Xerox WC 5016 5020 Service Manua

701P48365
June 2008
Work Center 5016, 5020
Service Documentation
CAUTION
Certain components in the Work Center 5016/ 5020
are susceptible to damage from electrostatic dis-
charge. Observe all ESD procedures to avoid com-
ponent damage.
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
While Xerox has tried to make this documentation accurate, Xerox will have
no liability arising out of any inaccuracies or ommissions. Changes are peri-
odically made to this document. Changes, technical inaccuracies, and typo-
graphical errors will be corrected in subsequent editions.
All service documentation is supplied to Xerox external customers for infor-
mational 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 mod-
ules, 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.
June, 2008
i WorkCentre 5016, 5020
Reissue Front Matter
WorkCentre 5016, 5020
Service Documentation
WorkCentre 5016, 5020 Service Documentation
701P48365
Reissue
June, 2008
***Xerox Private Data***
All service documentation is supplied to Xerox external customers for informational purposes
only. Xerox service documentation is intended for use by certified, product-trained service per-
sonnel only. Xerox does not warrant or represent that it will notify or provide to such customer
any future change to this documentation. Customer performed service of equipment, or mod-
ules, components, or parts of such equipment may affect whether Xerox is responsible to fix
machine defects under the warranty offered by Xerox with respect to such equipment. You
should consult the applicable warranty for its terms regarding customer or third-party provided
service.
If the customer services such equipment, modules, components or parts thereof, the customer
releases Xerox from any and all liability for the customer actions, and the 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 edi-
tions.
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 infor-
mation 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.
Printed in the United States of America.
XEROX and all Xerox product names mentioned in this publication are trademarks of
XEROX CORPORATION. Other company trademarks are also acknowledged.
PANTONE is a registered trademark of Pantone, Inc.
Changes are periodically made to this document. Changes, technical inaccuracies, and typo-
graphic errors will be corrected in subsequent editions.
CAUTION
This equipment generates, uses and can radiate radio frequency energy, and if not installed
and used in accordance with the instructions documentation, may cause interference to radio
communications. It has been tested and found to comply with the limits for a Class A comput-
ing device pursuant to subpart B of part 15 of FCC rules, which are designed to provide rea-
sonable protection against such interference when operated in a commercial environment.
Operation of this equipment in a residential area is likely to cause interference in which case
the user, at his own expense, will be required to correct the interference.
June, 2008
ii WorkCentre 5016, 5020
Reissue Front Matter
June, 2008
i WorkCentre 5016, 5020
Introduction Reissue
Introduction
How To Use This Manual ................................................................................................ iii
June, 2008
ii WorkCentre 5016, 5020
Reissue Introduction
June, 2008
iii WorkCentre 5016, 5020
Introduction Reissue
How To Use This Manual
This manual is used as the standard service manual for the WorkCentre 5016, 5020.
Enter any comments and/or corrections regarding the WorkCentre 5016, 5020 Service Docu-
mentationl on the Publication Comment Sheet, and send it to the Technical Support Center
SDEG.
This manual describes the standard procedures for servicing the WorkCentre 5016, 5020.
Refer to Section 1 Service Call Procedure for efficient and effective servicing during mainte-
nance calls.
Contents of Manual
This manual is divided into nine sections as described below.
Section 1 Service Call Procedures
This section describes the structured process for determining the type and sequence of actions
that are performed during a service call.
Section 2 Status Indicator RAPs
This section contains the Repair Analysis Procedures (RAPs) necessary to repair all faults
other than image quality faults.
Section 3 Image Quality RAPs
This section contains the Repair Analysis Procedures (RAPs) that are used to diagnose image
quality defect problems.
Section 4 Removal/Replacement and Adjustment Procedures
This section contains the removal, replacement, and adjustment procedures for components of
WorkCentre 5016, 5020.
Section 5 Parts List
This section contains a list of spare parts list for the WorkCentre 5016, 5020.
Section 6 General Procedures/Information
This section contains frequently used procedures that relate to the diagnosis, setup, or opera-
tion of the machine. It also contains pertinent information that will not be found in any other part
of the service documentation.
Section 7 Wiring Data
This section contains the wiring information for the WorkCentre 5016, 5020. It contains a con-
nector list/locator, wirenet diagrams, and Block Schematic Diagrams (BSDs) for the following
chains:
Chain 1 Standby Power
Chain 2 Mode Selection
Chain 3 Machine Run Control
Chain 4 Start Print Power
Chain 6 Imaging
Chain 7 Paper Supplying
Chain 8 Paper Transportation
Chain 9 Marking
Chain 10 Fusing and Copy Transportation
Description of Terminology and Symbols
The terminology and symbols used throughout this service manual are described as follows:
WARNING
A Warning statement indicates an operating or maintenance procedure, practice, or
condition that, if not strictly observed, could result in personal injury or loss of life.
CAUTION
A Caution statement indicates an operating or maintenance procedure, practice, or condition
that, if not strictly observed, could result in damage to, or destruction of, equipment.
NOTE: A Note statement indicates an operating or maintenance procedure, practice, or condi-
tion that is necessary to accomplish a task efficiently.
Reference:
Used when other explanations are given.
Purpose:
Used to describe the purposes of adjustment and troubleshooting.
REP:
Indicates the removal/replacement procedure for reference.
ADJ:
Indicates the adjustment procedure for reference.
PL:
Indicates the parts list for reference.
ASSY:
Means Assembly.
Safety Critical Components (SCC):
These are components, such as electrostatic-sensitive IC chips, which could be damaged if not
handled properly. Follow the regulations regarding Safety Critical Components set by XEROX
Corp.
June, 2008
iv WorkCentre 5016, 5020
Reissue Introduction
June, 2008
1-1 WorkCentre 5016, 5020
Service Call Procedures Reissue
1 Service Call Procedures
1.1 Before Starting Service ............................................................................................. 1-3
1.2 Service Call Procedure ............................................................................................. 1-4
1.3 Service Call Details ................................................................................................... 1-4
1.4 TRIM Checklist .......................................................................................................... 1-5
1.5 Periodic Replacement Parts/Consumables List ........................................................ 1-5
June, 2008
Reissue Service Call Procedures
June, 2008
1-3 WorkCentre 5016, 5020 1.1

1.1 Before Starting Service
1.1.1Safety
To prevent any accident that may occur during maintenance service, any warning or any cau-
tion regarding the service must be strictly observed. Do not perform any hazardous operation.
1. Power Supply
To prevent electrical shocks, burns, or injury, etc., be sure to switch OFF the machine and
disconnect the plug before starting the maintenance service. If the machine has to be
switched ON, such as when measuring a voltage, take extra care to avoid an electrical
shock.
2. Drive Area
Never inspect, clear or lubricate the drive components, such as chain belts, chain wheels
or gears, when the machine is in operation.
3. Heavy Parts
When removing or installing heavy parts, keep your back straight and lift with your legs.
Some parts should not be lifted by one person:
IOT (Platen): 31.5kg (requires 3 persons)
2 Tray Modules: 8.6kg (requires 2 persons)
Take extra care of your working posture to prevent backache.
4. Safety Devices
See that safety devices for preventing accidents, such as fuses, circuit breakers, interlock
switches, etc., and those for protecting customers from injury, such as panels and covers,
function properly. Modifications that hinder the function of any safety devices are strictly
prohibited.
5. Installing and Removing Parts
The edges of parts and covers may be sharp, so take care not to touch them. Be careful
not to touch those parts, and wipe off any oil that may have adhered to your fingers or
hands before servicing. When pulling out parts, cables, etc., do it gently. Do not use
excessive force.
6. Specified Tools
Follow the instructions when a particular tool is specified.
7. Cleaning Up Toner Spills
Since toner can be explosive, sweep or brush any spilled toner into a container to collect
it. To clean away the remaining toner using a vacuum cleaner, always use an FX standard
vacuum cleaner that is toner-tolerant. Never use the customer's vacuum cleaner.
8. Earthquake Preparedness Measures
If the customer requests earthquake proofing, an earthquake preparedness kit is avail-
able.
Check the Service Guide for more information on the earthquake preparedness kit.
9. Modifications to the Machine
Before altering the machine, submit an irregular use license application.
10. Other Safety Precautions
Follow the recommendations in WORKING PRACTICES FOR ENGINEERS issued by
FXAP EH&S (Environmental Health and Safety).
1.1.2Things to Note When Handling Customer Data
1. Handling of copied/printed customer data.
Before you bring back any sample for the purpose of investigation/analysis, always obtain
permission from the customer. Make sure you assure them that the data will not be used
for any other purpose.
2. Security-related NVM values that were changed during diagnostics.
If any security-related NVM values, such as polling, were set for test purposes, make sure
you restore them to their original values after the test.
3. Other things to note when handling customer data.
Follow the safety guidelines established within the OpCo and ensure that customer data
do not get compromised during service.
1.1.3 Other Precautions
To avoid performing wrong or unnecessary service, observe the following:
1. Reference Materials
Read all relevant service documentation, so that you can take a systematic approach.
2. Disassembling
Make sure to note the assembled condition of the machine before removing parts or dis-
assembling it.
3. Installation and Adjustment
After the installation or adjustment is complete, check that no parts or tools are left inside
the machine.
4. Handling of replaced parts and consumables
Make sure that any replaced parts or consumables, as well as the packaging materials,
are taken back to the Service Center.
WARNING
Never discard the Drum/Toner Cartridges into a fire. Always keep them away from
open flames to prevent them from igniting and causing a fire.
NOTE: For separation and processing methods for replaced parts or consumables, refer
to Common Technical Information No. 2-138 for all machines.
If you have replaced the following consumables, affix the "U-TAG" so that the recy-
clable parts will be handled appropriately.
a. Drum Cartridge
b. Toner Cartridge
For recyclable parts, fill in the necessary items on the "U-TAG."
5. General Precautions
Take care not to disturb the customer's daily work.
Place any service-related trash into a trash bag and bring it to the service office.
Clearly record the following information in the Machine Service Log:
Details of the service call
Parts and consumables replaced
June, 2008
1-4 WorkCentre 5016, 5020 1.2, 1.3
1.2 Service Call Procedure
1.2.1 Initial Actions
1. Ask the operator(s) about the machines condition.
2. Record the billing meter readings.
3. Inspect any faulty copies, then check the machine.
4. Check the Service Log.
1.2.2 Actions to Take During UM (Unscheduled Maintenance)
1. Perform the service flow in Section 2 Status Indicator RAPs.
2. Perform the applicable RAP in Section 2 Status Indicator RAPs.
If there are no applicable RAPs, troubleshoot by referring to the BSD in Section 7 Wiring
Data.
3. Check the copy quality.
Make several copies using the Test Pattern (499T247), then check the quality.
4. Look at the last 20 error codes in order to understand the machine status.
Enter Diagnostic Mode. Enter [40-01] (Display Error History How to Enter the Diag-
nostic Mode).
When the last error code is displayed, press 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.
1.2.3 Actions to Take During SM (Scheduled Maintenance)
1. Check the copy quality.
Make several copies using the Test Pattern (499T247), then check the quality.
2. Look at the last 20 error codes in order to understand the machine status.
Enter Diagnostic Mode. Enter [40-01] (Display Error History How to Enter the Diag-
nostic Mode).
When the last error code is displayed, press 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.
3. Perform TRIM servicing.
1.2.4 Final Actions
1. Check overall machine operation/features.
2. Check the machine exterior and consumables.
3. Train the operator as required.
4. Complete the Service Log and Service Report.
5. Keep the copy samples with the Service Log.
1.3 Service Call Details
1.3.1 Initial Actions
1. Ask the operator(s) about the machines condition.
Frequency and location of recent paper jams
Copy quality
2. Record the billing meter readings.
3. Inspect any faulty copies, then check the machine.
4. Check the copy sample and the Service Log from the last call.
1.3.2 Checking Reproducibility of Problem
1. Perform the service flow in Section 2 Status Indicator RAPs.
2. Perform the applicable RAP in Section 2 Status Indicator RAPs.
3. If there are no applicable RAPs, troubleshoot by referring to the BSD in Section 7 Wiring
Data.
1.3.3 Checking Copy Quality
1. Make several copies using the Test Pattern (499T247), then check the quality.
2. If there is a problem in copy quality, perform the applicable RAP in Section 3 Image Qual-
ity.
1.3.4 TRIM Servicing
Perform TRIM servicing during the maintenance call.
1. Perform the necessary TRIM items using the TRIM Checklist.
2. Check for parts that require periodic cleaning/replacement by referring to the TRIM
Checklist and the Periodic Replacement Parts/Consumables List. Clean them if neces-
sary. If replaced, always clear the counters of the corresponding items in the Chain Func-
tion.
June, 2008
1-5 WorkCentre 5016, 5020 1.4, 1.5
1.4 TRIM Checklist
A: Check. Clean, replace, or replenish if necessary.
B: Always check and clean.
*: Always replace at the specified interval.
CAUTION
Do not touch the Drum of the Drum Cartridge.
1.5 Periodic Replacement Parts/Consumables List
When servicing the machine, check the number of copies and the replacement interval for the
consumables and parts that require periodical cleaning/replacement. Clean or replace them if
necessary. The IOT history can be checked at Chain-Function > NVRAM R/W, while the IIT
history can be checked in the Counters (refer to Diagnostic Mode in Section 2 Status Indicator
RAPs). For items that cannot be checked in the Diagnostic Mode, clean or replace them
according to the replacement intervals (standard PV).
CAUTION
Do not keep toner and drum cartridges in your car for long periods of time.
Table 1
No. Service Items
Every
time Service Details
1.1 Check before servicing
(check machine operation)
A Turn on the machine, and make sure that there are
no abnormal sounds.
1.2 Check before Servicing
(copy the Test Pattern)
A Make several copies using the Test Pattern
(499T247), then check the image quality.
2 Clean the interior of the
machine (paper transport
system)
A Clean the paper dust and toner residue in the paper
path and on the jam sensor.
3 Clean the IIT A Clean the Platen Glass surface and the Platen
Cushion with the optical cleaning cloth.
Clean the Reflector, back of the Platen Glass,
mirrors and lens with the optical cleaning cloth.
5 Safety Precautions B Make sure that the power cord is plugged in
properly.
Make sure that there are no cracks in the
power plug and no holes or cuts in the power
cord insulation.
If an extension cord or power strip is used,
make sure it is of sufficient capacity to handle
the power requirements of the machine.
Make sure that no more than one power plug
is connected to a single socket.
6.1 Check after servicing
(copy quality check)
A Make several copies using the Test Pattern
(499T247), then check the image quality.
(check machine operation)
A Check the paper feed.
Make sure that there are no abnormal sounds.
(check the meter)
A Create the Service Log and Service Report.
Table 1
No
Parts/Consumables
Name/PL No.
Replacement
Interval (copies) Counters Check
1 Tray 1 Feed Roll/
Retard Pad
50,000 [29/34] [29/24] [29/14] [29/4]
Count up 1 for every feed. Replace both at the
same time.
2 Tray 2 Feed Roll/
Retard Roll
100,000 [29/25] [29/15] [29/5]
same time.
3 MSI Feed Roll/
Retard Pad
50,000 [29/39] [29/29] [29/19] [29/9]
same time.
4 Fuser Unit 100,000 [21/39] [21/29] [21/19] [21/9]
Count up 1 for every feed.
5 Toner Cartridge 6,000
6 Drum Cartridge 36,000 31,000 (Warning)
36,000 (Machine Stops)
June, 2008
1-6 WorkCentre 5016, 5020 1.4, 1.5
June, 2008
Status Indicator RAPS Reissue
2 Status Indicator RAPS
Error Codes
Fault Repair Overview and List of Error Codes............................................................... 2-3
RAPs
U0-1 Main Motor Stop Error ............................................................................................ 2-25
U1-1 Main Motor Rotation Error ...................................................................................... 2-25
U2-1 Carriage Module Fail .............................................................................................. 2-26
U3-5 Laser Power Or ROS Motor Fail ........................................................................... 2-26
U4-1 Fuser On Time Fail................................................................................................ 2-27
U4-2 Over Heat Temp Fail ............................................................................................. 2-27
U4-3 FS1 Thermistor Defect .......................................................................................... 2-28
U4-9 Fuser Fan Defect................................................................................................... 2-28
U6-2 RAM Read/Write Check Error ............................................................................... 2-29
U6-3 NVM Data Defect .................................................................................................. 2-29
U6-4 NVM Read/Write Cannot Be Executed ................................................................. 2-30
U6-5 CPU Power To Access NVM Is Not Enough......................................................... 2-30
U7-0 UI Communication TimeOut .................................................................................. 2-31
U7-1 UI Communication Error........................................................................................ 2-31
U8-1 Billing Counter Defect............................................................................................ 2-32
U9-0 HVPS Fail .............................................................................................................. 2-32
062-300 Platen Interlock Open ....................................................................................... 2-33
062-345 IISS EEPROM Failure....................................................................................... 2-33
062-360 Carriage Position Fail........................................................................................ 2-34
062-371 Lamp Illumination Fail ....................................................................................... 2-34
062-380 AGC Failure ...................................................................................................... 2-35
062-386 AOC Failure ...................................................................................................... 2-35
062-392 IPS PWB Memory Fail ...................................................................................... 2-36
062-393 IPS PWB Fail .................................................................................................... 2-36
005-170 DADF Feed Failure........................................................................................... 2-37
005-171 DADF Regi / Exit Failure.................................................................................. 2-38
005-172 DADF Inverted Document Jam......................................................................... 2-39
005-198 Short Scan Jam ................................................................................................ 2-40
005-199 Long Scan Jam................................................................................................. 2-40
005-305 Feeder Top Cover Open................................................................................... 2-41
005-920 Static Jam......................................................................................................... 2-41
June, 2008
Reissue Status Indicator RAPS
June, 2008

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:
.
Figure 1 Troubleshooting Procedure
Check the status of Installation
Check the problem status
Perform RAP
Check if the fault is repaired
Completed
Diagnostic Mode
Operating Principles
Wiring Data
Reference
Information
June, 2008
Check the Status of Installation
Before starting to troubleshoot, always check the following items:
The voltage of the power supply (measure the voltage at the power outlet to see if it is
within specification).
The power cord for damage, short circuits, open circuits, and wrong internal connections.
The machine for proper grounding.
The machine is not installed in a place with high temperature, high humidity, low tempera-
ture, 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 Diag-
nostics in Diagnostic Mode, make sure that all covers are installed unless specified other-
wise. 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.
Things to Note When Using RAPs
When troubleshooting using RAPs, prepare normally working parts such as the AIOC
PWB, LVPS, HVPS and Fuser in advance because they might be required to identify a
failure. In addition, if the fault cannot be repaired, replace the "parts considered to be the
cause" and related parts in sequence and check the operation.
When servicing, always disconnect the power cord unless required otherwise. When the
power cord is connected, never touch any current-carrying part unless absolutely neces-
sary.
Descriptions related to connectors are expressed as follows: P/J12" -> The connector (P/
J12) is in the connected state. "P12" -> The plug side when the connector (P/J12) is in the
disconnected state (except when it is directly connected to a board). "J12" -> The jack
side when the connector (P/J12) is in the disconnected state (except when it is directly
connected to a board).
In a RAP, "P/J1 <=> P/J2" means that all the opposing pins between "P/J1" and "P/J12"
(refer to Section 7, Wiring Data) should be measured.
The voltages on small connectors are measured using a special tool. Handle the tool
carefully because it has a sharp tip.
The numerical values described in the RAPs are for 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.
RAP Flow
RAPs are a good place to start in diagnosing a failure. RAPs guide you through the trouble-
shooting 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.
June, 2008
Figure 2 RAP Flow
Ask the operator about the problem
Did the operator operate the machine correctly?
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)?
Does the Control Panel display an Error
Code?
Explain how to operate the
machine
Procedure is complete
Refer to the Error Code List and perform the
relevant troubleshooting
Yes
No
Yes
No
Yes
June, 2008
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
C1-1
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
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.
O -
CH8.1
Figure 1
June, 2008
C1-2
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
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 Sen-
sor (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.
O -
CH8.1
Figure 1
CH8.4
Figure 4
Error
Record in
Error Log RAP BSD
June, 2008
C2-1
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
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.
O -
CH8.2
Figure 2
Error
Record in
Error Log RAP BSD
June, 2008
C2-2
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
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.
O -
CH8.1
Figure 1
CH8.2
Figure 2
Error
Record in
Error Log RAP BSD
June, 2008
2-10 WorkCentre 5016, 5020
C2-3
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
IOT Registration Sensor dirty and Sensor Actuator deformed or damaged
(PL 2.5) (REP 2.5.1).
sor (PL 2.9).
Replace the IOT Registration Clutch (PL 2.9) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
O -
CH8.1
Figure 1
CH8.4
Figure 4
C5-0
Error Name
No paper in the selected paper tray (Tray1)
Explanation
No paper is detected in Tray1 when ATS function is disabled and Tray1 is selected during a copy job.
No paper is detected in Tray1 when Tray1 is selected during a print job (the paper size setting matches the one specified for the job).
I/O Diagnostic Codes
[07-07] Tray1 No Paper Sensor
Check Items
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 Sen-
sor (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).
X -
CH7.1
Figure 1
Error
Record in
Error Log RAP BSD
June, 2008
2-11 WorkCentre 5016, 5020
C5-1
Error Name
Tray1 Paper Size Mismatch
Explanation
Paper that is different from the one in the Tray Settings is detected when feeding.
Or, paper size setting in Tray1 is different from the paper size specification of the job when Tray1 is selected during a print job.
Check Items
Change the paper size of Tray 1 to the one specified by the job.
X - -
C6-0
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
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 Sen-
sor (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).
X -
CH7.2
Figure 2
C6-1
Error Name
Tray2 Paper Size Mismatch
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.
X - -
C7-1
Error Name
MSI Paper Size Mismatch
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.
X - -
Error
Record in
Error Log RAP BSD
June, 2008
2-12 WorkCentre 5016, 5020
C0-1
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.
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.
X -
CH3.2
Figure 2
C9-3
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
IOT Registration Sensor dirty and Sensor Actuator deformed or damaged
Bypass Solenoid faulty
sor (PL 2.9).
Check that the Bypass Solenoid and the LVPS J502-1/3 ( P/J502) pins are connected securely with good electrical contact. If there is no
problem, replace the Bypass Solenoid (PL 7.5).
O -
CH8.3
Figure 3
CH8.4
Figure 4
Error
Record in
Error Log RAP BSD
June, 2008
2-13 WorkCentre 5016, 5020
C8-1
Error Name
F/O#1 SNR Static JAM
Explanation
Tray1 Feed Sensor ON is detected during standby.
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)
O -
CH8.1
Figure 1
C8-2
Error Name
F/O#2 SNR Static JAM
Explanation
STM Feed Sensor ON is detected during standby.
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.
O -
CH8.2
Figure 2
E0-1
Error Name
CPM Image Lost
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
O - -
Error
Record in
Error Log RAP BSD
June, 2008
2-14 WorkCentre 5016, 5020
E1-6
Error Name
Regi SNR Static JAM
Explanation
IOT Registration Sensor ON is detected during standby.
Check Items
Sensor dirty
sor (PL 2.9).
Replace the AIOC PWB (PL 8.1)(REP 8.1.1).
O -
CH8.4
Figure 4
E3-6
Error Name
Exit SNR JAM
Explanation
Fuser Exit Sensor ON is detected during standby.
[10-23] Fuser Exit Sensor
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
O -
CH10.2
Figure 2
Error
Record in
Error Log RAP BSD
June, 2008
2-15 WorkCentre 5016, 5020
E5-1
Error Name
IOT L/H Cover open
Explanation
The Left Hand Cover is open.
[01-01] LH Cover Interlock Switch
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.
X -
CH1.2
Figure 2
E5-2
Error Name
IOT Front Cover open
Explanation
The Front Cover is open.
[01-12] Front Cover Interlock Switch
Check Items
Check that the Front Cover closes correctly.
Check that the Front Cover Interlock Switch is correctly installed and that the electrical connection is good.
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Front Cover Interlock
Switch (PL 8.2).
Wire between Front Cover Interlock Switch FS153 ( FS153) and LVPS J506-2 ( P/J506)
Wire between Front Cover Interlock Switch FS154 ( FS154) and LVPS J506-1
X -
CH1.2
Figure 2
E6-1
Error Name
L/H Low Cover open
Explanation
Access Cover 1 is open.
[01-11] Tray1 Interlock Switch
Check Items
Check that Access Cover 1 closes correctly.
Check that the Tray 1 Interlock Switch is correctly installed and that the electrical connection is good.
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Tray 1 Interlock
Switch (PL 2.5).
Wire between Tray 1 Interlock Switch J161-2 ( P/J161) and LVPS J501-9 ( P/J501)
Wire between Tray 1 Interlock Switch J161-1 and LVPS J501-10
X -
CH7.1
Figure 1
Error
Record in
Error Log RAP BSD
June, 2008
2-16 WorkCentre 5016, 5020
E6-2
Error Name
STM L/H Cover open
Explanation
Access Cover 2 is open.
[01-10] STM Interlock Switch
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.
X -
CH7.2
Figure 2
E8-1
Error Name
Nup NG Out Of Range
Explanation
The magnification is not within the range of 50 to 200% during Nup.
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.
X -
CH3.2
Figure 2
E8-2
Error Name
Nup Paper direction mismatch
Explanation
The paper orientation of the document and the tray are not aligned during Nup.
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.
X -
CH3.2
Figure 2
Error
Record in
Error Log RAP BSD
June, 2008
2-17 WorkCentre 5016, 5020
E1-2
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
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).
O -
CH10.2
Figure 2
E3-1
Error Name
Exit SNR off JAM
Explanation
Timeout between Fuser Exit Sensor ON and Fuser Exit Sensor OFF.
Check Items
Paper damaged or not within specification
6.2).
O -
CH10.2
Figure 2
Error
Record in
Error Log RAP BSD
June, 2008
2-18 WorkCentre 5016, 5020
H9-7
Error Name
MCU-STM comm. error
Explanation
A communication failure has occurred between the MCU and the Tray Module.
Check Items
Turn the power OFF then ON.
Check for any open circuit or short circuit between the STM connectors.
Replace the STM PWB (PL 11.5) (REP 11.5.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
O -
CH3.1
Figure 1
L9-0
Error Name
Copy Counter Full
Explanation
The user that is logged in has reached the allotted copy limit in the Account Mode.
Check Items
X -
CH3.2
Figure 2
J1-0
Error Name
Toner Cartridge was PRENEAR empty
Explanation
The toner cartridge is low.
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).
X - -
J1-2
Error Name
Toner Empty
Explanation
The Toner Cartridge is empty.
[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).
O -
CH9.2
Figure 2
Error
Record in
Error Log RAP BSD
June, 2008
2-19 WorkCentre 5016, 5020
J3-1
Error Name
No Drum Cartridge
Explanation
Unable to detect the Drum Cartridge.
[09-02] Drum Cartridge
Check Items
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.
O -
CH9.2
Figure 2
J6-0
Error Name
Drum near end of life
Explanation
The Drum Cartridge is near the end of its life.
Check Items
Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).
X - -
J6-1
Error Name
Drum cartridge life end
Explanation
The Drum Cartridge has reached the end of its life.
Check Items
O - -
Error
Record in
Error Log RAP BSD
June, 2008
2-20 WorkCentre 5016, 5020
J7-1
Error Name
Drum CRUM comm. Error
Explanation
The AIOC PWB is unable to communicate with the Drum Cartridge.
[09-02] Drum Cartridge
Check Items
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.
O -
CH9.2
Figure 2
J7-2
Error Name
Drum CRUM Market Identity Mismatch
Explanation
The AIOC PWB has detected that the Drum CRUM destination does not match.
Check Items
O -
CH9.2
Figure 2
J7-3
Error Name
Drum CRUM ID error
Explanation
The AIOC PWB has detected that the Drum CRUM ID is incorrect.
Check Items
O -
CH9.2
Figure 2
N1-1
Error Name
EPC Memory Full
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
O - -
Error
Record in
Error Log RAP BSD
June, 2008
2-21 WorkCentre 5016, 5020
N4-0
Error Name
No Response from USB-Host
Explanation
Either "USB disconnected" or "Communication timed-out" is detected during a print job.
Or, either "USB disconnected" or "Communication timed-out" is detected during a scan job.
Check Items
Cancel the print job.
Reconnect the USB cable correctly.
O -
CH3.2
Figure 2
N4-1
Error Name
HBPL or XPJL Syntax Error
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.
O -
CH3.2
Figure 2
N4-2
Error Name
Download File Error
Explanation
There is an abnormal Product ID or there is a checksum error in the download file.
Check Items
-
N4-3
Error Name
Download Flash Write Error
Explanation
Unable to write the downloaded file into flash memory.
Check Items
-
E0-1
Error Name
CPM Image Lost
Explanation
During a copy job in CPM Priority Mode, the paper containing an image cannot be output after the image is deleted.
Check Items
O - -
N5-0
Error Name
Push Scan TimeOut
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.
O - -
Error
Record in
Error Log RAP BSD
June, 2008
2-22 WorkCentre 5016, 5020
N9-0
Error Name
Controller Logic fail
Explanation
A software defect that cannot be ignored is found in the Controller software.
Check Items
O -
CH3.2
Figure 2
N9-1
Error Name
IOT Communication Error
Explanation
The AIOC PWB has detected a Type-Di communication error.
Check Items
O -
CH3.2
Figure 2
U0-1
Error Name
Main Motor stop error
Explanation
The motor runs for over 120 seconds without any paper being fed.
O U0-1
CH4.1
Figure 1
U1-1
Error Name
Main Motor rotation error
Explanation
500ms after the IOT has started, the Main Motor Lock signal is "Low."
O U1-1
CH4.1
Figure 1
U2-1
Error Name
Carriage Module Fail
Explanation
An abnormality was detected in the Carriage Module.
O U2-1
CH6.2
Figure 2
U3-5
Error Name
Laser Power or ROS Motor Fail
Explanation
The ROS Motor is unable to rotate.
Or, the laser output is not normal.
O U3-5
CH6.3
Figure 3
U4-1
Error Name
Fuser On Time Fail
Explanation
The lamp did not turn OFF within the specified time after turning ON.
Or, Warm Up was not completed within the specified time after power ON.
O U4-1
CH10.1
Figure 1
U4-2
Error Name
Over Heat Temp Fail
Explanation
A temperature above 250C is continuously detected for 480ms.
O U4-2
CH10.1
Figure 1
U4-3
Error Name
FS1 thermistor defect
Explanation
FS1 cannot be monitored any more.
O U4-3
CH10.1
Figure 1
Error
Record in
Error Log RAP BSD
June, 2008
2-23 WorkCentre 5016, 5020
U4-9
Error Name
Fuser Fan defect
Explanation
After the start of Fan Fail Signal monitoring, the signal level was Low not more than 30 times.
O U4-9
CH10.3
Figure 3
U6-2
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.
O U6-2
CH3.2
Figure 2
U6-3
Error Name
NVM data defect
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.
O U6-3
CH3.2
Figure 2
U6-4
Error Name
NVM read/write cannot be executed
Explanation
An NVM Ack NG is detected during NVM Read.
An NVM Write Error is detected 5 times during NVM Recovery.
O U6-4
CH3.2
Figure 2
U6-5
Error Name
CPU Power to access NVM is not enough
Explanation
NVM queue full is detected during NVM Write.
O U6-5
CH3.2
Figure 2
U7-0
Error Name
UI Communication TimeOut
Explanation
At the Power On Sequence, the AIOC PWB did not communicate with the User Interface PWB.
X U7-0
CH2.1
Figure 1
U7-1
Error Name
UI Communication Error
Explanation
The User Interface PWB has detected a communication failure.
X U7-1
CH2.1
Figure 1
U8-1
Error Name
Billing Counter Defect
Explanation
It is detected that the Billing Counter Value is incorrect.
Or, the AOIC PWB has failed to read the Billing Counter.
O U8-1
CH3.2
Figure 2
U9-0
Error Name
HVPS fail
Explanation
A 500 msec cycle of the signal HVPS#ERR=High was detected twice in a row.
O U9-0
CH9.1
Figure 1
Error
Record in
Error Log RAP BSD
June, 2008
2-24 WorkCentre 5016, 5020
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
Unable to control the
display at the Control-
ler
2 U7-1 UI Communication Error
3 H9-7 MCU-STM comm. error
Fatal Error
4 N9-1 IOT Communication Error
5 N9-0 Controller Logic fail
6 U0-1 Main Motor stop error
7 U1-1 Main Motor rotation error
8 U2-1 Carriage Module Fail
9 U3-5 Laser Power or ROS Motor Fail
10 U4-1 Fuser On Time Fail
11 U4-2 Over Heat Temp Fail
12 U4-3 FS1 thermistor defect
13 U4-9 Fuser Fan defect
14 U6-2 RAM read/write check error
15 U6-3 NVM data defect
16 U6-4 NVM read/write cannot be executed
17 U6-5 RAM read/write check error
18 U8-1 Billing Counter Defect
19 U9-0 HVPS fail
20 E9-1 AMS NG Out Of Range
Dynamic Error
(Job Cancel)
21 E9-2 Paper direction mismatch
22 E8-1 Nup NG Out Of Range
23 E8-2 Nup Paper direction mismatch
24 L9-0 Copy Counter Full
25 N4-0 No Response from USB-Host
26 N4-1 HBPL or XPJL Syntax Error
27 N4-2 Download File Error
27 N4-3 Download Flash Write Error
29 N5-0 Push Scan TimeOut
30 A5-1 Platen Cover Open Document Cover
Open
32 E5-1 IOT L/H Cover open
Paper 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
36 A1-1 Doc Misfeed Jam
Document 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
Paper Jam
41 C1-2 Tray1 Regi SNR on JAM
42 C2-1 STM F/O#2 SNR on JAM
43 C2-2 Tray1 F/O#1 SNR on JAM from STM feed
44 C2-3 STM Regi SNR on JAM
46 C9-3 MSI Regi SNR on JAM
47 E1-2 Exit SNR on JAM
48 E3-1 Exit SNR off JAM
49 C8-1 F/O#1 SNR Static JAM
50 C8-2 F/O#2 SNR Static JAM
51 E1-6 Regi SNR Static JAM
52 E3-6 Exit SNR JAM
53 E0-1 CPM Image Lost
54 C0-1 APS NG Unselected
Tray-related errors
56 C5-1 Tray1 Paper Size Mismatch
57 C6-1 Tray2 Paper Size Mismatch
58 C7-1 MSI Paper Size Mismatch
59 C5-0 No paper in the select paper tray (Tray1)
60 C6-0 No paper in the select paper tray (Tray2)
61 J1-2 Toner Empty
Resolvable by replac-
ing parts
62 J3-1 No Drum cartridge
63 J6-1 Drum cartridge life end
64 J7-1 Drum CRUM comm. Error
65 J7-2 Drum CRUM Market Identity Mismatch
66 J7-3 Drum CRUM ID error
67 N1-1 EPC Memory Full An error that only
stops scanning
Priority
Order
Error
Code Error Name Error Characteristic
June, 2008
2-25 WorkCentre 5016, 5020 U0-1, U1-1
U0-1 Main Motor Stop Error
BSD-Reference: CH4.1 (Figure 1)
Explanation
The motor runs for over 120 seconds without any paper being fed.
Procedure
The problem can be solved according to RAP U1- 1 Main Motor Rotation Error (U1-1).
Y N
Execute diagnostics [29-49] (How to Enter the Diagnostic Mode) to check the ROM ver-
sion. The ROM is the latest version.
Y N
Upgrade the ROM to the latest version.
Replace the IOT Motor (PL 1.1) (REP 1.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in
that order.
Completed
U1-1 Main Motor Rotation Error
Explanation
500 ms after the IOT Motor starts, the IOT Motor Lock signal is Low.
Procedure
Close the Left Hand Cover and the Front Cover. Execute diagnostics [04--01 Main Motor On].
(How to Enter the Diagnostic Mode) The IOT Motor can be heard rotating.
Y N
Check P/J504 and P/J201. Both P/J504 and P/J201 are connected securely.
Y N
Connect P/J504 and P/J201 securely.
Measure the voltage between LVPS PWB P504-1 ( P/J504) (+) and GND (-). The volt-
age is approximately +24VDC.
Y N
Replace the LVPS (PL 8.1) (REP 8.1.2).
Check the wire between J504-3 ( P/J504) and J201-3 ( P/J201). The wire is not
shorted or open.
Y N
Repair the wire.
Replace the IOT Motor (PL 1.1) (REP 1.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in
that order.
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). The wire is not shorted
or open.
Y N
Repair the wire.
Replace the IOT Motor (PL 1.1) (REP 1.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that
order.
June, 2008
2-26 WorkCentre 5016, 5020 U2-1, U3-5
U2-1 Carriage Module Fail
Explanation
A carriage fault was detected.
Procedure
Execute diagnostics [05-22 Move scanner to home position] and [05-23 Move scanner to main-
tenance position]. (How to Enter the Diagnostic Mode) The carriage moves.
