Xerox WC 5016 5020 Service Manua PDF

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-
701P48365 ponent damage.
June 2008
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.
Acknowledgements
Prepared by Global Knowledge & Llanguage Services - North America
800 Phillips Road - Building 0218-01A
Webster, New York 14580-9791
ISO9001 AND ISO27001 Certified
Copyright 2007-2008 by Xerox Corporation. All rights reserved.
Xerox and all product names and number names
are trademarks of Xerox Corporation.
Printed in the USA
WorkCentre 5016, 5020 Printed in the United States of America.
Service Documentation XEROX and all Xerox product names mentioned in this publication are trademarks of
XEROX CORPORATION. Other company trademarks are also acknowledged.
WorkCentre 5016, 5020 Service Documentation
PANTONE is a registered trademark of Pantone, Inc.
701P48365
Changes are periodically made to this document. Changes, technical inaccuracies, and typo-
Reissue graphic errors will be corrected in subsequent editions.
June, 2008 CAUTION

This equipment generates, uses and can radiate radio frequency energy, and if not installed
***Xerox Private Data*** 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-
All service documentation is supplied to Xerox external customers for informational purposes ing device pursuant to subpart B of part 15 of FCC rules, which are designed to provide rea-
only. Xerox service documentation is intended for use by certified, product-trained service per- sonable protection against such interference when operated in a commercial environment.
sonnel only. Xerox does not warrant or represent that it will notify or provide to such customer Operation of this equipment in a residential area is likely to cause interference in which case
any future change to this documentation. Customer performed service of equipment, or mod- the user, at his own expense, will be required to correct the interference.
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.
Front Matter June, 2008 Reissue

i WorkCentre 5016, 5020
Front Matter June, 2008 Reissue
ii WorkCentre 5016, 5020
Introduction
How To Use This Manual................................................................................................ iii
Reissue June, 2008 Introduction

WorkCentre 5016, 5020 i
Introduction June, 2008 Reissue
ii WorkCentre 5016, 5020
How To Use This Manual Chain 1 Standby Power
Chain 2 Mode Selection
Chain 3 Machine Run Control
This manual is used as the standard service manual for the WorkCentre 5016, 5020.
Chain 4 Start Print Power
Enter any comments and/or corrections regarding the WorkCentre 5016, 5020 Service Docu- Chain 6 Imaging
mentationl on the Publication Comment Sheet, and send it to the Technical Support Center Chain 7 Paper Supplying
SDEG. Chain 8 Paper Transportation
Chain 9 Marking
This manual describes the standard procedures for servicing the WorkCentre 5016, 5020.
Chain 10 Fusing and Copy Transportation
Refer to Section 1 Service Call Procedure for efficient and effective servicing during mainte-
nance calls.
Contents of Manual Description of Terminology and Symbols

This manual is divided into nine sections as described below. The terminology and symbols used throughout this service manual are described as follows:
Section 1 Service Call Procedures WARNING

A Warning statement indicates an operating or maintenance procedure, practice, or
This section describes the structured process for determining the type and sequence of actions condition that, if not strictly observed, could result in personal injury or loss of life.
that are performed during a service call. CAUTION
A Caution statement indicates an operating or maintenance procedure, practice, or condition
Section 2 Status Indicator RAPs
that, if not strictly observed, could result in damage to, or destruction of, equipment.
This section contains the Repair Analysis Procedures (RAPs) necessary to repair all faults NOTE: A Note statement indicates an operating or maintenance procedure, practice, or condi-
other than image quality faults. tion that is necessary to accomplish a task efficiently.
Section 3 Image Quality RAPs Reference:

Used when other explanations are given.
This section contains the Repair Analysis Procedures (RAPs) that are used to diagnose image
quality defect problems. Purpose:
Used to describe the purposes of adjustment and troubleshooting.
Section 4 Removal/Replacement and Adjustment Procedures
REP:
This section contains the removal, replacement, and adjustment procedures for components of Indicates the removal/replacement procedure for reference.
WorkCentre 5016, 5020.
ADJ:
Section 5 Parts List
Indicates the adjustment procedure for reference.
This section contains a list of spare parts list for the WorkCentre 5016, 5020.
PL:
Section 6 General Procedures/Information Indicates the parts list for reference.
This section contains frequently used procedures that relate to the diagnosis, setup, or opera- ASSY:
tion of the machine. It also contains pertinent information that will not be found in any other part Means Assembly.
of the service documentation.
Safety Critical Components (SCC):
Section 7 Wiring Data 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
This section contains the wiring information for the WorkCentre 5016, 5020. It contains a con- Corp.
nector list/locator, wirenet diagrams, and Block Schematic Diagrams (BSDs) for the following
chains:
Reissue June, 2008 Introduction

WorkCentre 5016, 5020 iii
Introduction June, 2008 Reissue
iv WorkCentre 5016, 5020
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
Reissue June, 2008 Service Call Procedures

