AND DUPLEX

1
10-8
10-9
AIOC PWB
PL8.1
LVPS AIOC PWB

PL8.1 PL8.1
DUPLEX PWB
PL8.2
EXIT MOTOR
J416 CURR
J550
1
BLU
EXIT MOTOR
ON CLOCK
8 BLU
2
BLU
EXIT MOTOR
ON CLOCK
7 BLU
3
BLU
9 BLU
6 BLU
5 BLU
EXIT MOTOR
ON CLOCK
BLU
EXIT MOTOR
ON CLOCK
BLU
EXIT MOTOR
J551 ON +24V CLOCK
FUSER EXIT
SENSOR
PL6.3
EXIT MOTOR
PL6.3
5 BLK
4 ORN
3 BRN
EXIT MOTOR
ON +24V CLOCK
+5VDC
3
BLU
P/J407
A3
E1-2
E3-1
E3-6
+5VDC
J505J153
1 BLU BLU 3
EXIT MOTOR
ON +24V CLOCK
EXIT MOTOR
ON +24V CLOCK
J153
1 BLU
LVPS
PL8.1
6 YEL
10-23
FUSER EXIT SENSOR

J505
MOT
2 BLU
BLU
DC COM
(1.1)
2 RED
F1
1 RED
INTLK
+24VDC
(1.2)
Simplex Transport:
Duplex (Side 2) Transport:
Exit Roll is driven by IOT Motor.
Exit Roll is driven by EXIT Motor.
Fail Code
E1-2
Fuser Exit Sensor on JAM
E3-1
Fuser Exit Sensor off JAM
E3-6
EXIT MOTOR
Exit Roll
Fuser Exit Sensor Static JAM
Exit Roll
5
1
The actual H/L level is displayed
inversely on the UI display.
IOT Motor
IOT Motor
FUSER EXIT SENSOR
FUSER EXIT SENSOR
Figure 2 10.2 Exit

Wiring Data
June, 2008
7-32
Reissue
10.3 MACHINE COOLING

1
AIOC PWB
PL8.1
1
4-2
+24VDC
J405
3
NOHAD FAN
PL9.2
AIOC PWB
PL8.1
NOHAD FAN ON(H) +24VDC
RED
+5VDC
10-60
MOT
NOHAD FAN FAIL(H) +5VDC

BLK
J405
BLU
U4-9
DC COM
(1.1)
Fail Code
U4-9
1
Nohad Fan defect
NOHAD FAN rotates at low speed when Diag is off,

and at high speed when Diag is on.
Voltage levels are as follows:
Low Speed: approx. 15VDC
High Speed: approx. 24VDC
4
NOHAD FAN
Figure 3 10.3 Machine Cooling

Reissue
June, 2008
7-33
Wiring Data
Wiring Data
June, 2008
7-34
Reissue
Wirenets
7.2.1 WIRE NET AC POWER (HOT)
POWER CORD
POWER SWITCH
FS11
FS31
LOW
VOLTAGE
POWER
SUPPLY
LOW
VOLTAGE
POWER
SUPPLY
1.1
CHOKE COIL
J5
FS32
J5
1
BLK
FS60
BLK
BRN
2
BLK
BLK
GN/YL
WHT
(SEE WIRE NET

AC POWER (NEUT))
FUSER
J3
P600
J600
2
F28
THERMOSTAT
F25
10.1
F26
FUSER LAMP
BLK
BLK
Wire Color
BLK: 100V M/C, BRN: 200V M/C
7.2.2 WIRE NET AC POWER (NEUT)

POWER CORD
POWER SWITCH
FS12
FS33
LOW VOLTAGE
POWER SUPPLY
FUSER
FS34
J3
1
WHT
FS60
WHT
BLU
P600
J600
1
10.1
F27
FUSER LAMP
WHT
1
GN/YL
BLK
(SEE WIRE NET

AC POWER (HOT))
DC POWER
GENERATION
Wire Color
WHT: 100V M/C, BLU: 200V M/C
Reissue
June, 2008
7-35
Wiring Data
7.2.3 WIRE NET +3.3VDC

LOW VOLTAGE
POWER SUPPLY
LENS
ASSEMBLY
AIOC PWB
+3.3VDC
IIT PWB
P/J407
A16
A17
J409
J721
17
FLAT
CABLE
B16
B17
B6
Wiring Data
18
J414
June, 2008
7-36
YEL
J731
ADF PWB
B7
Reissue
7.2.4 WIRE NET +5VDC-1