Y N
Check each IIT Carriage connector. Each connector is connected securely.
Y N
Connect each connector securely.
Check for foreign substances and deformed parts in the carriage. None is found.
Y N
Remove the foreign substances and repair the deformed parts.
Replace the IIT Carriage (PL 10.3)(REP 10.3.1).
Execute diagnostics [05-23 Move scanner to maintenance position]. When the IIT Carriage
has moved to the leftmost position, press the [Stop] button to put the Carriage Sensor into the
blocked state. Execute diagnostics [5-11 Home Sensor], and "H" is displayed.
Y N
Check each IIT Carriage and Carriage Sensor connector. Each connector is con-
nected 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.
Replace the IIT Carriage (PL 10.3) (REP 10.3.1).
U3-5 Laser Power Or ROS Motor Fail
Explanation
The ROS Motor does not turn, or the laser output is not normal.
Procedure
Execute diagnostics [6-15 ROS Motor ON]. (How to Enter the Diagnostic Mode) The ROS
Motor can be heard rotating.
Y N
Measure the voltage between the AIOC PWB P403-7 ( P/J403) (+) and GND (-). The
voltage is approximately +24VDC.
Y N
Replace the AIOC PWB (PL 8.1) (REP 8.1.1) and the LVPS (PL 8.1) (REP 8.1.2) in
that order.
Replace the ROS (PL 3.1) (REP 3.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that
order.
Measure the voltage between the AIOC PWB P403-1 ( P/J403) (+) and GND (-). The volt-
age is approximately +5VDC.
Y N
Check the AIOC PWB P/J403 ( P/J403), LD PWB P/J140 ( P/J140), and P/J130 ( P/J130) con-
nectors. 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.
June, 2008
2-27 WorkCentre 5016, 5020 U4-1, U4-2
U4-1 Fuser On Time Fail
Explanation
The lamp did not turn OFF within the specified time after turning ON.
Or, Warm Up was not completed within the specified time after power ON.
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 contacts
are conductive.
Y N
Replace the Fuser (PL 5.1) (REP 5.1.1).
Check the Heater Rod for an open circuit. There is no open circuit between J600-1 ( P/
J600) and J600-2.
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). The wire between J408 and
P601 is not shorted or open.
Y N
Repair the wire.
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.
U4-2 Over Heat Temp Fail
Explanation
A temperature of 250C or higher was detected continuously for 480 ms.
Procedure
When U4-2 occurs, [NVM 50-20 FSR Reset FuserOverTemp] becomes "1." Run [NVM 50-20
FSR Reset FuserOverTemp] using "0" to reset it. (How to Enter the Diagnostic Mode) Check
the resistance of the Thermistor. 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
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.
June, 2008
2-28 WorkCentre 5016, 5020 U4-3, U4-9
U4-3 FS1 Thermistor Defect
Explanation
Thermistor FS1 cannot be monitored any more.
Procedure
Check the condition of the Fuser. The Fuser is installed properly.
Y N
Install the Fuser properly.
Check the resistance of the Thermistor. There is no open circuit between J601-1 ( P/J601)
and J601-2, and the resistance is a minimum of 228k ohms (cold).
Y N
Check the wire between J408 ( P/J408) and P601 ( P/J601). The wire is not shorted or
open.
Y N
Repair the wire.
Replace the Fuser (PL 5.1) (REP 5.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
U4-9 Fuser Fan Defect
Explanation
After the start of Fan Fail Signal monitoring, the signal level was Low not more than 30 times.
Procedure
Turn the power ON. Visually check the NOHAD Fan (PL 9.2). The NOHAD Fan is rotating.
Y N
Measure the voltage between the AIOC PWB P405-3 ( P/J405) (+) and GND (-). The
voltage is approximately +24VDC.
Y N
Replace the NOHAD Fan (PL 9.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Measure the voltage between the AIOC PWB P405-2 P/J405 (+) and GND (-). The voltage
is 0.
Y N
Replace the NOHAD Fan (PL 9.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
June, 2008
2-29 WorkCentre 5016, 5020 U6-2, U6-3
U6-2 RAM Read/Write Check Error
Explanation
When the AIOC PWB checked RAM read/write at activation, a mismatch of read and write data
was detected.
Procedure
Check each AIOC PWB connector. Each connector is connected securely
Y N
Turn the power OFF and ON. U6-2 recurs.
Y N
Completed
U6-3 NVM Data Defect
Explanation
NVM Header data and NVM 3 page data are mismatched.
Or, the NVM Write & Read area is not found.
Or, the NVM or Counter area is full.
Procedure
Check each AIOC PWB connector. Each connector is connected securely.
Y N
Y N
Completed
June, 2008
2-30 WorkCentre 5016, 5020 U6-4, U6-5
U6-4 NVM Read/Write Cannot Be Executed
Explanation
During NVM read/write, the NVM Ack NG state was detected.
Or, during NVM repairs, an NVM write error was detected five times.
Procedure
Check each AIOC PWB connector. Each connector is connected securely.
Y N
Y N
Completed
U6-5 CPU Power To Access NVM Is Not Enough
Explanation
At NVM write, the NVM queue full state was detected.
Procedure
Execute diagnostics [29-49] to check the ROM version. (How to Enter the Diagnostic
Mode) The ROM is the latest version.
Y N
Upgrade the ROM to the latest version.
June, 2008
2-31 WorkCentre 5016, 5020 U7-0, U7-1
U7-0 UI Communication TimeOut
Explanation
At Power ON, the AIOC PWB does not communicate with the User Interface PWB.
Procedure
Measure each voltage between AIOC PWB J401-1 ( P/J401) (+), J401-2 (+), and GND (-).
The voltages are approximately +5VDC.
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.
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.
U7-1 UI Communication Error
Explanation
The User Interface PWB detected a communication failure.
Procedure
Check each User Inferface PWB connector. Each connector is connected securely.
Y N
Y N
Completed
Replace the User Interface PWB (PL 8.4) (REP 8.4.1).
June, 2008
2-32 WorkCentre 5016, 5020 U8-1, U9-0
U8-1 Billing Counter Defect
Explanation
An illegal Billing Counter value was detected.
Or, the AIOC PWB failed to read the Billing Counter.
Procedure
TBD
U9-0 HVPS Fail
Explanation
A 500 ms cycle of HVPS#ERR=High was detected twice in a row.
Procedure
Close the Left Hand Cover and the Front Cover. Make sure that the Drum Cartridge and the
Transfer Corotron are properly seated. Measure the voltages between P406-2 ( P/J406) (+)/
P406-4(+)/P406-5(+) on the AIOC PWB and ground (-). 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
June, 2008
2-33 WorkCentre 5016, 5020 062-300, 062-345
062-300 Platen Interlock Open
BSD-Reference: CH 5.6
Explanation
Detected the opened Platen Interlock.
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)
Check that the Platen Interlock is functioning properly. The Platen Interlock is functioning
properly.
Y N
Replace the Platen Interlock Sensor.
Replace the SLCC PWB (AIOC/Network PWB). (REP 8.1.3) (PL 8.1)
062-345 IISS EEPROM Failure
Explanation
Error in writing on or communicatiing with the EEPROM.
Procedure
Switch off the machine power then switch on the power. The problem is solved.
Y N
Replace the SLCC PWB (AIOC/Network PWB). (REP 8.1.3) (PL 8.1)
Problem is resolved.
June, 2008
2-34 WorkCentre 5016, 5020 062-360, 062-371
062-360 Carriage Position Fail
Explanation
Detected no input of Regi Sensor when carriage was working or detected the failure of the
Regi Sensor position, or detected the failure of the IIT Regi Sensor level.
Procedure
Check that the Lamp Carriage can move freely and has no loose cables. The Lamp Carriage
and cables are good.
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)
Replace the SLCC PWB (AIOC/Network PWB). (PL 8.1) (REP 8.1.3)
062-371 Lamp Illumination Fail
Explanation
Detected incufficient light provided from the Lamp to the CCD.
Procedure
Check for any obstructions in the optical path between the lamp, the lens or the mirror. The
optical path is clear of any obstructions.
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)
June, 2008
2-35 WorkCentre 5016, 5020 062-380, 062-386
062-380 AGC Failure
Explanation
Control logic has detected insufficient light from the Illumination Lamp during AGC (Automatic
Gain Congrol) of the auto IIT Calibration at Start.
Procedure
Check for any obstructions in the optical path. Clean the Mirror, lens and the white balance
strip. Switch off the power then switch it on again. 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)
Replace the SLCC PWB and (3) EEPROMS (AIOC/Network PWB). (PL 8.1) (REP 8.1.3)
POPO the machine and retry.
062-386 AOC Failure
Explanation
Control logic has detected an output defect of the CCD at AOC (Automatic Offset Control) of
the auto IIT Calibration at Start.
Procedure
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.
June, 2008
2-36 WorkCentre 5016, 5020 062-392, 062-393
062-392 IPS PWB Memory Fail
Explanation
Control logic has detected RAM malfunction of IISS PWB.
Procedure
Switch off the power then switch it on again. If the problem is not solved, replace the SLCC
PWB (AIOC/Network) and the 3 EEPROMs. (REP 8.1.3)
062-393 IPS PWB Fail
Explanation
Control logic has detected a test error or a writing error to the SLCC EEPROMs.
Procedure
Switch off the power then switch it on again. If the problem is not solved, replace the SLCC
PWB (AIOC/Network) and the 3 EEPROMs. (REP 8.1.3)
June, 2008
2-37 WorkCentre 5016, 5020 005-170
005-170 DADF Feed Failure
Explanation
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 han-
dler.
Y N
The Document Drive Motor operates.
Y N
Enter the Diagnostic Mode. Enter Component Control Code [05-01]. The Docu-
ment 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 con-
nection.
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 Doc-
ument Feed Clutch operates.
Y N
Check the connector of the Document Feed Clutch (PL 13.9) If the con-
nector is good, replace the Document Feed Clutch (PL 13.9).
Replace the Document Feed Clutch (PL 13.9)
Replace the Pick Up Roller and Feed Roller. (REP 13.9.1)
Y N
ment Feed Clutch operates.
Y N
Check the connector of the Document Feed Clutch (PL 13.9) If the connector is
good, replace the Document Feed Clutch (PL 13.9).
Replace the Document Feed Sensor (PL 13.9).
A
A
B
B
C
C
June, 2008
2-38 WorkCentre 5016, 5020 005-171
005-171 DADF Regi / Exit Failure
Explanation
Control logic has detected no paper at the Registration Sensor after turning on the Registration
Clutch or detected no paper at the Exit/Invert Sensor after turning on the Registration Clutch.
Procedure
dler.
Y N
Y N
Y N
Y N
connections
nection.
open circuit.
13.2.4)
Y N
Y N
Y N
Y N
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)
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)
A
A
B
B
C
C
June, 2008
2-39 WorkCentre 5016, 5020 005-172
005-172 DADF Inverted Document Jam
Explanation
When inverting documents, the control logic detected a failure of a document at the Feed Sen-
sor after turning off the Feedout Forward or document failure at the Exit/Invert Sensor after
turning on the Document Registration Sensor.
Procedure
dler.
Y N
Y N
Y N
Y N
connections
nection.
open circuit.
13.2.4)
Y N
Y N
Y N
Y N
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)
A
A
B
B
June, 2008
2-40 WorkCentre 5016, 5020 005-198, 005-199
005-198 Short Scan Jam
Explanation
The control logic has found that the length of slow scan is less than 80mm.
Procedure
Choose a document size equal to or larger than A4 paper or 208mm SEF or larger, in the Doc-
ument Tray. The problem is solved.
Y N
Inform the customer of the minimum size limitation of documents used in the DADF Document
Tray.
005-199 Long Scan Jam
Explanation
The control logic has detected that the length of slow scan is 450mm or more.
Procedure
Choose a document size equal to or less than A3 paper or 294mm SEF or less in the Docu-
ment Tray. The problem is solved.
Y N
Inform the customer of the maximum size limitation of documents used in the DADF Document
Tray.
June, 2008
2-41 WorkCentre 5016, 5020 005-305, 005-920
005-305 Feeder Top Cover Open
Explanation
The control logic has detected that the Feeder Top Cover 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)

005-920 Static Jam
Explanation
At power on, the control logic detected either the Platen Interlock is close when the Feeder
Cover is open or the Feeder Cover Interlock is close when the Platen Interlock is open.
Procedure
If this occurs frequently, confirm if there is any interferance with the Feed Sensor (PL 13.9),
the Document Registration Sensor (PL 13.7) or the Exit/Invert Sensor (PL 13.7). Check the
sensor connectors for prober connection. Replace one sensor at a time until the problem is
solved.
June, 2008
2-42 WorkCentre 5016, 5020 005-305, 005-920
June, 2008
Image Quality Reissue
3 Image Quality
Image Quality RAPs
IQ1 IOT Image Quality Entry RAP .................................................................................. 3-3
IQ2 IIT Image Quality Entry RAP .................................................................................... 3-3
IQ3 Low Image Density RAP .......................................................................................... 3-4
IQ4 Wrinkled Image RAP................................................................................................ 3-4
IQ5 Residual Image (Ghosting) RAP .............................................................................. 3-5
IQ6 Background RAP...................................................................................................... 3-5
IQ7 Deletion RAP............................................................................................................ 3-6
IQ8 Skew/Misregistration RAP........................................................................................ 3-6
IQ9 Process Direction Bands, Streaks, and Smears RAP.............................................. 3-7
IQ10 Unfused Copy/Toner Offset RAP ........................................................................... 3-7
IQ11 Repeating Bands, Streaks, Spots, and Smears RAP............................................. 3-8
IQ12 Mottle RAP ............................................................................................................. 3-8
IQ13 Spots RAP.............................................................................................................. 3-9
IQ14 Black Prints RAP.................................................................................................... 3-9
IQ15 Blank Image RAP................................................................................................... 3-10
Copy Quality Specification .............................................................................................. 3-10
Samples of Image Quality Defects.................................................................................. 3-16
June, 2008
Reissue Image Quality
June, 2008
3-3 WorkCentre 5016, 5020 IQ1, IQ2

IQ1 IOT Image Quality Entry RAP
Initial Actions
Determine whether the image quality problem occurs in Copy Mode or Print Mode. If the prob-
lem occurs in Copy Mode, go to IQ2.
Procedure
Determine the image quality problem and go to the relevant RAP.
IQ2 IIT Image Quality Entry RAP
Initial Actions
Clean the IIT Upper Cover (PL 10.2) (REP 10.2.1).
Clean the mirrors and lens with a lint-free cloth.
Determine the image quality problem and go to the relevant RAP.
Table 1 IOT Image Quality Problems
Image Quality Problem Symptom RAP
Low image density Overall low density of images. IQ3
Wrinkled images The printed paper is creased, folded or torn. IQ4
Ghost images Ghost images appear on the paper. Parts of the
previous page or current page appear as ghost
images on the paper.
IQ5
Background contamination The whole page or part of the page is contami-
nated by toner. The contamination appears as a
very light grayish color.
IQ6
Deletion Part of the image is missing. IQ7
Skew/Misregistration Printed images are not parallel to the edges of
the paper.
IQ8
Black lines, blank areas, or
smears in the process direction
Black lines or white streaks running parallel to
the direction of paper transport.
IQ9
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-
larly over the whole page.
IQ13
Solid black copy The output is completely black. IQ14
Blank copy The output is completely white. IQ15
Table 1 IIT Image Quality Problems
Image Quality Problem Symptom RAP
Low image density Overall low density of images. IQ3
Background contamination The whole page or part of the page is contami-
nated by toner. The contamination appears as a
IQ6
smears in the process direction.
Black lines or white streaks running parallel to
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
Spotted blanks Toner spots and blank areas are spread irregu-
larly over the whole page.
IQ13
Solid black copy The output is completely black. IQ14
June, 2008
IQ3 Low Image Density RAP
Overall low density of images.
Procedure
Check for dirt on the Platen Glass. The Platen Glass is clean.
Y N
Clean any dirt on the Platen.
If unable to clean the dirt, replace the IIT Upper Cover (PL 10.2) (REP 10.2.1).
Check the drum ground contact. The drum ground contact is clean and not damaged.
Y N
Clean the drum ground contact. If necessary, restore it to its proper shape.
Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF
then ON and make a print. The problem recurs.
Y N
Completed
Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a
print. The problem recurs.
Y N
Completed
Print a page that is entirely black. During the print cycle, turn OFF the power after you hear the
paper feed (to force a stop during image transfer). Check the surface of the Drum. There is a
considerable amount of toner left on the surface of the Drum.
Y N
Replace the 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).
IQ4 Wrinkled Image RAP
The output is creased, folded or torn.
Procedure
Check the paper type. The paper used is within specifications.
Y N
Use paper that is within specifications.
Use paper from a freshly opened packet. The problem recurs.
Y N
Completed
Remove the Fuser (PL 5.1) (REP 5.1.1) and reinstall it properly. Turn the power OFF then ON
and make a print. The problem recurs.
Y N
Completed
Check for foreign substances and damaged components in the paper transport path. No for-
eign substances or damaged components are found in the paper transport path.
Y N
Remove the foreign substances. Reshape or replace any damaged components.
June, 2008
IQ5 Residual Image (Ghosting) RAP
Ghost images appear on the paper. Parts of the previous page or current page appear as ghost
images on the paper.
Procedure
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 sur-
face 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).
IQ6 Background RAP
The whole page or part of the page is contaminated by toner. The contamination appears as a
Procedure
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
Install a new Drum Cartridge (PL 4.1) (REP 4.1.1) and install it properly. Turn the power OFF
then ON and make a print.
The problem recurs.
Y N
Completed
Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron (PL 4.3) (REP
4.3.1) is clean and not damaged.
Y N
Clean the Transfer Corotron (PL 4.3) (REP 4.3.1). If it is damaged, replace it.
Remove the HVPS (PL 8.2) (REP 8.2.1) and reinstall it properly. Turn the power OFF then ON
and make a print.
The problem recurs.
Y N
Completed
Replace the AIOC PWB (PL 8.1) (REP 8.1.1), followed by the HVPS (PL 8.2) (REP 8.2.1).
June, 2008
IQ7 Deletion RAP
Part of the image is missing.
Procedure
Y N
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).
IQ8 Skew/Misregistration RAP
Printed images are not parallel to the edges of the paper.
Procedure
Check the location where the machine is installed. The machine is installed on a stable,
level surface.
Y N
Install the machine on a stable, level surface.
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.
June, 2008
IQ9 Process Direction Bands, Streaks, and Smears RAP
Black lines or white streaks running parallel to the direction of paper transport.
Procedure
Check the IIT Carriage Mirrors. The mirrors are not dirty, scratched, or damaged.
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.
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).
IQ10 Unfused Copy/Toner Offset RAP
Printed images are not properly fused onto the paper. When rubbed, the image comes off eas-
ily.
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.
June, 2008
3-8 WorkCentre 5016, 5020 IQ11, IQ12
IQ11 Repeating Bands, Streaks, Spots, and Smears RAP
Black lines or white streaks running at right angles to the direction of paper transport.
Procedure
Check the IIT Carriage. The carriage has no foreign substances or damaged parts.
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 approxi-
mately 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).
IQ12 Mottle RAP
Procedure
Y N
Y N
Completed
Y N
Completed
Y N
Completed
damaged.
Y N
Y N
Completed
June, 2008
3-9 WorkCentre 5016, 5020 IQ13, IQ14
IQ13 Spots RAP
Toner spots and blank areas are spread irregularly over the whole page.
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).
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
IQ14 Black Prints RAP
The paper is printed completely black.
Procedure
Check the IIT Carriage for foreign substances and damaged parts. The carriage has no for-
eign substances or damaged parts.
Y N
Remove any foreign substances. If any parts of the IIT Carriage Assembly (cable, cap-
stan, etc.) (PL 10.3) are damaged, replace them.
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
3-10 WorkCentre 5016, 5020 IQ15,
IQ15 Blank Image RAP
The paper is printed completely white.
Procedure
Check the ROS (PL 3.1) (REP 3.1.1). The ROS is installed correctly.
Y N
Install the ROS (PL 3.1) (REP 3.1.1) correctly.
Check the drum ground contact. The drum ground contact is clean and not damaged.
Y N
Clean the drum ground contact. If it is damaged, reshape or replace it.
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.
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).
Copy Quality Specification
1. Copy Alignment
How to measure
Make a copy of the Test Pattern STP3600 (A3) (Figure 1) and measure.
Table 1 Copy Alignment: Measurement
Item How to measure (Refer to Figure 1)
Lead Edge Registration (mm) (P1~P2) Standard Value *1
Side Edge Registration (mm) (P7~P19) Standard Value *1: A3S
Lead Skew (mm) (P5~P6) (P3~P4)
Vertical Ratio (%) ((P2~P14) - 200) / 200 x 100: A3S
Horizontal Ratio (%) ((P8~P13) - 280) / 280 x 100
Perpendicularity (mm) Difference between the perpendicular line of the intersection
point between the line that connects P4 and P6, and P14.
Linearity (Vertical) (mm)
400mm
Maximum difference between the [Intersection point of the
vertical line A and each vertical line] and the line that con-
nects 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 Maximum difference between the [Intersection point of the
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.
June, 2008
3-11 WorkCentre 5016, 5020
Specification
[System] IOT + IIT
[DC] IOT + IIT
Table 2 Copy Alignment: Specification
Item
Specification
SYSTEM Application
Lead Edge Registration (mm) +/- 2.90
Side Edge Registration (mm) +/- 3.40
Lead Skew (mm) +/- 2.30 280 mm
Vertical Ratio (%) 100% +/- 1.40 400 mm
Horizontal Ratio (%) 100% +/- 1.40 280 mm
Perpendicularity (mm) +/- 3.40 400 mm
Linearity (Vertical) (mm) +/- 2.00 400 mm
Linearity (Horizontal) (mm) +/- 1.40 280 mm
Linearity (Skew) (mm) +/- 1.42 280 mm
Parallelism +/- 3.70 400 mm
Item Specification Measurement Length
Simplex MSI
Skew H +/-1.9 +/-2.2 200mm
Perpendicularity +/-2.8 +/-3.0 400mm
Linearity: V 1.4 -- 400mm
Linearity: H 1.4 -- 280mm
Linearity: D 1.4 -- 283mm
Registration: Lead +/-2.4 +/-3.1
Registration: Side +/-3.0 +/-3.2
Magnification: V (%) +/-0.95 (100%)
+/-1.16 (50%-99%)
+/-1.47 (101%-200%)
-- 400mm
Magnification: H (%) +/-0.95 (100%)
+/-1.16 (50%-99%)
+/-1.47 (101%-200%)
-- 280mm
June, 2008
3-12 WorkCentre 5016, 5020
Figure 1 Copy Alignment Measurement Positions (Test Pattern STP3600)
2. Image Quality
How to measure
Make a copy of the Test Pattern 499T247 (A3) and measure. See Table 5 for specifications.
Table 4
Text/Image Density
(100%/Normal mode only)
Measure the 0.7G line image (10) at 3 locations.
Determine the maximum and minimum mean value measured
(within the same copy).
June, 2008
3-13 WorkCentre 5016, 5020
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.
Reproducibility of the blue
color density
(100% only)
Normal mode: Check that the 0.2B line image 14 can be read.
Darker mode: Measure the 0.2B line image 14 at 3 locations.
Solid Density Reproduc-
ibility
(100%/Normal mode only)
Measure the 1.0G solid 16 at 3 locations.
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.
Table 4
June, 2008
3-14 WorkCentre 5016, 5020
Figure 2 Image Quality Measurement Positions (Test Pattern 499T247)
Image Quality Specification
Total System
June, 2008
3-15 WorkCentre 5016, 5020
Table 5
Item
Reduce/
Enlarge
(%) INPUT
OUTPUT
(Density
Settings
Button)
Lighter 3
OUTPUT
(Density
Settings
Button)
Normal
OUTPUT
(Density
Settings
Button)
Darker 3
OUTPUT
(Density
Settings
Button)
Auto
Text/Image Density 100 0.7 Gray - >=1.08 - >=1.08
Text/Image Density Evenness 100 0.7 Gray - =<0.2 - =<0.2
Low Contrast Reproducibility 100 0.2 Gray - >=0.17 >=0.46 >=0.22
Low Contrast Evenness 100 0.2 Gray - - =<0.4 -
Low Contrast Reproducibility 100 0.1 Gray Does not
reproduce
- - -
Reproducibility of the blue color den-
sity
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 den-
sity
100 0.1 Blue Does not
reproduce
- - -
Solid Density Reproducibility 100 1.0 Solid - >=1.0 - >=1.0
Solid Density Evenness 100 1.0 Solid - =<0.3 - =<0.3
Background (SIR#302) 100 - - =<1.2 - =<1.2
Resolution
(Excluding Skip/Smear)
100 NBS Target - - - 4.3 Lo/mm
(Min)
Resolution
(Min)
Resolution
(Min)
Resolution
Depth of Focus 100 NBS Target - - - 3 Lo/mm
(Min)*1
Skip/Smear 100 Ladder A3 Entire
Page
- - - 2.5 Lo/mm
(Min)*1
Page
- - - 1.8 Lo/mm
(Min)
Page
- - - 2.5 Lo/mm
(Min)
Page
- - - 2.5 Lo/mm
(Min)*1
June, 2008
3-16 WorkCentre 5016, 5020
Samples of Image Quality Defects
IOT Image Quality Defects
These are samples of image quality defects due to IOT problems and their corresponding solu-
tions.
Auger Marks (Figure 1)
Strobing (28mm or 14mm Pitch Density) (Figure 2)
White Streaks (Process Direction) (Figure 3)
Black Bands (Figure 4)
Toner Contamination (Figure 5)
Toner Splattering (Figure 6)
White Spots (Irregular) (Figure 7)
Regular Blanks in the Process Direction (Spots, Streaks, Bands etc.) (Figure 8)
Regular Toner Contamination in the Process Direction (Spots, Streaks, Bands etc.) (Fig-
ure 9)
IIT Image Quality Defects
These are samples of image quality defects due to IIT problems and their corresponding solu-
tions.
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)
June, 2008
3-17 WorkCentre 5016, 5020
Auger Marks
Figure 1 Auger Marks
Cause
1. Magnetic field failure in the Developer Magnetic Roll.
2. There was a drop in the level of developer material.
Action
1. Replace the Drum Cartridge (PL 4.1) (REP 4.1.1). The problem may occur immediately
after you install a new Drum Cartridge. This can be corrected by feeding a few sheets of
paper.
June, 2008
3-18 WorkCentre 5016, 5020
Strobing (28mm or 14mm Pitch Density)
Figure 2 Strobing (28mm or 14mm Pitch Density)
Cause
1. Developer Magnetic Roll bias.
Action
1. Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).
June, 2008
3-19 WorkCentre 5016, 5020
White Streaks (Process Direction)
Figure 3 White Streaks (Process Direction)
Cause
1. Foreign substances are blocking the ROS Laser.
2. Developer material clogging on the Developer Magnetic Roll due to foreign substances.
Action
1. Clean the optical path between the ROS (PL 3.1) (REP 3.1.1) and the Drum Cartridge (PL
4.1) (REP 4.1.1), and clean the seal glass.
June, 2008
3-20 WorkCentre 5016, 5020
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.
June, 2008
3-21 WorkCentre 5016, 5020
Toner Contamination
Figure 5 Toner Contamination
Cause
1. Cloud of toner falling from the Drum Cartridge (PL 4.1) (REP 4.1.1).
Action
1. Mix the developer material by processing blank paper.
June, 2008
3-22 WorkCentre 5016, 5020
Toner Splattering
Figure 6 Toner Splattering
Cause
1. Paper size mismatch (tray settings and paper size are different).
2. Increased paper resistance due to dry conditions.
Action
1. Check the tray settings.
2. Use paper from a freshly opened packet.
June, 2008
3-23 WorkCentre 5016, 5020
White Spots (Irregular)
Figure 7 White Spots
Cause
1. Increased paper resistance due to dry conditions.
Action
1. Use paper from a freshly opened packet.
June, 2008
3-24 WorkCentre 5016, 5020
Regular Deletions in the Process Direction (Spots, Streaks, Bands,
etc.)
Figure 8 Regular Deletions in the Process Direction (Spots, Streaks, Bands, etc.)
Cause
1. 94mm Pitch (Drum): Scratches or foreign substances.
2. 57mm Pitch (Developer Roll): Developer material clogging on the Magnetic Roll.
3. 44mm Pitch (Charger): Scratches or foreign substances.
4. 80mm Pitch (Fuser Heat Roll): Scratches or foreign substances.
Action
1. 1,4: Clean or replace the Drum Cartridge (PL 4.1) (REP 4.1.1)/Fuser (PL 5.1) (REP
5.1.1).
2. 2,3: Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).
June, 2008
3-25 WorkCentre 5016, 5020
Regular Toner Contamination In the Process Direction (Spots, Streaks,
Bands, etc.)
Figure 9 Regular Toner Contamination In the Process Direction (Spots, Streaks, Bands, etc.)
Cause
1. 94mm Pitch (Drum): Scratches or foreign substances.
2. 57mm Pitch (Magnetic Roll): Developer material clogging on the Magnetic Roll.
3. 44mm Pitch (Charger): Scratches or foreign substances.
4. 80mm Pitch (Heat Roll): Scratches or foreign substances.
5. 19mm Pitch (Fuser Roll-Exit): Dirt.
6. 44mm Pitch (Registration): Dirt.
Action
1. 1,4,5,6: Clean or replace the Drum Cartridge (PL 4.1) (REP 4.1.1)/Fuser (PL 5.1) (REP
5.1.1).
2. 2,3: Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).
June, 2008
3-26 WorkCentre 5016, 5020
Moire Due to Interference with Copy Original
Cause
Copying originals with certain line patterns may cause moire (wavy lines) on the copy. Combi-
nations of certain angles of screen ruling near 150dpi and certain Reduce/Enlarge ratios may
also cause moire.
Action
1. Reduce sharpness.
Secondary defect: Text is blurred.
2. Make copies at a different Reduce/Enlarge ratio.
3. Change the orientation of the original.
Fluctuation in Background Suppression Values for Copies of Originals
of Medium Density
When [Auto] is selected for originals with a background of medium density (0.5G), the effec-
tiveness of Automatic Exposure fluctuates for each job.
Cause
Since medium density (0.5G) is near the upper limit value for background detection, the Back-
ground 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.
June, 2008
3-27 WorkCentre 5016, 5020
Light Background in Copies of Originals with Frames
When [Auto] is selected for originals with dark frames along the Lead Registration Edge, the
background suppression value is set so large that areas of medium density appear extremely
light.
Figure 10 Light Background in Copies of Originals with Frames
Cause
[Auto] performs background detection of images at a distance of up to 10mm from the Lead
Registration Edge. If there are dark frames along the Lead Registration Edge, Automatic Expo-
sure cannot detect the original background density. Therefore, Background Suppression is cal-
culated based on the density of the frames.
Action
Select [Off] for [Auto].
June, 2008
3-28 WorkCentre 5016, 5020
June, 2008
Repairs and Adjustments Reissue
4 Repairs and Adjustments
Introduction
Introduction ..................................................................................................................... 4-3
Repairs
1. Drive
REP 1.1.1 IOT Motor (SCC)............................................................................................ 4-5
2. Paper Transport
REP 2.2.1 Tray 1 Feed Clutch (SCC) ............................................................................. 4-7
REP 2.3.1 Tray 1 Feed Roll (SCC) ................................................................................. 4-9
REP 2.5.1 Tray 1 Feed Sensor ...................................................................................... 4-10
REP 2.7.1 Tray 1 No Paper Sensor ............................................................................... 4-12
REP 2.8.1 Registration (SCC)......................................................................................... 4-13
3. ROS
REP 3.1.1 ROS (SCC) .................................................................................................... 4-17
4. CRU
REP 4.1.1 Drum Cartridge .............................................................................................. 4-19
REP 4.2.1 Toner Empty Sensor...................................................................................... 4-20
REP 4.2.2 Erase Lamp ................................................................................................... 4-21
REP 4.3.1 Transfer Module............................................................................................. 4-23
REP 4.4.1 Corotron Wire ................................................................................................ 4-27
5. Fuser
REP 5.1.1 Fuser (SCC)................................................................................................... 4-29
REP 5.1.2 Temperature Control Sensor Assembly......................................................... 4-31
REP 5.1.3 Fuser Lamp.................................................................................................... 4-32
REP 5.1.4 Fuser Roll ...................................................................................................... 4-35
REP 5.1.5 Fuser Pressure Roll ....................................................................................... 4-38
6. Exit
REP 6.1.1 Exit Transport (Simplex) ................................................................................ 4-39
REP 6.1.2 Exit Transport (Duplex).................................................................................. 4-42
7. Simplex Module and Bypass Tray
REP 7.1.1 Simplex, Duplex Module................................................................................ 4-45
REP 7.5.1 Bypass Feed Roll........................................................................................... 4-47
8. Electrical
REP 8.1.1 AIOC PWB (SCC).......................................................................................... 4-49
REP 8.1.2 LVPS (SCC)................................................................................................... 4-52
REP 8.1.3 AIOC/Network PWB (DADF/Network Only)................................................... 4-55
REP 8.2.1 HVPS (SCC) .................................................................................................. 4-58
REP 8.2.2 Duplex PWB (SCC) ....................................................................................... 4-61
REP 8.3.1 Control Panel (SCC) ...................................................................................... 4-62
REP 8.4.1 User Interface PWB (SCC) ............................................................................ 4-64
9. Cover
REP 9.1.1 Output Tray.................................................................................................... 4-67
REP 9.1.2 Front Left Cover ............................................................................................. 4-68
REP 9.2.1 Rear Cover..................................................................................................... 4-69
REP 9.2.2 Right Cover .................................................................................................... 4-70
10. IIT
REP 10.1.1 IIT Platen Cover ........................................................................................... 4-71
REP 10.2.1 IIT Upper Cover (SCC) ................................................................................ 4-72
REP 10.3.1 IIT Carriage (SCC) ....................................................................................... 4-73
REP 10.3.2 Flexible Print Cable (SCC)........................................................................... 4-79
REP 10.6.1 Exposure Lamp............................................................................................ 4-81
REP 10.7.1 Carriage Cable and Drum............................................................................ 4-82
REP 10.7.2 Inverter PWB................................................................................................ 4-85
11. Single Tray Module
REP 11.1.1 Tray 2........................................................................................................... 4-89
REP 11.1.2 Single Tray Module (Separation from IOT) .................................................. 4-89
REP 11.4.1 Tray 2 Feed Roll .......................................................................................... 4-91
REP 11.4.2 Tray 2 Retard Roll........................................................................................ 4-93
REP 11.5.1 STM Feed Sensor........................................................................................ 4-96
REP 11.5.2 STM PWB (SCC) ......................................................................................... 4-97
REP 11.6.1 STM Feed Clutch......................................................................................... 4-98
REP 11.6.2 STM Feed Motor .......................................................................................... 4-99
REP 11.7.1 STM No Paper Sensor................................................................................. 4-100
13. ADF
REP 13.1.1 ADF Assembly ............................................................................................. 4-101
REP 13.1.2 ADF/DADF Platen Cushion.......................................................................... 4-102
REP 13.2.1 Document Tray Assembly (ADF) ................................................................. 4-104
REP 13.2.2 ADF Feeder Assembly................................................................................. 4-106
REP 13.2.3 Front Cover .................................................................................................. 4-109
REP 13.2.4 Rear Cover................................................................................................... 4-110
REP 13.2.5 DADF Eject Roller Solenoid......................................................................... 4-111
REP 13.2.6 DADF Assembly........................................................................................... 4-112
REP 13.2.7 Document Tray Assembly (DADF)............................................................... 4-113
REP 13.2.8 DADF Feeder Assembly .............................................................................. 4-116
REP 13.3.1 ADF Control PWB........................................................................................ 4-119
REP 13.3.2 Left Counter Balance (SCC) ........................................................................ 4-121
REP 13.3.3 Right Counter Balance (SCC)...................................................................... 4-122
REP 13.3.4 DADF PWB.................................................................................................. 4-124
REP 13.4.1 Top Cover .................................................................................................... 4-125
REP 13.8.1 Retard Roll ................................................................................................... 4-126
REP 13.9.1 Pickup Roll, Feed Roll.................................................................................. 4-128
Adjustments
ADJ 8.1.1 Edge Erase Adjustment.................................................................................. 4-131
ADJ 8.1.2 Controller Firmware Version Upgrade............................................................ 4-131
ADJ 10.3.1 IIT Lead Edge/Side Edge Registration ......................................................... 4-132
June, 2008
Reissue Repairs and Adjustments
ADJ 11.1.1 Carriage Assembly Alignment (Parallelism) ................................................. 4-133
ADJ 13.1.1 ADF/DADF Positional Adjustment ................................................................ 4-134
June, 2008
4-29 WorkCentre 5016, 5020

Introduction
This section contains procedures required for parts replacement and adjustment.
How to Use the Replacement and Adjustment Section
For installation procedures, only NOTEs are described here since installation procedures are
the reverse of removal ones.
