Service Manual WorkCentre 5016 5020 Multifunction Printer WC5016 WC5020 Black-and-white Multifunction Printer
Work Center 5016, 5020 Service Documentation 701P48365 June 2008 CAUTION Certain components in the Work Center 5016/ 5020 are susceptible to damage from electrostatic discharge. Observe all ESD procedures to avoid component damage.
How To Use This Manual... iii Introduction i Introduction
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 1 Service Call Procedures 1-1 Service Call Procedures
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 2-1 Status Indicator RAPS
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 3-1 Image Quality
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 4-1 Repairs and Adjustments
ADJ 11.1.1 Carriage Assembly Alignment (Parallelism)... 4-133 ADJ 13.1.1 ADF/DADF Positional Adjustment... 4-134 Repairs and Adjustments 4-2
5 Parts List Overview Introduction... 5-3 Subsystem Information... 5-4 Symbology... 5-5 Parts Lists Drive PL 1.1 IOT Motor... 5-7 Paper Transport PL 2.1 Tray 1... 5-8 PL 2.2 Tray 1 Frame Accessory... 5-9 PL 2.3 Tray 1 Components (1 OF 2)... 5-10 PL 2.4 Tray 1 Components ( 2 OF 2)... 5-11 PL 2.5 Tray 1 Frame Components... 5-12 PL 2.6 Tray 1 Frame Components (2 OF 2)... 5-13 PL 2.7 No Paper Sensor Housing... 5-14 PL 2.8 Registration... 5-15 PL 2.9 Registration Component... 5-16 ROS PL 3.1 ROS... 5-17 CRU PL 4.1 Drum Cartridge... 5-18 PL 4.2 Toner Empty Sensor and Erase Lamp... 5-19 PL 4.3 Transfer... 5-20 PL 4.4 Transfer Corotron Housing Component... 5-21 Fuser PL 5.1 Fuser... 5-22 Exit Transport PL 6.1 Exit Transport... 5-23 PL 6.2 Exit Transport Component (Simplex)... 5-24 PL 6.3 Exit Transport Component (Duplex)... 5-25 Simplex / Duplex Module and Bypass Tray PL 7.1 Simplex Module... 5-26 PL 7.2 Left Hand Cover Assembly... 5-27 PL 7.3 Duplex Module Component (1 OF 2)... 5-28 PL 7.4 Duplex Module Component (2 OF 2)... 5-29 PL 7.5 Bypass Tray Accessory... 5-30 PL 7.6 Bypass Tray Component... 5-31 Electrical PL 8.1 AIOC PWB, LVPS, Power Switch... 5-32 PL 8.2 HVPS, Interlock Switch, Duplex PWB... 5-33 PL 8.3 Control Panel Accessory... 5-34 PL 8.4 Control Panel Component... 5-35 Cover PL 9.1 Front / Top Cover... 5-36 PL 9.2 Rear / Right Cover and NOHAD Fan... 5-37 IIT PL 10.1 IIT Accessory... 5-38 PL 10.2 IIT Component (1 OF 2)... 5-39 PL 10.3 IIT Component (2 OF 2)... 5-40 PL 10.4 IIT Upper Cover Cover Component... 5-41 PL 10.5 IIT Under Cover Component... 5-42 PL 10.6 IIT Carriage Component... 5-43 PL 10.7 Center Plate Component... 5-44 Single Tray Module PL 11.1 Single Tray Module... 5-45 PL 11.2 Tray 2 Component (1 OF 3)... 5-46 PL 11.3 Tray 2 Component (2 OF 3)... 5-47 PL 11.4 Tray 2 Component (3 OF 3)... 5-48 PL 11.5 Single Tray Frame Component (1 OF 2)... 5-49 PL 11.6 Single Tray Frame Component (2 OF 2)... 5-50 PL 11.7 STM No Paper Sensor... 5-51 Stand PL 12.1 Stand Component... 5-52 ADF/DADF PL 13.1 ADF/DADF Accessory... 5-53 PL 13.2 Component, Cover... 5-54 PL 13.3 Base Cover Component... 5-55 PL 13.4 Feeder Component... 5-56 PL 13.5 Lower Feeder Component... 5-57 PL 13.6 Retard Roll Component... 5-58 PL 13.7 Lower Feeder Assembly... 5-59 PL 13.8 Retard Roll Assembly... 5-60 PL 13.9 Upper Feeder Assembly... 5-61 PL 13.10 Document Tray... 5-62 Common Hardware Common Hardware... 5-63 Part Number Index... 5-64 5-1 Parts Lists