LOW VOLTAGE
POWER SUPPLY
J501
P203
J203
3
J157
3
BLU
BLU
7.1
8.1
J158
+5VDC
TRAY1 NO PAPER
SENSOR
TRAY1 FEED SENSOR
IOT REGISTRATION
SENSOR
FUSER EXIT SENSOR
BLU
J503
J156
1
BLU
J505
8.4
10.2
J153
1
BLU
STM PWB
J508
J540
J542
1
J171
STM NO PAPER
SENSOR
STM FEED SENSOR
BLU
GRY
8.2
J172
6
7.2
BLU
AIOC PWB
P/J407
A11
J401
USER INTERFACE
PWB
J710
2.1
8
BLU
B11
7
BLU
(SEE WIRE NET +5VDC-2)
Reissue
June, 2008
7-37
Wiring Data

(FROM WIRE NET +5VDC-1)
LENS
ASSEMBLY
IIT PWB
6
J409
J721
16
CN3
IIT4
CARRIAGE
1 SENSOR
6.2
DF3
DOCUMENT TRAY
1 WIDTH SENSOR1
5.1
DF2
DOCUMENT TRAY
1 WIDTH SENSOR2
5.1
DF5
DOCUMENT TRAY
1 LENGTH SENSOR1
5.1
DF4
DOCUMENT TRAY
1 LENGTH SENSOR2
5.1
DF8
DOCUMENT
1 FEEDER WIDTH
SENSOR
5.1
DF9
DOCUMENT SET
1 SENSOR
5.2
DOCUMENT LEAD
1 EDGE SENSOR
5.2
GRY
15
FLAT
CABLE
B5
J416
J550
BLU
J414
YEL
J731
7 DUPLEX PWB
ADF PWB
B8
CN4
WHT
WHT
AIOC PWB
WHT
WHT
CN5
WHT
WHT
DF10
WHT
Wiring Data
June, 2008
7-38
Reissue
7.2.6 WIRE NET DC COM (+5V RTN)-1

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

DC COM (+5VRTN)-2)
Reissue
June, 2008
7-39
Wiring Data
7.2.7 WIRE NET DC COM(+5V RTN)-2

(FROM WIRE NET
DC COM(+5VRTN)-1)
LOW VOLTAGE
POWER SUPPLY
AIOC PWB
P/J407
A12
A13
B12
DRUM CARTRIDGE
4
J402
BLU
P610
BLU
J416
J550
BLU
J610
1 CRUM
9.2
DUPLEX PWB
LENS
ASSEMBLY
IIT PWB
J721
21
B13
1
J409
20
FLAT
CABLE
+3.3VRTN
A14
A15
B14
B14
J410
J720
29
11
24
15
20
17
18
19
16
21
14
23
12
25
10
27
29
31
34
(SEE WIRE NET
DC COM(+5VRTN)-3)
Wiring Data
34
CN3
GRY
IIT4
CARRIAGE
3 SENSOR
6.2
1
FLAT
CABLE
June, 2008
7-40
Reissue
7.2.8 WIRE NET DC COM(+5V RTN)-3

(FROM WIRE NET
DC COM(+5VRTN)-2)
10
J401
J710
BLU
USER INTERFACE
PWB
J711
PLATEN OPEN
SWITCH
BLK
6.1
BLU
J630
BLU
P630
BILLING COUNTER
3.2
ROS
2
J403
J140
BLU
6.3
7 LD PWB
FUSER
2
J408
P601
BLU
J601
THERMISTOR
10.1
ADF PWB
B3
J414
YEL
J731
B10
CN4
DF3
DOCUMENT TRAY
3 WIDTH SENSOR1
5.1
DF2
DOCUMENT TRAY
3 WIDTH SENSOR2
5.1
DF4
DOCUMENT TRAY
3 LENGTH SENSOR1
5.1
DF5
DOCUMENT TRAY
3 LENGTH SENSOR2
5.1
DF14
ADF TOP COVER

1 SWITCH
5.2
DF8
DOCUMENT
3 FEEDER WIDTH
SENSOR
5.1
DF9
DOCUMENT SET
3 SENSOR
5.2
DOCUMENT LEAD
3 EDGE SENSOR
5.2
WHT
WHT
B4
YEL
B9
WHT
WHT
AIOC PWB
Reissue
June, 2008
7-41
CN5
WHT
WHT
WHT
DF10
WHT
Wiring Data