1. (Figure X) at the beginning of a procedure indicates that its detailed steps are shown in
the illustration. Numbers in the illustration indicate the sequence of the steps.
2. (REP X.X.X) at the end of a procedure indicates the replacement procedure to be referred
to.
3. Item numbers of replacement and adjustment procedures (i.e. REP/ADJ No.) correlate to
the PL No. in Section 5 Parts List. Therefore, an appropriate replacement or adjustment
procedure can easily be referred to a PL No. and vice versa. For example, the replace-
ment or adjustment procedure of Component PL 1.1 is REP 1.1.X or ADJ 1.1.X.
4. When replacement/adjustment procedures or title items vary by modification or model,
the modification number or the model is indicated at the beginning or the end of the
respective titles or procedures.
Example 1: REP X.X.X Main PWB [Models with 1V] indicates that the entire procedure
under this title applies to machines with Tag 1V.
Example 2: See Table 1.
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.
Terms and Symbols
Terms and symbols used throughout this section are explained here.
WARNING
A Warning statement indicates an operating or maintenance procedure, practice, or
condition that, if not strictly observed, could result in personal injury or loss of life.
CAUTION
A Caution statement indicates an operating or maintenance procedure, practice, or condition
that, if not strictly observed, could result in damage to, or destruction of, equipment.
NOTE: A Note statement indicates an operating or maintenance procedure, practice, or condi-
tion that is necessary to accomplish a task efficiently.
Reference: Used when other explanations are given.
Purpose: Used to describe the purpose of the Adjustment.
Safety Critical Components (SCC):
Safety Critical Components are components, such as static-sensitive integrated circuit chips,
that require special precautions to prevent them from being damaged. Follow the regulations
regarding Safety Critical Components set by FUJI XEROX Co., Ltd.
Important Information Stored Component (ISC):
This component stores all the important customer information that is input after the installation.
When replacing this component, follow the procedures in Section 4 Repairs and Adjustments.
Make absolutely sure that no customer information gets revealed.
Table 1
Symbol Description
Figure 1 Illustration 1
Illustration 1: Indicates that a specific part has been modified by the
tag number within the circle.
Figure 2 Illustration 2
Illustration 2: Indicates that the configuration of the part shown is the
configuration before the part was modified by the number within the
circle.
June, 2008
4-30 WorkCentre 5016, 5020
June, 2008
4-31 WorkCentre 5016, 5020 REP 1.1.1
REP 1.1.1 IOT Motor (SCC)
Parts List on PL 1.1
Removal
WARNING
To avoid personal injury or electrical shock, ensure that the machine is completely off
before disassembling or adjusting. Turn OFF the power and unplug the machine.
1. Remove the Drum Cartridge (REP 4.1.1).
2. Remove the Rear Cover (REP 9.2.1).
3. Disconnect the connector (Figure 1).
1 Remove the screw that secures the Ground Wires (2).
2 Disconnect P/J 504.
3 Release the wire harness of the IOT Motor from the hook.
4 Remove the wire harness of the IOT Motor from the slot in the frame.
Figure 1
June, 2008
4-32 WorkCentre 5016, 5020 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.
June, 2008
4-33 WorkCentre 5016, 5020 REP 2.2.1
REP 2.2.1 Tray 1 Feed Clutch (SCC)
Removal
WARNING
1 Disconnect the connector.
2 Release the wire harness from the clamp.
Figure 1
3. Remove the screws (3) that secure the Clutch Bracket (Figure 2).
1 Remove the screws (3).
Figure 2
June, 2008
4-34 WorkCentre 5016, 5020 REP 2.2.1
4. Remove the Tray 1 Feed Clutch (Figure 3).
1 Remove the Clutch Bracket.
2 Remove the bearing.
3 Remove the Tray 1 Feed Clutch.
4 Pull out the wire harness through the hole.
Figure 3
Replacement
2. When installing the Tray 1 Feed Clutch, place the tab of Clutch Bracket in the notch of
Tray 1 Feed Clutch (Figure 4).
Figure 4
June, 2008
4-35 WorkCentre 5016, 5020 REP 2.3.1
REP 2.3.1 Tray 1 Feed Roll (SCC)
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 1
4. Remove the Tray 1 Feed Roll (Figure 2).
1 Gently lift up the tab to remove the Tray 1 Feed Roll.
Figure 2
June, 2008
4-36 WorkCentre 5016, 5020 REP 2.3.1, REP 2.5.1
Replacement
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).
Figure 3
REP 2.5.1 Tray 1 Feed Sensor
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.
June, 2008
4-37 WorkCentre 5016, 5020 REP 2.5.1
5. Remove the Tray 1 Feed Sensor (Figure 1).
1 Remove the Tapping Screw.
2 Remove the cable bands (2).
3 Release the wire harness from the clamps (2).
4 Move the wire harness toward you and disconnect the connector.
5 Remove the Tray 1 Feed Sensor.
Figure 1
Replacement
2. Insert the Connector Housing of the Tray 1 Interlock Switch into the square hole of the
frame (Figure 2).
A Square hole
Figure 2
June, 2008
4-38 WorkCentre 5016, 5020 REP 2.7.1
REP 2.7.1 Tray 1 No Paper Sensor
Removal
WARNING
1. Remove Tray 1.
3. Remove the Sensor Housing (Figure 1).
2 Release the tabs (2) to remove the Sensor Housing.
Figure 1
4. Remove the Tray 1 No Paper Sensor (Figure 2).
1 Remove the Actuator.
2 Release the tabs to remove the Tray 1 No Paper Sensor.
Figure 2
Replacement
June, 2008
4-39 WorkCentre 5016, 5020 REP 2.8.1
REP 2.8.1 Registration (SCC)
Removal
WARNING
3. Remove the Transfer Corotron Housing (REP 4.3.1).
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
June, 2008
4-40 WorkCentre 5016, 5020 REP 2.8.1
5. Remove the Connector Housing (Figure 2).
1 Remove the wire harness from the guide.
2 Slide the Connector Housing through the hole.
Figure 2
6. Remove the Front Stopper (Figure 3).
1 Remove the Front Stopper.
Figure 3
June, 2008
4-41 WorkCentre 5016, 5020 REP 2.8.1
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
June, 2008
4-42 WorkCentre 5016, 5020 REP 2.8.1
June, 2008
4-43 WorkCentre 5016, 5020 REP 3.1.1
REP 3.1.1 ROS (SCC)
Removal
WARNING
NOTE: Attach the attachment in the ROS Replacement Kit to a Stubby Driver to remove the
screws (Figure 1).
Figure 1
1. Open the Front Cover.
2. Remove the Output Tray (REP 9.1.1).
4. Remove the HVPS and Contact Block (REP 8.2.1).
5. Remove the Laser Housing (Figure 2).
2 Remove the Laser Housing.
Figure 2
June, 2008
4-44 WorkCentre 5016, 5020 REP 3.1.1
6. Disconnect the ROS connectors (Figure 3).
1 Disconnect the Ground connectors (2).
2 Disconnect the connectors (2).
4 Remove the wire harness from the hook.
Figure 3
7. Remove the ROS (Figure 4).
2 Remove the ROS.
Figure 4
Replacement
NOTE: When powering up to perform operations with the ROS installed, read the warning
label pasted on the ROS before proceeding with the operation.
June, 2008
4-45 WorkCentre 5016, 5020 REP 4.1.1
REP 4.1.1 Drum Cartridge
Removal
WARNING
1. Open the Simplex/Duplex Module.
3. Remove the Drum Cartridge (Figure 1).
1 Release the tab.
2 Remove the Drum Cartridge.
Figure 1
Replacement
2. When installing the Drum Cartridge, align the protruding end of the Drum Cartridge with
the cavity in the frame (Figure 2).
Figure 2
June, 2008
4-46 WorkCentre 5016, 5020 REP 4.2.1
REP 4.2.1 Toner Empty Sensor
Removal
WARNING
2. Remove Tray 1.
Figure 1
5. Remove the Toner Empty Sensor (Figure 2).
1 Release the tabs (2) to remove the Toner Empty Sensor.
Figure 2
June, 2008
Replacement
2. Insert the Connector Housing of the Toner Empty Sensor into the square hole of the frame
(Figure 3).
A Square hole
Figure 3
REP 4.2.2 Erase Lamp
Removal
WARNING
5. Remove the HVPS and Contact Block (REP 8.2.1).
June, 2008
4-48 WorkCentre 5016, 5020 REP 4.2.2
6. Release the Erase Lamp tabs (7) (Figure 1).
1 Release the tabs (upper: 3).
2 Release the tabs (lower: 4).
Figure 1
7. Remove the Erase Lamp (Figure 2).
1 Remove the Erase Lamp.
Figure 2
June, 2008
Replacement
2. Insert the Connector Housing of the Erase Lamp into the square hole in the frame (Figure
3).
A Square hole
Figure 3
REP 4.3.1 Transfer Module
Removal
WARNING
4. Remove the Exit Transport (REP 6.1.1).
5. Remove the Fuser (REP 5.1.1).
June, 2008
4-50 WorkCentre 5016, 5020 REP 4.3.1
6. Remove the Transfer Corotron Housing (Figure 1).
1 Release the hooks (2).
2 Remove the Transfer Corotron Housing by pulling its front side in the direction of the
arrow.
Figure 1
7. Remove the Tapping Screws that secure the Corotron Block (Figure 2).
2 Move the Fuser Connector Bracket.
Figure 2
June, 2008
4-51 WorkCentre 5016, 5020 REP 4.3.1
8. Remove the Corotron Block (Figure 3).
1 Press the Spring Plate.
2 Remove the Corotron Block by pulling it in the direction of arrow.
Figure 3
9. Disconnect the Corotron Block cables (Ground/Detack/Transfer) (Figure 4).
1 Disconnect the Ground Cable (white).
2 Remove the Ground Cable (white) from the guides (2).
3 Remove the Detack Cable (black).
4 Remove the Detack Cable (black) from the guides (2).
5 Disconnect the Transfer Cable (white).
6 Remove the Transfer Cable (white) from the guides (3).
Figure 4
June, 2008
4-52 WorkCentre 5016, 5020 REP 4.3.1
Replacement
2. Perform the following steps to install the Corotron Block (Figure 5).
1 Press the Spring Plate.
2 Install the Corotron Block.
Figure 5
3. Attach the cables (Ground/Detack/Transfer) to the Corotron Block hooks as shown in Fig-
ure 6.
Figure 6
June, 2008
4. When installing the Transfer Corotron Housing, insert the tabs of Transfer Corotron Hous-
ing into the square holes of the Corotron Bracket (Figure 7).
Figure 7
REP 4.4.1 Corotron Wire
Removal
WARNING
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 1
June, 2008
4-54 WorkCentre 5016, 5020 REP 4.4.1
4. Attach the Corotron Wire (Figure 2).
1 Attach the Corotron Wire.
Figure 2
5. Attach the spring (Figure 3).
1 Attach the spring to the Corotron Wire.
2 Attach the spring.
Figure 3
Replacement
June, 2008
4-55 WorkCentre 5016, 5020 REP 5.1.1
REP 5.1.1 Fuser (SCC)
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 1
3. Disconnect the connectors (Figure 2).
Figure 2
June, 2008
4-56 WorkCentre 5016, 5020 REP 5.1.1
4. Remove the Fuser (Figure 3).
2 Remove the Fuser by shifting it in the direction of the arrow.
Figure 3
Replacement
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 4
June, 2008
4-57 WorkCentre 5016, 5020 REP 5.1.2
REP 5.1.2 Temperature Control Sensor Assembly
Removal
WARNING
WARNING
2. Slide the Cover to the left and remove (Figure 1).
Figure 1 Removing the Cover
3. Remove the Temperature Control Sensor Assembly (Figure 2).
1 Remove the Screw.
2 Remove the Harness.
Figure 2 Removing the Temperature Control Sensor Assembly
Cover
Screw
Harness
June, 2008
Replacement
NOTE: Before tightening the Screw, make sure that the Tab on the Sensor Block is
inserted in the notch of the Frame (Figure 3).
Figure 3 Installing the Temperature Control Sensor Assembly
REP 5.1.3 Fuser Lamp
Removal
WARNING
WARNING
2. Slide the Cover to the left and remove (Figure 1).
Figure 1 Removing the Cover
Tab Notch
Screw
Sensor Block
Cover
June, 2008
4-59 WorkCentre 5016, 5020 REP 5.1.3
3. Disconnect the hot side of the Fuser Lamp (Figure 2).
1 Disconnect the Terminal.
2 Remove the Screw.
Figure 2 Disconnecting the hot side of the Fuser Lamp
4. Disconnect the neutral side of the Fuser Lamp (Figure 3).
1 Disconnect the white wire from theTerminal.
2 Remove the Screw.
Figure 3 Disconnecting the neutral side of the Fuser Lamp
Terminal
Screw
White Wire
Terminal
Screw
June, 2008
4-60 WorkCentre 5016, 5020 REP 5.1.3
5. Remove the Fuser Lamp Housing (Figure 4).
1 Remove 2 Screws.
2 Carefully remove the Fuser Lamp Housing.
Figure 4 Removing the Fuser Lamp Housing
6. Remove the Fuser Lamp by pulling it through the Fuser Roll (Figure 5).
NOTE: Do not lose the Fuser Lamp Mount.
Figure 5 Removing the Fuser Lamp
Replacement
CAUTION
Do not touch the glass part of the Fuser Lamp unless you are are wearing gloves.
Screws
Fuser Lamp Housing Fuser Lamp
Fuser Roll
Fuser Lamp Mount
June, 2008
4-61 WorkCentre 5016, 5020 REP 5.1.4
REP 5.1.4 Fuser Roll
Removal
WARNING
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).
Figure 1 Removing the Fuser Cover
3. Remove the Stripper Finger Assembly (Figure 2 and Figure 3).
1 Remove the Screw.
2 Remove the Stripper Finger Assembly.
Figure 2 Fuser Cover Removed
Figure 3 Removing the Stripper Finger Assembly
Screws
Fuser Cover
Fuser Cover
Cover Mount
Stripper Finger Assembly
Screw
Stripper Finger Assembly
June, 2008
4-62 WorkCentre 5016, 5020 REP 5.1.4
4. Remove the Fuser Roll Retaining Rings and Drive Gear (Figure 4).
1 Remove the Retaining Ring.
2 Remove the Drive Gear.
3 Remove the Retaining Ring from the other end of the Fuser Roll.
Figure 4 Removing the Retaining Rings and Drive Gear
5. Remove the Fuser Roll by pulling it through the Bushings in the Frame (Figure 5).
Figure 5 Removing the Fuser Roll
Retaining Ring
Drive Gear
Fuser Roll
Bushing
Frame
Fuser Roll
June, 2008
4-63 WorkCentre 5016, 5020 REP 5.1.4
Replacement
CAUTION
Do not touch the glass part of the Fuser Lamp unless you are wearing gloves.
NOTE: When installing the Drive Gear, make sure that the Locating Key is oriented as
shown in Figure 6.
Figure 6 Installing the Drive Gear
CAUTION
Make sure the stripper fingers are oriented correctly when reinstalling the Stripper Finger
Assembly, as shown in Figure 7.
Figure 7 Setting the Stripper Fingers
Locating Key
June, 2008
4-64 WorkCentre 5016, 5020 REP 5.1.5
REP 5.1.5 Fuser Pressure Roll
Removal
WARNING
WARNING
CAUTION
1. Remove the Fuser Roll (REP 5.1.4).
2. Remove the Bushings (Figure 1).
Figure 1 Removing the Bushings
3. Remove the Fuser Pressure Roll (Figure 2).
1 Remove the Levers.
2 Remove the Spring Mount Assemblies.
3 Remove the Fuser Pressure Roll.
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.
Bushings
Levers
Spring Mount Assemblies
Fuser Pressure Roll
June, 2008
4-65 WorkCentre 5016, 5020 REP 6.1.1
REP 6.1.1 Exit Transport (Simplex)
Removal
WARNING
WARNING
4 Release the wire harness from the clamps (2).
Figure 1
June, 2008
4-66 WorkCentre 5016, 5020 REP 6.1.1
Figure 2
5. Lower the Fuser levers (2) (Figure 3).
1 Lower the levers (2).
Figure 3
June, 2008
4-67 WorkCentre 5016, 5020 REP 6.1.1
6. Remove the Exit Transport (Figure 4).
2 Remove the Exit Transport.
3 Remove the Belt from the Exit Transport Drive Gear, and disconnect J153 from the
Fuser Exit Sensor.
4 Remove the J153 wire harness from the Exit Transport.
Figure 4
Replacement
2. When installing the Connector Cover, insert the stud of the Connector Cover into the hole
in the frame (Figure 5).
Figure 5
J153
June, 2008
4-68 WorkCentre 5016, 5020 REP 6.1.2
REP 6.1.2 Exit Transport (Duplex)
Removal
WARNING
WARNING
1. Open the Duplex Module.
2. Disconnect P/J 551.
Figure 1
June, 2008
4-69 WorkCentre 5016, 5020 REP 6.1.2
Figure 2
5. Lower the Fuser levers (2) (Figure 3).
1 Lower the levers (2).
Figure 3
June, 2008
4-70 WorkCentre 5016, 5020 REP 6.1.2
6. Remove the Exit Transport (Figure 4).
2 Remove the Exit Transport.
3 Remove the Wire Harness through the hole.
Replacement
2. When installing the Connector Cover, insert the stud of the Connector Cover into the hole
in the frame (Figure 5).
Figure 4
June, 2008
4-71 WorkCentre 5016, 5020 REP 7.1.1

REP 7.1.1 Simplex, Duplex Module
Parts List on PL 7.1, PL 7.3
Removal
WARNING
2. Tape the Bypass Tray so that it cannot open by itself (Figure 1).
1 Apply 2 pieces of tape as shown.
Figure 1
3 Remove the wire harness from the groove in the frame.
5 Remove the wire harness from the groove in the frame.
6 Remove the wire harness from the hooks (3).
Figure 2
June, 2008
4-72 WorkCentre 5016, 5020 REP 7.1.1
5. Remove the Front Stopper (Figure 3).
1 Remove the Front Stopper from the Registration.
2 Release the tab to remove the Front Stopper.
Figure 3
6. Remove the Rear Stopper (Figure 4).
1 Release the tab to remove the Rear Stopper.
Figure 4
June, 2008
7. Remove the Simplex Module (Figure 5).
1 Loosen the Tapping Screws (2).
2 Move the Pivot Retainers (2) in the direction of the arrow.
3 Remove the Simplex Module.
Figure 5 Removing the Left Hand Cover Assembly
Replacement
REP 7.5.1 Bypass Feed Roll
Removal
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 1
June, 2008
4-74 WorkCentre 5016, 5020 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
June, 2008
4-75 WorkCentre 5016, 5020 REP 8.1.1
REP 8.1.1 AIOC PWB (SCC)
Removal
WARNING
CAUTION
Static electricity may damage electrical parts. Always wear an anti-static wrist band during ser-
vice. If a wrist band is not available, touch a metallic section to discharge the static electricity.
2. Disconnect the AIOC PWB connectors (9) (Figure 1).
Figure 1
3. Remove the Core Clip (Figure 2).
1 Remove the Core Clip.
Figure 2 Removing the Core Clip
June, 2008
4-76 WorkCentre 5016, 5020 REP 8.1.1
4. Disconnect the Flexible Print Cables (2) from the AIOC PWB (Figure 3).
1 Disconnect the Flexible Print Cables (2).
2 Remove the Cores (2).
Figure 3
5. Remove the screw of the USB connector (Figure 4).
1 Remove the screw.
Figure 4
June, 2008
4-77 WorkCentre 5016, 5020 REP 8.1.1
6. Remove the AIOC PWB (Figure 5)
3 Slide the the AIOC PWB up and out of P/J 407.
Figure 5
Replacement
2. When replacing the AIOC PWB, transfer the EP ROM (U2) from the old board to the new
one (Figure 6).
A EP ROM (U2)
Figure 6
June, 2008
4-78 WorkCentre 5016, 5020 REP 8.1.2
REP 8.1.2 LVPS (SCC)
Removal
WARNING
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 1
5. Remove the IIT Ground Plate (Figure 2).
1 Remove the Screws (4).
2 Remove the IIT Ground Plate.
Figure 2 Removing the IIT Ground Plate
June, 2008
4-79 WorkCentre 5016, 5020 REP 8.1.2
6. Move the Inlet Bracket (Figure 3).
1 Disconnect the connector (wire: blue).
2 Disconnect the connector (wire: brown).
5 Move the Power Inlet Bracket.
Figure 3
Figure 4
June, 2008
4-80 WorkCentre 5016, 5020 REP 8.1.2
8. Disconnect the connectors (7) (Figure 5).
Figure 5
9. Remove the LVPS (Figure 6).
1 Remove the screw to remove the Ground Wire.
3 Remove the LVPS.
Figure 6
Replacement
June, 2008
4-81 WorkCentre 5016, 5020 REP 8.1.3
REP 8.1.3 AIOC/Network PWB (DADF/Network Only)
Removal
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.
WARNING
CAUTION
Static electricity may damage electrical parts. Always wear an anti-static wrist band during ser-
vice. If a wrist band is not available, touch a metallic section to discharge the static electricity.
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
3. Remove the EMI Cover (Figure 2).
2 Remove the EMI Cover.
3 Remove the Cable Clip from the EMI Cover.
Figure 2 Removing the EMI Cover
Screw (10) EMI Cover Cable Clip
June, 2008
4-82 WorkCentre 5016, 5020 REP 8.1.3
4. Remove the SLCC PWB (Figure 3).
a. Disconnect the Flexible Print Cables (2) from the AIOC PWB (Figure 4).
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.
Figure 3 SLCC PWB for DADF/Network
Figure 4 Disconnecting the Flexible Print Cables
Screw (6) LVPS Connectors
Connectors
Flexible Print Cables AIOC PWB
June, 2008
4-83 WorkCentre 5016, 5020 REP 8.1.3
Replacement
2. When replacing the SLCC PWB, transfer the EPROMs (3) from the old PWB to the new
one (Figure 5).
NOTE: If you do not transfer the EPROMs, the existing NVM values for skew, copy qual-
ity, etc. will be lost.
NOTE: If one or more of the EPROMs are damaged during replacement or the informa-
tion 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 repro-
gramed manually.
Figure 5 Transferring the EPROMs
EPROM
EPROM
EPROM
June, 2008
4-84 WorkCentre 5016, 5020 REP 8.2.1
REP 8.2.1 HVPS (SCC)
Removal
WARNING
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 1
NOTE: When removing the HVPS, use a Stubby Driver (499T00353).
5. Remove the Tapping Screws that secure the Contact Block (Figure 2).
1 Release the hook to remove the Harness Block.
Figure 2
June, 2008
4-85 WorkCentre 5016, 5020 REP 8.2.1
6. Remove the HVPS and Contact Block (Figure 3).
2 Disconnect the connector at the inner side of the HVPS.
3 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.
Figure 4
June, 2008
4-86 WorkCentre 5016, 5020 REP 8.2.1
Replacement
2. Insert the wire harness of the HVPS into the slot of the Laser Housing (Figure 5).
A Slot
Figure 5
3. When installing the HVPS and Contact Block, insert the slot of the Contact Block into the
guide of the frame (Figure 6).
Figure 6
June, 2008
4-87 WorkCentre 5016, 5020 REP 8.2.2
REP 8.2.2 Duplex PWB (SCC)
Removal
WARNING
2. Disconnect the Connector (Figure 1).
2 Remove the Wire Harness from the Hook.
3 Remove the Wire Harness from the Guides (3).
3. Remove the Duplex PWB (Figure 2).
2 Remove the Guide.
3 Disconnect the Connector.
5 Remove the Duplex PWB.
Replacement
June, 2008
4-88 WorkCentre 5016, 5020 REP 8.3.1
REP 8.3.1 Control Panel (SCC)
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 1
3. Remove the screws that secure the Control Panel (Figure 2).
Figure 2
June, 2008
4-89 WorkCentre 5016, 5020 REP 8.3.1
4. Remove the Control Panel (Figure 3).
1 Slide the rear of the Control Panel in the direction of the arrow.
3 Remove the Cable Band from the Control Panel Hook (Figure 4, B).
Figure 3
Replacement
2. When installing the Control Panel, attach the Control Panel hooks (3) to the IIT Frame
(Figure 4).
A Spring - On top
B Hook - Below
Figure 4
June, 2008
3. Thread the wire harness of the Control Panel as shown (Figure 5).
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 1
June, 2008
4-91 WorkCentre 5016, 5020 REP 8.4.1
4. Remove the User Interface PWB (Figure 2).
2 Remove the User Interface PWB.
Figure 2
Replacement
June, 2008
4-92 WorkCentre 5016, 5020 REP 8.4.1
June, 2008
4-93 WorkCentre 5016, 5020 REP 9.1.1
REP 9.1.1 Output Tray
Removal
WARNING
2. Remove the Output Tray (Figure 1).
2 Remove the Output Tray by pulling it in the direction of the arrow.
Figure 1
Replacement
2. Perform the following steps to install the Output Tray (Figure 2).
1 Insert the tabs (2) into the square hole of the frame.
2 Attach the hook.
Figure 2
June, 2008
4-94 WorkCentre 5016, 5020 REP 9.1.2
REP 9.1.2 Front Left Cover
Removal
WARNING
2. Remove the Front Left Cover (Figure 1).
2 Remove the Front Left Cover by pulling in the direction of the arrow.
Figure 1
Replacement
2. When installing the Front Left Cover, attach the hooks (Figure 2).
A Hooks (3)
Figure 2
June, 2008
4-95 WorkCentre 5016, 5020 REP 9.2.1
REP 9.2.1 Rear Cover
Removal
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.
2 Remove the cable band.
Figure 1
2. Remove the Rear Cover (Figure 2).
2 Remove the Rear Cover.
Figure 2
Replacement
June, 2008
4-96 WorkCentre 5016, 5020 REP 9.2.2
REP 9.2.2 Right Cover
Removal
WARNING
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 1
Replacement
2. When installing the Right Cover, insert the tabs (Figure 2).
A Tabs (5)
Figure 2
June, 2008
4-97 WorkCentre 5016, 5020 REP 10.1.1
REP 10.1.1 IIT Platen Cover
Removal
WARNING
1. Remove the Platen Cover (PL 10.1) (Figure 1) by lifting it straight up.
Figure 1
Replacement
NOTE: The Platen Cover comes as a kit, consisting of a Platen Cover and a Platen Cushion
(Figure 1).
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).
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.
Platen Cover
Platen Cushion
When installing a new Platen
Cushion, place it against this
corner
mounting posts
June, 2008
4-98 WorkCentre 5016, 5020 REP 10.2.1
REP 10.2.1 IIT Upper Cover (SCC)
Removal
WARNING
1. Remove the following parts:
Platen Cover (PL 10.1)
Control Panel (REP 8.3.1)
2. Remove the screws that secure the IIT Upper Cover (Figure 1).
3 Remove the cap.
Figure 1
3. Remove the IIT Upper Cover (Figure 2).
1 Press the tabs (2) to release them.
NOTE: The tabs are visible through the Platen Glass.
2 Open the right side of the IIT Upper Cover.
3 Press the tabs (2) to release them, and remove the IIT Upper Cover.
Figure 2
Replacement
June, 2008
4-99 WorkCentre 5016, 5020 REP 10.3.1
REP 10.3.1 IIT Carriage (SCC)
Removal
WARNING
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 1
4. At the right side of the IIT Carriage, secure the Carriage Cable with tape so that it does
not come loose (Figure 2).
1 Secure the Carriage Cable with 2 pieces of tape.
Figure 2
June, 2008
4-100 WorkCentre 5016, 5020 REP 10.3.1
5. While maintaining tension on the Carriage Cable (silver) at the front left side, disconnect it
(Figure 3).
1 Disconnect the Carriage Cable.
2 Remove the Cable Spring.
3 Remove the Carriage Cable from the pulley.
4 Remove the Carriage Cable from the guide.
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).
A Secure the Carriage Cable with tape
1 Pulley
Figure 4
June, 2008
4-101 WorkCentre 5016, 5020 REP 10.3.1
7. While maintaining tension on the Carriage Cable (black) at the front right side, disconnect
it (Figure 5).
1 Disconnect the Carriage Cable (black).
2 Remove the Carriage Cable (black) from the guide.
3 Remove the Carriage Cable (black) from the guide.
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).
A Pulley
1 Secure the Carriage Cable with tape
Figure 6
June, 2008
4-102 WorkCentre 5016, 5020 REP 10.3.1
9. While maintaining tension on the Carriage Cable (black) at the rear left side, disconnect it
(Figure 7).
1 Remove the Cable Spring.
3 Remove the Carriage Cable from the pulley.
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 Secure the Carriage Cable with tape.
Figure 8
June, 2008
4-103 WorkCentre 5016, 5020 REP 10.3.1
11. While maintaining tension on the Carriage Cable (silver) at the rear right side, disconnect
it (Figure 9).
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 10
June, 2008
4-104 WorkCentre 5016, 5020 REP 10.3.1
13. Turn the left side of the IIT Carriage face up.
14. Disconnect the Flexible Print Cable connectors (2) (Figure 11).
Figure 11
Replacement
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 12
June, 2008
3. Attach the Carriage Cables (black and silver) to the IIT Frame in the sequence shown
(Figure 13).
Figure 13
REP 10.3.2 Flexible Print Cable (SCC)
Removal
WARNING
3. Remove the IIT Carriage (REP 10.3.1).
4. Remove the Core Clip (Figure 1).
1 Remove the Core Clip.
Figure 1 Removing the Core Clip
June, 2008
4-106 WorkCentre 5016, 5020 REP 10.3.2
5. Disconnect the Flexible Print Cables (2) from the AIOC PWB (Figure 2).
Figure 2
6. Remove the Flexible Print Cable (Figure 3).
1 Peel off the pieces of tape to remove the Flexible Print Cable.
2 Slide the Flexible Print Cable through the hole in the IIT Frame.
Figure 3
Replacement
June, 2008
4-107 WorkCentre 5016, 5020 REP 10.6.1
REP 10.6.1 Exposure Lamp
Removal
WARNING
3. Remove the Inverter PWB Bracket 2 (Figure 1).
1 Remove the screw.
2 Remove the Inverter PWB Bracket 2.
Figure 1
Figure 2
June, 2008
5. Remove the Exposure Lamp (Figure 3).
1 Remove the screw.
2 Remove the Exposure Lamp from the Lamp Holder.
Figure 3
Replacement
REP 10.7.1 Carriage Cable and Drum
Removal
WARNING
3. Remove the IIT Carriage (REP 10.3.1).
4. Turn the IIT Carriage upside down.
June, 2008
4-109 WorkCentre 5016, 5020 REP 10.7.1
5. Remove the Carriage Cables (black and silver) (Figure 1).
1 Peel off the pieces of tape to remove the Carriage Cables.
Figure 1
Replacement
2. Attach the Carriage Cables (black/silver) to the holes in the Drum (Figure 2).
Figure 2
June, 2008
4-110 WorkCentre 5016, 5020 REP 10.7.1
3. Wind the Carriage Cables around the Drum and secure them with tape (Figure 3).
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 4
June, 2008
Figure 5 Cable Winding Schematic
REP 10.7.2 Inverter PWB
Removal
WARNING
1 Remove the screw.
Figure 1
June, 2008
4-112 WorkCentre 5016, 5020 REP 10.7.2
Figure 2
1 Remove the screw.
Figure 3
June, 2008
4-113 WorkCentre 5016, 5020 REP 10.7.2
6. Remove the Inverter PWB (Figure 4).
2 Remove the Inverter PWB.
Figure 4
Replacement
June, 2008
4-114 WorkCentre 5016, 5020 REP 10.7.2
June, 2008

REP 11.1.1 Tray 2
Removal
WARNING
1. Remove all paper from Tray 2.
2. Pull out Tray 2.
3. Lift the front side of Tray 2 and remove the tray (Figure 1).
Figure 1
Replacement
To install, do the removal steps in reverse order.
REP 11.1.2 Single Tray Module (Separation from IOT)
Removal
WARNING
WARNING
The IOT is heavy. Do this procedure with 2 persons.
1. Disconnect the connector. (Figure 1).
2 Pull out the cable clamp.
Figure 1
June, 2008
4-116 WorkCentre 5016, 5020 REP 11.1.2
2. Remove the Countersunk Head Screws at the rear (Figure 2).
1 Remove the Countersunk Head Screws (2).
Figure 2
3. Remove the Countersunk Head Screws at the front (Figure 3).
1 Pull out Tray 1.
2 Remove the Countersunk Head Screws (2).
Figure 3
June, 2008
4. Hold onto A (2) and B (2), and remove the IOT from the Single Tray Module (Figure 4).
Figure 4
Replacement
REP 11.4.1 Tray 2 Feed Roll
Removal
WARNING
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 1
June, 2008
4-118 WorkCentre 5016, 5020 REP 11.4.1
3. Remove the Tray 2 Feed Roll (Figure 2).
1 Remove the KL-Clip.
2 Remove the Tray 2 Feed Roll.
Figure 2
Replacement
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 3
June, 2008
4-119 WorkCentre 5016, 5020 REP 11.4.2
REP 11.4.2 Tray 2 Retard Roll
Removal
WARNING
2. Remove the Tray 2 Feeder (Figure 1).
2 Remove the Tray 2 Feeder.
Figure 1
3. Remove the Tray 2 Retard Roll Housing (Figure 2).
1 Release the hooks (2).
2 Remove the Tray 2 Retard Roll Housing from the tabs (2).
Figure 2
June, 2008
4-120 WorkCentre 5016, 5020 REP 11.4.2
4. Remove the Retard Shaft (Figure 3).
1 Remove the Retard Shaft.
Figure 3
5. Remove the Tray 2 Retard Roll (Figure 4).
1 Release the tab to remove the Tray 2 Retard Roll.
Figure 4
June, 2008
4-121 WorkCentre 5016, 5020 REP 11.4.2
Replacement
2. When installing the Tray 2 Retard Roll, align the coupling of the Friction Clutch with the
Tray 2 Retard Roll (Figure 5).
Figure 5
3. When installing the Tray 2 Retard Roll Housing, check that the Tray 2 Retard Roll rises
when the Holder Arm is pressed (Figure 6).
A Holder Arm
B Tray 2 Retard Roll
Figure 6
June, 2008
4-122 WorkCentre 5016, 5020 REP 11.5.1
REP 11.5.1 STM Feed Sensor
Removal
WARNING
1. Remove the IOT from the Single Tray Module (REP 11.1.2).
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
Replacement
June, 2008
4-123 WorkCentre 5016, 5020 REP 11.5.2
REP 11.5.2 STM PWB (SCC)
Removal
WARNING
1. Remove the STM Rear Cover (PL 11.5).
2. Remove the STM PWB (Figure 1).
3 Remove the STM PWB.
Figure 1
Replacement
June, 2008
4-124 WorkCentre 5016, 5020 REP 11.6.1
REP 11.6.1 STM Feed Clutch
Removal
WARNING
2. Remove the gears (Figure 1).
1 Remove the E-rings.
2 Release the tabs.
Figure 1
3. Remove the STM Feed Clutch (Figure 2).
4 Release the tab on the gear, and remove the gear together with the STM Feed Clutch.
5 Slide the wire harness through the hole.
Figure 2
Replacement
June, 2008
4-125 WorkCentre 5016, 5020 REP 11.6.2
REP 11.6.2 STM Feed Motor
Removal
WARNING
2. Remove the gears (Figure 1).
1 Release the tab, and remove the gear.
2 Release the tab, and remove the gear.
Figure 1
3. Remove the STM Feed Motor (Figure 2).
4 Remove the STM Feed Motor.
Figure 2
Replacement
June, 2008
4-126 WorkCentre 5016, 5020 REP 11.7.1
REP 11.7.1 STM No Paper Sensor
Removal
WARNING
1. Remove Tray 1.
3. Remove the STM No Paper Sensor (Figure 1).
2 Release the tabs, and remove the STM No Paper Sensor.
Figure 1
Replacement
June, 2008
4-127 WorkCentre 5016, 5020 REP 13.1.1
REP 13.1.1 ADF Assembly
Removal
WARNING
1. Disconnect the Connector.
2. Remove the Cable Band.
Figure 1 (johu41301)
3. Remove the Screws (Figure 2).
1. Remove the Screws (2).
Figure 2 (j0hu41302)
June, 2008
2. Remove the ADF (Figure 3).
1. Remove the ADF.
Replacement
REP 13.1.2 ADF/DADF Platen Cushion
Removal
WARNING
1. Remove the Platen Cushion ([Figure 1]).
1. Remove the Platen Cushion.
June, 2008
4-129 WorkCentre 5016, 5020 REP 13.1.2
Replacement
1. Paste the Platen Cushion ([Figure 2]).
1. Place the Platen Cushion on the Platen Glass.
2. Adjust the Platen Glass for the correct gap between it and the Registration Guide.
3. Slowly lower the ADF/DADF and press it onto the Platen Cushion.
June, 2008
4-130 WorkCentre 5016, 5020 REP 13.2.1
REP 13.2.1 Document Tray Assembly (ADF)
Removal
WARNING
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.