Overview Introduction... 5-3 Subsystem Information... 5-4 Symbology... 5-5 Parts Lists Drive PL 1.1 IOT Motor... 5-7 Paper Transport PL 2.1 Tray 1... 5-8 PL 2.2 Tray 1 Frame Accessory... 5-9 PL 2.3 Tray 1 Components (1 OF 2)... 5-10 PL 2.4 Tray 1 Components ( 2 OF 2)... 5-11 PL 2.5 Tray 1 Frame Components... 5-12 PL 2.6 Tray 1 Frame Components (2 OF 2)... 5-13 PL 2.7 No Paper Sensor Housing... 5-14 PL 2.8 Registration... 5-15 PL 2.9 Registration Component... 5-16 ROS PL 3.1 ROS... 5-17 CRU PL 4.1 Drum Cartridge... 5-18 PL 4.2 Toner Empty Sensor and Erase Lamp... 5-19 PL 4.3 Transfer... 5-20 PL 4.4 Transfer Corotron Housing Component... 5-21 Fuser PL 5.1 Fuser... 5-22 Exit Transport PL 6.1 Exit Transport... 5-23 PL 6.2 Exit Transport Component (Simplex)... 5-24 PL 6.3 Exit Transport Component (Duplex)... 5-25 Simplex / Duplex Module and Bypass Tray PL 7.1 Simplex Module... 5-26 PL 7.2 Left Hand Cover Assembly... 5-27 PL 7.3 Duplex Module Component (1 OF 2)... 5-28 PL 7.4 Duplex Module Component (2 OF 2)... 5-29 PL 7.5 Bypass Tray Accessory... 5-30 PL 7.6 Bypass Tray Component... 5-31 Electrical PL 8.1 AIOC PWB, LVPS, Power Switch... 5-32 PL 8.2 HVPS, Interlock Switch, Duplex PWB... 5-33 PL 8.3 Control Panel Accessory... 5-34 PL 8.4 Control Panel Component... 5-35 Cover PL 9.1 Front / Top Cover... 5-36 PL 9.2 Rear / Right Cover and NOHAD Fan... IIT PL 10.1 IIT Accessory... 5-38 PL 10.2 IIT Component (1 OF 2)... 5-39 PL 10.3 IIT Component (2 OF 2)... 5-40 PL 10.4 IIT Upper Cover Cover Component... 5-41 PL 10.5 IIT Under Cover Component... 5-42 PL 10.6 IIT Carriage Component... 5-43 PL 10.7 Center Plate Component... 5-44 Single Tray Module PL 11.1 Single Tray Module... 5-45 PL 11.2 Tray 2 Component (1 OF 3)... 5-46 PL 11.3 Tray 2 Component (2 OF 3)... 5-47 PL 11.4 Tray 2 Component (3 OF 3)... 5-48 PL 11.5 Single Tray Frame Component (1 OF 2)... 5-49 PL 11.6 Single Tray Frame Component (2 OF 2)... 5-50 PL 11.7 STM No Paper Sensor... 5-51 Stand PL 12.1 Stand Component... 5-52 ADF/DADF PL 13.1 ADF/DADF Accessory... 5-53 PL 13.2 Component, Cover... 5-54 PL 13.3 Base Cover Component... 5-55 PL 13.4 Feeder Component... 5-56 PL 13.5 Lower Feeder Component... 5-57 PL 13.6 Retard Roll Component... 5-58 PL 13.7 Lower Feeder Assembly... 5-59 PL 13.8 Retard Roll Assembly... 5-60 PL 13.9 Upper Feeder Assembly... 5-61 PL 13.10 Document Tray... 5-62 Common Hardware Common Hardware... 5-63 Part Number Index... 5-64 5-1 Parts Lists
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 Parts Lists PL 1.1
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 6-1 General Procedures
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 7-1 Wiring Data