LH COVER
INTERLOCK
SWITCH
LOW VOLTAGE
POWER SUPPLY
4
+24VDC
J506
FS151
ORN
FRONT
COVER
INTERLOCK
SWITCH
LOW VOLTAGE
POWER
SUPPLY
FS152
J506
ORN
J506
FS153
ORN
FS154
ORN
F1
J506
ORN
F3
F2
J504
J201
BLU
4.1
1 IOT MOTOR
J508
N.C
AIOC PWB
P/J407
A1
B1
J406
P520
BLU
J416
J550
BLU
HIGH VOLTAGE
POWER
SUPPLY
DUPLEX PWB
9
1
2
J501
P202
BLU
J502
J202
P640
BLU
TRAY1 FEED
CLUTCH
8.1
IOT
REGISTRATION
CLUTCH
8.4
BLU
J210
2 ERASE LAMP
10.2
J551
RED
9.3
EXIT MOTOR
RED
8.3
BYPASS
SOLENOID
RED
J503
J521
J640
STM PWB
10
J508
ORN
J540
J542
P212
BLU
J212
STM FEED
CLUTCH
8.2
(SEE WIRE NET +24VDC-2)
Wiring Data
June, 2008
7-42
Reissue

(FROM WIRE NET +24VDC-1)
J509
P110
BLU
J110
RED
AIOC PWB
P/J407
A7
9.2
TONER EMPTY
SENSOR
ROS
J403
P620
BLU
J620
J130
6.3
5 ROS MOTOR
A8
LENS
ASSEMBLY
B7
9
B8
J409
J721
IIT PWB
13
10
12
11
11
FLAT
CABLE
B1
B2
J414
YEL
YEL
J731
ADF PWB
B12
B11
CN4
CN3
Reissue
INV CN1
GRY
CN3
WHT
DF13
6.2
CARRIAGE
5 MOTOR
INVERTER
1PWB
6.2
DF13
WHT
DOCUMENT FEED
CLUTCH
5.3
5.3
CN2
LOW VOLTAGE
POWER SUPPLY
IIT5
RED
DOCUMENT DRIVE
MOTOR
BLK
June, 2008
7-43
Wiring Data
7.2.11 WIRE NET DC COM(+24V RTN)