4. Remove the Support Bracket (Figure 2) .
i. Release the Wire Harness from the Clamp.
ii. Remove the Tapping Screw.
iii. Remove the Tapping Screw.
iv. Remove the Ground Wire.
v. Remove the Support Bracket.
June, 2008
4-131 WorkCentre 5016, 5020 REP 13.2.1
5. Disconnect the Connector (Figure 3) .
i. Disconnect the Connector.
ii. Remove the Cable Tie.
6. Remove the Ground Wires (Figure 4) .
i. Remove the Screw to remove the Ground Wires (2).
June, 2008
7. Remove the Document Tray Assembly (Figure 5) .
1. Remove the Document Tray Assembly.
Replacement
REP 13.2.2 ADF Feeder Assembly
Removal
WARNING
1. Remove the following covers.
3. Remove the Document Tray Assembly (REP 13.2.1).
June, 2008
4-133 WorkCentre 5016, 5020 REP 13.2.2
4. Remove the Rear Blind Cover (Figure 1).
1. Remove the Tapping Screw.
2. Remove the Rear Blind Cover.
3. Disconnect the ADF PWB Connectors ([Figure 2]):
CN2
CN3
CN5
NOTE: The configuration of the ADF PWB on the WorkCentre 5020 (DADF/Net-
work) is slightly different, but the Connector reference numbers are the same.
i. Disconnect the Connectors (3).
June, 2008
4-134 WorkCentre 5016, 5020 REP 13.2.2
4. Remove the Screws at the front ([Figure 3]).
1. Remove the Screw (short).
2. Remove the Screw (long).
1. Remove the Screws at the rear ([Figure 4]).
2. Remove the Screw (long).
3. Remove the Tapping Screw to remove the Ground Wire.
NOTE: There is no Ground Wire on the WorkCentre 5020 (DADF/Network).
June, 2008
4. Remove the ADF Feeder Assembly ([Figure 5]).
1. Remove the ADF Feeder Assembly.
Replacement
REP 13.2.3 Front Cover
Removal
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.
June, 2008
Replacement
REP 13.2.4 Rear Cover
Removal
WARNING
1. Remove the Rear Cover while pressing the sections indicated by the arrow ([Figure 1]).
1. Remove the Screw.
3. Remove the Rear Cover.
June, 2008
Replacement
REP 13.2.5 DADF Eject Roller Solenoid
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.
Figure 1 Removing the Eject Roller Solenoid
Replacement
1. Install the DADF Eject Roller Solenoid and ensure that the Solenoid linkage is properly
install into the Eject Roller control arm.
2. Perform the remainder of the replacement procedure in reverse order of the removal pro-
cedure.
1
Disconnect the con-
nector
2
Remove the screws
(2)
3
Remove wire clamp
4
Remove the
Solenoid
June, 2008
4-138 WorkCentre 5016, 5020 REP 13.2.6
REP 13.2.6 DADF Assembly
Removal
WARNING
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)
1. Disconnect the Connectors (2).
2. Remove the DADF Cable.
Figure 1 Disconnecting the DADF Cable
3. Remove the Screws (Figure 2).
Disconnect the con-
nectors (2)
June, 2008
2. Remove the DADF (Figure 3).
1. Remove the DADF.
Replacement
REP 13.2.7 Document Tray Assembly (DADF)
Removal
WARNING
3. Loosen the Tapping Screw (Figure 1).
a. Loosen the Screw.
Figure 1 Loosening the screw
4. Remove the Support Bracket (Figure 2).
i. Release the Wire Harness from the Clamp.
ii. Remove the Tapping Screw.
iii. Remove the Tapping Screw.
iv. Remove the Ground Wire.
v. Remove the Support Bracket.
Loosen the screw
(1)
June, 2008
4-140 WorkCentre 5016, 5020 REP 13.2.7
i. Disconnect the Connector.
ii. Remove the Cable Tie.
Figure 3 Disconnecting the connecgor
Remove cable tie Disconnect the connector
June, 2008
4-141 WorkCentre 5016, 5020 REP 13.2.7
6. Remove the Ground Wires (Figure 4).
i. Remove the Screw to remove the Ground Wires (2).
7. Remove the Document Tray Assembly (Figure 5).
1. Remove the Document Tray Assembly.
Replacement
June, 2008
4-142 WorkCentre 5016, 5020 REP 13.2.8
REP 13.2.8 DADF Feeder Assembly
Removal
WARNING
1. Remove the following covers.
3. Remove the Document Tray Assembly (REP 13.2.7).
4. Remove the Rear Blind Cover (Figure 1).
i. Remove the Tapping Screw.
ii. Remove the Rear Blind Cover.
June, 2008
4-143 WorkCentre 5016, 5020 REP 13.2.8
5. Disconnect the ADF PWB Connectors (Figure 2):
CN2
CN3
CN5
CN7
i. Disconnect the Connectors (4).
Figure 2 Disconnect the connectors (4)
6. Remove the DADF Eject Roller Solenoid.
a. Disconnect the connector.
b. Remove the screws (3).
c. Remove the Eject Roller Solenoid.
Figure 3 Removing the Eject Roller Solenoid Bracket
7. Remove the Screws at the front ([Figure 3]).
i. Remove the Screw (short).
ii. Remove the Screw (long).
Disconnect the connectors
2
Remove the screws (3)
3
Remove
the Sole-
noid
Bracket
1
Disconnect the connector
June, 2008
4-144 WorkCentre 5016, 5020 REP 13.2.8
i. Remove the Screws at the rear ([Figure 4]).
ii. Remove the Screw (long).
iii. Remove the Tapping Screw to remove the Ground Wire.
June, 2008
9. Remove the ADF Feeder Assembly ([Figure 5]).
1. Remove the ADF Feeder Assembly.
Replacement
REP 13.3.1 ADF Control PWB
Removal
WARNING
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.
June, 2008
4-146 WorkCentre 5016, 5020 REP 13.3.1
2. Disconnect the PWB Connectors ([Figure 2]).
1. Disconnect the PWB Connectors (5).
2. Remove the ADF Control PWB ([Figure 3]).
4. Remove the ADF Control PWB.
Replacement
June, 2008
4-147 WorkCentre 5016, 5020 REP 13.3.2
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).
4. Remove the Film Cover (Figure 1).
1. Remove the Film Cover.
June, 2008
2. Remove the Left Counter Balance (Figure 2).
2. Remove the Left Counter Balance.
Replacement
REP 13.3.3 Right Counter Balance (SCC)
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).
June, 2008
4-149 WorkCentre 5016, 5020 REP 13.3.3
3. Remove the Film Cover (Figure 1).
1. Remove the Film Cover.
2. Remove the screws that secure the Right Counter Balance (Figure 2).
1. Use the marking tool and make a marking line.
2. Remove the screws (4).
3. Remove the Right Counter Balance.
Replacement
2. Check the ADF/DADF Positional Adjustment (ADJ 13.1.1).
June, 2008
4-150 WorkCentre 5016, 5020 REP 13.3.4
REP 13.3.4 DADF PWB
Removal
WARNING
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.
3. Disconnect the PWB Connectors (Figure 2).
1. Disconnect the PWB Connectors (5).
Discon-
nect the
connec-
tors
Disconnect the
connectors
June, 2008
2. Remove the DADF Control PWB (Figure 3).
4. Remove the DADF Control PWB.
Figure 3 Removing the DADF Control PWB
Replacement
REP 13.4.1 Top Cover
Removal
WARNING
1. Open the Upper Feeder Assembly.
2. Remove the Top Cover (Figure 1).
2. Release the Hooks (2).
3. Push in the Hooks (3).
4. Remove the Top Cover.
1
Remove screws
(2)
2
Remove the screw
(1)
3
Remove the screw (1)
4
Remove the PWB
June, 2008
Replacement
REP 13.8.1 Retard Roll
Removal
WARNING
2. Open the Retard Roll Assembly (Figure 1).
1. Open the Retard Roll Assembly.
June, 2008
4-153 WorkCentre 5016, 5020 REP 13.8.1
2. Remove the Plate (Figure 2).
a. Remove the Tapping Screws (2).
b. Remove the Plate.
3. Remove the Retard Roll together with the Bearings (Figure 3).
1. Remove the Retard Roll.
June, 2008
2. Remove the Retard Roll (Figure 4).
1. Remove the Bearings (2).
Replacement
2. After a replacement, enter the Diagnostic Mode How to Enter the Diagnostic Mode and
clear the simplex and duplex feed counters.
REP 13.9.1 Pickup Roll, Feed Roll
Removal
WARNING
1. Open the Upper Feeder Assembly.
2. Remove the Top Cover (REP 13.4.1).
3. Remove the Sensor Holder (Figure 1).
2. Remove the Sensor Holder.
June, 2008
4-155 WorkCentre 5016, 5020 REP 13.9.1
3. Remove the E-Clip and the Bearing.
a. Remove the Spring (Figure 2).
b. Remove the E-Clips (2).
c. Remove the Spring.
4. Remove the Feed Roll Assembly (Figure 3).
1. Move the Shaft.
2. Remove the Feed Roll Assembly.
June, 2008
4-156 WorkCentre 5016, 5020 REP 13.9.1
3. Remove the Feed Roll (Figure 4).
1. Remove the E-Clip.
2. Remove the Shaft.
3. Remove the Feed Roll.
4. Remove the Pickup Roll (Figure 5).
a. Remove the Bearing.
b. Remove the Pickup Roll.
Replacement
2. After a replacement, enter the Diagnostic Mode and clear the simplex and duplex feed
counters.
June, 2008
4-157 WorkCentre 5016, 5020 ADJ 8.1.1, ADJ 8.1.2
ADJ 8.1.1 Edge Erase Adjustment
Purpose
To set the right amount of edge erase at the lead edge and trail edge, as well as at both sides
(left/right) of the image.
NOTE: Do the IOT Lead Edge/Side Edge Registration adjustment first.
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.
ADJ 8.1.2 Controller Firmware Version Upgrade
Purpose
To upgrade the version of the Controller.
Check
Check the current version:
Enter the Diagnostic Mode and check the Controller Firmware version xxx using Chain-Func-
tion [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.
Table 1
Chain Func Name Min Initial Max Step
6 59 Normal Side Edge Erase Adjust-
ment
0 16 32 0.254mm
6 60 Normal Lead Edge Erase Adjust-
ment
0 16 32 0.145mm
6 63 Normal Trail Edge Erase Adjust-
ment
0 16 32 0.145mm
June, 2008
4-158 WorkCentre 5016, 5020 ADJ 10.3.1
ADJ 10.3.1 IIT Lead Edge/Side Edge Registration
Purpose
To obtain the home position in the IIT lead edge (slow scan)/IIT side edge (fast scan) direction.
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).
Lead edge: part A in the figure
Side edge: part B in the figure
Figure 1 IIT Lead Edge/Side Edge Registration
3. Check that the measured values for lead edge (A) and side edge (B) meet the specifica-
tions of the corresponding mode.
Adjustment
1. Enter the Diagnostic Mode, and use the following Chain Functions to perform adjustments
until the measured values for lead edge (A) and side edge (B) registration are within the
specifications.
When the measured value is short, reduce the setting value.
When the measured value is long, increase the setting value.
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.
Table 1 Specification
Item Simplex MSI
Lead edge (A) 10 1.6mm 10 2.2mm
Side edge (B) 5 2.1mm 5 3.0mm
Table 2
Chain Func Sub
System
Name Value Initial
Value
1 Count
Min. Max.
20 1 PH REGI ADJUSTMENT - ALL 0 60 30 0.146mm
20 41 PH TRAY 1 for Normal LEAD REGI
ADJ
0 60 30 0.146mm
20 42 PH TRAY 2 for Normal LEAD REGI
ADJ
0 60 30 0.146mm
20 43 PH MSI for Normal LEAD REGI
ADJ
0 60 30 0.146mm
6 20 ROS ALL TRAY - LASER SIDE REGI
ADJUSTMENT
1 99 50 0.254mm
6 21 ROS TRAY 1 - LASER SIDE REGI
ADJUSTMENT
1 99 50 0.254mm
6 22 ROS TRAY 2 - LASER SIDE REGI
ADJUSTMENT
1 99 50 0.254mm
6 26 ROS MSI - LASER SIDE REGI
ADJUSTMENT
1 99 50 0.254mm
June, 2008
4-159 WorkCentre 5016, 5020 ADJ 11.1.1
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
IIT Upper Cover (REP 10.2.1)
2. 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 Car-
riage Assembly to the left.
Figure 1 Carriage Assembly Alignment (Parallelism)
3. Return the machine to its original state, and make a copy in Platen Mode.
4. Check for optical skew, and repeat from step 1 as needed.
June, 2008
4-160 WorkCentre 5016, 5020 ADJ 13.1.1
ADJ 13.1.1 ADF/DADF Positional Adjustment
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 1 ADF Adjustment - 1 (j0hu41334)
Result when the ADF/DADF is moved in direction A (Figure 2):
Figure 2 ADF Adjustment - Direction A (j0hu41335)
June, 2008
4-161 WorkCentre 5016, 5020 ADJ 13.1.1
Result when the ADF/DADF is moved in direction B (Figure 3):
Figure 3 ADF Adjustment - Direction B (j0hu41336)
June, 2008
4-162 WorkCentre 5016, 5020 ADJ 13.1.1
June, 2008
Parts Lists Reissue
5 Parts List
Overview
Introduction ..................................................................................................................... 5-3
Subsystem Information ................................................................................................... 5-4
Symbology ...................................................................................................................... 5-5
Parts Lists
Drive
PL 1.1 IOT Motor............................................................................................................. 5-7
Paper Transport
PL 2.1 Tray 1................................................................................................................... 5-8
PL 2.2 Tray 1 Frame Accessory...................................................................................... 5-9
PL 2.3 Tray 1 Components (1 OF 2) ............................................................................... 5-10
PL 2.4 Tray 1 Components ( 2 OF 2).............................................................................. 5-11
PL 2.5 Tray 1 Frame Components.................................................................................. 5-12
PL 2.6 Tray 1 Frame Components (2 OF 2) ................................................................... 5-13
PL 2.7 No Paper Sensor Housing................................................................................... 5-14
PL 2.8 Registration.......................................................................................................... 5-15
PL 2.9 Registration Component ...................................................................................... 5-16
ROS
PL 3.1 ROS..................................................................................................................... 5-17
CRU
PL 4.1 Drum Cartridge .................................................................................................... 5-18
PL 4.2 Toner Empty Sensor and Erase Lamp ................................................................ 5-19
PL 4.3 Transfer ............................................................................................................... 5-20
PL 4.4 Transfer Corotron Housing Component............................................................... 5-21
Fuser
PL 5.1 Fuser.................................................................................................................... 5-22
Exit Transport
PL 6.1 Exit Transport ...................................................................................................... 5-23
PL 6.2 Exit Transport Component (Simplex)................................................................... 5-24
PL 6.3 Exit Transport Component (Duplex) .................................................................... 5-25
Simplex / Duplex Module and Bypass Tray
PL 7.1 Simplex Module ................................................................................................... 5-26
PL 7.2 Left Hand Cover Assembly .................................................................................. 5-27
PL 7.3 Duplex Module Component (1 OF 2)................................................................... 5-28
PL 7.5 Bypass Tray Accessory ....................................................................................... 5-30
PL 7.6 Bypass Tray Component ..................................................................................... 5-31
Electrical
PL 8.1 AIOC PWB, LVPS, Power Switch........................................................................ 5-32
PL 8.2 HVPS, Interlock Switch, Duplex PWB ................................................................. 5-33
PL 8.3 Control Panel Accessory ..................................................................................... 5-34
PL 8.4 Control Panel Component.................................................................................... 5-35
Cover
PL 9.1 Front / Top Cover................................................................................................. 5-36
PL 9.2 Rear / Right Cover and NOHAD Fan................................................................... 5-37
IIT
PL 10.1 IIT Accessory ..................................................................................................... 5-38
PL 10.2 IIT Component (1 OF 2)..................................................................................... 5-39
PL 10.4 IIT Upper Cover Cover Component ................................................................... 5-41
PL 10.5 IIT Under Cover Component.............................................................................. 5-42
PL 10.6 IIT Carriage Component .................................................................................... 5-43
PL 10.7 Center Plate Component ................................................................................... 5-44
Single Tray Module
PL 11.1 Single Tray Module............................................................................................ 5-45
PL 11.2 Tray 2 Component (1 OF 3)............................................................................... 5-46
PL 11.5 Single Tray Frame Component (1 OF 2) ........................................................... 5-49
PL 11.7 STM No Paper Sensor....................................................................................... 5-51
Stand
PL 12.1 Stand Component .............................................................................................. 5-52
ADF/DADF
PL 13.1 ADF/DADF Accessory ....................................................................................... 5-53
PL 13.2 Component, Cover............................................................................................. 5-54
PL 13.3 Base Cover Component..................................................................................... 5-55
PL 13.4 Feeder Component ............................................................................................ 5-56
PL 13.5 Lower Feeder Component ................................................................................. 5-57
PL 13.6 Retard Roll Component ..................................................................................... 5-58
PL 13.7 Lower Feeder Assembly .................................................................................... 5-59
PL 13.8 Retard Roll Assembly ........................................................................................ 5-60
PL 13.9 Upper Feeder Assembly .................................................................................... 5-61
PL 13.10 Document Tray ................................................................................................ 5-62
Common Hardware
Common Hardware ......................................................................................................... 5-63
Part Number Index .......................................................................................................... 5-64
June, 2008
Reissue Parts Lists
June, 2008
5-3 WorkCentre 5016, 5020 Introduction
Parts Lists Reissue
Introduction
Overview
The Parts List section identifies all part numbers and the corresponding location of all spared
subsystem components.
Organization
Parts Lists
Each item number in the part number listing corresponds to an item number in the related
illustration. All the parts in a given subsystem of the machine will be located in the same
illustration or in a series of associated illustrations.
Electrical Connectors and Fasteners
This section contains the illustrations and descriptions of the plugs, jacks, and fasteners used
in the machine. A part number listing of the connectors is included.
Common Hardware
The common hardware is listed in alphabetical order by the letter or letters used to identify
each item in the part number listing and in the illustrations. Dimensions are in millimeters
unless otherwise identified.
Part Number Index
This index lists all the spared parts in the machine in numerical order. Each number is followed
by a reference to the parts list on which the part may be found.
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:
Symbology
Symbology used in the Parts List section is identified in the Symbology section.
Service Procedure Referencing
If a part or assembly has an associated repair or adjustment procedure, the procedure number
will be listed at the end of the part description in the parts lists e.g. (REP 5.1, ADJ 5.3)
Table 1
Abbreviation Meaning
A3 297 x 594 Millimeters
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
R/E Reduction/Enlargement
REF: Refer to
SCSI Small Computer Systems Interface
W/ With
W/O Without
Table 2
Operating Companies
AO Americas Operations
NASG - US North American Solutions Group - US
NASG -
Canada
North American Solutions Group -
Canada
XE Xerox Europe
Table 1
June, 2008
5-4 WorkCentre 5016, 5020 Subsystem Information
Reissue Parts Lists
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.
June, 2008
5-5 WorkCentre 5016, 5020 Symbology
Parts Lists 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.
Figure 1 With Tag Symbol
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
June, 2008
5-6 WorkCentre 5016, 5020 Symbology
Reissue Parts Lists
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.
Figure 3 Entire Drawing With Tag Symbol
A tag number within a circle with no apex and having a shaded bar shows that the entire
drawing was the configuration before being changed by the tag number within the circle
(Figure 4).
Figure 4 Entire Drawing Without Tag Symbol
June, 2008
Parts Lists Reissue
Overview
Introduction ..................................................................................................................... 5-3
Subsystem Information ................................................................................................... 5-4
Symbology ...................................................................................................................... 5-5
Parts Lists
Drive
PL 1.1 IOT Motor............................................................................................................. 5-7
Paper Transport
PL 2.1 Tray 1................................................................................................................... 5-8
PL 2.2 Tray 1 Frame Accessory...................................................................................... 5-9
PL 2.3 Tray 1 Components (1 OF 2) ............................................................................... 5-10
PL 2.4 Tray 1 Components ( 2 OF 2).............................................................................. 5-11
PL 2.5 Tray 1 Frame Components.................................................................................. 5-12
PL 2.6 Tray 1 Frame Components (2 OF 2) ................................................................... 5-13
PL 2.7 No Paper Sensor Housing................................................................................... 5-14
PL 2.8 Registration.......................................................................................................... 5-15
PL 2.9 Registration Component ...................................................................................... 5-16
ROS
PL 3.1 ROS..................................................................................................................... 5-17
CRU
PL 4.1 Drum Cartridge .................................................................................................... 5-18
PL 4.2 Toner Empty Sensor and Erase Lamp ................................................................ 5-19
PL 4.3 Transfer ............................................................................................................... 5-20
PL 4.4 Transfer Corotron Housing Component............................................................... 5-21
Fuser
PL 5.1 Fuser.................................................................................................................... 5-22
Exit Transport
PL 6.1 Exit Transport ...................................................................................................... 5-23
PL 6.2 Exit Transport Component (Simplex)................................................................... 5-24
PL 6.3 Exit Transport Component (Duplex) .................................................................... 5-25
Simplex / Duplex Module and Bypass Tray
PL 7.1 Simplex Module ................................................................................................... 5-26
PL 7.2 Left Hand Cover Assembly .................................................................................. 5-27
PL 7.5 Bypass Tray Accessory ....................................................................................... 5-30
PL 7.6 Bypass Tray Component ..................................................................................... 5-31
Electrical
PL 8.1 AIOC PWB, LVPS, Power Switch........................................................................ 5-32
PL 8.2 HVPS, Interlock Switch, Duplex PWB ................................................................. 5-33
PL 8.3 Control Panel Accessory ..................................................................................... 5-34
PL 8.4 Control Panel Component ................................................................................... 5-35
Cover
PL 9.1 Front / Top Cover................................................................................................. 5-36
PL 9.2 Rear / Right Cover and NOHAD Fan................................................................... 5-37
IIT
PL 10.1 IIT Accessory ..................................................................................................... 5-38
PL 10.4 IIT Upper Cover Cover Component ................................................................... 5-41
PL 10.5 IIT Under Cover Component.............................................................................. 5-42
PL 10.6 IIT Carriage Component .................................................................................... 5-43
PL 10.7 Center Plate Component ................................................................................... 5-44
Single Tray Module
PL 11.1 Single Tray Module............................................................................................ 5-45
PL 11.7 STM No Paper Sensor....................................................................................... 5-51
Stand
PL 12.1 Stand Component .............................................................................................. 5-52
ADF/DADF
PL 13.1 ADF/DADF Accessory ....................................................................................... 5-53
PL 13.2 Component, Cover............................................................................................. 5-54
PL 13.3 Base Cover Component..................................................................................... 5-55
PL 13.4 Feeder Component ............................................................................................ 5-56
PL 13.5 Lower Feeder Component ................................................................................. 5-57
PL 13.6 Retard Roll Component ..................................................................................... 5-58
PL 13.7 Lower Feeder Assembly .................................................................................... 5-59
PL 13.8 Retard Roll Assembly ........................................................................................ 5-60
PL 13.9 Upper Feeder Assembly .................................................................................... 5-61
PL 13.10 Document Tray ................................................................................................ 5-62
Common Hardware
Common Hardware ......................................................................................................... 5-63
Part Number Index .......................................................................................................... 5-64
June, 2008
Reissue Parts Lists
June, 2008
5-3 WorkCentre 5016, 5020 PL 1.1
Parts Lists Reissue
PL 1.1 IOT Motor
Item Part Description
1 007K94880 IOT Motor (REP 1.1.1)
2 120E22470 Push Tie
3 Gear Pulley (Not Spared)
4 Cover (Not Spared)
5 Belt (Not Spared)
6 Traceability Label (Not Spared)
June, 2008
5-4 WorkCentre 5016, 5020 PL 2.1
Reissue Parts Lists
PL 2.1 Tray 1
1 050K62940 Tray 1 Assembly
2 Tray Stopper (Not Spared)
3 Label (P/O Item 1)
4 Tray 1 (P/O Item 1)
June, 2008
5-5 WorkCentre 5016, 5020 PL 2.2
Parts Lists Reissue
PL 2.2 Tray 1 Frame Accessory
1 Tray 1 Frame (P/O PL2.1 Item 1)
2 848K01660 No Paper Sensor
3 007K97780 Drive Gear Assembly
4 Bracket (P/O Item 3)
5 Gear (37T/23T) (P/O Item 3)
6 Gear (41T/22T) (P/O Item 3)
7 007K97790 Link Gear
8 807E19430 Gear (61T)
9 809E73520 Link Spring
10 Clutch Bracket (Not Spared)
11 807E19440 Gear (29T/29T)
12 013E25920 Bearing
13 121K40770 Tray 1 Feed Clutch (REP 2.2.1)
14 801K25580 Interlock Switch Frame Assembly
June, 2008
5-6 WorkCentre 5016, 5020 PL 2.3
Reissue Parts Lists
PL 2.3 Tray 1 Components (1 OF 2)
1 Tray (Not Spared)
2 Tray Front Cover (Not Spared)
3 Bottom Plate Assembly (Not
Spared)
4 Bottom Plate (P/O Item 3)
5 Bottom Pad (P/O Item 3)
6 013E25881 Bearing
7 059K33051 Roll And Shaft Assembly
8 Feed Shaft (P/O Item 7)
9 059K32773 Feed Roll (REP 2.3.1)
10 Cover (Not Spared)
11 End Guide (Not Spared)
12 Pivot (Not Spared)
13 Spring (Not Spared)
14 Stopper (Not Spared)
June, 2008
5-7 WorkCentre 5016, 5020 PL 2.4
Parts Lists Reissue
PL 2.4 Tray 1 Components ( 2 OF 2)
1 Front Side Guide (Not Spared)
2 Paper Guide (Not Spared)
3 Rear Side Guide (Not Spared)
4 Retard Shaft (Not Spared)
5 Pad Spring (Not Spared)
6 019K07086 Retard Pad
7 Label (Max) (Not Spared)
8 Pinion Gear (Not Spared)
9 Bottom Stopper (Not Spared)
10 809E54170 Stopper Spring
11 Earth Plate (Not Spared)
June, 2008
5-8 WorkCentre 5016, 5020 PL 2.5
Reissue Parts Lists
PL 2.5 Tray 1 Frame Components
1 Sensor Block (Not Spared)
2 110E11580 Tray 1 Interlock Switch
3 130E87090 Tray 1 Feed Sensor (REP 2.5.1)
4 120E29540 Actuator
5 Feed Chute (Not Spared)
6 Upper Baffle (Not Spared)
7 Plate Spring (P/O Item 6)
8 Shaft (P/O Item 6)
9 Roll (P/O Item 6)
10 Upper Baffle (P/O Item 6)
11 Eliminator (Not Spared)
12 Sensor Bracket (Not Spared)
13 Feed Sensor Spring (Not Spared)
14 Access Cover 1 (Not Spared)
June, 2008
5-9 WorkCentre 5016, 5020 PL 2.6
Parts Lists Reissue
PL 2.6 Tray 1 Frame Components (2
OF 2)
1 Tray Spacer (Not Spared)
2 Enclosure Plate (Not Spared)
4 005E26740 Coupling Clutch
5 006K25751 Drive Feed Shaft
6 807E19460 Gear (21T)
7 059K48200 Take Away Roll Assembly
8 413W77559 Bearing
9 809E54180 Coupling Spring
10 013E90840 Bearing
11 013E32690 Coupling Bearing
12 807E19450 Gear (16T/29T)
13 Sensor Wire Harness (Not Spared)
June, 2008
5-10 WorkCentre 5016, 5020 PL 2.7
Reissue Parts Lists
PL 2.7 No Paper Sensor Housing
1 120E23791 No Paper Actuator
2 Sensor Housing (Not Spared)
3 130E87090 Tray 1 No Paper Sensor (REP
2.7.1)
4 Bracket (Not Spared)
June, 2008
5-11 WorkCentre 5016, 5020 PL 2.8
Parts Lists Reissue
PL 2.8 Registration
1 059K48250 Registration Roll Assembly (REP
2.8.1)
June, 2008
5-12 WorkCentre 5016, 5020 PL 2.9
Reissue Parts Lists
PL 2.9 Registration Component
1 Corotron Bracket (P/O PL2.8 Item
1)
2 Registration Frame (P/O PL2.8
Item 1)
3 Sensor Plate (P/O PL2.8 Item 1)
4 130K71230 Registration Sensor Assembly
5 Wire Harness (P/O PL2.8 Item 1)
6 Registration Press Spring (P/O
PL2.8 Item 1)
7 Ground Spring (P/O PL2.8 Item 1)
8 121K39710 Registration Clutch Assembly
9 Press Level Arm (P/O PL2.8 Item
1)
10 Corotron Press Spring (P/O PL2.8
Item 1)
11 Transfer Corotron Spring (P/O
PL2.8 Item 1)
12 Ground Sleeve (P/O PL2.8 Item 1)
13 Washer (P/O PL2.8 Item 1)
14 Press Roll (P/O PL2.8 Item 1)
15 Closing Roll (P/O PL2.8 Item 1)
16 Bearing (P/O PL2.8 Item 1)
17 059K53230 Registration Roll
18 Clamp (P/O PL2.8 Item 1)
June, 2008
5-13 WorkCentre 5016, 5020 PL 3.1
Parts Lists Reissue
PL 3.1 ROS
1 062K18161 ROS Assembly (REP 3.1.1)
2 Laser Housing (Not Spared)
3 Label (Not Spared)
4 ROS Wire Harness (Not Spared)
5 Ground Harness (Not Spared)
June, 2008
5-14 WorkCentre 5016, 5020 PL 4.1
Reissue Parts Lists
PL 4.1 Drum Cartridge
1 101R00432 Drum Cartridge (REP 4.1.1)
2 Spring (P/O Item 5)
3 CRU Block (P/O Item 5)
4 106R01277 Toner Bottle
5 604K43851 CRU Blocker Kit
June, 2008
5-15 WorkCentre 5016, 5020 PL 4.2
Parts Lists Reissue
PL 4.2 Toner Empty Sensor and Erase
Lamp
1 130K71400 Toner Empty Sensor (REP 4.2.1)
2 122K94091 Erase Lamp (REP 4.2.2)
June, 2008
5-16 WorkCentre 5016, 5020 PL 4.3
Reissue Parts Lists
PL 4.3 Transfer
1 Transfer Module (Not Spared) (REP
4.3.1)
2 125K93751 Transfer Corotron Housing
3 014K83123 Corotron Block Assembly
June, 2008
5-17 WorkCentre 5016, 5020 PL 4.4
Parts Lists Reissue
PL 4.4 Transfer Corotron Housing
Component
1 125K93751 Transfer Corotron Housing
2 604K43810 Corotron Wire Kit (REP 4.4.1)
4 Outboard Cover (Not Spared)
5 Latch (Not Spared)
6 Corotron Wire (P/O Item 2)
June, 2008
5-18 WorkCentre 5016, 5020 PL 5.1
Reissue Parts Lists
PL 5.1 Fuser
1 Connector Cover (Not Spared)
2 126K23581 Fuser Assembly (220V) (REP
5.1.1)
126K24411 Fuser Assembly (110V) (REP
5.1.1)
3 AC Fuser Harness (Not Spared)
4 DC Fuser Harness (Not Spared)
5 Baffle Clip (Not Spared)
6 122E92530 Fuser Lamp (220V) (REP 5.1.3)
122E92550 Fuser Lamp (110V) (REP 5.1.3)
7 022E30121 Fuser Roll (REP 5.1.4)
8 022K74110 Pressure Roll Assembly (REP
5.1.5)
9 130K71361 Temperature Control Sensor (REP
5.1.2)
June, 2008
5-19 WorkCentre 5016, 5020 PL 6.1
Parts Lists Reissue
PL 6.1 Exit Transport
1 059K48230 Exit Transport Assembly (Simplex)
(REP 6.1.1)
2 059K48240 Exit Transport Assembly (Duplex)
(REP 6.1.2)
June, 2008
5-20 WorkCentre 5016, 5020 PL 6.2
Reissue Parts Lists
PL 6.2 Exit Transport Component
(Simplex)
1 Lower Chute (P/O PL6.1 Item 1)
2 059K43000 Exit Roll
3 059E99331 Pinch Roll
4 Pinch Roll Support (P/O PL6.1 Item
1)
5 809E76520 Pinch Spring
6 013E30050 Bearing
7 Sensor Wire Harness (P/O PL6.1
Item 1)
9 Earth Plate (P/O PL6.1 Item 1)
10 Gear (19T) (P/O PL6.1 Item 1)
11 Gear Pulley (P/O PL6.1 Item 1)
12 Cap (P/O PL6.1 Item 1)
13 Sensor Support (P/O Item 18)
14 130E87090 Fuser Exit Sensor
15 Actuator (P/O Item 18)
16 Actuator Spring (P/O Item 18)
17 Insulator (P/O Item 18)
18 604K43840 Exit Sensor Kit
June, 2008
5-21 WorkCentre 5016, 5020 PL 6.3
Parts Lists Reissue
PL 6.3 Exit Transport Component
(Duplex)
1 Lower Chute (Not Spared)
2 059K43000 Exit Roll
4 Pinch Roll Support (Not Spared)
5 809E76520 Pinch Spring
6 013E30050 Bearing
8 Bearing (Not Spared)
10 Gear Pulley
11 Gear (24T) (Not Spared)
12 Sensor Support (P/O Item 19)
13 130E87090 Fuser Exit Sensor
14 Actuator (P/O Item 19)
15 Actuator Spring (P/O Item 19)
16 Motor Frame (Not Spared)
17 127K51590 Exit Motor
18 423W06555 Belt
19 Insulator (P/O Item 20)
20 604K43840 Exit Sensor Kit
June, 2008
5-22 WorkCentre 5016, 5020 PL 7.1
Reissue Parts Lists

PL 7.1 Simplex Module
1 802K99450 Simplex Module (REP 7.1.1)
June, 2008
5-23 WorkCentre 5016, 5020 PL 7.2
Parts Lists Reissue
PL 7.2 Left Hand Cover Assembly
1 Left Hand Cover (Not Spared)
2 Left Hand Upper Chute (Not
Spared)
3 Left Hand Chute (Not Spared)
4 Front Stopper (P/O Item 12)
5 Pivot Retainer (P/O Item 12)
6 Latch Handle (P/O Item 13)
7 Latch (P/O Item 13)
8 Latch Shaft (P/O Item 13)
9 Main Baffle (Not Spared)
10 Rear Stopper (P/O Item 12)
11 Latch Spring (P/O Item 13)
12 604K43860 Left Hand Door Kit
13 604K43870 Left Hand Door Latch Kit
14 Jam Clear Label (P/O Item 1)
June, 2008
5-24 WorkCentre 5016, 5020 PL 7.3
Reissue Parts Lists
PL 7.3 Duplex Module Component (1
OF 2)
1 802K97500 Left Hand Cover Assembly (REP
7.1.1)
3 Pinch Spring (P/O Item 1)
4 Left Hand Chute (P/O Item 1)
5 Left Hand Upper Chute (P/O Item
1)
6 Front Stopper (P/O Item 1)
7 Duplex Roll 1 (P/O Item 1)
8 013E33260 Bearing
9 Pulley (P/O Item 1)
10 023E26660 Belt
11 Pivot Retainer (P/O Item 13)
12 Rear Stopper (P/O Item 13)
13 604K43860 Left Hand Door Kit
14 Left Hand Cover (P/O Item 1)
June, 2008
5-25 WorkCentre 5016, 5020 PL 7.4
Parts Lists Reissue
PL 7.4 Duplex Module Component (2
OF 2)
1 Duplex Main Baffle (P/O PL7.3 Item
1)
2 Duplex in Chute (P/O PL7.3 Item 1)
3 809E76630 Idler Spring
4 Idler Shaft (P/O PL7.3 Item 1)
5 059E03650 Idler Roll
6 Latch Spring (P/O Item 14)
7 Latch Handle (P/O Item 14)
8 Latch (P/O Item 14)
9 013E33260 Bearing
10 Latch Shaft (P/O Item 14)
11 807E21180 Gear (18T)
12 006K86440 Duplex Roll 2
13 Label (Jam Clear) (Not Spared)
14 604K43870 Left Hand Door Latch Kit
June, 2008
5-26 WorkCentre 5016, 5020 PL 7.5
Reissue Parts Lists
PL 7.5 Bypass Tray Accessory
1 Bypass Feed Shaft (P/O Item 22)
2 Bearing (P/O Item 22, Item 27)
3 Idler Roll (P/O Item 22, Item 28)
4 Idler Shaft (P/O Item 22, Item 28)
5 Bypass Idler Spring (P/O Item 22,
Item 24, Item 28)
6 Drive Support Bracket (P/O Item
22, Item 26)
7 Gear (42/30T) (P/O Item 22, Item
26)
8 Shaft (P/O Item 22, Item 26)
9 Idler Arm (P/O Item 22, Item 26)
10 Gear (49T) (P/O Item 22, Item 26)
13 Sector Gear Spring (P/O Item 22,
Item 24, Item 26)
14 Idler Arm Spring (P/O Item 22, Item
24, Item 26)
15 807E17870 Gear Pulley
16 Sector Gear (P/O Item 22, Item 27)
17 Cam (P/O Item 22, Item 27)
18 121E20950 Bypass Solenoid
19 059K54730 Bypass Feed Roll (REP 7.5.1)
20 Feed Roll Cap (P/O Item 22, Item
29)
21 Bypass Tray (P/O Item 22)
22 059K48260 Bypass Feeder Assembly
24 604K43820 MSI Spring Kit
25 022E29860 Nudge Roller
26 604K45750 MSI Assembly No. 2 Repair Kit
June, 2008
5-27 WorkCentre 5016, 5020 PL 7.6
Parts Lists Reissue
PL 7.6 Bypass Tray Component
1 050K58051 Bypass Tray Assembly
2 Bearing (P/O Item 15)
3 Bypass Take Away Roll (P/O Item
15)
4 Lower Baffle (P/O Item 15)
5 Nudger Plate (P/O Item 14)
6 Nudger Pad (P/O Item 13, Item 14)
7 Nudger Spring (P/O Item 13, PL7.5
Item 29)
8 Gear (18T) (P/O Item 15)
9 Roll (Not Spared)
10 Retard Spring (P/O PL7.5 Item 24)
11 019K08890 Retard Pad Assembly
12 Pre Shingler Bracket (P/O Item 15)
13 604K43830 Bypass Retard Kit
June, 2008
5-28 WorkCentre 5016, 5020 PL 8.1
Reissue Parts Lists
PL 8.1 AIOC PWB, LVPS, Power
Switch
1 110E11320 Power Switch
2 Screw (With Washer) (Not Spared)
3 Inlet Bracket (Not Spared)
4 PWB Bracket (Not Spared)
5 Inlet (Not Spared)
6 CRUM ID Harness (Not Spared)
7 Inlet Wire Harness (Not Spared)
8 Billing Counter Harness (Not
Spared)
9 960K43421 AIOC PWB (REP 8.1.1)
960K44250 AIOC/Network PWB ((DADF Only))
(REP 8.1.3)
10 105E17391 LVPS (220V) (REP 8.1.2)
105E17411 LVPS (110V) (REP 8.1.2)
105E18010 DADF LVPS (220V) (REP 8.1.2)
105E18020 DADF LVPS (110V) (REP 8.1.2)
11 Choke Coil (Not Spared)
12 Power Cord (Not Spared)
13 960K28611 Exit PWB
June, 2008
5-29 WorkCentre 5016, 5020 PL 8.2
Parts Lists Reissue
PL 8.2 HVPS, Interlock Switch, Duplex
PWB
1 014K83141 HV Contact Block
2 105E17401 HVPS (REP 8.2.1)
3 801K25570 Left Hand Interlock Switch
4 Interlock Switch Wire Harness (Not
Spared)
5 Core (Not Spared)
7 Front Cover Interlock Switch (Not
Spared)
9 Harness Block (Not Spared)
10 Harness Block (Not Spared)
11 Core Clip (Not Spared)
June, 2008
5-30 WorkCentre 5016, 5020 PL 8.3
Reissue Parts Lists
PL 8.3 Control Panel Accessory
1 Support Bracket (Not Spared)
2 Control Panel Cover (Not Spared)
3 962K66150 Control Panel Wire Harness
4 802K97694 Control Panel (ADF, DADF Only)
(REP 8.3.1)
848K04904 Control Panel (110V, 220V) (REP
8.3.1)
5 896E58070 Label (WorkCentre 5020)
June, 2008
5-31 WorkCentre 5016, 5020 PL 8.4
Parts Lists Reissue
PL 8.4 Control Panel Component
1 Control Panel Panel Case (With
Key) (P/O PL8.3 Item 4)
2 960K32602 UI Platen PWB Assembly (REP
8.4.1)
960K32783 UI PWB Assembly (ADF Only)
(REP 8.4.1)
960K38300 UI PWB Assembly (DADF Only)
(REP 8.4.1)
3 Middle Panel (P/O PL8.3 Item 4)
4 Label (P/O PL8.3 Item 4)
June, 2008
5-32 WorkCentre 5016, 5020 PL 9.1
Reissue Parts Lists
PL 9.1 Front / Top Cover
1 848E04480 Exit Cover
2 848K17300 Front Cover Assembly
3 Front Left Cover (REP 9.1.2)
4 Output Tray (Not Spared) (REP
9.1.1)
5 Right Top Cover (Not Spared)
6 Xerox Badge Plate (P/O Item 2)
7 IIT Support Bracket (Not Spared)
8 Duct (Not Spared)
9 848E04511 Front Cover
10 801E04660 Strap
11 105E12210 Static Eliminator
June, 2008
5-33 WorkCentre 5016, 5020 PL 9.2
Parts Lists Reissue
PL 9.2 Rear / Right Cover and NOHAD
Fan
1 848E04501 Rear Cover (Remove Data Plate
and Place on New Rear Cover)
(REP 9.2.1)
2 848E04451 Right Cover (REP 9.2.2)
3 127K51632 NOHAD Fan
4 053E93650 Ozone Filter
5 Data Plate (Not Spared) (Remove
Data Plate and Place on New Rear
Cover)
June, 2008
5-34 WorkCentre 5016, 5020 PL 10.1
Reissue Parts Lists
PL 10.1 IIT Accessory
1 IIT Right Bracket (Not Spared)
2 IIT (Not Spared)
4 Platen Cover (P/O Item 8)
5 Platen Cushion (P/O Item 8)
6 Cap (Not Spared)
7 604K47130 Error Code Label Kit
8 604K46500 Platen Cover Kit (REP 10.1.1)
June, 2008
5-35 WorkCentre 5016, 5020 PL 10.2
Parts Lists Reissue
PL 10.2 IIT Component (1 OF 2)
1 848K07410 IIT Upper Cover (REP 10.2.1)
2 604K44330 Hinge Kit
3 Blind Cover (Not Spared)
June, 2008
5-36 WorkCentre 5016, 5020 PL 10.3
Reissue Parts Lists
PL 10.3 IIT Component (2 OF 2)
1 041K95870 IIT Carriage (REP 10.3.1)
2 IIT Under Cover (Not Spared)
3 962K59950 Flexible Print Cable (REP 10.3.2)
4 Plate Spring (Not Spared)
5 809E79910 Cable Spring (Rear)
6 809E79920 Cable Spring (Front)
7 Pulley (Not Spared)
June, 2008
5-37 WorkCentre 5016, 5020 PL 10.4
Parts Lists Reissue
PL 10.4 IIT Upper Cover Cover
Component
1 802K71882 IIT Upper Cover
2 090E02380 Small Platen Glass
3 090E91720 Platen Glass
4 815E08650 White Referance
5 815E42250 Sheet (Black and White)
June, 2008
5-38 WorkCentre 5016, 5020 PL 10.5
Reissue Parts Lists
PL 10.5 IIT Under Cover Component
1 Under Cover (P/O PL10.3 Item 2)
2 801K30780 Front Rail
3 Rear Frame (P/O PL10.3 Item 2)
4 801E05970 Rear Rail
5 Hinge Sleeve (P/O PL10.3 Item 2)
6 Pulley (P/O PL10.3 Item 2)
7 Cable Bracket (P/O PL10.3 Item 2)
8 110E11551 Platen Open Switch
June, 2008
5-39 WorkCentre 5016, 5020 PL 10.6
Parts Lists Reissue
PL 10.6 IIT Carriage Component
1 Center Plate (P/O PL10.3 Item 1)
2 Front Mirror Frame (P/O PL10.3
Item 1)
3 Rear Mirror Frame (P/O PL10.3
Item 1)
4 Mirror Clip (P/O PL10.3 Item 1)
5 Mirror 2 Damper (P/O PL10.3 Item
1)
6 Mirror 3 Damper (P/O PL10.3 Item
1)
7 Rear Mirror Stopper (P/O PL10.3
Item 1)
8 Rear Mirror Stopper (P/O PL10.3
Item 1)
9 Mirror Weight (P/O PL10.3 Item 1)
10 Front Lamp Holder (P/O PL10.3
Item 1)
11 Rear Lamp Holder (P/O PL10.3
Item 1)
12 Sensor Plate (P/O PL10.3 Item 1)
13 Reflector (P/O PL10.3 Item 1)
14 IIT Carriage Cover (P/O PL10.3
Item 1)
15 Reflector Cover (P/O PL10.3 Item
1)
16 868E12730 Sensor Plate Spring
17 Rail Contact (P/O PL10.3 Item 1)
18 Mirror Weight (P/O PL10.3 Item 1)
19 121K41690 Carriage Sensor
20 122E92570 Exposure Lamp (REP 10.6.1)
21 127K57140 Carriage Motor
22 Mirror 1 (P/O PL10.3 Item 1)
June, 2008
5-40 WorkCentre 5016, 5020 PL 10.7
Reissue Parts Lists
PL 10.7 Center Plate Component
1 Len Assembly (P/O PL10.3 Item 1)
2 Drum and Carriage Cable (P/O
PL10.3 Item 1) (ACO) (REP 10.7.1)
3 Pulley (P/O PL10.3 Item 1)
4 Mirror Clip (P/O PL10.3 Item 1)
5 Mirror Frame (P/O PL10.3 Item 1)
6 Side Slider (P/O PL10.3 Item 1)
7 Rail Contact (P/O PL10.3 Item 1)
8 Rail Slider (P/O PL10.3 Item 1)
9 Front Slider (P/O PL10.3 Item 1)
10 Gear (P/O PL10.3 Item 1)
11 Gear (P/O PL10.3 Item 1)
12 Mirror Frame Bracket (P/O PL10.3
Item 1)
13 CCD Support (P/O PL10.3 Item 1)
14 Lock Plate (P/O PL10.3 Item 1)
15 Inverter PWB Bracket 1 (P/O
PL10.3 Item 1)
16 Inverter PWB Bracket 2 (Not
Spared)
17 Bracket (P/O PL10.3 Item 1)
18 140E88751 Inverter PWB (REP 10.7.2)
21 Carriage Cable (Black) (Not
Spared)
22 Carriage Cable (Silver) (P/O
PL10.3 Item 1)
23 Drum (P/O PL10.3 Item 1)
June, 2008
5-41 WorkCentre 5016, 5020 PL 11.1
Parts Lists Reissue
PL 11.1 Single Tray Module
1 050K57701 Tray 2 (REP 11.1.1)
2 Single Tray Frame (Not Spared)
3 896E41981 End Guide Label
4 896E42140 Install Label
June, 2008
5-42 WorkCentre 5016, 5020 PL 11.2
Reissue Parts Lists
PL 11.2 Tray 2 Component (1 OF 3)
1 End Guide (P/O PL11.1 Item 1)
2 Tray (P/O PL11.1 Item 1)
3 Tray Front Cover (P/O PL11.1 Item
1)
4 End Guide Spring (P/O PL11.1 Item
1)
6 Cover (P/O PL11.1 Item 1)
7 End Guide Lock (P/O PL11.1 Item
1)
8 Mini Bottom Plate (P/O PL11.1 Item
1)
9 Spring (Side) (P/O PL11.1 Item 1)
10 Spring (Center) (P/O PL11.1 Item 1)
June, 2008
5-43 WorkCentre 5016, 5020 PL 11.3
Parts Lists Reissue
1 038K89761 Front Side Guide
2 038K89821 Rear Side Guide
3 Tapping Screw (P/O PL11.1 Item 1)
4 Rack (P/O PL11.1 Item 1)
5 Latch (P/O PL11.1 Item 1)
6 Pinion (P/O PL11.1 Item 1)
7 Latch Spring (P/O PL11.1 Item 1)
8 Rack (P/O PL11.1 Item 1)
June, 2008
5-44 WorkCentre 5016, 5020 PL 11.4
Reissue Parts Lists
1 059K48430 Tray 2 Feeder Assembly
2 Feed Chute (P/O Item 1)
3 059K48660 Tray 2 Feed Roll (REP 11.4.1)
4 Feed Shaft (P/O Item 1)
5 013E90840 Bearing
6 Earth Spring (P/O Item 1)
7 Core Roll (P/O Item 1)
8 Holder Seal (P/O Item 1)
9 003K15530 Front Latch Assembly
10 Holder Arm (Not Spared)
11 Spring (Not Spared)
12 019K09250 Retard Roll Housing
13 Retard Housing (P/O Item 12)
14 Retard Holder (P/O Item 12)
15 Retard Shaft (P/O Item 12)
16 Friction Clutch (P/O Item 12)
17 Tray 2 Retard Roll (P/O Item 12)
(REP 11.4.2)
18 Retard Plate (P/O Item 12)
19 Retard Spring (P/O PL11.1 Item 1)
20 Latch Cover (P/O PL11.1 Item 1)
21 003K15540 Rear Latch Assembly
22 Spring (P/O PL11.1 Item 1)
June, 2008
5-45 WorkCentre 5016, 5020 PL 11.5
Parts Lists Reissue
PL 11.5 Single Tray Frame
Component (1 OF 2)
1 STM Rear Cover (Not Spared)
2 STM Wire Harness (Not Spared)
3 Earth Cushion (Not Spared)
5 110E11580 STM Interlock Switch
6 Sensor Block (Not Spared)
7 130E87090 STM Feed Sensor (REP 11.5.1)
8 120E28091 Feed Sensor Actuator
9 055K31090 STM Baffle Assembly
10 Roll (P/O Item 9)
12 Shaft (P/O Item 9)
13 Baffle (P/O Item 9)
14 Eliminator (P/O Item 9)
15 960K28562 STM PWB (REP 11.5.2)
16 Guide Spring (Not Spared)
17 Arm Guide (Not Spared)
18 Tray Stopper (Not Spared)
19 Upper Feed Chute (Not Spared)
20 809E74030 Feed Sensor Spring
21 Access Cover 2 (Not Spared)
June, 2008
5-46 WorkCentre 5016, 5020 PL 11.6
Reissue Parts Lists
PL 11.6 Single Tray Frame
Component (2 OF 2)
1 Harness Holder (Not Spared)
2 807E18360 Gear (Helical 21T)
3 059K48440 Take Away Roll
4 848K02140 No Paper Sensor Assembly
5 013E32180 Bearing (220v)
013E90840 Bearing (110V)
6 807E18410 Gear (Helical 20T/36T)
7 068K53590 STM Feed Clutch (REP 11.6.1)
8 127K52180 STM Feed Motor (REP 11.6.2)
11 807E18400 Gear (Helical 37T)
12 Tray Rear Stopper (Not Spared)
June, 2008
5-47 WorkCentre 5016, 5020 PL 11.7
Parts Lists Reissue
PL 11.7 STM No Paper Sensor
1 Actuator Support (P/O PL11.6 Item
4)
2 120E29630 No Paper Sensor Actuator
3 130E87090 No Paper Sensor (REP 11.7.1)
4 Sensor Housing (P/O PL11.6 Item
4)
June, 2008
5-48 WorkCentre 5016, 5020 PL 12.1
Reissue Parts Lists
PL 12.1 Stand Component
1 Stand (Not Spared)
2 017K93121 Caster
3 017K93132 Caster (With Stopper)
4 017E12010 Locator Peg
5 121E93360 Catch Magnet
6 Front Door (Not Spared)
7 Stand Hinge (Not Spared)
8 Door Hinge (Not Spared)
9 Guide (Not Spared)
10 017E98760 Support
11 Screw (Not Spared)
12 Foot Cover (Not Spared)
13 Adjuster Foot (Not Spared)
14 Front Foot (Not Spared)
15 Foot Bracket (Not Spared)
June, 2008
5-49 WorkCentre 5016, 5020 PL 13.1
Parts Lists Reissue
PL 13.1 ADF/DADF Accessory
1 022K74860 ADF Assembly (with Item 2) (REP
13.1.1, ADJ 13.1.1)
2 004E17510 Platen Cushion (REP 13.1.2)
3 Screw (Not Spared)
4 Push Tie (Not Spared)
June, 2008
5-50 WorkCentre 5016, 5020 PL 13.2
Reissue Parts Lists
PL 13.2 Component, Cover
1 022K75730 DADF Scanner Assembly
059K55590 ADF Scanner Assembly (REP
13.2.2)
2 Rear Cover (Not Spared)
3 Front Cover (Not Spared)
4 050K60800 ADF Document Tray Assembly
(REP 13.2.1)
050K63270 DADF Document Tray Assembly
5 Front Blind Cover (Not Spared)
6 Rear Blind Cover (Not Spared)
7 Support Bracket (Not Spared)
8 Base Cover Assembly (Not Spared)
June, 2008
5-51 WorkCentre 5016, 5020 PL 13.3
Parts Lists Reissue
PL 13.3 Base Cover Component
1 960K42980 DADF PWB (REP 13.3.4)
960K32370 ADF PWB (REP 13.3.1)
2 Bracket (Not Spared)
3 962K60840 ADF Cable
4 Exit Chute (Not Spared)
5 Stamp Cover (Not Spared)
6 Lead In Pinch Roller (Not Spared)
7 604K44340 Spring Plate Kit (5/Kit)
8 059K55600 Exit Pinch Roller
9 016E93560 Bush
10 Base Cover (Not Spared)
11 003K86760 Right Counter Balance (REP
13.3.3)
12 003K13560 Left Counter Balance (ADF Only)
(REP 13.3.2)
003K15950 Left Counter Balance (DADF Only)
(REP 13.3.2)
13 Pinch Roll Bracket (Not Spared)
14 604K44350 Read Out Pinch Roller Kit (5/Kit)
15 Spring Plate (Read Out) (Not
Spared)
16 Interlock Magnet (Not Spared)
17 Bottom Plate (Not Spared)
18 ADF Earth Spring (Not Spared)
19 Film Cover (Not Spared)
20 Film Cover (Not Spared)
21 Earth Wire (Not Spared)
22 059K55860 Pinch Roll Assembly
June, 2008
5-52 WorkCentre 5016, 5020 PL 13.4
Reissue Parts Lists
PL 13.4 Feeder Component
1 Upper Feeder Assembly (P/O
PL13.2 Item 1)
2 Top Cover (Not Spared)
3 ADF Lower Feeder Assembly (P/O
PL13.2 Item 1)
4 Pin (P/O PL13.2 Item 1)
5 Stopper Belt (P/O PL13.2 Item 1)
June, 2008
5-53 WorkCentre 5016, 5020 PL 13.5
Parts Lists Reissue
PL 13.5 Lower Feeder Component
1 Document Drive Motor (P/O Item
24) (ADF Only)
2 Motor Plate (P/O Item 24)
3 Gear (40T-21T) (P/O Item 24)
4 Bracket (P/O Item 24)
8 Gear (28T) (P/O PL13.4 Item 3)
9 Gear (39T-26T) (P/O PL13.4 Item
3)
10 Bush (P/O PL13.4 Item 3)
3)
3)
13 Gear (16T) (P/O PL13.4 Item 3)
15 Gear (17T) (P/O PL13.4 Item 3)
16 Gear (24T) (P/O PL13.4 Item 3)
17 Gear (19T) (P/O PL13.4 Item 3)
3)
3)
20 Registration Clutch (P/O PL13.4
Item 3)
21 Eject Torque Limiter (P/O PL13.4
Item 3)
22 Cable Fence (P/O PL13.4 Item 3)
(DADF Only)
23 Exit/Invert Clutch (P/O PL13.4 Item
3) (DADF Only)
24 127K58700 Motor Assembly (DADF Only)
127K57120 Motor Assembly (ADF Only)
25 Gear Plate (P/O PL13.4 Item 3)
26 Gear (21T-18T) (P/O Item 24)
(DADF Only)
June, 2008
5-54 WorkCentre 5016, 5020 PL 13.6
Reissue Parts Lists
PL 13.6 Retard Roll Component
1 Retard Roll Assembly (Not Spared)
2 Registration Mylar (P/O Item 1)
3 Retard Mylar (P/O Item 1)
4 Base Lower Feeder Assembly (Not
Spared)
5 Arm Pin (Not Spared)
6 Shaft (Not Spared)
7 Paper Guide Plate (Not Spared)
8 Bearing (Oil Less) (Not Spared)
10 Roll Assembly (P/O Item 1)
June, 2008
5-55 WorkCentre 5016, 5020 PL 13.7
Parts Lists Reissue
PL 13.7 Lower Feeder Assembly
1 Bottom Chute (Not Spared)
2 White Sheet (Not Spared)
3 Bottom Sheet (Not Spared)
4 Base Frame (Not Spared)
5 059K55620 Lead In Roll
6 059K55630 Lead Out Roll
8 059K55610 Registration Roll
9 Front Bracket (Not Spared)
10 Rear Bracket (Not Spared)
11 ADF Invert Gate (Not Spared)
12 Seal (Not Spared)
13 Exit/Invert Sensor (Not Spared)
(DADF Only)
14 Sensor Holding Bracket (Not
Spared) (DADF Only)
15 Registration Sensor (Not Spared)
(DADF Only)
16 Registration Sensor Actuator (Not
Spared) (DADF Only)
17 Registratin Sensor Spring (Not
Spared) (DADF Only)
18 Exit/Invert Sensor Spring (Not
Spared) (DADF Only)
19 Exit/Invert Sensor Actuator (Not
Spared) (DADF Only)
20 Exit/Invert Solenoid Bracket (Not
Spared) (DADF Only)
21 Solenoid Bracket (Not Spared)
(DADF Only)
22 Exit/Invert Solenoid (Not Spared)
(DADF Only)
June, 2008
5-56 WorkCentre 5016, 5020 PL 13.8
Reissue Parts Lists
PL 13.8 Retard Roll Assembly
1 Plate (Not Spared)
4 Exit Roller (Not Spared)
5 Rear Exit Arm (Not Spared)
6 809E56440 Spring (Coil)
7 Front Exit Arm (Not Spared)
9 Exit Roll Drive Shaft (Not Spared)
10 Spring Plate (Not Spared)
11 Spring Plate (Not Spared)
12 Plate (Not Spared)
13 Retard Roll Chute (Not Spared)
(REP 13.8.1)
14 Retard Roll Drive Shaft (Not
Spared)
15 Bush (Not Spared)
16 Bush (Not Spared)
17 Spring (Coil) (Not Spared)
18 059E04080 Retard Roll (REP 13.8.1)
June, 2008
5-57 WorkCentre 5016, 5020 PL 13.9
Parts Lists Reissue
PL 13.9 Upper Feeder Assembly
1 Lock Lever (P/O PL13.4 Item 1)
3 Main Shaft (P/O Item 22)
4 Bearing (P/O Item 22)
5 Pickup Roll (P/O Item 22) (REP
13.9.1)
6 Pickup Roll Shaft (P/O Item 22)
7 Housing (P/O Item 22)
9 Feed Roll (P/O Item 22) (REP
13.9.1)
10 Gear (22T) (P/O Item 22)
11 Plate (P/O PL13.4 Item 1)
12 Spring Box (P/O PL13.4 Item 1)
13 Spring (Coil) (P/O PL13.4 Item 1)
14 Spring Housing (P/O PL13.4 Item
1)
15 Front Lock Arm (P/O PL13.4 Item
1)
16 Top Frame (P/O PL13.4 Item 1)
17 Rear Lock Arm (P/O PL13.4 Item 1)
18 Sensor Holder (P/O Item 32)
19 Document Set Sensor Actuator
(P/O Item 32)
20 Document Feeder Width Sensor
Actuator (P/O Item 32)
21 Document Feeder Width Sensor,
Document Set Sensor (P/O Item
32)
22 059K55640 Feeder Assembly
23 Sensor Holder (P/O Item 37)
24 Document Feed Sensor (P/O Item
37)
25 Document Feed Sensor Actuator
(P/O Item 37)
27 121K41670 Clutch (One Way)
28 Shaft (P/O PL13.4 Item 1)
29 059E99690 Registration Pinch Roller
30 Plate (P/O PL13.4 Item 1)
31 110E11570 DADF/ADF Top Cover Switch
32 121K41650 Document Set Sensor Assembly
33 121K41600 Document Feed Clutch
34 Gear (20T) (P/O PL13.4 Item 1)
35 Adjust Plate (P/O PL13.4 Item 1)
37 121K41660 Read Sensor Assembly
June, 2008
5-58 WorkCentre 5016, 5020 PL 13.10
Reissue Parts Lists
PL 13.10 Document Tray
2 Front Side Guide (P/O PL13.2 Item
4)
3 Rear Side Guide (P/O PL13.2 Item
4)
4 Width Sensor Actuator (P/O PL13.2
Item 4)
5 Eliminator (P/O PL13.2 Item 4)
6 Pinion Gear (P/O PL13.2 Item 4)
7 Pinion Spring (P/O PL13.2 Item 4)
8 Lower Document Tray (P/O PL13.2
Item 4)
9 Document Tray Width Sensor 1,
Document Tray Width Sensor 2
(P/O PL13.2 Item 4)
10 Actuator (P/O PL13.2 Item 4)
11 Document Tray Length Sensor 1,
Document Tray Length Sensor 2
(P/O PL13.2 Item 4)
12 Upper Document Tray (P/O PL13.2
Item 4)
June, 2008
5-59 WorkCentre 5016, 5020 Common Hardware
Parts Lists Reissue
Common Hardware
AA 102W37178 Countersunk Head Screw (M4x25)
AB 102W38278 Countersunk Head Screw (M4x45)
AC 112W27898 Pan Head Screw (M3x8)
AD 113W20878 Screw (M3x8)
AE 113W21478 Screw (M3x14)
AF 113W27688 Pan Head Screw (M3x6)
AG 114W27678 Bind Head Tapping Screw (M3x6)
AH 114W27878 Bind Head Tapping Screw (M3x8)
AJ 153W16088 Tapping Screw (M4x10)
AK 153W16288 Tapping Screw (4Mx12)
AL 153W17688 Tapping Screw (3Mx6)
AM 153W17888 Tapping Screw (3Mx8)
AN 153W18088 Tapping Screw (3Mx10)
AP 153W18288 Tapping Screw (3Mx12)
AQ 153W18488 Tapping Screw (3Mx14)
AR 153W27678 Bind Head Tapping Screw (M3x6)
AS 153W27878 Bind Head Tapping Screw (M3x8)
AT 153W28078 Bind Head Tapping Screw (M3x10)
AU 158W27678 Screw (M3x6)
AV 158W27878 Screw (M3x8)
AW 252W27450 Nylon Washer (6)
AX 354W15278 E-Clip
AY 354W18278 E-Clip
AZ 354W19278 E-Clip
BA 354W21278 E-Clip
BB 354W24278 E-Clip
BC 354W27254 KL-Clip
BD 354W27278 E-Clip
BE 158W36878 Screw (M4x8)
BF 158W36078 Screw (M4x10)
June, 2008
5-60 WorkCentre 5016, 5020 Part Number Index
Reissue Parts Lists
Part Number Index
Table 1 Part Number Index
Part Number Part List
003K13560 PL 13.3
003K15530 PL 11.4
003K15540 PL 11.4
003K15950 PL 13.3
003K86760 PL 13.3
004E17510 PL 13.1
005E26740 PL 2.6
006K25751 PL 2.6
006K86440 PL 7.4
007K94880 PL 1.1
007K97780 PL 2.2
007K97790 PL 2.2
013E25881 PL 2.3
013E25920 PL 2.2
013E30050 PL 6.2
013E30050 PL 6.3
013E32180 PL 11.6
013E32690 PL 2.6
013E33260 PL 7.3
013E33260 PL 7.4
013E90840 PL 11.4
013E90840 PL 2.6
013E90840 PL 11.6
014K83123 PL 4.3
014K83141 PL 8.2
016E93560 PL 13.3
017E12010 PL 12.1
017K93121 PL 12.1
017K93132 PL 12.1
017E98760 PL 12.1
019K07086 PL 2.4
019K08890 PL 7.6
019K09250 PL 11.4
022E29860 PL 7.5
022E30121 PL 5.1
022K74110 PL 5.1
022K74860 PL 13.1
022K75730 PL 13.2
023E26660 PL 7.3
038K89761 PL 11.3
038K89821 PL 11.3
041K95870 PL 10.3
050K57701 PL 11.1
050K58051 PL 7.6
050K60800 PL 13.2
050K62940 PL 2.1
050K63270 PL 13.2
053E93650 PL 9.2
055K31090 PL 11.5
059E03090 PL 7.3
059E03650 PL 7.4
059E04080 PL 13.8
059K32773 PL 2.3
059K33051 PL 2.3
059K43000 PL 6.2
059K43000 PL 6.3
059K48200 PL 2.6
059K48230 PL 6.1
059K48240 PL 6.1
059K48250 PL 2.8
059K48260 PL 7.5
059K48430 PL 11.4
059K48440 PL 11.6
059K48660 PL 11.4
059K53230 PL 2.9
059K54730 PL 7.5
059K55590 PL 13.2
059K55600 PL 13.3
059K55610 PL 13.7
059K55620 PL 13.7
059K55630 PL 13.7
059K55640 PL 13.9
059K55860 PL 13.3
059E99331 PL 6.2
059E99331 PL 6.3
059E99690 PL 13.9
062K18161 PL 3.1
068K53590 PL 11.6
090E02380 PL 10.4
090E91720 PL 10.4
June, 2008
Parts Lists Reissue
101R00432 PL 4.1
105E12210 PL 9.1
105E17391 PL 8.1
105E17401 PL 8.2
105E17411 PL 8.1
105E18010 PL 8.1
105E18020 PL 8.1
106R01277 PL 4.1
110E11320 PL 8.1
110E11551 PL 10.5
110E11570 PL 13.9
110E11580 PL 11.5
110E11580 PL 2.5
120E22470 PL 1.1
120E23791 PL 2.7
120E28091 PL 11.5
120E29540 PL 2.5
120E29630 PL 11.7
121E20950 PL 7.5
121K39710 PL 2.9
121K40770 PL 2.2
121K41600 PL 13.9
121K41650 PL 13.9
121K41660 PL 13.9
121K41670 PL 13.9
121K41690 PL 10.6
121E93360 PL 12.1
122E92530 PL 5.1
122E92550 PL 5.1
122E92570 PL 10.6
122K94091 PL 4.2
125K93751 PL 4.3
125K93751 PL 4.4
126K23581 PL 5.1
126K24411 PL 5.1
127K51590 PL 6.3
127K51632 PL 9.2
127K52180 PL 11.6
127K57120 PL 13.5
127K57140 PL 10.6
127K58700 PL 13.5
130K71230 PL 2.9
130K71361 PL 5.1
130K71400 PL 4.2
130E87090 PL 11.5
130E87090 PL 11.7
130E87090 PL 6.3
130E87090 PL 6.2
130E87090 PL 2.7
130E87090 PL 2.5
140E88751 PL 10.7
413W77559 PL 2.6
423W06555 PL 6.3
604K43810 PL 4.4
604K43820 PL 7.5
604K43830 PL 7.6
604K43840 PL 6.2
604K43840 PL 6.3
604K43851 PL 4.1
604K43860 PL 7.2
604K43860 PL 7.3
604K43870 PL 7.2
604K43870 PL 7.4
604K44330 PL 10.2
604K44340 PL 13.3
604K44350 PL 13.3
604K45740 PL 7.6
604K45750 PL 7.5
604K45760 PL 7.6
604K45770 PL 7.5
604K45780 PL 7.5
604K45790 PL 7.5
604K46500 PL 10.1
604K47130 PL 10.1
801E04660 PL 9.1
801E05970 PL 10.5
801K25570 PL 8.2
801K25580 PL 2.2
801K30780 PL 10.5
802K71882 PL 10.4
802K97500 PL 7.3
802K97694 PL 8.3
June, 2008
Reissue Parts Lists
802K99450 PL 7.1
807E17870 PL 7.5
807E18360 PL 11.6
807E18380 PL 11.6
807E18390 PL 11.6
807E18400 PL 11.6
807E18410 PL 11.6
807E19430 PL 2.2
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
960K32783 PL 8.4
960K38300 PL 8.4
960K42980 PL 13.3
960K43421 PL 8.1
960K44250 PL 8.1
962K59950 PL 10.3
962K60840 PL 13.3
962K66150 PL 8.3
June, 2008
General Procedures Reissue
6 General Procedures
Diagnostics
Diagnostic Mode ............................................................................................................. 6-3
Basic Operations of the Diagnostic Mode....................................................................... 6-4
IOT Diagnostics............................................................................................................... 6-7
General Procedures
GP1 Serial Number Locations......................................................................................... 6-43
GP 2 Viewing the Six Digit Error Code............................................................................ 6-43
General Information
Specifications.................................................................................................................. 6-45
Tools ............................................................................................................................... 6-52
Consumables .................................................................................................................. 6-52
Glossary of Terms........................................................................................................... 6-53
June, 2008
Reissue General Procedures
June, 2008
6-3 WorkCentre 5016, 5020 Diagnostic Mode

Diagnostic Mode
This mode is used by service engineers to solve problems in the field and is intended to iden-
tify the fault areas in terms of replaceable components. In the Diagnostic Mode, the following
diagnostic functions can be run from the Control Panel:
Function Overview
Parts Diagnostics Input Diagnostics 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.
Program Function 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.
NVM Check and Change of Settings 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
Basic Operations of the Diagnostic Mode
Display: Displays the menus and their results.
Keypad: Inputs Chain Function Codes.
[Start] button: Displays the Diagnostics Menu.
[Stop] button: Pauses/Stops the diagnostic.
How to Enter the Diagnostic Mode
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.
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.
Once in the Diagnostic Mode, "C_ " (Chain Code input screen) is shown on the display.
The "_" is blinking.
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)
The following shows the Chain and Function input method in the Diagnostic Mode.
A Chain/Function Code must be input as 2 digits. If the Chain/Function Code is "1,"
it must be input as "01." Any input value that goes beyond the 2nd digit will be ignored.
To clear the Chain/Function Code that was input, press the "C" button.
Both digits will be cleared, and you will be returned to the Code input screen.
When inputting the Function Code, pressing the [Start] button after inputting a Function Code
that is out of the specified range will transfer you to the initial screen of Function input.
Enter the Diagnostic Mode and check that the "C_ " (Chain Code input screen) is shown on the
display. The "_" should be blinking.
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 _
C _
C 1 _
June, 2008
Input the next number, and it will appear in the second digit space.
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.
Use the keypad to enter the 2-digit Function Code.
Pressing the [Start] button will then run the specified Diagnostic Code.
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.
Enter 6, 7, 8, and 9 then press the Start button.
Once in the Diagnostic Mode, "C_ " (Chain Code input screen) is shown on the display.
The "_" is blinking.
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)
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.
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.
Enter the Diagnostic Mode and check that the "C_ " (Chain Code input screen) is shown on the
display. The "_" should be blinking.
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.
C 1 2
F _
F 2 _
F 2 3
June, 2008
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 show the "L_ " (Link Code input screen) on the display.
An "L" and the blinking "_" are shown on the Link Code input screen.
Use the keypad to enter the Link Code first digit.
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 [AC] button will return you to the Chain Code input screen (C_).
June, 2008
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.
lnput Component ControI Codes
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
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
June, 2008
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.
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.
To resume the operation of the specified component, press the [Start] button again.
05 217 DADF Document Width Sen-
sor
L:
H:
62 212 IIT Regi Sensor L:
H:
62 272 IIT Scan Start L:
H:
62 300 IIT Platen I/L Switch L:
H:
5 212 DADF Feeder Cover Switch L:
H:
5 102 DADF Document Set Sensor L:
H:
5 215 DADF Doc Feeder Width Sen-
sor
L:
H:
5 216 DADF Doc Tray Width Sensor
1
L:
H:
5 217 DADF Doc Tray Width Sensor
2
L:
H:
5 218 DADF Doc Tray Length Sen-
sor 1
L:
H:
5 219 DADF Doc Tray Length Sen-
sor 2
L:
H:
5 204 ADF/
DADF
Document Feed Sensor L:
H:
5 206 ADF/
DADF
Doc Regi Sensor L:
H:
5 205 ADF/
DADF
Doc Feedout Sen sor/
Exit Invert Sensor
L:
H:
Chain
Func
or
Output Component ControI Codes
Chain Func Sub Contents of Data Meaning
04 01 PH IOT Motor ON
04 02 FUSER Nohad Fan Motor
(HIGH SPEED)
Fuser Fan changes from
Low to High speed
r u n
F 2 3
June, 2008
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] but-
ton again returns the Car-
riage 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.
05 21 IIT Carriage Motor High
Speed return
Move the Carriage
toward home position at
80mm/sec. NOTE: See
05-20.
05 22 IIT Carriage Motor Low
Speed scan
Move the Carriage in the
scan direction at 40mm/
sec. NOTE: See 05-20.
05 23 IIT Carriage Motor Low
Speed return
Move the Carriage
toward home position at
40mm/sec. NOTE: See
05-20.