LOW VOLTAGE
POWER SUPPLY
+24VRTN
J504
J201
BLU
J508
J540
VIO
4.1
2 IOT MOTOR
5 STM PWB
AIOC PWB
ROS
P/J407
A7
A8
B1
B7
J403
P620
BLU
J620
6.3
J130
4 ROS MOTOR
10.3
J405
NOHAD FAN
BLK
J406
J520
BLU
9.1
HIGH VOLTAGE
7 POWER SUPPLY
BLU
LENS
ASSEMBLY
B8
20
J409
J721
21
IIT PWB
2
CN3
GRY
INV CN1
INVERTER PWB
6.2
1
FLAT
CABLE
A11
A12
Wiring Data
J416
J550
BLU
J414
YEL
YEL
J731
8 DUPLEX PWB
A2
ADF PWB
A1
June, 2008
7-44
Reissue
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.
Reissue
June, 2008
7-45
Wiring Data
7.1.2 P/J List
Table 1
Table 1
P/J No.
Figure
No.
Item No.
Description
INV CN1
Figure 1
Inverter PWB
P/J No.
Figure
No.
Item No.
Description
INV CN2
Figure 1
Inverter PWB
CN1
Figure 12
DADF Control PWB
J333
Figure 13
23
SLCC PWB
CN2
Figure 11
ADF PWB
J340
Figure 13
22
SLCC PWB
CN2
Figure 12
DADF Control PWB
J341
Figure 13
21
SLCC PWB
CN3
Figure 11
ADF PWB
J342
Figure 13
20
SLCC PWB
CN3
Figure 12
DADF Control PWB
J411
Figure 7
AIOC PWB
CN4
Figure 11
ADF PWB
J508
Figure 6
STM
CN4
Figure 12
DADF Control PWB
J610
Figure 8
CRU
CN5
Figure 11
ADF PWB
NBCR CN6
Figure 1
NBCR PWB
CN5
Figure 12
DADF Control PWB
NSC CN1
Figure 1
NSC PWB
CN6
Figure 12
DADF Control PWB
P412
Figure 7
14
AIOC PWB
CN7
Figure 12
DADF Control PWB
P417
Figure 7
16
AIOC PWB
DF2
Figure 10
P418
Figure 7
15
AIOC PWB
DF3
Figure 10
P419
Figure 7
AIOC PWB
DF4
Figure 10
P508
Figure 9
15
LVPS
DF5
Figure 10
P610
Figure 8
CRU
DF8
Figure 10
Document Feeder Width Sensor
P/J3
Figure 9
18
Fuser Lamp
DF9
Figure 10
Document Tray Set Sensor
P/J5
Figure 9
17
Choke Coil
DF10
Figure 10
Document Lead Edge Sensor
P/J5
Figure 13
SLCC PWB
DF13
Figure 10
ADF Top Cover Switch
P/J110
Figure 3
Toner Empty Sensor
DF14
Figure 11
ADF Top Cover Switch
P/J130
Figure 2
ROS MPA
DF14
Figure 12
14
Feeder Cover Switch
P/J140
Figure 2
ROS
F25
Figure 5
Fuser Thermostat
P/J153
Figure 4
Fuser Exit Sensor
F26
Figure 5
Fuser Lamp
P/J156
Figure 4
IOT Regi. Sensor
F27
Figure 5
Fuser Lamp
P/J157
Figure 3
Tray 1 No Paper Sensor
F28
Figure 5
Fuser Thermostat
P/J158
Figure 4
Tray 1 Feed Sensor
FS11
Figure 9
Inlet
P/J160
Figure 2
ROS, Video
FS12
Figure 9
Inlet
P/J161
Figure 4
Tray 1 Interlock Sensor
FS151
Figure 4
LH Cover Interlock Switch
P/J171
Figure 6
STM No Paper Sensor
FS152
Figure 4
LH Cover Interlock Switch
P/J172
Figure 6
STM Feed Sensor
FS153
Figure 3
Front Cover Interlock Switch
P/J173
Figure 6
STM Interlock Switch
FS154
Figure 3
Front Cover Interlock Switch
P/J201
Figure 8
IOT Motor
FS31
Figure 9
Power Switch
P/J201
Figure 2
ROS, SOS PWB
FS32
Figure 9
Power Switch
P/J2011
Figure 2
ROS, SOS PWB
FS33
Figure 9
Power Switch
P/J202
Figure 8
Tray 1 Feed Clutch
FS34
Figure 9
Power Switch
P/J203
Figure 8
Tray 1 No Paper Sensor
FS60
Figure 9
Inlet GND
P/J210
Figure 3
Erase Lamp
IIT4
Figure 1
Carriage Sensor
P/J212
Figure 6
STM Feed Clutch
IIT5
Figure 1
Carriage Motor
P/J380
Figure 13
SLCC PWB
Wiring Data
June, 2008
7-46
Reissue
Table 1
Table 1
P/J No.
Figure
No.
Item No.
Description
P/J No.
Figure
No.
Item No.
Description
P391
Figure 13
24
SLCC PWB
P/J550
Figure 8
Duplex PWB
P/J401
Figure 7
UI
P/J551
Figure 8
Duplex PWB
P/J401
Figure 13
SLCC PWB
P/J600
Figure 4
Fuser Lamp
P/J402
Figure 7
11
CRU ID
P/J601
Figure 4
Fuser Thermistor
P/J402
Figure 13
13
SLCC PWB
P/J620
Figure 2
ROS MPA
P/J403
Figure 7
12
ROS
P/J630
Figure 8
Billing ID
P/J403
Figure 13
14
SLCC PWB
P/J640
Figure 8
IOT Regi Clutch
P/J404
Figure 7
ROS, Video
P/J710
Figure 1
UI
P/J404
Figure 13
19
SLCC PWB
P/J711
Figure 1
10
Platen Switch
P/J405
Figure 7
Nohad Fan
P/J720
Figure 1
IIT Data
P/J405
Figure 13
12
SLCC PWB
P/J721
Figure 1
IIT Power
P/J406
Figure 7
HVPS
P/J731A/B
Figure 11
ADF
P/J406
Figure 13
10
SLCC PWB
P/J801
Figure 12
11
P/J407
Figure 9
16
LVPS-AIOC PWB
P/J802
Figure 12
12
Exit/Invert Sensor
P/J407
Figure 13
18
LVPS-SLCC PWB
P/J803
Figure 12
13
Registration Sensor
P/J408
Figure 7
13
AIOC PWB
P/J804
Figure 12
10
Registration Clutch
P/J408
Figure 13
15
SLCC PWB
P/J805
Figure 12
Exit/Invert Clutch
P/J409
Figure 7
AIOC PWB
P/J806
Figure 12
Exit/Invert Solenoid
P/J409
Figure 13
SLCC PWB
P/J410
Figure 7
AIOC PWB
P/J410
Figure 13
SLCC PWB
P/J412
Figure 13
16
SLCC PWB
P/J414A/B
Figure 7
AIOC PWB
P/J414A/B
Figure 13
SLCC PWB
P/J415
Figure 13
SLCC PWB
P/J416
Figure 7
10
AIOC PWB
P/J416
Figure 13
11
SLCC PWB
P/J418
Figure 13
17
SLCC PWB
P/J501
Figure 9
13
LVPS
P/J502
Figure 9
10
LVPS
P/J503
Figure 9
12
LVPS
P/J504
Figure 9
LVPS
P/J505
Figure 9
14
LVPS
P/J506
Figure 9
11
LVPS
P/J509
Figure 9
LVPS
P/J520
Figure 3
HVPS
P/J521
Figure 3
HVPS
P/J540
Figure 6
STM
P/J541
Figure 6
STM Feed Motor
P/J542
Figure 6
STM (TOTAL CL, SNR, SW)
Reissue
June, 2008
7-47
Wiring Data
Figure 1 IIT
Wiring Data
June, 2008
7-48
Reissue
Figure 2 ROS
Reissue
June, 2008
7-49
Wiring Data
Figure 3 HVPS
Wiring Data
June, 2008
7-50
Reissue
Figure 4 LH
Reissue
June, 2008
7-51
Wiring Data
Figure 5 Fuser
Wiring Data
June, 2008
7-52
Reissue
Figure 6 STM
Reissue
June, 2008
7-53
Wiring Data
Figure 7 AIOC PWB
Wiring Data
June, 2008
7-54
Reissue
Figure 8 Rear
Reissue
June, 2008
7-55
Wiring Data
P/
J503
P/
J505
Figure 9 Inlet & LVPS