05 40 ADF Document Drive Motor
High Speed
Run the Document Drive
Motor at 80 mm/sec.
05 41 ADF Document Drive Motor
Low Speed
Run the Document Drive
Motor at 40 mm/sec.
05 42 ADF Document Feed Clutch Turn the Document Feed
Clutch on.
06 15 ROS ROS Motor ON ROS Motor Start & Stop.
08 10 PH IOT Registration
Clutch
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 NOTE: Ejects paper.
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 Sole-
noid
62 05 IIT Scan Motor, Scan
Direction
Used with locking posi-
tion
62 06 IIT Scan Motor Return
Direction
Used with locking posi-
tion
62 07 IIT Scan Locking Position
05 01 DADF DADF Motor
62 2 IIT Exposure Lamp
62 86 IIT Image Area H8_PS
June, 2008
6-10 WorkCentre 5016, 5020
Program Function
The Program Function can access the NVM (the EEPROM on the AIOC PWB) to perform the
following functions:
Test Print
Initialize NVM
Check Error History
Check Print Count
Display Version
Clear Error History
Display Serial Number, Product Number
Test Print [23-10], [23-01]
There are two test print modes: one that outputs the Controller built-in pattern, and another that
outputs the MCU built-in pattern.
NOTE: Before running either of these test prints, you must check and make sure that the appli-
cable NVM settings are correct. See Summary of Program Functions.
During a test print, "run" is displayed.
Once the test print starts, an error code will be displayed if an error occurs while printing.
Clearing the error will return you to the Function Code input screen.
To resume the test print, press the [Start] button again.
Pressing the [Stop] button in the middle of a test print will stop the feeding of additional paper,
output any paper that was already fed, and return you to the Function Code input screen.
Initialize NVM [20-58]
This will return the NVM settings to their default values.
While the NVM is being initialized, "run" is displayed.
When NVM initialization is complete, you will be returned to the Function Code input screen.
r u n
C 1
F _
r u n
June, 2008
6-11 WorkCentre 5016, 5020
Display Error History [40-01]
This can be used to check for the last 20 errors.
Pressing the [Start] button will display the error codes, starting with the most recent error.
When the last error is displayed, press the [Start] key to return to the Function Code input
screen.
Pressing the [Stop] key during the display will stop it and return you to the Function Code input
screen.
Check Print Count [25-01]
This can be used to check the total print count. The display is in decimal numbers.
The initial display shows the first 3 digits of the print count. Pressing the [Start] button will show
you the next 3 digits.
Pressing the [Start] button again will return you to the Function Code input screen.
Display Firmware Version [29-49]
This can be used to check the firmware versions of the Controller and the MCU.
Pressing the [Start] button will display the firmware version, starting from the highest order (left-
most) digit.
Once everything has been displayed, you will be returned to the Function Code input screen.
Clear Error History [20-59]
This can be used to clear the Error History.
While the Error History is being cleared, "run" is displayed.
Once the Error History has been cleared, you will be returned to the Function Code input
screen.
Display Serial Number [25-20]
This can be used to display the serial number of the machine.
Pressing the [Start] button will display the serial number, starting from the highest order (left-
most) digit.
Once the whole serial number has been displayed, you will be returned to the Function Code
input screen.
J 6 1 E 1 6 J 1 6
F _
1 7 1 6
F 1
12a F 1
r u n
1 2 3 4 5 6 7 8 9 0 F 1
June, 2008
6-12 WorkCentre 5016, 5020
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 (left-
most) digit.
Once the whole product code has been displayed, you will be returned to the Function Code
input screen.
F _
June, 2008
6-13 WorkCentre 5016, 5020
Summary of Program Functions
Chain Function Sub Contents of Data Meaning
05 22 IIT Move Scanner Moves the Scanner to the home position.
05 23 IIT Move Scanner Moves the Scanner to the maintenance position.
20 58 Initialize MCU NVM Initialize Sets the initial value in the MCU's system data.
20 59 Initialize Clear Error History Clears the Error History.
20 60 Initialize MCU NVM Update Sets the initial value in additional system data between old and new MCU
versions.
Use "DIAG EXECUTE" command.
23 10 Test Print Test Print Executes test pattern printing.
23 01 Test Print Print Controller built-in pattern Prints the Controller built-in grid, using the following NVM settings:
1-Sided or 2-Sided: 23-20
Paper Source: 23-21
Number of prints: 23-27 (high-order digits) and
23-26 (low-order digits)
25 01 Check Display total print counter Displays the total print count (6 digits). The display is divided into 2
portions: the high-order digits and the low-order digits.
25 20 Check Display machine serial number Displays the machine serial number (10 digits). The display is divided into 4
portions: the highest-order digit, followed by 3 sets of 3 digits.
25 21 Check Display machine product code Displays the machine product code (8 digits). The display is divided into 3
portions: the 2 highest-order digits, followed by 2 sets of 3 digits.
29 50 Check Display Controller firmware version Displays the firmware version of the Controller. The display is divided into
3 portions, starting from the highest-order digit.
29 49 Check Display MCU firmware version Displays the firmware version of the MCU. The display is divided into 3
portions, starting from the highest-order digit.
40 01 Check Display Error History Displays the Error History, starting with the most recent error code.
June, 2008
6-14 WorkCentre 5016, 5020
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.
Using the keypad to input a value shows the value as blinking.
Pressing the [C] button clears the value that was input and leaves the current value as blinking.
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.
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).
3
3 3 1
3
3
June, 2008
6-15 WorkCentre 5016, 5020
List of NVM Settings (WC 5016, 5020 ADF)
NOTE: In the CE Access columns, O = yes and X = no.
Chain
Func
tion Sub Contents of Data Range Unit
Initial
Value
CE
Access
Remarks R W Init
06 20 ROS ALL TRAY-LASER SIDE
REGI ADJUSTMENT
1~99 0.254
mm
50 O O O
06 21 ROS TRAY1-LASER SIDE REGI
ADJUSTMENT
1~99 0.254
mm
50 O O O
06 22 ROS TRAY2-LASER SIDE REGI
ADJUSTMENT
1~99 0.254
mm
50 O O O
06 26 ROS MSI-LASER SIDE REGI
ADJUSTMENT
1~99 0.254
mm
50 O O O
06 28 ROS DUP ALL TRAY-LASER
SIDE REGI ADJUSTMENT
1~99 0.254
mm
50 O O O
06 29 ROS DUP TRAY1-LASER SIDE
REGI ADJUSTMENT
1~99 0.254
mm
50 O O O
06 30 ROS DUP TRAY2-LASER SIDE
REGI ADJUSTMENT
1~99 0.254
mm
50 O O O
06 34 ROS DUP MSI-LASER SIDE
REGI ADJUSTMENT
1~99 0.254
mm
50 O O O
06 52 ROS IMAGE AREA 0~1 - 0 O O O 0:Normal Image Area
1:Wide Image Area
07 46 TRAY Tray1-paper size 0~254 1mm 2 O O O value paper type
1: 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)
June, 2008
6-16 WorkCentre 5016, 5020
07 47 TRAY Tray2-paper size 0~254 1mm 2 O O O 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 2 O O O 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 O O O Image input is delayed when Set Value is
increased.
Min(0)=-4.46mm, Max(66)=4.46mm,
Initial(33)=0mm
20 41 PH TRAY1 for Normal LEAD
REGI ADJ
0~60 0.146
mm
increased.
20 42 PH TRAY2 for Normal LEAD
REGI ADJ
0~60 0.146
mm
increased.
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
June, 2008
6-17 WorkCentre 5016, 5020
20 43 PH SMH for Normal LEAD REGI
ADJ
0~60 0.146
mm
increased.
20 45 PH DUP ALL SIZE for Normal
LEAD REGI ADJ
0~60 0.146
mm
increased.
20 46 PH ALL TRAY - REGI LOOP
TIMER
0~66 0.438
mm
33 O O O Loop increases when Set Value is
increased.
20 47 PH TRAY1 for Normal Paper -
REGI LOOP TIMER
0~66 0.438
mm
increased.
20 48 PH TRAY2 for Normal Paper -
REGI LOOP TIMER
0~66 0.438
mm
increased.
20 49 PH SMH for Normal Paper - REGI
LOOP TIMER
0~66 0.438
mm
increased.
20 51 PH DUP for Normal Paper - REGI
LOOP TIMER
0~66 0.438
mm
increased.
21 09 HFSI Last 2 of Fuser discharging
Number
0~99 1 0 O O X Only 0 clearance is possible in the write
mode.
("0 clearance" means all bytes change to 0
at the same time.)
21 19 HFSI 5th & 6th Fuser discharging
Number
mode.
at the same time.)
21 29 HFSI 3rd & 4th Fuser discharging
Number
mode.
at the same time.)
21 39 HFSI 1st 2 of Fuser discharging
Number
mode.
at the same time.)
23 20 PH Simplex/Duplex 0~1 1 O O O 0: Simplex
1: Duplex
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
June, 2008
6-18 WorkCentre 5016, 5020
23 21 PH Feed Tray 1~6 1 O O O 1: Tray1. 2: Tray2. 3: Tray3. 4: Tray4.
5: HCF. 6: MSI
23 22 PH Output Tray 0~4 0 O O O 0: FACE DOWN TRAY#1.
1: FACE DOWN TRAY#2.
2: FACE UP TRAY.
3: FINISHER Bin1.
4: FINISHER Top Tray
23 26 PH Test Print Run Length Low
Byte
0~99 1 O O O Number of Test Prints
23 27 PH Test Print Run Length High
Byte
0~99 0 O O O Number of Test Prints
29 01 Billing Last 2 Dig Total Copy
Counter(8 Digits)
0~99 0 O X X
29 11 Billing 3rd & 4th Dig Total Copy
Counter(8 Digits)
0~99 0 O X X
29 21 Billing 1st 2 Dig Total Copy
Counter(8 Digits)
0~99 0 O X X
29 04 HFSI Tray1 Last 2 Digits of Feed
Capacity (8 Digits)
mode.
at the same time.)
29 14 HFSI Tray1 5th & 6th Digits of Feed
Capacity (8 Digits)
mode.
at the same time.)
29 24 HFSI Tray1 3rd & 4th Digits of
Feed Capacity (8 Digits)
mode.
at the same time.)
29 34 HFSI Tray1 1st 2 Digits of Feed
Capacity (8 Digits)
mode.
at the same time.)
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
June, 2008
6-19 WorkCentre 5016, 5020
29 05 HFSI Tray2 Last 2 Digits of Feed
Capacity (6 Digits)
mode.
at the same time.)
29 15 HFSI Tray2 5th & 6th Digits of Feed
Capacity (6 Digits)
mode.
at the same time.)
29 25 HFSI Tray2 3rd & 4th Digits of
mode.
at the same time.)
29 09 HFSI MSI Last 2 Digits of Feed
Capacity (8 Digits)
mode.
at the same time.)
29 19 HFSI MSI 5th & 6th Digits of Feed
Capacity (8 Digits)
mode.
at the same time.)
29 29 HFSI MSI 3rd & 4th Digits of Feed
Capacity (8 Digits)
mode.
at the same time.)
29 39 HFSI MSI 1st 2 Digits of Feed
Capacity (8 Digits)
mode.
at the same time.)
30 04 Recycle Last 2 Digits of MSI Feed
Capacity (8 Digits)
0~99 1 0 O X X
30 14 Recycle 5th & 6th Digits of MSI Feed
Capacity (8 Digits)
0~99 1 0 O X X
30 24 Recycle 3rd & 4th Digits of MSI Feed
Capacity (8 Digits)
0~99 1 0 O X X
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
June, 2008
6-20 WorkCentre 5016, 5020
30 34 Recycle 1st 2 Digits of MSI Feed
Capacity (8 Digits)
0~3 1 0 O X X
30 05 Recycle Last 2 of IOT Starting Number 0~99 1 0 O X X
30 15 Recycle 3rd & 4th IOT Starting
Number
0~99 1 0 O X X
30 25 Recycle 1st 2 of IOT Starting Number 0~99 1 0 O X X
30 06 Recycle Tray1 Last 2 Digits of Feed
Capacity (8 Digits)
0~99 1 0 O X X
30 16 Recycle Tray1 5th & 6th Digits of Feed
Capacity (8 Digits)
0~99 1 0 O X X
30 26 Recycle Tray1 3rd & 4th Digits of
0~99 1 0 O X X
30 36 Recycle Tray1 1st 2 Digits of Feed
Capacity (8 Digits)
0~3 1 0 O X X
30 07 Recycle Tray2 Last 2 Digits of Feed
Capacity (6 Digits)
0~99 1 0 O X X
30 17 Recycle Tray2 5th & 6th Digits of Feed
Capacity (6 Digits)
0~99 1 0 O X X
30 27 Recycle Tray2 3rd & 4th Digits of
0~99 1 0 O X X
30 37 Recycle Tray2 1st 2 Digits of Feed
Capacity (8 Digits)
0~3 1 0 O X X
30 41 HFSI Last 2 Digits of the number of
Sheets Reaching BIAS transfer
Roll (8 Digits)
mode.
at the same time.)
30 42 HFSI 5th & 6th Digits of the number
of Sheets Reaching BIAS
transfer Roll (8 Digits)
mode.
at the same time.)
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
June, 2008
6-21 WorkCentre 5016, 5020
30 43 HFSI 3rd & 4th Digits of the number
mode.
at the same time.)
30 44 HFSI 1st Two Digits of the number
mode.
at the same time.)
30 61 Recycle Tray Feed Capacity MAX
Over
0~1 1 0 O X X It is shown whether the Recycle Tray
Feed Capacity NVM was written more
than 4000000 times.
0: not exceed
1: exceeded.
30 62 Recycle IOT Starting Number MAX
Over
0~1 1 0 O X X It is shown whether the IOT Starting
Number NVM was written more than
1000000 times.
0: not exceed
1: exceeded.
33 04 CRU CRU Remain 0~100 1% 100 O X X CRU Remain percentage
33 05 ESS IF UI Auto Clear Time 0~4 - 3 O O O 0=OFF(Disabled), 1=20sec
2=30sec, 3=60sec, 4=90sec
33 06 ESS IF Priority Paper Tray 1~3 - 1 O O O 1=Tray1
2=Tray2
3=MSI
33 07 ESS IF Document Type 1~3 - 1 O O O 1=Text
2=Text & Photo
3=Photo
33 08 ESS IF Density Adjustment 0~4 - 2 O O O 0=Lightest
1=Light
2=Normal
3=Dark
4=Darkest
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
June, 2008
6-22 WorkCentre 5016, 5020
33 09 ESS IF Default Reduction /
Enlargement
0~4 - 0 O O O 0=100%
1=50%
2=70%(Metic),78%(Inch13&14)
3=129%(Metic),141%(Inch13&14)
4=200%
33 11 ESS IF Auto Tray Switch 0~1 - 1 O O O 0=Disable
1=Enable
33 12 ESS IF Auto Paper Selection 0~1 - 1 O O O 0=Disable
1=Enable
33 13 ESS IF Default Customizing
Reduction / Enlargement
50~200 - 82 O O O China 82=82%(=82)
XC 64=64%(=64)
33 14 ESS IF Sharpness Adjustment for
Copy Job
0~4 - 2 O O O 0=Weakest
1=Weaker
2=Normal
3=Stronger
4=Strongest
33 15 ESS IF Sharpness Adjustment for
Scan Job
0~4 - 2 O O O 0=Weakest
1=Weaker
2=Normal
3=Stronger
5=Strongest
33 16 ESS IF MCU Low Power Mode 1~254 - 2 O O O 0=0min(Shift immediately)
1=5min
2=20min
3=60min
4=120min
5=240min
254=OFF(Disable)
33 17 ESS IF MCU Sleep Mode 0~254 - 2 O O O 0=0min(Shift immediately)
1=5min
2=20min
3=60min
4=120min
5=240min
254=OFF(Disable)
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
June, 2008
6-23 WorkCentre 5016, 5020
33 18 ESS IF Device Power Off Mode 0~254 - 0 O O O 0=0min(Shift immediately)
1=5min
2=20min
3=60min
4=120min
5=240min
254=OFF(Disable)
33 19 ESS IF Background removal for
COPY
0~5 - 2 O O O 0=OFF
1=Level1
2=Level2
3=Level3
4=Level4
5=Level5
33 20 ESS IF Background removal for
SCAN
0~5 - 2 O O O 0=OFF
1=Level1
2=Level2
3=Level3
4=Level4
5=Level5
33 21 ESS IF Account Mode 0~2 - 0 O O O 0=Disable
1=Single User Password Mode
2=Multi User Password Mode
33 22 ESS IF Paper Class 0~2 - 0 O O O 0=Metric
1=Inch13
2=Inch14
33 23 ESS IF Add Original Auto Clear Time 0~4 - 3 O O O 0=OFF(Disabled)
1=20sec
2=30sec
3=60sec
4=90sec
33 24 ESS IF Wait Time After MSI Jam
Clear
0~60 1sec 8 O O O 0- 60sec
33 25 ESS IF Carriage Return Default
Position
0~60 1sec 7 O O O 0- 60sec
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
June, 2008
6-24 WorkCentre 5016, 5020
33 26 ESS IF Platen Fast Scan REGI
Adjustment
0~144 1dot
(600dpi)
72 O O O 0-71=-72 to -1dot
72=0dot
73-144=1 to 72dot
33 27 ESS IF Platen Slow scan REGI
Adjustment
0~151 1dot
(600dpi)
24 O O O 0-23=-24 to -1dot
24=0dot
25-144=1 to 151dot
33 28 ESS IF ADF Fast Scan REGI
Adjustment
0~144 1dot
(600dpi)
72 O O O 0-71=-72 to -1dot
72=0dot
73-144=1 to 72dot
33 29 ESS IF ADF Slow scan REGI
Adjustment
0~79 0.1mm 40 O O O 0-39=-4.0 to -0.1mm
40=0mm
41-80=0.1 to 4.0mm
33 30 ESS IF Shading Offset for ADF 1~254 1 100 O O O complement
100=x1
1-99=x0.01-x0.99 (dark)
101-254=x1.01-x2.54 (light)
33 31 ESS IF Shading Offset for ADF 1~254 1 100 O O O complement
100=x1
1-99=x0.01-x0.99 (dark)
101-254=x1.01-x2.54 (light)
33 33 ESS IF Platen Slow Scan scale
Adjustment
0~20 0.10% 10 O O O 0-9=-1.0% to -0.1%
10=0%
11-20=0.1% to 1.0%
33 35 ESS IF ADF Slow Scan scale
Adjustment
0~20 0.10% 10 O O O 0-9=-1.0% to -0.1%
10=0%
11-20=0.1% to 1.0%
33 36 ESS IF ADF Loop Adjustment 0~10 1mm 5 O O O 0-4=-5 to -1mm
5=0mm
1-5=1 to 5mm
33 37 ESS IF M/C config 0~1 - 1 O X X 0 : DC
1 : CPS
33 38 ESS IF ADF installation 0~1 - 0 O O X 0 : not installed
1 : installed
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
June, 2008
6-25 WorkCentre 5016, 5020
34 01 ESS IF Administrator User Login
Password Low byte
48~57 - 49 O O O 48-57
Password Mid byte
48~57 - 49 O O O
Password High Byte
48~57 - 49 O O O
34 02 ESS IF User1 Login Password Low
Byte
48~57 - 48 O O O
34 12 ESS IF User1 Login Password Mid
byte
48~57 - 48 O O O
34 22 ESS IF User1 Login Password High
byte
48~57 - 48 O O O
Byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
Byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
Byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
June, 2008
6-26 WorkCentre 5016, 5020
Byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
Byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
Byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
Byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
Byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
June, 2008
6-27 WorkCentre 5016, 5020
Byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
byte
48~57 - 48 O O O
35 23 ESS IF User1 Copy Credit 0~60 1000 0 O O O
36 01 ESS IF User1 Copy Count Low byte 0~99 - 0 O O O
36 11 ESS IF User1 Copy Count Mid byte 0~99 - 0 O O O
36 21 ESS IF User1 Copy Count High byte 0~99 - 0 O O O
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
June, 2008
6-28 WorkCentre 5016, 5020
36 20 ESS IF User10 Copy Count Mid Byte 0~99 - 0 O O O
36 30 ESS IF User10 Copy Count High Byte 0~99 - 0 O O O
42 01 ESS IF Last 20 Fault History 1st Last 48~122 - 48 O O O
42 11 ESS IF Last 20 Fault History 1st 2nd 48~122 - 48 O O O
42 21 ESS IF Last 20 Fault History 1st 1st 48~122 - 48 O O O
42 02 ESS IF Last 20 Fault History 2nd Last 48~122 - 48 O O O
42 12 ESS IF Last 20 Fault History 2nd 2nd 48~122 - 48 O O O
42 22 ESS IF Last 20 Fault History 2nd 1st 48~122 - 48 O O O
42 03 ESS IF Last 20 Fault History 3rd Last 48~122 - 48 O O O
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
June, 2008
6-29 WorkCentre 5016, 5020
42 13 ESS IF Last 20 Fault History 3rd 2nd 48~122 - 48 O O O
42 23 ESS IF Last 20 Fault History 3rd 1st 48~122 - 48 O O O
42 04 ESS IF Last 20 Fault History 4th Last 48~122 - 48 O O O
42 14 ESS IF Last 20 Fault History 4th 2nd 48~122 - 48 O O O
42 24 ESS IF Last 20 Fault History 4th 1st 48~122 - 48 O O O
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
June, 2008
6-30 WorkCentre 5016, 5020
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
June, 2008
6-31 WorkCentre 5016, 5020
43 40 ESS IF Offset to the latest error 0~19 - 0 O O O
50 15 EXIT Enable OCT & Inverter 0~2 - 2 O O O 0:Disable
1:Inverter+OCT
2:Inverter Only
50 20 FUSER FSR Reset FuserOverTemp 0~3 - 0 O O O 0:reset
1:FS1 Detected over temp
2:FS2 Detected over temp
3:On time Fail
5:Cold Sagging Fail(Only reset is possible
in the diagnostics mode.)
60 01 ESS IF MCU VERSION 0~1 - - O X X
60 02 ESS IF MCU Release Number 0~99 - - O X X
60 03 ESS IF MCU Patch Level 0~99 - - O X X
60 06 ESS IF STM Version 0~99 - - O X X
60 07 ESS IF STM Release Number 0~99 - - O X X
60 18 General CPM 0~99 - - O X X 20:20PPM
Other:PPM NG
60 19 General Market Identity 0~254 - - O X X 22: DMO
60 26 MC Code Serial Code1 0~254 1 0 O X X
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
June, 2008
6-32 WorkCentre 5016, 5020
Reprograming the DADF EPROMS on the SLCC PWB when replacing them with new ones.
60 36 Product Product code 1 0~254 1 0 O X X
Chain
Func
Initial
Value
CE
Access
Remarks R W Init
Table 1 Reprogaming the EPROMS on the SLCC PWB (DADF)
Chain Link
XC(DMO-W)
110 V
100S12656
Serial No.
KMA469001-
MMA484000
XC(DMO-W)
220 V
100S12657
Serial No.
KMX484001-
KMX494000
XC(DMO-E)
220 V
100S12655
Serial No.
331494001x-
331524000x NVM Destination Remarks Reference
700 339
Get the information from the latest
soft ware version.
700 340
700 341
700 342
700 343
700 344
700 348
700 349
700 350
700 165 840 840 826 Country Code 840:USA 826:UK This list
700 402 2 2 4 Paper Size Group 1: Japan, 2:NA, 4:AP, 5:SA This list
700 337 15 15 15 Device Type CPFS:15 This list
700 338 2 2 2 Territory 0x01:FX 0x02:XC 0x03:XE
0x04:AP
This list
700 700 6 6 6 Machine serial number format 6 This list
June, 2008
6-33 WorkCentre 5016, 5020
700 329 75 75 75 Product Code #1
Refer to this list or the Serial Number
Plate.
700 330 77 77 76 Product Code #2
700 331 65 88 66 Procuct Code #3
700 332 0 0 o Product Code #4
700 333 0 0 0 Product Code #5
700 334 0 0 0 Product Code #6
700 335 0 0 0 Product Code #7
700 336 0 0 0 Product Code #8
700 701 3 3 3 DMP Indication 2:DMP5/6 3:DMP7 This list
709 11 85 85 85 XJ Code #1
This list
709 12 67 67 67 XJ Code #2
709 13 78 80 77 XJ Code #3
709 14 0 0 0 XJ Code #4
700 297 75 75 51 Upper 3Byte Serial No. #1 This list or the Serial Number Plate
780 203 1:LEF 1:LEF 1:LEF Tray 1 Standard paper size-Orienta-
tion
0:none specified, 1:LEF,
2:SEF
This list
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-Orienta-
tion
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 This list
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 2 2 2 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 14 14 14 END Video Enable Timing Adjust-
ment
Initial Value: 6 This list
Table 1 Reprogaming the EPROMS on the SLCC PWB (DADF)
Chain Link
XC(DMO-W)
110 V
100S12656
Serial No.
KMA469001-
MMA484000
XC(DMO-W)
220 V
100S12657
Serial No.
KMX484001-
KMX494000
XC(DMO-E)
220 V
100S12655
Serial No.
331494001x-
331524000x NVM Destination Remarks Reference
June, 2008
6-34 WorkCentre 5016, 5020
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
CE Access
R W Init Remarks
715 1 IISS Major Version 0 ~ 65535 - 65535 O O O IISS Major Version number
715 2 IISS Minor Version 0 ~ 65535 - 65535 O O O IISS Minor Version number
715 3 IISS Revision Version 0 ~ 65535 - 65535 O O O IISS Revision Version number
715 10 Platen/DADF 0 ~ 1 - 1 O O O Switch Platen model and DADF Model
0: Platen
1: DADF
715 11 Change Size Table 0 ~ 3 - 0 O O O Switch document size detection table of DADF
0: mm (AP)
1: inch 13-12 (EU/South America)
2: inch 14 (North America)
3: Mexico
715 20 Platen SS Registration Adjustment 80 ~ 260 1 dot 120 O O O Platen SS Registration Correction Value. NVM initial
value is Adjustment Value 0. Adjust by 1 dot. (Not
include the adjustment value from Module Sensor ~
Registration)
715 21 Platen PRadjF 0 ~ 240 1 dot 120 O O O Platen FS Registration Correction Value. NVM value
120 is Adjustment Value 0. Adjust by 1 dot.
715 22 CVT Image Reading Position 0 ~ 500 0.1 mm 100 O O O DADF Reading Position Correction Value
715 23 SS Feed Position Correction (Side 1) 400 ~ 600 0.1 mm 505 O O O SS Feed Position Correction Value (Side 1) Includes
the adjustment value from Doc Regi Sensor (SNS8)
ON~Start of Reading Side 1
715 24 SS Feed Position Correcation (Side 2) 400 ~ 600 0.1 mm 505 O O O SS Feed Position Correction Value (Side 2) Includes
the adjustment value from Doc Regi Sensor (SNS8)
ON~Start of Reading Side 2.
715 25 SS Tail Registration Corerection (Side 1) 400~600 0.1 mm 446 O O O Includes the adjustment value from Doc Regi Sensor
(SNS8) OFF~Finish of Reading Side 1.
715 26 SS Tail Registration Correction (Side 2) 400~600 0.1 mm 446 O O O Includes the adjustment value from Doc Regi Sensor
(SNS8) Off~Finish of Reading Side 2.
715 27 Registration Loop Degree Adjustment A 50~200 0.1 mm 89 O O O Feed Sensor (SNS7) ON~Feed CL (EMC1) OFF after
feeding the document (Adjustment Value A)
715 28 Registration Loop Degree Adjustment B 50~200 0.1 mm 150 O O O Feed Sensor (SNS7) ON~Regi Cl (ENC2) ON when
inverting document. (Adjustment Value B)
715 29 Feed Clutch Timing Adjustment (output) 700~1000 0.1 mm 940 O O O Feedout Sensor OFF~Feedout Clutch OFF when out-
putting
715 30 Feedout Clutch Timing Adjustment (invert) 0~500 0.1 mm 210 O O O Feedout Sensor) OFF~Feedout Clutch OFF when
inverting
715 31 CVT FS OFFset Side 1 0~240 1 dot 120 O O O CVT FS Registration Correction Value for Side 1 (front
side) NVM value 120 is Adjustment Value 0. Adjust by 1
dot.
June, 2008
6-35 WorkCentre 5016, 5020
715 32 CVT FS OFFset Side 2 0~240 1 dot 120 O O O CVT FS Registration Correction Value for Side 2 (back
side) NVM value 120 is Adjustment Value 0. Adjust by 1
dot.
715 40 FS Magnification Adjustment 0~100 0.1% 50 O O O Fine Adjustment Value of FS magnification. Shows =/-
5% (by 0.1%) fine adjustment value with 50 for 0%, ) for
-5% and 100 for 5%.
715 41 Platen SS Magnification Adjustment 40~60 0.1% 50 O O O Fine Adjustment Value of Platen SS Magnification.
Shows +/- 1% (by 0.1%) fine adjustment value with 50
for 0%, 40 for -1% and 60 for +1%/
715 42 CVT SS Magnification Adjustment 40~60 0.1% 50 O O O Fine Adjustment Value of CVT SS Magnification.
Shows +/- 1% (by 0.1%) fine adjustment value with 50
for 0%, 40 for -1% and 60 for +1%.
715 90 Fail Bypass 0 ~ 1 - 0 O O O 0: With out Fail Bypass
1: With Fail Bypass
715 91 Error Information 0~65535 - 0 O O O Debug information
715 92 Size detection: Sensor Information of Cus-
tom Size
0~65535 - 0 O O O Sensor information in the case of the size detection
result being Custom Size. If the result is not Custom
Size, this NVM update will not be done.
bit 0: Sensor 6
bit 1: Sensor 5
bit 2: Sensor 4
bit 3: Sensor 3
bit 4: Sensor 2
bit 5-15: (spare)
Meaning of bit = 0: Sensor OFF, 1: Sensor ON
715 100 WREF ADJ Platen 50~255 - 111 O O O Correction Factor of Blue W-Fef (for Platen)
715 101 Density Level ADJ RGBK 80~120 - 100 O O O Highlight Fine Adjustment (x 1/100, dommon to RGBK)
715 102 102WDL STD CL 30 B 0~1023 - 0 O O O Standard Data of White Variation Correction.
715 103 WREF ADJ CVT 50~255 - 78 O O O Correction factor of Blue W-Fef (for CVT)
715 110 AGOC SHD NVM 0~8 - 0 O O O 0: PROM used
1: NVM of (*1) enabled.
715 111 FBLM 0~1023 - 984 O O O AGC Maximum Allowable Value (*1)
715 112 FBLI 0~1023 - 64 O O O AGC Minimum Allowable Value (81)
715 113 PLSnCL 0~255 - 32 O O O Reading Line Number of Shading RGB. (*1)
715 114 FL CHK NG Count 0~65535 Once 0 O O O Number of Lamp Check Failure (Reset by lamp
replacement)
715 115 FL CHK NG Data 0~1023 - 0 O O O Downloaded Dtaat at Lamp Check Failure (Get data
when white is read, which is compared at the check)
715 120 AGC ADJ BW 1~200 - 100 O O O AGC BW for Target Value Correction (x1/100: 100=x1)
715 121 Gap (1) 0~1023 - 128 O O O CCD Ch-1 Gain Value
715 122 Gap (2) 0~1023 - 128 O O O CCD Ch-2 Gain Value
715 123 AGCP (1) 0~511 - 128 O O O CCD Ch-1 AGC Setting Value
715 124 AGCP (2) 0~511 128 O O O CCD Ch-2 AGC Setting Value
Table 2
Initial
Value
CE Access
R W Init Remarks
June, 2008
6-36 WorkCentre 5016, 5020
715 125 Gsmp (1) 0~1023 0 O O O CCD Ch-1 AGC Downloaded Data
715 126 Gsmp (2) 0~1023 0 O O O CCD Ch-2 AGC Downloaded Date
715 127 Gloop (1) 0~255 0 O O O CCD CH-1 AGC Loop Number
715 128 Gloop (2) 0~255 0 O O O CCD CH-2 AGC Loop Number
715 130 Oadj 0~255 0 O O O AOC BW Level Correction Value (Complement of 2: -
128 +127)
715 131 AOCP (1) 0~1023 128 O O O CCD Ch-1 AOC Setting Value
715 132 AOCP (2) 0~1023 128 O O O CCD Ch-2 AOC Setting Value
715 133 Osmp (1) 0~1023 0 O O O CCD Ch-1 AOC Downloaded Average Data
715 134 Osmp (2) 0~1023 0 O O O CCD Ch-2 AOC Downloaded Average Data
715 135 Osmpx (1) 0~1023 0 O O O CCD Ch-1 AOC Max Value Downloaded Average Data
715 136 Osmpx (2) 0~1023 0 O O O CCD Ch-2 AOC Max Value Downloaded Average Data
715 137 Osmpn (1) 0~1023 0 O O O CCD Ch-1 AOC Max Value Downloaded Average Data
715 138 Osmpn (2) 0~1023 0 O O O CCD Ch-2 AOC Max Value Downloaded Average Data
715 139 AOCerr 0~255 0 O O O Number of AOC Plow Abnormal End
715 150 BWPG Density 0~255 128 O O O PG Density of Entire Solid Imagae (0: white)
715 161 PreIPS_Through 1 0~65535 0 O O O bit 0: ALLCBTF
bit 1: ALLKTF
bit 2: ALLCTF
bit 3: SSFCTF
bit 4: MRCTF
bit 5: WDVCTF0
bit 6: WDVCTF1
bit 7: DKCTF
bit 8: FSFTF0
bit 9: FSFTF1
bit 10: DCBCTF
bit 11: DCACTF
bit 12: GPCTF
bit 13: (SPARE)
bit 14: (SPARE)
bit 15: (SPARE)
meaning of Bit
0: Through (Skip) Val;id. 1: Through (Skip) Invalid
Table 2
Initial
Value
CE Access
R W Init Remarks
June, 2008
6-37 WorkCentre 5016, 5020
715 162 PreIPS_Through2 0~65535 0 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
715 163 PreIPS_Through3 0~65535 0 O O O bit 0: BWTF
bit 1: IPKTF
bit 2: EETF
bit 3: EDTF
bit 4: MKKTF
bit 5: GFBTF
bit 6: BTBTF
bit 7: MWTF
bit 8: ECTF
bit 9: MKBTF
bit 10: FOBTF
bit 11: SSRTF
bit 12: (spare)
bit 13: (spare)
bit 14: (spare)
bit 15: (spare)
Meaning of Bit
0: Through Valid, 1: Through Invalid
Table 2
Initial
Value
CE Access
R W Init Remarks
June, 2008
6-38 WorkCentre 5016, 5020
715 200 Post IPS Bypass Setting 0~65535 0 O O O Make each function of image process block forcibly
through (sk;ipped).
Change values at S/W & H/W DEBUG.
Should be 0 for usual use without fail. (Careful han-
dling 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.
715 201 S2X_OUT CONTROL 0~7 0 O O O Specify the intake of image for scanning jig.
0: AMAO intake (Lab)*
1: AMAO intake (Shipping Inspection)*
2: DAIMAJIN intake
3: PRIDE intake
4: TOTODB intake (CMY)
5: WOZDB intake
6: FLC intake
7: TOTODB intake (YMC)
*If NVM value is 0 or 1, release athe Mask for
AMAO.
715 202 VIPOUT Select 0~255 255 O O O Switch the image path of VIPOUT. If this value is 255,
nothing should be done. (Keep current SET VIP)
VDO-MASK release will be carried out according to thie
setting. Related register: SETVIP
715 205 AE FS External Area 0~65535 1dot 255 O O O AE-FS Undetected Area INSTV For AES parameter
calculation Related Register: SMPST, SMPED
715 206 0~65535 0.16mm 60 O O O AE-SS Variation Fix Line-NCON AE detected amount
of SS lead edge Sep number of NCON regis-
ter=0.16mm
Table 2
Initial
Value
CE Access
R W Init Remarks
June, 2008
6-39 WorkCentre 5016, 5020
715 207 AE Detect Variation Control 0~1 1 O O O LIM Control Mode
0: Variaable Mode
1: Fixed Mode (NCON preferred mode)
Related register: AESMOD
715 208 AE Control of FS Length 0~1 1 O O O 0: Minimum lenmgth of FS detection size will FS detec-
tion length
1: Input the document size or regard the result of auto-
matic size detection as FS detected length. For AES
parameter calculation Related registaer: SMPST,
SMPED
715 209 Minimum FS Length for AE 0~65535 0.1mm 500 O O O Minimum FS detection lengath (1 step=0.1mm)
For AES parameter calculation
715 210 AE Upper Limit of SS Magnification adjust-
ing
0~4000 0.1% 4000 O O O Maximum SS detection length (1 step=0.1%) For RAE.
715 211 SS Not Detect Area for Platen Job 0~65535 0 O O O SS Dead Zone Setting Value at REal-Time AE for
Platen Job
Related registaer: BASE
715 212 SS Not Detect Area for ADF Job 0~65535 0 O O O SS Dead Zone Setting Value at REal-Time AE for
DADF Job
Related register: BASE
715 213 Background removal for COPY 0~4 1 O O O AE Remval Level for Copy Job
0: Standare
1: High +1
2: High +2
3: High +3
4: High +4
Since this NVM is written by Controller, direct modifica-
tion of this value will be invalid. (Overwritten later) Refer
to the procedire of Cont. side of Removal Level change.
715 219 Background removal for SCAN 0~4 1 O O O AE Removal Level for Copy Job
0: Standard
1: High +1
2: High +2
3: High +3
4: High +4
Since the NVM is written by Conroller, direct modifica-
tion of this value will be invalid. (Overwritten Later)
Refer to the procedure of Cont. Side of Removal Level
change.
715 230 AE Detection Level (Copy Platen) 0~4 2 O O O Parameter Level of Detecxted Background Amount.
(For Platen copy Job)
1: Low ~4: High
0: Ruby 1 Compatible Mode (not fully correspond)
Table 2
Initial
Value
CE Access
R W Init Remarks
June, 2008
6-40 WorkCentre 5016, 5020
715 231 AE Detection Level (Copy ADF) 0~4 2 O O O Parameter Level of Detected Background Amount
(For ADF copy job)
1: Low ~4: High
0: Ruby 1 Compatible Mode (Not fully correspond)
715 232 AE Detection Level (SCAN Platen) 0~4 2 O O O Parameter Level of Detected Background Amount
(For Platen scanning job)
0: Low ~4: High
715 233 AE Detection Level (SCAN ADF) 0~4 2 O O O Parameter Lelel of Detected Background Amount
(For ADF scanning job)
0: Low ~4: High
715 240 Density Correction LUT enaabling flag for
Job Type
0~3 0 O O O Select the job type applying the corrective LUT of
A*X+B.
0(0x00)~3(0x03)
Bit assign
0 bit: Copy Job
1 bit: Scan Job
2 - 7 bit: Not use.
(0=disable, 1=enable)
715 241 Density Corrective LUT enabling flag for
Org Type
0~7 0 O O O Select the document mode applying the corrective LUT
of A*X+B.
0(0x00)~7(0x07)
Bit assign
0bit: TX Mode
1bit: T/P Mode
2bit: Photo Mode
3-7bit: Not use.
(0=disable 1=enable)
715 242 Density Corrective LUT enabling flag for
Density
0~31 0 O O O Select the density level applying the corrective LUT of
A*X+B.
0(0x00)~31(0x1f)
Bit assign
0bit: Lighter2
1bit: Lighter1
2bit: Nomal Density
3bit: Darker1
4bit: Darker2
5-7bit: Not use.
(0=disable, 1=enable)
715 243 Density Corrective LUT Parameter A 0~255 64 O O O Paramaeeter A to create the corrective LUT of A*X+B.
Settable range of A is 0~3.984375.
0(0x00)~3.984375(0xff)
Bit assign
7-6bit: Interger number area.
5-0bit: decimal number area.
Table 2
Initial
Value
CE Access
R W Init Remarks
June, 2008
6-41 WorkCentre 5016, 5020
715 244 Density Corrective LUT Parameter B 0~255 0 O O O Parameter B to create the corrective LUT of A*X+B.
Settable range of B is -128~+127.Minus value shows
complement number of 2.
-128(0x80)~+127(0x7f)
Table 2
Initial
Value
CE Access
R W Init Remarks
June, 2008
6-42 WorkCentre 5016, 5020
June, 2008
6-43 WorkCentre 5016, 5020 GP1, GP 2

GP1 Serial Number Locations
The Serial Number is located in three places on the machine:
NOTE: If the Rear cover has to be replaced, do not worry about saving the data plate (which
has the machine serial number), since the serial number can be found in two other locations.
On the Data Plate on the Rear Cover.
In software on the machine. The serial number can be displayed by accessing Diagnos-
tics (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.
GP 2 Viewing the Six Digit Error Code
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.
1. When the two digit error code appears in the Display, press the Display Button.
a. The first three digits of the six digit error code appears in the display.
2. Press the Display Button.
a. The second half of the six digit error code appears in the display.
3. Press the Display Button.
a. The display switches back to the two digit error codes.
June, 2008
6-44 WorkCentre 5016, 5020 GP1, GP 2
June, 2008
6-45 WorkCentre 5016, 5020

Specifications
This subsection contains the performance specifications of the WorkCentre 5020, the multi-
functional machine that has copier, printer, and scanner functions.
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)
Scans documents for copying and scanning. The IIT resolution is 600 dpi at multi-level.
2. IOT (Image Output Terminal)
Writes video data on paper for copying and printing. A laser xerography system is applied.
Images can be written at 600dpi on paper up to 11"x17"/ A3 size.
3. UI (User Interface)
Displays various settings, errors.
4. Controller
Controls the whole machine. Processes and stores input from IIT, printer I/F, and images
to be output to IOT. Controls UI as well.
5. Printer I/F (GDI)
Receives data from the computer and passes it to the IOT (printer). In scan mode, outputs
image data to the computer.
6. I/F (NetWork)
Network I/F receives data from the computer and passes the data to IOT (printer).
For scanning, Network I/F outputs image data to the network.
7. User Registration and Department Management
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.
GDI
Number of Account: 10 users
Password: 3 digits, Numerical only
Network
Number of Account: 99
Password: 4-12 columns digits, Numerical only, ommissible
8. Duplex Copy
Duplex copies can be made using simplex documents or duplex documents. Simplex cop-
ies can be made using duplex documents.
Side images (input:output): Simp:simp, *Dup:Simp, Simp:Dup, *Dup:Dup.
*Dup (DADF needed)
Standard Specification of IIT, IOT, and Control UI
Standard Specification of Controller
Standard Specification of Host
Product Codes
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)
PANEL LED
Table 2
Item GDI Controller NW Controller Notes
CPU OTI4110 MPC8311E --
Standard memory SDRAM 64M --
Serial EEPROM 4Mbit --
Extended slot Not supported --
Table 3
Item Description GDI
Host I/F USB (2.0) x 1 Yes
Table 4
Product
Code Code
XJ
CODE Model
IOT
speed
Prt/
Scan Dup IIT Platen ADF FINAL ASSY
June, 2008
6-46 WorkCentre 5016, 5020
Options
Warm-up Time
In an ambient environment of 22C and 55% R.H. and in the power off or power save mode,
the machine will reach a "ready to copy" condition within 45 seconds.
Low Power Mode
When the machine is not operated for a certain period of time, the machine enters Low Power
Mode automatically.
Control Panel: LED: ON
Device Control: The fuser reduces its temperature.
Printer I/F: Activated status.
After a certain amount of time in Standby Mode, the machine enters Low Power Mode. This
time can be changed by a software program (setting range: 0-240 minutes). The factory default
is 5 minutes.
Low Power Mode is cancelled when a button is pressed on the Control Panel or when a printer
job is received.
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
FCOT shall be 7.5 sec or less. FCOT (Warm Start) is measured from the time the Start button
is pressed (when the engine receives a START command in the "STAND-BY" state) till the trail
edge of the first sheet is fed out, under the following conditions:
Documents are placed on Platen
Power is on
Engine motor is not running
Fuser is ready
Laser scanner motor (ROS: Raster Output Scanner) is ready
Paper size and feeding orientation: A4 or 8.5x11 LEF
Paper tray: Tray 1
FPOT
FPOT: First Print Output Time
FPOT shall be 12sec or less
Resolution
Copy print: 600 X 600 dpi. Printer print: 600 X 600 dpi.
Software Download
Controller Part: User can upgrade the software by downloading the object from the PC.
IOT Engine Part
MCU: Replacing the board. Optional Tray: Replacing the board.
Table 5
Product name Installation
Code
User
STM (500sheets) O EL200735
Stand O EL200736
June, 2008
6-47 WorkCentre 5016, 5020
Count-up for Print/Copy jobs: GDI
The purpose of the Count-up Meter is to categorize the number of sheets of print output by
print job, copy job, and test prints (Diagnostic Mode). The NLM Count-up Meter is not guaran-
teed as a meter for billing purposes. The Count-up Meter is managed by the device unit and
can be confirmed with device UI.
The Count-up Meter has only one total counter.
Report: One (Printer).
GDI: not supported.
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:
Electrical/Mechanical Characteristics
Electrical Characteristics
*Power consumption is specified assuming full configuration.
Rated Power Consumption
[GDI]
Network
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.)
Table 7
Paper size Number of counter increments
Billing Life
A3, B4, 8K, 11x17, Non-fixed 1 2
A4 or less (A4, Letter, ....) 1 1
Table 8
Input Voltage
(VAC)
Frequency
(Hz)
Rated input cur-
rent Max (A)
Power Con-
sumption*
Spec (VA)
Sleep Mode
(Off Mode)
Reference
220 - 240V 240+10%
220-10%
50/60+/-3 Hz 6A 1320VA (Max) 6 W (Max)
110 - 127V 110+10%
110-10%
50/60 +/-3 Hz 12A 1320VA (Max) 6 W (Max)
Table 9 GDI
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
Table 10 NetWork
Mode Power consumption Configuration
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)
Full configuration
June, 2008
6-48 WorkCentre 5016, 5020
TEC Method (New E-Star) Machine Size/Weight
The machine specified below does not include a drum and toner cartridge.
1. Size
[Optional Devices]
Size of Package:
DC: 710x660x716 (mm)
IBG ADF, DADF: 710x660x840 (mm)
2. Weight
Table 11
Config TEC
GDI Network
DC20 3.0Kwh -
CP20 6.0Kwh -
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
Table 13
Width (mm) Depth (mm) Height (mm)
STM (500 Sheets) 551+/-5 522+/-5 130+/-5
Stand 551+/-5 506+/-5 385+/-5
Table 14
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 Consum-
ables
Net weight (full configura-
tion)
38.0 Kg TBD IIT/MSI/Std Tray (250sheets) including toner car-
tridge
Stand 18 Kg TBD
June, 2008
6-49 WorkCentre 5016, 5020
Storage Environment (According to Egret)
A machine (without CRU and Toner Cartridge)which has been stored in the following environ-
ment shall attain the specified performance when installed in the environment specified.
1. In operation (guaranteed copy quality environment): 10 - 32 degrees C @ 15 - 85% RH
2. Shipping and storage conditions:
Noise (Sound Power Level: LWAd)
Unit: B
Impulse Sound Power (FX) Impulse Sound Power Level (LWAI)
LWAI B(A)
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
Copy Speed
Continuous copy speed at 100% magnification.
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 15
Type Transit (48 hrs) Storage (18 mo) Comments
Temperature -29 to 66 degrees C
(-20 to 150 degrees F)
-29 to 66 degrees C
(-20 to 150 degrees F)
After storage or transit,
the machine must normal-
ize to the operating envi-
ronment 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
Table 16
Standby Mode Operation Mode
Base Machine 4.0 6.8
Full System 4.0 6.8
Table 17
Base Machine 6.6
Full system 7.1
Table 18
Paper Size
and
Paper Orientation
Paper Tray
Tray 1 STM (Add 1 Tray) MSI
Fixed Mode
Plain Paper Plain Paper
A4 LEF 20 20 10
8.5" x 11" LEF
16K LEF
B5 LEF
A4 SEF 15 15 10
8.5" x 11" SEF
16K SEF
B5 SEF
8.5"x13"SEF 8.5"x14"
SEF
12 12 10
Mexico Folio
(8.5" x13.4")
A3 SEF
11" x 17" SEF
10 10 10
8K SEF
B4 SEF
A5 SEF
5.5" ( 8.5" SEF)
Not supported 10
10
A5 LEF Not supported
5.5" x 8.5" LEF
June, 2008
6-50 WorkCentre 5016, 5020
Alignment
1. [Full System] IOT + IIT + ADF + DADF
2. [DC] IOT+IIT
Paper Supply
All paper trays (excluding MSI) are universal trays, which are front-loading trays.
1. Capacity
Tray 1: 250 sheets (Business 80gsm/sheet).
The height of a stack of paper shall be 27mm or less.
STM (optional): 500 sheets (Busines 70gsm/sheet).
450 sheets (Business 80gsm/sheet).
The height of a stack of paper shall be 54mm or less.
2. Standard paper
Standard paper is indicated by "Standard Paper" on "Paper List."
3. Weight
Tray 1: 60gsm to 90gsm
STM: 60gsm to 90gsm
4. Size
Standard paper sizes: A4L/S, A3, B5L/S, B4, 8K, 16KL/S, 8.5 x11L/S, 8.5 x 13, 8.5 x 13.4
(Mexico Folio), 8.5 x 14, 11 x 17
5. Usage rate
Tray 1: 60%
STM: 30%
Item
Specification
SYSTEM
1 Sided
Specification
SYSTEM
2 Sided Application
Lead Edge Registra-
tion (mm)
+/- 2.90 +/- 3.80
Side Edge Registra-
tion (mm)
+/- 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
Linearity (Skew) (mm) +/- 1.42 - 280 mm
Parallelism +/- 3.70 -4.00 400 mm
Item Specification Measurement
Length
SYSTEM
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%)
+/-1.56 (50%-99%)
+/-1.8 (101%-200%)
+/-1.72 (100%)
+/-1.89 (50%-99%)
+/-2.42 (101%-
200%)
400mm
Magnification: H (%) +/-1.4 (100%)
+/-1.56 (50%-99%)
+/-1.8 (101%-200%)
+/-1.72 (100%)
+/-1.89 (50%-99%)
+/-2.42 (101%-
200%)
280mm
June, 2008
6-51 WorkCentre 5016, 5020
Bypass Tray(MSI)
1. Capacity
50 sheets of paper (70 gsm)
2. 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
Weight of paper that can be supplied from MSI is 60g/m2 to 110g/m2.
4. Usage rate
10%
Paper List
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.
Table 21
Media Type Paper Code CIM Bypass
Baseline Paper
Flag Ship (80 gsm) O O
Xerox Business Multipurpose 4200
20 lb O O
Standard Paper
Xerox Xcite (80 gsm) O O
Xerox Xplore (70 gsm) O O
Xerox Premier (80 gsm) O O
Xerox Business (80 gsm) O O
Flag Ship (70/80 gsm) O O
Canary (70/80 gsm) O O
Transmate (70/80 gsm) O O
Jetset (70/80 gsm) O O
HOOPOE(70/80 gsm) [APP Co] O O
Colotec+ 90 gsm O O
Colotec+ 100 gsm O
Topgun (70/80 gsm) O O

Transparency
Plain 3R96002 O
Removable Bar Stripe 3R96023 0
Xerox 3R12050
(TBD)
O O
Label O O
Recycle Paper O O
Other
Business 80 gsm-4 Hole (Hole on TE) 3R91823 O
Primier A4 80 gsm-4 Hole (Hole on
TE)
3R91723 O
3- Hole (hole on TE) 3R2193 O
June, 2008
6-52 WorkCentre 5016, 5020
Tools
Most maintenance procedures can be done with the following standard tools:
* 499T 353 STUBBY DRIVER should be used when replacing the ROS ASSEMBLY.
Consumables
Machine CRU Strategy
Machine LCB is designed to interface with a CRUM and Billing Counter on all configurations.
The CRUM can be used to provide a "hard stop" capability for markets requiring this feature.
The primary uses of the CRUM are to ensure that the CRU being used is correct for the market
& service/warranty agreements, store the number of copies made on the CRU, and enforce the
end-of-life point. The primary uses of the Counter are to indentify the machine's market loca-
tion, electronically store the machine's serial number, and store the number of copies made on
the machine.
Consumable Replacement Intervals (TBD)
This specification is applied when the machine is operated under the following conditions:
Paper: A4 LEF
Paper Tray: Tray 1
Copy Mode (not Print Mode)
Table 1
No. TOOL NO. /TOOL NAME No. TOOL NO. /TOOL NAME
1 499T 1423 BOX DRIVER 5.5 8 499T 247 TEST PATTERN (A3)
2 499T 355 SCREWDRIVER (+) 9 499T 301 MINI DRIVER
3 499T 2004 ROUND NOSE PLIERS 10 499T 1901 SIDE CUTTING NIPPER
4 499T 2320 S/E TESTER SET
5 499T 2601 SILVER SCALE (ISO M/N) 12 499T 9507 TESTER LEAD WIRE
(Red)
6 499T 8104 FLASHLIGHT (UM-2) 13 499T 9508 TESTER LEAD WIRE
(Black)
7 499T 8902 BRUSH 14 499T 353 * STUBBY DRIVER
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 Car-
tridge
Hard Stop: 22K @ 5% A4 area cover-
age for XC
Job Size = 4 pages
End of life Warning/Hard Stop
- Warning at 16K
Hard Stop at 22K (XC)
June, 2008
6-53 WorkCentre 5016, 5020 Glossary of Terms
Glossary of Terms
Table 1
Term Description
A3 Paper size 297 millimeters (11.69 inches) x 420 millimeters (16.54 inches).
A4 Paper size 210 millimeters (8.27 inches) x 297 millimeters (11.69 inches).
AC Alternating Current is type of current available at power source for machine.
ACT Advanced Customer Training: teaches customers to perform some of service that is
normally performed by Xerox Service Representative.
A/D Analog to Digital refers to conversion of signal
ADF Automatic Document Feeder
ADJ Adjustment Procedure
Bit Binary digit, either 1 or 0, representing an electrical state.
CCD Charge Coupled Device (Photoelectric Converter)
CD 1: Circuit Diagram; 2: Compact Disc
CF Copier Fax
CP Copier Printer
CPF Copier Printer Fax
Chip Integrated Circuit (IC)
CRU Customer Replaceable Unit
CVT Constant Velocity Transport
DADF Duplexing Automatic Document Feeder
DC Direct Current is type of power for machine components. Machine converts AC
power from power source to DC power.
DC Digital Copier
DMM Digital Multimeter is generic name for meter that measures voltage, current, or elec-
trical resistance.
Duplex 2-sided printing or copying
EME 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 Fax Scanner
FS Fast Scan (direction) - Inboard - to - Outboard
ESS Electronic Sub-System
ENG English
2TM Two Tray Module
FAX Facsimile
FIC Final Integration Center
GND Ground
HFSI High Frequency Service Item
HVPS High Voltage Power Supply
Hz Hertz (Cycles per second)
IIT Image Input Terminal - the Scanner/CCD portion of the machine
IOT Image Output Terminal - the ROS/Xero/paper handling/ fusing portion of the
machine
IQ Image Quality
KC 1000 copies
LCD Liquid Crystal Display
LE Lead Edge of copy or print paper, with reference to definition of term TE
LED Light Emitting Diode
LEF Long Edge Feed
LTR Letter size paper (8.5 x 11 inches)
LUT Look Up Table - array of NVM locations that store process control data
LVPS Low Voltage Power Supply
MF Multi-Function
MN Multinational
MPT Multi Purpose Tray
NBCR New Book Scanner Control Relay
NIC Network Interface Card
NSC New Scanner Controller
NVM Non Volatile Memory
OEM Original equipment manufacturer
OGM On-going Maintenance
PC Personal Computer
PL Parts List
PO Part of (Assembly Name)
PS Post Script
PSW Portable Standard Workstation
PWB Printed Wiring Board
PWS Portable Workstation for Service
PJ Plug Jack (electrical connections)
RAM Random Access Memory
RAP Repair Analysis Procedure for diagnosis of machine status codes and abnormal con-
ditions
R/E Reduction/Enlargement refers to features selection or components that enable
reduction or enlargement
REP Repair Procedure for disassembly and reassembly of component on machine
RIS Raster Input Scanner
ROM Read Only Memory
ROS Raster Output Scanner - Device that transfers digitally processed image, using laser
light, to photoreceptor.
SAD Solid Area Density
Table 1
Term Description
June, 2008
6-54 WorkCentre 5016, 5020 Glossary of Terms
SCP Service Call Procedure
SEF Short Edge Feed
Self-
test
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
Table 1
Term Description
June, 2008
Wiring Data Reissue
7 Wiring Data
BSDs
Chain 1 Standby Power ................................................................................................. 7-3
Chain 2 Mode Selection................................................................................................. 7-5
Chain 3 Machine Run Control ........................................................................................ 7-6
Chain 4 Start Power ....................................................................................................... 7-8
Chain 5 ADF/DADF........................................................................................................ 7-9
Chain 6 Imaging............................................................................................................. 7-18
Chain 7 Paper Supplying ............................................................................................... 7-21
Chain 8 Paper Transportation........................................................................................ 7-23
Chain 9 Marking............................................................................................................. 7-28
Chain 10 Fusing and Copy Transportation .................................................................... 7-31
Wirenets
Wirenets .......................................................................................................................... 7-35
P/J Locations
7.1 P/J Locations............................................................................................................ 7-45
June, 2008
Reissue Wiring Data
June, 2008
Wiring Data Reissue
Chain 1 Standby Power
Figure 1 1.1 Main Power Generation
A B C D E F G H J
1
2
3
4
5
6
1.2
T21
LENSASSEMBLY
PL10.7
FS60
FS12
FS11
FS34 FS33
FS31 FS32
POWER
CORD
PL8.1
1.1MAINPOWERGENERATION
POWER
SWITCH
PL8.1
CHOKE
COIL
PL8.1
AIOCPWB
PL8.1
LVPS
PL8.1
DCPOWER
GENERATION
+3.3VDC
DCCOM
AIOCPWB
PL8.1
P/J407
A16,A17
,B16,B1
7
+5VDC
DCCOM
A14,A15
,B14,B1
5
A11,B11
A12,A13
,B12,B1
3
+24VDC
DCCOM
A7,A8,
B7,B8
A9,A10,
B9,B10
ALL
ALL
ALL
P/J407
B18
ON/
OFF
10.1
10.1
J5
2
1
ACH
ACN
ACH
ACN
J508
1
3
8
10
STMPWB
PL11.5
J540
1
2
5
7
+5VDC
DCCOM
24VRTN
+24V
J409
4,5
6,7
J409
1,2
9,10,1
1
20,21
J410
1,6,11,15,1
7,
19,21,23,2
5,27,29,31,
34
J414
B6
B5
B3,B4
B1,B2
A11,A12
ALL
IITPWB
J721
18,1
7
16,1
5
J721
21,2
0
13,12,11
2,1
J720
34,29,24,2
0,18,16,14
,12,10,8,6,
4,1
ADFPWB
PL13.3
J731
B7
B8
B10,B
9
B12,B11
A2,A1
ALL
GN/YL
+3.3VDC
DCCOM
DCCOM
+5VDC
+24VDC
DCCOM
+3.3VDC
+5VDC
DCCOM
+24VDC
DCCOM
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
BLK
WHT
BLK
BRN
WHT
BLU
ACH
1
2
GRY
VIO
VIO
ORN
GRY
VIO
VIO
ORN
DUPLEXPWB
PL8.2
J550
7
6
8
ALL
ALL
J416
3
4
2
DCCOM
DCCOM
+5VDC
BLU BLU
BLU BLU
BLU BLU
BLK
BLK
2
2
2
YEL
YEL
YEL
YEL
YEL
YEL
YEL
YEL
YEL
YEL
1
2
WireColor
BLK:100VM/C,BRN:200VM/C
WireColor
WHT:100VM/C,BLU:200VM/C
ALL
F1
June, 2008
Reissue Wiring Data
Figure 2 1.2 Interlock Switching
A B C D E F G H J
1
2
3
4
5
6
FS153 FS152
LVPS
PL8.1
FS151
LVPS
PL8.1
J506
4
LHCOVER
INTERLOCK
SWITCH
PL8.2
J506
3
J506
2
FS154
FRONTCOVER
INTERLOCK
SWITCH
PL8.2
LVPS
PL8.1
J506
1
10.1
+24VDC
(1.1)
AIOCPWB
PL8.1
P/J407
A2 E5-1
AIOCPWB
PL8.1
P/J407
A1 E5-2
B1
INTLK
+24VDC
INTLK
+24VDC
1.2INTERLOCKSWITCHING
LHCOVER
INTERLOCKSWITCH
COVEROPEN(L)+24VDC
1-1
FRONTCOVER
INTERLOCKSWITCH
COVEROPEN(L)+24VDC
1-12
ORN ORN ORN ORN
LHCOVERINTERLOCKSWITCH
FRONTCOVERINTERLOCKSWITCH
FailCode
E5-1
E5-2
LHCoverOpen
FrontCoverOpen
J416
1
DUPLEXPWB
PL8.2
J550
9
INTLK+24VDC
10.2
BLU
BLU
1 1
1 TheactualH/LlevelisdisplayedinverselyontheUIdisplay.
4.1
F2
June, 2008
Wiring Data Reissue
Chain 2 Mode Selection
Figure 1 2.1 Control Panel
A B C D E F G H J
1
2
3
4
5
6
1 2 3
4 5 6
7 8 9
C 0
1
2
AIOC PWB
PL8.1
2.1 CONTROL PANEL
J401
8
7
5
4
3
2
1
USER INTERFACE PWB
PL8.4
J710
1
2
4
5
6
7
8
J710
3
AIOC PWB
PL8.1
U7-0
J401
6
U7-1
+5VDC
(1.1)
DC COM
(1.1)
WAKE
UP
UI
RESET
UI
TXD
UI RXD
Fail
Code
U7-0
U7-1
UI Communication
Timeout
UI Communication
Error
6.1
DC COM
+5VDC
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU BLU
June, 2008
Reissue Wiring Data
Chain 3 Machine Run Control
Figure 1 3.1 PWB Communication (STM PWB)
A B C D E F G H J
1
2
3
4
5
6
LVPS
PL8.1
LVPS
PL8.1
AIOC PWB
PL8.1
3.1 PWB COMMUNICATION (STM PWB)
J508
9
7
STM PWB
PL11.5
J540
6
4
J540
3
AIOC PWB
PL8.1
H9-7
J508
6
STM IIC SCL
STM IIC SDA STM REQ
Fail Code
H9-7 MCU (AIOC PWB) - STM PWB Communication Error
P/ J407
B19
B20
P/ J407
B21
YEL
YEL
YEL
YEL YEL YEL
June, 2008
Wiring Data Reissue
Figure 2 3.2 Billing and Machine Control
A B C D E F G H J
1
2
3
4
5
6
3.2BILLINGANDMACHINECONTROL
AIOCPWB
PL8.1
J401
9
10
P630
1
2
J630
2
1
BILLING
COUNTER
PL8.1
DCCOM
(1.1)
U8-1
U6-2
U6-3
U6-4
U6-5
RAM
NVM
P/J411
1,2,3
,4,5
USB2.0
BLU
BLU
BLU
BLU
N9-0
N9-1
E9-1
E9-2
E8-1
E8-2
L9-0
N4-0
N4-1
N4-2
C0-1
C0-2
BILLID
U8-1
U6-2
U6-3
U6-4
U6-5
N9-0
N9-1
E9-1
E9-2
E8-1
E8-2
L9-0
N4-0
N4-1
N4-2
C0-1
C0-2
BillingCounterDefect
RAMRead/WriteCheckError
NVMDataDefect
NVMRead/WriteCannotbeExcuted
CPUPowertoaccessNVMisnotenough
ControllerLogicFail
IOTCommunicationError
AMSNGOutOfRange
PaperDirectionMismatch
NupNGOutOfRange
PaperDirectionMismatch
CopyCounterFull
NoResponsefromUSB-Host
HBPLorXPJLSyntaxError
CPMImageLost
APSNGUnselected
ADFNGoutofrange
FailCode
9.2
June, 2008
Reissue Wiring Data
Chain 4 Start Power
Figure 1 4.1 Main Drive
A B C D E F G H J
1
2
3
4
5
6
T81 T82
AIOCPWB
PL8.1
LVPS
PL8.1
J504
4
1
2
P/J407
B2
INTLK
+24VDC
(1.2)
DCCOM
(1.1)
IOTMOTOR
PL1.1
J201
4
1
2
J201
3 MOT
AIOCPWB
PL8.1
LVPS
PL8.1
J504
3
P/J407
B3
+5VDC
4.1MAINDRIVE
U0-1
U1-1
IOTMOTOR
ON(H)+5VDC
4-1
IOTMOTORLOCK(H)+5VDC
Fuser CRU
Regi
Dupulex
Tray
FailCode
U0-1
U1-1
IOTMotorStopError
IOTMotorRotationError
BLU BLU
RED RED
BLK BLK
YEL
YEL
INLETFRAME DRVESDGND
F155 T30
IOTESDGND DRVESDGND
GN/YL
GRN
F3
Duplex
June, 2008
Wiring Data Reissue
Chain 5 ADF/DADF
Figure 1 Document Size Sensing
A B C D E F G H J
1
2
3
4
5
6
DOCUMENT
TRAYLENGTH
SENSOR1
PL13.10
5.1DOCUMENTSIZESENSING
ADFPWB
PL13.3
DF4
1
3
DF4
2
DOCUMENT
TRAYLENGTH
SENSOR2
PL13.10
DF5
1
3
DF5
2
DOCUMENT
TRAYWIDTH
SENSOR1
PL13.10
DF3
1
3
DF3
2
DOCUMENT
TRAYWIDTH
SENSOR2
PL13.10
DF2
1
3
DF2
2
DOCUMENT
FEEDER
WIDTH
SENSOR
PL13.9
DF8
1
3
DF8
2
ADFPWB
PL13.3
CN5
3
4
DCCOM
(1.1)
+5VDC
(1.1)
CN5
5
8
+3.3VDC
CN4
7
+3.3VDC
CN4
5
6
DCCOM
(1.1)
+5VDC
(1.1)
WHT
WHT
1
2
DCCOM
(1.1)
+5VDC
(1.1)
WHT
WHT
WHT
WHT
WHT
WHT
3
4
BLU
BLK
RED
YEL
+3.3VDC
+3.3VDC
+3.3VDC
YEL
WHT
WHT
DOCUMENTTRAY
LENGTHSENSOR1
DOCUMENTSENSED(H)+3.3VDC
DOCUMENTFEEDER
WIDTHSENSOR
5-34
DOCUMENTTRAY
LENGTHSENSOR2
5-35
DOCUMENTTRAY
WIDTHSENSOR1
5-32
DOCUMENTTRAY
WIDTHSENSOR2
5-33
5-31
DOCUMENTTRAY
LENGTHSENSOR2
DOCUMENTTRAYLENGTHSENSOR1
DOCUMENTTRAYWIDTHSENSOR2
DOCUMENTFEEDERWIDTHSENSOR
AIOCPWB
PL8.1
A2-2 B8
J414
A10
B7
J731
A3
B5
B6
FailCode
A2-2 NotSupportedDocSize
ADFSEL0
ADFSEL1
ADFSEL2
YEL
YEL
YEL
YEL
YEL
YEL
1
1
1
1
1
1 AcombinationofHandLlevelsofthesefivesensorsdeterminesadocumentsize.
FortherelationbetweenH/Lofeachsensoranddocumentsize,
seethemarginaltableunder5.4DOCUMENTPATH.
June, 2008
7-10 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 2 Document Setting and Transport
A B C D E F G H J
1
2
3
4
5
6
DOCUMENT
SETSENSOR
PL13.9
5.2DOCUMENTSETTINGANDTRANSPORT
ADFPWB
PL13.3
DF9
1
3
DF9
2
DOCUMENT
FEEDSENSOR
PL13.9
DF10
1
3
DF10
2
ADFPWB
PL13.3
10
8
+3.3VDC
6
7
DCCOM
(1.1)
+5VDC
(1.1)
WHT
WHT
WHT
WHT
BLU
+3.3VDC
FailCode
A5-2
DOCUMENTSETSENSOR
5-30
DOCUMENTFEEDSENSOR
DOCUMENTSENSED(L)+3.3VDC
5-36
ADFCoverOpen
9
DCCOM
(1.1)
WHT
WHT
ADFTOP
COVER
SWITCH
PL13.9
CN5
2
DCCOM
(1.1)
DF14
2
DF14
1
CN5
1
+3.3VDC
ADFTOPCOVERSWITCH
COVEROPEN(L)+3.3VDC
5-29
WHT WHT WHT WHT
BLU
WHT
A1-1
A4-1
A4-2
DocMisfeedJam
ShortLengthDetect
LongLengthDetect
AIOCPWB
PL8.1
A9
J414
A8
A7
A1-1
A5-2
A4-1
A4-2
+3.3VDC
+3.3VDC
+3.3VDC
J731
A5
A6
A4
YEL
YEL
YEL
YEL
YEL
YEL
ADFTOPCOVERSWITCH
DOCUMENTFEEDSENSOR
DOCUMENTSETSENSOR
June, 2008
7-11 WorkCentre 5016, 5020
Wiring Data Reissue
Figure 3 Document Feed and Transport Mechanism
A B C D E F G H J
1
2
3
4
5
6
5.3DOCUMENTFEEDANDTRANSPORTMECHANISM
ADFPWB
PL13.3
CN3
2
1
DOCUMENT
FEEDCLUTCH
PL13.9
DCCOM
DF13
2
DF13
1
1 2
DOCUMENT
DRIVEMOTOR
PL13.5
+24VDC
MOT
CN2
2
3
5
6
1
4
DCCOM
DCCOM
DCCOM
DCCOM
+24VDC
(1.1)
ORN
YEL
BRN
BLK
WHT
BLK
DOCUMENT
FEEDCLUTCH
ON(L)+24VDC
DOCUMENTDRIVEMOTOR
ON+24VCLOCK
DOCUMENTDRIVEMOTOR
ON+24VCLOCK
DOCUMENTDRIVEMOTOR
ON+24VCLOCK
DOCUMENTDRIVEMOTOR
ON+24VCLOCK
5-42
5-40
5-41
HighSpeed
LowSpeed
DOCUMENT
DRIVEMOTOR
DOCUMENTLEADEDGESENSOR
DOCUMENTFEEDCLUTCH
DOCUMENTFEEDER
WIDTHSENSOR
DOCUMENTSETSENSOR
ReedInRoll
ReedOutRoll
RegiRoll
ExitRoller
FeedRoller
WHT
WHT
AIOCPWB
PL8.1
J731
A7
J414
A6
A1
B12
A2
A12
MOTM1
B1
MOTM2
A11
MOTM3
A3
B11
B10
A4
B9
A5
B2
A10
B3
A9
B4
A8
MOTCLOCK
MOTON
MOTCURR1
MOTCURR2
MOTRST
MOTCW/CCW
YEL
YEL
YEL
YEL
YEL
YEL
YEL
YEL
YEL
YEL
YEL
YEL
YEL
YEL
YEL
YEL
YEL
YEL
YEL
YEL
Feed In Roll
Feed Out Roll
June, 2008
7-12 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 4 Document Path
A B C D E F G H J
1
2
3
4
5
6
DocumentSize
DOCUMENT
FEEDERWIDTH
SENSOR
DOCUMENT
TRAYWIDTH
SENSOR1
DOCUMENT
TRAYWIDTH
SENSOR2
DOCUMENT
TRAYLENGTH
SENSOR1
DOCUMENT
TRAYLENGTH
SENSOR2
5.5"x8.5"SEF
A5SEF
B5SEF
A4SEF
A5LEF
5.5"x8.5"LEF
8.5"x11"SEF(Letter)
8.5"x13"SEF(Legal)
8.5"x14"SEF(Legal)
B5LEF
B4SEF
ExecutiveLEF
16KLEF
8KSEF
8.5"x11"LEF(Letter)
11"x17"SEF(Ledger)
A4LEF
A3SEF
L
L
L
L
L
L
L
L
L
H
H
H
H
H
H
H
H
H
L
H
H
H
H
L
L
L
L
H
H
L
L
L
H
H
L
L
L
L
L
H
H
H
H
H
H
H
H
H
H
H
L
L
L
L
L
L
H
H
L
L
H
H
H
L
H
L
L
H
L
H
L
H
L
L
L
L
L
L
L
H
H
L
H
L
L
H
L
H
L
H
5.4DOCUMENTPATH
DOCUMENTFEEDSENSOR
DOCUMENTFEEDERWIDTHSENSOR
DOCUMENTSETSENSOR
ReadInRoll
ReadOutRoll
RegiRoll
FeedRoll
ExitRoller
Thetableat the right showstherelationshipbetweenHigh/Low
ofeachdocumentsizesensoranddocumentsize.
Thestandardsizeofadocumentissensedatthetime the
DOCUMENTFEEDERWIDTHSENSORdetectsitafteritisfed.