Wiring Data
June, 2008
7-56
Reissue
Figure 10 ADF/DADF
Reissue
June, 2008
7-57
Wiring Data
Figure 11 ADF 2
Wiring Data
June, 2008
7-58
Reissue
Figure 12 DADF Control PWB
Reissue
June, 2008
7-59
Wiring Data
Figure 13 SLCC PWB
Wiring Data
June, 2008
7-60
Reissue

WC5016 5020 Service

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WC5016 5020 Service

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Work Center 5016, 5020

WorkCentre 5016, 5020

Printed in the United States of America.

WorkCentre 5016, 5020 Service Documentation

***Xerox Private Data***

How To Use This Manual

Chain 1 Standby Power

Chain 4 Start Print Power

Chain 7 Paper Supplying

Chain 10 Fusing and Copy Transportation

Description of Terminology and Symbols

This manual is divided into nine sections as described below.

Section 1 Service Call Procedures

A Warning statement indicates an operating or maintenance procedure, practice, or

Section 2 Status Indicator RAPs

A Caution statement indicates an operating or maintenance procedure, practice, or condition

Section 3 Image Quality RAPs

Section 4 Removal/Replacement and Adjustment Procedures

Indicates the removal/replacement procedure for reference.

Section 5 Parts List

Indicates the adjustment procedure for reference.

Section 6 General Procedures/Information

Indicates the parts list for reference.

Section 7 Wiring Data

1 Service Call Procedures

WorkCentre 5016, 5020

Service Call Procedures

Service Call Procedures

1.1 Before Starting Service

1.1.2Things to Note When Handling Customer Data

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

1.1.3 Other Precautions

2 Tray Modules: 8.6kg (requires 2 persons)

Take extra care of your working posture to prevent backache.

Installation and Adjustment

Handling of replaced parts and consumables

Installing and Removing Parts

Other things to note when handling customer data.

Security-related NVM values that were changed during diagnostics.

Handling of copied/printed customer data.

Cleaning Up Toner Spills

Earthquake Preparedness Measures

If the customer requests earthquake proofing, an earthquake preparedness kit is available.

Modifications to the Machine

10. Other Safety Precautions

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

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

Clearly record the following information in the Machine Service Log:

Details of the service call

Parts and consumables replaced

Service Call Procedures

1.2 Service Call Procedure

1.3 Service Call Details

1.2.1 Initial Actions

1.3.1 Initial Actions

Ask the operator(s) about the machines condition.

Record the billing meter readings.

Frequency and location of recent paper jams

Inspect any faulty copies, then check the machine.

Check the Service Log.

Ask the operator(s) about the machines condition.

Record the billing meter readings.

1.2.2 Actions to Take During UM (Unscheduled Maintenance)

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