June, 2008
7-13 WorkCentre 5016, 5020
Wiring Data Reissue
Figure 5 BSD 5.5 Document Size Sensing - DADF/Network Configuration
June, 2008
7-14 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 6 BSD 5.6 Document Setting & Transport - DADF/Network Configuration
June, 2008
7-15 WorkCentre 5016, 5020
Wiring Data Reissue
Figure 7 BSD 5.7 Document Feed & Transport Mechanism- DADF/Network Configuration
June, 2008
7-16 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 8 BSD 5.8 Document Inversion - DADF/Network Configuration
June, 2008
7-17 WorkCentre 5016, 5020
Wiring Data Reissue
Figure 9 BSD 5.9 Document Path - DADF/Network Configuration
June, 2008
7-18 WorkCentre 5016, 5020
Reissue Wiring Data
Chain 6 Imaging
Figure 1 6.1 Image Input
A B C D E F G H J
1
2
3
4
5
6
IIT PWB
AIOC PWB
PL8.1
6.1 IMAGE INPUT
J410
22
24
LENS ASSEMBLY
PL10.7
J720
13
11
J720
2,3,4,5
,7,8,9,
10,
12,13,
14,16,
18,20
AIOC PWB
PL8.1
CCD SHFT CLK0
CCD SHFT CLK1
VIDEO DATA
26
28
30
CCD
9
7
5
CCD RST CLK
CCD CLMP CLK
CCD TRNSF CLK
J410
33,32,
31,30,
28,27,
26,25,
23,22,
21,19,
17,15
USER INTERFACE
PWB
PL8.4
J711
1
PLATEN OPEN
SWITCH
PL10.5
MAGNET
DC COM
(2.1)
USER INTERFACE PWB
PL8.4
J711
2
+5VDC
PLATEN OPEN SWITCH
COVER CLOSED(L) +5VDC
5-10
PLATEN OPEN SWITCH
LENS ASSEMBLY
A5-1
A5-1
Fail Code
Platen Cover Open
BLK BLK
June, 2008
7-19 WorkCentre 5016, 5020
Wiring Data Reissue
Figure 2 6.2 Carriage Scan
A B C D E F G H J
1
2
3
4
5
6
CARRIAGE
SENSOR
PL10.6
INV CN2
6.2 CARRIAGE SCAN
AIOC PWB
PL8.1
U2-1 Carriage Module Fail
Fail Code
J409
12
13
14
15
16
17
18
19
IIT PWB
LENS
ASSEMBLY
PL10.7
J721
10
9
8
7
6
5
4
3
CLOCK A
CLOCK A
CLOCK /A
CLOCK /A
CLOCK /B
CLOCK /B
CLOCK B
CLOCK B
CN4
1
2
3
4
5
+24VDC
(1.1)
CARRIAGE
MOTOR
PL10.6
IIT5
1
2
3
4
5
MOT
CARRIAGE MOTOR
ON +24V CLOCK
CARRIAGE MOTOR
ON +24V CLOCK
CARRIAGE MOTOR
ON +24V CLOCK
CARRIAGE MOTOR
ON +24V CLOCK
5-20 High speed scan
5-21 High speed return
5-22 Low speed scan
5-23 Low speed return
J410
32
J720
3
DC COM
CN3
2
1
3
INVERTER PWB
PL10.7
INV CN1
2
1
3
+24VDC
(1.1)
DC COM
(1.1)
EXPOSURE
LAMP
PL10.6
x
6
5
IIT4
1
3
IIT4
2
DC COM
(1.1)
+5VDC
(1.1)
EXPOSURE
LAMP ON
IIT PWB
LENS
ASSEMBLY
PL10.7
CN3
4
J720
2
AIOC PWB
PL8.1
J410
33
+3.3VDC
U2-1
CARRIAGE SENSOR
BLOCKED(H) +5VDC
CARRIAGE MOTOR
EXPOSURE LAMP
CARRIAGE SENSOR
YEL
ORN
BRN
BLK
RED
GRY
GRY
GRY
GRY
GRY
GRY
5-11 1
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.
CAUTION
High Voltage
June, 2008
7-20 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 3 6.3 Laser Control and Scanning
A B C D E F G H J
1
2
3
4
5
6
F171 T24
ROS
PL3.1
6.3 LASER CONTROL AND SCANNING
AIOC PWB
PL8.1
J404
2
1
LD PWB SOS PWB LD PWB
J160
2
1
RED
BLU
J403
6
4
5
1
2
J140
1
5
4
8
7
DC COM
(1.1)
9.2
LASER DIODE
ENABLE ON(L) +5VDC
LD INTLK
+5VDC
LD INTLK
+5VDC
POWER CONTROL
ON(L) +5VDC
ROS VREF
OUT SIGNAL
LASER DIODE
PD
LD
COM
J201
3
1
LD INTLK
+5VDC
LD INTLK
+5VDC
DC COM
J2011
1
3
SOS
SENSOR
J2011
2
J201
2
J140
6
LD INTLK
+5VDC
AIOC PWB
PL8.1
J403
3
+5VDC
U3-5
SOS SENSED
SIGNAL
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
RED
BLU
9
10
7
8
J620
3
4
1
2
P620
2
1
4
3
ROS MOTOR
J130
3
1
5
4
+24VDC
(1.1)
DC COM
(1.1)
MOT
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
ROS MOTOR
LD PWB
SOS PWB
ROS MOTOR
ON(L) +5VDC
ROS MOTOR
CLOCK
6-15
6-16
6-17
Fail Code U3-5
Laser Power or ROS Motor
Fail
GRN
INLET FRAME ROS GND
F170 F156
GRN
IIT GND
ROS GND
June, 2008
7-21 WorkCentre 5016, 5020
Wiring Data Reissue
Chain 7 Paper Supplying
Figure 1 7.1 Tray 1 Paper Stacking
A B C D E F G H J
1
2
3
4
5
6
AIOC PWB
PL8.1
7.1 TRAY1 PAPER STACKING
LVPS
PL8.1
J501
3
4
TRAY1 NO PAPER
SENSOR
PL2.7
J157
3
P203
3
J203
1
2 2 2
J157
1
J203
3
P203
1
+5VDC
(1.1)
DC COM
(1.1)
LVPS
PL8.1
J501
5 C5-0
+5VDC
P/ J407
A19
TRAY1 NO PAPER SENSOR
PAPER SENSED(L) +5VDC
TRAY1
INTERLOCK
SWITCH
PL2.5
9
DC COM
(1.1)
J161
2
J161
1 10 B22
+5VDC
E6-1
TRAY1 INTERLOCK SWITCH
COVER OPEN(H) +5VDC
7-7
1-11
Fail Code
C5-0
E6-1
TRAY1 INTERLOCK SWITCH
TRAY1 NO PAPER SENSOR
L/H Lower Cover open
BLU
BLU
BLU
BLU
BLU BLU
BLU BLU BLU BLU
June, 2008
7-22 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 2 7.2 STM Paper Stacking
A B C D E F G H J
1
2
3
4
5
6
STM PWB
PL11.5
7.2 STM PAPER STACKING
STM PWB
PL11.5
J542
3
4
STM NO PAPER
SENSOR
PL11.7
J171
3
2
J171
1
+5VDC
(1.1)
DC COM
(1.1)
J542
5 C6-0
+5VDC
STM NO PAPER SENSOR
PAPER SENSED(L) +5VDC
STM INTERLOCK
SWITCH
PL11.5
9
DC COM
(1.1)
J173
2
J173
1 10
+5VDC
E6-2
STM INTERLOCK SWITCH
COVER OPEN(H) +5VDC
7-8
1-10
Fail Code
C6-0
E6-2
STM INTERLOCK SWITCH
STM NO PAPER SENSOR
STM L/H Cover open
BLU
BLU
BLU
BLU
BLU BLU
BLU BLU BLU BLU
June, 2008
7-23 WorkCentre 5016, 5020
Wiring Data Reissue
Chain 8 Paper Transportation
Figure 1 8.1 Tray 1 Paper Feeding
A B C D E F G H J
1
2
3
4
5
6
AIOCPWB
PL8.1
8.1TRAY1PAPERFEEDING
LVPS
PL8.1
J501
6
7
TRAY1FEED
SENSOR
PL2.5
J158
3
2
J158
1
+5VDC
(1.1)
DCCOM
(1.1)
LVPS
PL8.1
J501
8 C1-1
+5VDC
P/J407
A20
TRAY1FEEDSENSOR
PAPERSENSED(L)+5VDC
TRAY1FEED
CLUTCH
PL2.2
1
+24VDC
(1.1)
P202
2
TRAY1FEEDCLUTCH
ON(L)+24VDC
8-7
8-12
FailCode
C1-1 Tray1FeedSensoronJAM
TRAY1FEEDSENSOR
TRAY1FEEDCLUTCH
BLU BLU
BLU BLU
AIOCPWB
PL8.1
2
J202
1
1 2
DCCOM
P/J407
A18
IOTMotor
BLU BLU
BLU
BLU
BLU
BLU
C2-2
C2-2 Tray1FeedSensoronJAMfromSTMFeed
TakeAwayRoll1
Tray1FeedRoll
C8-1
C8-1 Tray1FeedSensorStaticJAM
TheactualH/LlevelisdisplayedinverselyontheUIdisplay.
1
1
June, 2008
7-24 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 2 8.2 STM Paper Feeding
A B C D E F G H J
1
2
3
4
5
6
STMPWB
PL11.5
8.2STMPAPERFEEDING
STMPWB
PL11.5
J542
6
7
STMFEED
SENSOR
PL11.5
J172
3
2
J172
1
+5VDC
(1.1)
DCCOM
(1.1)
J542
8 C2-1
+5VDC
STMFEEDSENSOR
PAPERSENSED(L)+5VDC
STMFEED
CLUTCH
PL11.6
1
+24VDC
(1.1)
P212
2
STMFEEDCLUTCH
ON(L)+24VDC
8-6
8-11
FailCode
C2-1 STMFeedSensoronJAM
STMFEEDSENSOR
STMFEEDCLUTCH
BLU BLU
BLU BLU
2
J212
1
1 2
DCCOM
STMFEEDMOTOR
BLU BLU
BLU
BLU
BLU
BLU
TakeAwayRoll2
Tray2FeedRoll
C8-2
C8-2 STMFeedSensorStaticJAM
J541
1
2
MOT
STMFEED
MOTOR
PL11.6
3
4
STMFEEDMOTOR
ON+24VCLOCK
STMFEEDMOTOR
ON+24VCLOCK
STMFEEDMOTOR
ON+24VCLOCK
STMFEEDMOTOR
ON+24VCLOCK
8-13
TheactualH/LlevelisdisplayedinverselyontheUIdisplay. 1
1
YEL
RED
ORN
BRN
June, 2008
7-25 WorkCentre 5016, 5020
Wiring Data Reissue
Figure 3 8.3 Manual Bypass
A B C D E F G H J
1
2
3
4
5
6
8.3 MANUAL BYPASS
LVPS
PL8.1
BYPASS
SOLENOID
PL7.5
1
+24VDC
(1.1)
BYPASS SOLENOID
ON(L) +24VDC
8-17
AIOC PWB
PL8.1
J502
3
DC COM
P/ J407
A5
BYPASS SOLENOID
Bypass Feed Roll
Bypass Take Away Roll
RED
RED
June, 2008
7-26 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 4 8.4 Paper Registration
A B C D E F G H J
1
2
3
4
5
6
AIOCPWB
PL8.1
8.4PAPERREGISTRATION
LVPS
PL8.1
J503
1
2
IOTREGI.
SENSOR
PL2.9
J156
3
2
J156
1
+5VDC
(1.1)
DCCOM
(1.1)
LVPS
PL8.1
J503
3
C2-3
+5VDC
P/J407
A4
IOTREGI.SENSOR
PAPERSENSED(L)+5VDC
IOTREGI.
CLUTCH
PL2.9
5
+24VDC
(1.1)
P640
1
IOTREGI.CLUTCH
ON(L)+24VDC
8-5
8-10
BLU BLU
BLU BLU
AIOCPWB
PL8.1
4
J640
2
2 1
DCCOM
P/J407
A6
BLU BLU
BLU
BLU
BLU
BLU
IOTREGI.SENSOR
IOTREGI.CLUTCH
C6-2
C9-3
E1-6
FailCode
STMIOTRegi.SensoronJAM
C2-3
C6-2
C9-3
E1-6
DuplexIOTRegi.SensoronJAM
ManualBypassIOTRegi.SensoronJAM
IOTRegi.SensorStaticJAM
IOTMotor
Regi.Roll
C1-2
Tray1Regi.SensoronJAM
C1-2
1
June, 2008
7-27 WorkCentre 5016, 5020
Wiring Data Reissue
Figure 5 8.5 Paper Path
A B C D E F G H J
1
2
3
4
5
6
8.5PAPERPATH
TRAY1FEEDSENSOR
IOTMOTOR
TakeAwayRoll1
Tray1FeedRoll
STMFEEDSENSOR STMFEEDMOTOR
TakeAwayRoll2
Tray2FeedRoll
TRAY1NOPAPERSENSOR
STMNOPAPERSENSOR
IOTREGI.SENSOR
Regi.Roll
Fuser
Drum
BypassFeedRoll
BypassTakeAwayRoll
DuplexRoll1
DuplexRoll2
FUSEREXITSENSOR
EXITMOTOR
ExitRoll
Exit Roll
June, 2008
7-28 WorkCentre 5016, 5020
Reissue Wiring Data
Chain 9 Marking
Figure 1 9.1 Xerographics
A B C D E F G H J
1
2
3
4
5
6
AIOC PWB
PL8.1
9.1 XEROGRAPHICS
J406
2
4
HVPS PWB
PL8.2
J520
2
4
J520
1
AIOC PWB
PL8.1
U9-0
J406
1
CHARGE ON(L) +5VDC
DEVE BIAS AC/DC ON(L) +5VDC
HVPS ERROR(L) +5VDC
Fail Code
U9-0 HVPS fail
DC COM
DC COM
5
3
DC COM
DC COM
9
7
8
5
3
9
7
8
TRANSFER ON(L) +5VDC
TRANSFER S/D ON
DRUM CARTRIDGE
PL4.1
CHARGE
GRID
DEVE
BIAS
TRANSFER COROTRON
HOUSING
PL4.3
GND
DETACK
TRANSFER
GND
+5VDC
INTLK
+24VDC
DC COM
(1.1)
RED RED
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
9-4
9-5
9.3
INTLK
+24VDC
Drum
Charge Corotron
Grid
Transfer Corotron
Detack Saw
Magnet Roll
Paper
Deve Bias
June, 2008
7-29 WorkCentre 5016, 5020
Wiring Data Reissue
Figure 2 9.2 Toner Sense and CRUM
A B C D E F G H J
1
2
3
4
5
6
9.2TONERSENSEANDCRUM
AIOCPWB
PL8.1
LVPS
PL8.1
J509
1
3
+24VDC
(1.1)
DCCOM
(1.1)
TONEREMPTY
SENSOR
PL4.2
LVPS
PL8.1
J110
1
3
P110
4
2
P110
3
1
J110
2
4 J1-2
J509
2
4
P/J407
B4
+5VDC
TONEREMPTYSENSOR
TONERSENSED(L)+5VDC
9-7
AIOCPWB
PL8.1
J402
1
2
+12VDC
3.2
DCCOM
INTLK
+24VDC
(1.2)
DRUMCARTRIDGE
PL4.1
P610
7
J610
1
3 5
4
5
5 3
6 2
7 1
P610
4
J610
4
CRUM
DCCOM
(1.1)
2
1
CRUID
INTLK+5VDC
+5VDC
6
J402
3
INTLK+5VDC
DRUMCARTRIDGE
SENSED(L)+5VDC
+5VDC
6.3
J3-1
J7-1
J7-2
J7-3
9-2
J1-2
J3-1
J7-1
J7-2
J7-3
FailCode
TonerEmpty
NoDrumcartridge
DrumCRUMcommunicationerror
DrumCRUMMarketidentitymismatch
DrumCRUMIDerror
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU GRN
WHT RED
BLK
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
BLU
INTLK
+5VDC
TONEREMPTYSENSOR
CRUM
DRUMCARTRIDGE
1
J6-1
J6-1
Drumcartridgelifeend
June, 2008
7-30 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 3 9.3 Erase Lamp
A B C D E F G H J
1
2
3
4
5
6
9.3 ERASE LAMP
AIOC PWB
PL8.1
HVPS PWB
PL8.2
J406
6
J520
6
J521
1
3
2
DC COM DC COM
DC COM
+24VDC
INTLK
+24VDC
(9.1)
ERASE LAMP
PL4.2
ERASE LAMP ON(L) +5VDC
ERASE LAMP
9-6
BLU BLU BLU
BLU
BLU
J210
1
3
2
June, 2008
7-31 WorkCentre 5016, 5020
Wiring Data Reissue
Chain 10 Fusing and Copy Transportation
Figure 1 10.1 Fuser Temperature Control
A B C D E F G H J
1
2
3
4
5
6
F26
F25
J601
1
P601
2
F27
F28
AIOC PWB
PL8.1
10.1 FUSER TEMPERATURE CONTROL
LVPS
PL8.1
Fail Code
Fuser On Time Fail
Over Heat Temp Fail
+5VDC
P/ J407
B6
B5
J3
3
DC COM
ACH
SWITCHED
(1.1)
DC COM
+24VDC
INTLK
(1.2)
1
ACN
(1.1)
J600
2
1
FUSER LAMP ON ACH
FUSER
PL5.1
THERMOSTAT
FUSER LAMP
THERMISTOR
J408
2
P601
1
J601
2
AIOC PWB
PL8.1
DC COM
(1.1)
J408
1
+5VDC
U4-1
U4-2
U4-3
FUSER THERMISTOR
SENSED SIGNAL
10-20
U4-1
U4-2
U4-3 FS1 thermistor defect
THERMOSTAT
THERMISTOR
FUSER LAMP
BLU BLU
BLK BLK
WHT WHT
BLK
BLU BLU
June, 2008
7-32 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 2 10.2 Exit
A B C D E F G H J
1
2
3
4
5
6
LVPS
PL8.1
AIOCPWB
PL8.1
10.2EXITANDDUPLEX
LVPS
PL8.1
J505
1
2
FUSEREXIT
SENSOR
PL6.3
J153
3
2
J153
1
+5VDC
DCCOM
(1.1)
J505
3
E1-2
+5VDC
FUSEREXITSENSOR
PAPERSENSED(L)+5VDC
E3-1
10-23
FailCode
BLU
BLU
BLU
BLU
BLU BLU
DUPLEXPWB
PL8.2
P/J407
A3
E3-6
J551
6
5
4
EXITMOTOR
PL6.3
3
2
1
J550
1
2
3
4
5
AIOCPWB
PL8.1
J416
9
8
7
6
5
MOT
EXITMOTOR
ONCLOCK
EXITMOTOR
ONCLOCK
EXITMOTOR
ONCLOCK
EXITMOTOR
ONCLOCK
EXITMOTOR
ON+24VCLOCK
BLU BLU
BLU BLU
BLU BLU
BLU BLU
EXITMOTOR
ON+24VCLOCK
EXITMOTOR
ON+24VCLOCK
EXITMOTOR
ON+24VCLOCK
INTLK
+24VDC
(1.2)
E1-2
E3-1
E3-6
FuserExitSensoronJAM
FuserExitSensoroffJAM
FuserExitSensorStaticJAM
SimplexTransport:
ExitRollisdrivenbyIOTMotor.
IOTMotor
EXITMOTOR
FUSEREXITSENSOR
IOTMotor
FUSEREXITSENSOR
ExitRoll
ExitRoll
Duplex(Side2)Transport:
ExitRollisdrivenbyEXITMotor.
10-8
10-9
BLU BLU
EXITMOTOR
CURR
YEL
BLK
ORN
BRN
RED
RED
1
TheactualH/Llevelisdisplayed
inverselyontheUIdisplay.
1
F1
June, 2008
7-33 WorkCentre 5016, 5020
Wiring Data Reissue
Figure 3 10.3 Machine Cooling
A B C D E F G H J
1
2
3
4
5
6
+24VDC
10.3 MACHINE COOLING
4-2
10-60
AIOC PWB
PL8.1
J405
3
2
DC COM
(1.1)
NOHAD FAN
PL9.2
AIOC PWB
PL8.1
J405
1
+5VDC
U4-9
MOT
NOHAD FAN ON(H) +24VDC
NOHAD FAN FAIL(H) +5VDC
Fail Code
U4-9 Nohad Fan defect
BLU
RED
BLK
1
NOHAD FAN
1
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
June, 2008
7-34 WorkCentre 5016, 5020
Reissue Wiring Data
June, 2008
7-35 WorkCentre 5016, 5020
Wiring Data Reissue
Wirenets
FS32 FS31
F25 F28
THERMOSTAT
J600
LOW
VOLTAGE
POWER
SUPPLY
F26
FS11
POWER CORD
BLK
WHT
POWER SWITCH
7.2.1 WIRE NET AC POWER (HOT)
BLK
BRN
GN/YL
FS60
LOW
VOLTAGE
POWER
SUPPLY
J5
1
CHOKE COIL
J5
2
J3
3 FUSER LAMP
BLK
P600
2
BLK
1.1
10.1
(SEE WIRE NET
AC POWER (NEUT))
1
1 Wire Color
BLK: 100V M/C, BRN: 200V M/C
BLK BLK
FUSER
J600 F27
7.2.2 WIRE NET AC POWER (NEUT)
FS34 FS33 FS12
POWER CORD
WHT
POWER SWITCH
GN/YL
FS60
LOW VOLTAGE
POWER SUPPLY
J3
1 FUSER LAMP
WHT
P600
1
WHT
10.1
(SEE WIRE NET
AC POWER (HOT)) BLK
DC POWER
GENERATION
1
Wire Color
WHT: 100V M/C, BLU: 200V M/C
1
FUSER
BLU
June, 2008
7-36 WorkCentre 5016, 5020
Reissue Wiring Data
LENS
ASSEMBLY
ADFPWB
7.2.3WIRENET+3.3VDC
LOWVOLTAGE
POWERSUPPLY
+3.3VDC
AIOCPWB
A16
A17
B16
B17
J409
4
5
J414
B6
IITPWB
J721
18
17
J731
B7
P/J407
FLAT
CABLE
YEL
June, 2008
7-37 WorkCentre 5016, 5020
Wiring Data Reissue
USER INTERFACE
PWB
7.2.4 WIRE NET +5VDC-1
LOW VOLTAGE
POWER SUPPLY
+5VDC
TRAY1 NO PAPER
SENSOR
J501
3
6
J503
1
J505
1
BLU
BLU
BLU
BLU
FUSER EXIT SENSOR
J153
3
IOT REGISTRATION
SENSOR
TRAY1 FEED SENSOR
P203
3
J203
1
J157
3
BLU
J508
1
GRY
STM PWB
J540
1
J542
3
6
STM NO PAPER
SENSOR
STM FEED SENSOR
J171
3
J172
3
BLU
BLU
J156
3
J158
3
AIOC PWB
A11
B11
J401
1
2
BLU
BLU
J710
8
7
P/J407
(SEE WIRE NET +5VDC-2)
7.2
8.2
8.1
8.4
10.2
7.1
2.1
June, 2008
7-38 WorkCentre 5016, 5020
Reissue Wiring Data
LENS
ASSEMBLY
IITPWB
DUPLEXPWB
AIOCPWB
J409
6
J721
16
7 15
J416
3
BLU
J550
7
J414
B5
7.2.5WIRENET+5VDC-2
(FROMWIRENET+5VDC-1)
DOCUMENT
FEEDERWIDTH
SENSOR
ADFPWB
6
J731
B8
WHT
CN4
1
DOCUMENTTRAY
WIDTHSENSOR1
DF3
1
DOCUMENTTRAY
WIDTHSENSOR2
DF2
1
WHT
DF8
1
CN5
3
DOCUMENTSET
SENSOR
DOCUMENTLEAD
EDGESENSOR
DF9
1
DF10
1
WHT
WHT
WHT
5.1
5.1
5.1
5.2
5.2
DOCUMENTTRAY
LENGTHSENSOR1
DF5
1
DOCUMENTTRAY
LENGTHSENSOR2
5.1
5.1
5
WHT
WHT
DF4
1
FLAT
CABLE
CN3
6
CARRIAGE
SENSOR
IIT4
1
6.2
GRY
YEL
June, 2008
7-39 WorkCentre 5016, 5020
Wiring Data Reissue
7.2.6 WIRE NET DC COM (+5V RTN)-1
LOW VOLTAGE
POWER SUPPLY
TRAY1 NO PAPER
SENSOR
J501
4
7
9
J505
2
BLU
BLU
BLU
BLU
FUSER EXIT SENSOR
J153
2
TRAY1 INTERLOCK
SWITCH
TRAY1 FEED SENSOR
P203
2
J203
2
J157
2
BLU
J508
3
STM PWB
J540
2
J542
4
7
STM NO PAPER
SENSOR
STM FEED SENSOR
J171
2
J172
2
BLU
BLU
J161
2
J158
2
J503
2
BLU
IOT REGISTRATION
SENSOR
J156
2
VIO
9
BLU
STM INTERLOCK
SWITCH
J173
2
J509
3
TONER EMPTY
SENSOR
P110
2
J110
3
BLU BLK
(SEE WIRE NET
DC COM (+5VRTN)-2)
7.1
8.1
7.1
8.4
10.2
7.2
8.2
7.2
9.2
+5VRTN
June, 2008
7-40 WorkCentre 5016, 5020
Reissue Wiring Data
LENS
ASSEMBLY
DUPLEXPWB
IITPWB
AIOCPWB
J416
4
BLU
J409
1
LOWVOLTAGE
POWERSUPPLY
A12
A13
B12
7.2.7WIRENETDCCOM(+5VRTN)-2
B13
P/J407
J550
6
J721
21
2 20
J410
1
6
11
15
17
19
21
23
25
27
J720
34
29
31
34
29
24
20
18
16
14
12
10
8
6
4
1
(FROMWIRENET
DCCOM(+5VRTN)-1)
(SEEWIRENET
DCCOM(+5VRTN)-3)
FLAT
CABLE
CARRIAGE
SENSOR
IIT4
3
CN3
5
GRY
FLAT
CABLE
6.2
J402
4
BLU
BLU
P610
3 CRUM
J610
5 1
9.2
5 2 6
DRUMCARTRIDGE
+3.3VRTN A14
A15
B14
B14
June, 2008
7-41 WorkCentre 5016, 5020
Wiring Data Reissue
USERINTERFACE
PWB
AIOCPWB
7.2.8WIRENETDCCOM(+5VRTN)-3
J401
3
4
10
J403
2
BLU
BLU
BLU
BLU
J710
6
5
J630
1
P630
2 BILLINGCOUNTER
LDPWB
J711
2
PLATENOPEN
SWITCH
(FROMWIRENET
DCCOM(+5VRTN)-2)
6.1
3.2
6.3
P601
2
J601
1 THERMISTOR
J408
2
BLU
10.1
BLK
FUSER
ADFPWB
6
J414
B3
J731
B10
DOCUMENTTRAY
LENGTHSENSOR1
WHT
WHT
DOCUMENTTRAY
LENGTHSENSOR2
DF4
3
DF5
3
5.1
5.1
YEL
B4 B9
WHT
CN4
2
DOCUMENTTRAY
WIDTHSENSOR1
DF3
3
DOCUMENTTRAY
WIDTHSENSOR2
DF2
3
WHT
DOCUMENT
FEEDERWIDTH
SENSOR
DF8
3 4
7
DOCUMENTSET
SENSOR
DOCUMENTLEAD
EDGESENSOR
DF9
3
DF10
3
WHT
WHT
9
CN5
2
ADFTOPCOVER
SWITCH
DF14
1
WHT
WHT
5.1
5.1
5.1
5.2
5.2
5.2
YEL
ROS
J140
7
June, 2008
7-42 WorkCentre 5016, 5020
Reissue Wiring Data
STMPWB
7.2.9WIRENET+24VDC-1
LOWVOLTAGE
POWERSUPPLY
+24VDC
J501
1
J502
1
J503
5
J508
10
BLU
BLU
P202
1
J202
2
TRAY1FEED
CLUTCH
BYPASS
SOLENOID
P640
2
J640
1
IOT
REGISTRATION
CLUTCH
ORN
J540
7
J542
1
STMFEED
CLUTCH
BLU
P212
1
J212
2
F1
AIOCPWB
FRONT
COVER
INTERLOCK
SWITCH
LOWVOLTAGE
POWER
SUPPLY
J506
4
ORN
LHCOVER
INTERLOCK
SWITCH
FS151
3
FS152
1
ORN
J506
3
J506
2
ORN
FS153
3
FS154
1
ORN
J506
1
A1
B1
J508
4
J504
1
BLU
IOTMOTOR
N.C
J201
1
P/J407
F3
F2
(SEEWIRENET+24VDC-2)
4.1
8.1
8.3
8.4
8.2
J406
9
P520
9
J521
2
BLU BLU
ERASELAMP
J210
2
9.3
RED
J416
1
DUPLEXPWB
J550
9
BLU
J551
1
2
EXITMOTOR
10.2
ORN
RED
RED
HIGH VOLTAGE
POWER
SUPPLY
June, 2008
7-43 WorkCentre 5016, 5020
Wiring Data Reissue
LENS
ASSEMBLY
ROS
INVERTER
PWB
AIOCPWB
7.2.10WIRENET+24VDC-2
LOWVOLTAGE
POWERSUPPLY
A7
A8
B8
B7
J403
7
J409
9
10
IITPWB
J721
13
12
P620
4
J620
1 ROSMOTOR
J130
5
BLU
J414
B1
B2
ADFPWB
J731
B12
B11
CN3
1
WHT
CN2
1
4
WHT
BLK
DOCUMENTDRIVE
MOTOR
DF13
2
DF13
1
DOCUMENTFEED
CLUTCH
P/J407
(FROMWIRENET+24VDC-1)
5.3
5.3
6.3
FLAT
CABLE
CARRIAGE
MOTOR
6.2 IIT5
5
11 11
RED
CN4
5
CN3
1
GRY
INVCN1
1
6.2
YEL
YEL
J509
1
P110
4
BLU
J110
1
RED
TONEREMPTY
SENSOR
9.2
June, 2008
7-44 WorkCentre 5016, 5020
Reissue Wiring Data
LENS
ASSEMBLY
ROS
IOTMOTOR
7.2.11WIRENETDCCOM(+24VRTN)
AIOCPWB
LOWVOLTAGE
POWERSUPPLY
+24VRTN
J504
2
J508
8
A7
B8
A8
B1
B7
J201
2
J540
5
J403
8
J405
2
J406
7
8
21
J416
2
BLU
VIO
P/J407
J409
20
J414
A11
A12
BLU
BLU
BLU
BLU
P620
3
J620
2
NOHADFAN
ADFPWB J731
A2
A1
J550
8
IITPWB
J721
2
1
HIGHVOLTAGE
POWERSUPPLY
8
ROSMOTOR
J130
4
10.3
6.3
4.1
FLAT
CABLE
CN3
3
INVERTERPWB INVCN1
3
GRY
9.1
BLK
YEL
YEL
6.2
J520
7
STM PWB
DUPLEX PWB
June, 2008
7-45 WorkCentre 5016, 5020
Wiring Data 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.
June, 2008
7-46 WorkCentre 5016, 5020
Reissue Wiring Data
7.1.2 P/J List
Table 1
P/J No.
Figure
No. Item No. Description
CN1 Figure 12 1 DADF Control PWB
CN2 Figure 11 6 ADF PWB
DF2 Figure 10 3 Document Tray Width Sensor 2
DF3 Figure 10 2 Document Tray Width Sensor 1
DF4 Figure 10 4 Document Tray Length Sensor 1
DF5 Figure 10 5 Document Tray Length Sensor 2
DF8 Figure 10 6 Document Feeder Width Sensor
DF9 Figure 10 7 Document Tray Set Sensor
DF10 Figure 10 8 Document Lead Edge Sensor
DF13 Figure 10 1 ADF Top Cover Switch
DF14 Figure 11 3 ADF Top Cover Switch
DF14 Figure 12 14 Feeder Cover Switch
F25 Figure 5 1 Fuser Thermostat
F26 Figure 5 4 Fuser Lamp
F27 Figure 5 3 Fuser Lamp
F28 Figure 5 2 Fuser Thermostat
FS11 Figure 9 4 Inlet
FS12 Figure 9 6 Inlet
FS151 Figure 4 8 LH Cover Interlock Switch
FS152 Figure 4 7 LH Cover Interlock Switch
FS153 Figure 3 4 Front Cover Interlock Switch
FS154 Figure 3 5 Front Cover Interlock Switch
FS31 Figure 9 7 Power Switch
FS60 Figure 9 5 Inlet GND
IIT4 Figure 1 5 Carriage Sensor
IIT5 Figure 1 6 Carriage Motor
INV CN1 Figure 1 2 Inverter PWB
INV CN2 Figure 1 1 Inverter PWB
J333 Figure 13 23 SLCC PWB
J411 Figure 7 1 AIOC PWB
J508 Figure 6 8 STM
J610 Figure 8 2 CRU
NBCR CN6 Figure 1 7 NBCR PWB
NSC CN1 Figure 1 8 NSC PWB
P412 Figure 7 14 AIOC PWB
P508 Figure 9 15 LVPS
P610 Figure 8 9 CRU
P/J3 Figure 9 18 Fuser Lamp
P/J5 Figure 9 17 Choke Coil
P/J5 Figure 13 3 SLCC PWB
P/J110 Figure 3 6 Toner Empty Sensor
P/J130 Figure 2 2 ROS MPA
P/J140 Figure 2 5 ROS
P/J153 Figure 4 1 Fuser Exit Sensor
P/J156 Figure 4 4 IOT Regi. Sensor
P/J157 Figure 3 7 Tray 1 No Paper Sensor
P/J158 Figure 4 6 Tray 1 Feed Sensor
P/J160 Figure 2 6 ROS, Video
P/J161 Figure 4 5 Tray 1 Interlock Sensor
P/J171 Figure 6 2 STM No Paper Sensor
P/J172 Figure 6 1 STM Feed Sensor
P/J173 Figure 6 3 STM Interlock Switch
P/J201 Figure 8 6 IOT Motor
P/J201 Figure 2 4 ROS, SOS PWB
P/J2011 Figure 2 1 ROS, SOS PWB
P/J202 Figure 8 7 Tray 1 Feed Clutch
P/J203 Figure 8 8 Tray 1 No Paper Sensor
P/J210 Figure 3 1 Erase Lamp
P/J212 Figure 6 4 STM Feed Clutch
Table 1
P/J No.
Figure
June, 2008
7-47 WorkCentre 5016, 5020
Wiring Data Reissue
P391 Figure 13 24 SLCC PWB
P/J401 Figure 7 6 UI
P/J402 Figure 7 11 CRU ID
P/J403 Figure 7 12 ROS
P/J404 Figure 7 5 ROS, Video
P/J405 Figure 7 9 Nohad Fan
P/J406 Figure 7 8 HVPS
P/J407 Figure 9 16 LVPS-AIOC PWB
P/J407 Figure 13 18 LVPS-SLCC PWB
P/J408 Figure 7 13 AIOC PWB
P/J414A/B Figure 7 7 AIOC PWB
P/J414A/B Figure 13 8 SLCC PWB
P/J501 Figure 9 13 LVPS
P/J540 Figure 6 7 STM
P/J541 Figure 6 5 STM Feed Motor
P/J542 Figure 6 6 STM (TOTAL CL, SNR, SW)
Table 1
P/J No.
Figure
P/J550 Figure 8 3 Duplex PWB
P/J551 Figure 8 4 Duplex PWB
P/J600 Figure 4 2 Fuser Lamp
P/J601 Figure 4 3 Fuser Thermistor
P/J620 Figure 2 3 ROS MPA
P/J630 Figure 8 1 Billing ID
P/J640 Figure 8 5 IOT Regi Clutch
P/J710 Figure 1 9 UI
P/J711 Figure 1 10 Platen Switch
P/J720 Figure 1 4 IIT Data
P/J721 Figure 1 3 IIT Power
P/J731A/B Figure 11 1 ADF
P/J801 Figure 12 11 Document Feed Clutch
P/J802 Figure 12 12 Exit/Invert Sensor
P/J803 Figure 12 13 Registration Sensor
P/J804 Figure 12 10 Registration Clutch
P/J805 Figure 12 9 Exit/Invert Clutch
P/J806 Figure 12 8 Exit/Invert Solenoid
Table 1
P/J No.
Figure
June, 2008
7-48 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 1 IIT
June, 2008
7-49 WorkCentre 5016, 5020
Wiring Data Reissue
Figure 2 ROS
June, 2008
7-50 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 3 HVPS
June, 2008
7-51 WorkCentre 5016, 5020
Wiring Data Reissue
Figure 4 LH
June, 2008
7-52 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 5 Fuser
June, 2008
7-53 WorkCentre 5016, 5020
Wiring Data Reissue
Figure 6 STM
June, 2008
7-54 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 7 AIOC PWB
June, 2008
7-55 WorkCentre 5016, 5020
Wiring Data Reissue
Figure 8 Rear
June, 2008
7-56 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 9 Inlet & LVPS
P/
J505
P/
J503
June, 2008
7-57 WorkCentre 5016, 5020
Wiring Data Reissue
Figure 10 ADF/DADF
June, 2008
7-58 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 11 ADF 2
June, 2008
7-59 WorkCentre 5016, 5020
Wiring Data Reissue
Figure 12 DADF Control PWB
June, 2008
7-60 WorkCentre 5016, 5020
Reissue Wiring Data
Figure 13 SLCC PWB

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