WorkCentre 5016, 5020 1-1
Service Call Procedures June, 2008 Reissue
1-2 WorkCentre 5016, 5020
1.1 Before Starting Service 1.1.2Things to Note When Handling Customer Data
1.1.1Safety 1. Handling of copied/printed customer data.
Before you bring back any sample for the purpose of investigation/analysis, always obtain
To prevent any accident that may occur during maintenance service, any warning or any cau-
permission from the customer. Make sure you assure them that the data will not be used
tion regarding the service must be strictly observed. Do not perform any hazardous operation.
for any other purpose.
1. Power Supply 2. Security-related NVM values that were changed during diagnostics.
To prevent electrical shocks, burns, or injury, etc., be sure to switch OFF the machine and If any security-related NVM values, such as polling, were set for test purposes, make sure
disconnect the plug before starting the maintenance service. If the machine has to be you restore them to their original values after the test.
switched ON, such as when measuring a voltage, take extra care to avoid an electrical 3. Other things to note when handling customer data.
shock. Follow the safety guidelines established within the OpCo and ensure that customer data
2. Drive Area do not get compromised during service.
Never inspect, clear or lubricate the drive components, such as chain belts, chain wheels 1.1.3 Other Precautions
or gears, when the machine is in operation.
To avoid performing wrong or unnecessary service, observe the following:
3. Heavy Parts
When removing or installing heavy parts, keep your back straight and lift with your legs. 1. Reference Materials
Some parts should not be lifted by one person: Read all relevant service documentation, so that you can take a systematic approach.
IOT (Platen): 31.5kg (requires 3 persons) 2. Disassembling
2 Tray Modules: 8.6kg (requires 2 persons) Make sure to note the assembled condition of the machine before removing parts or dis-
Take extra care of your working posture to prevent backache. assembling it.
4. Safety Devices 3. Installation and Adjustment
See that safety devices for preventing accidents, such as fuses, circuit breakers, interlock After the installation or adjustment is complete, check that no parts or tools are left inside
switches, etc., and those for protecting customers from injury, such as panels and covers, the machine.
function properly. Modifications that hinder the function of any safety devices are strictly 4. Handling of replaced parts and consumables
prohibited. Make sure that any replaced parts or consumables, as well as the packaging materials,
5. Installing and Removing Parts are taken back to the Service Center.
The edges of parts and covers may be sharp, so take care not to touch them. Be careful WARNING
not to touch those parts, and wipe off any oil that may have adhered to your fingers or
Never discard the Drum/Toner Cartridges into a fire. Always keep them away from
hands before servicing. When pulling out parts, cables, etc., do it gently. Do not use
open flames to prevent them from igniting and causing a fire.
excessive force.
6. Specified Tools NOTE: For separation and processing methods for replaced parts or consumables, refer
Follow the instructions when a particular tool is specified. to Common Technical Information No. 2-138 for all machines.
7. Cleaning Up Toner Spills If you have replaced the following consumables, affix the "U-TAG" so that the recy-
Since toner can be explosive, sweep or brush any spilled toner into a container to collect clable parts will be handled appropriately.
it. To clean away the remaining toner using a vacuum cleaner, always use an FX standard a. Drum Cartridge
vacuum cleaner that is toner-tolerant. Never use the customer's vacuum cleaner.
b. Toner Cartridge
8. Earthquake Preparedness Measures For recyclable parts, fill in the necessary items on the "U-TAG."
If the customer requests earthquake proofing, an earthquake preparedness kit is avail- 5. General Precautions
able.
Take care not to disturb the customer's daily work.
Check the Service Guide for more information on the earthquake preparedness kit.
Place any service-related trash into a trash bag and bring it to the service office.
9. Modifications to the Machine
Clearly record the following information in the Machine Service Log:
Before altering the machine, submit an irregular use license application.
Details of the service call
10. Other Safety Precautions
Parts and consumables replaced
Follow the recommendations in WORKING PRACTICES FOR ENGINEERS issued by
FXAP EH&S (Environmental Health and Safety).

WorkCentre 5016, 5020 1-3 1.1
1.2 Service Call Procedure 1.3 Service Call Details
1.2.1 Initial Actions 1.3.1 Initial Actions
1. Ask the operator(s) about the machines condition. 1. Ask the operator(s) about the machines condition.
2. Record the billing meter readings. Frequency and location of recent paper jams
3. Inspect any faulty copies, then check the machine. Copy quality
4. Check the Service Log. 2. Record the billing meter readings.
1.2.2 Actions to Take During UM (Unscheduled Maintenance) 3. Inspect any faulty copies, then check the machine.
1. Perform the service flow in Section 2 Status Indicator RAPs. 4. Check the copy sample and the Service Log from the last call.
2. Perform the applicable RAP in Section 2 Status Indicator RAPs. 1.3.2 Checking Reproducibility of Problem
If there are no applicable RAPs, troubleshoot by referring to the BSD in Section 7 Wiring 1. Perform the service flow in Section 2 Status Indicator RAPs.
Data. 2. Perform the applicable RAP in Section 2 Status Indicator RAPs.
3. Check the copy quality. 3. If there are no applicable RAPs, troubleshoot by referring to the BSD in Section 7 Wiring
Make several copies using the Test Pattern (499T247), then check the quality. Data.
4. Look at the last 20 error codes in order to understand the machine status. 1.3.3 Checking Copy Quality
Enter Diagnostic Mode. Enter [40-01] (Display Error History How to Enter the Diag- 1. Make several copies using the Test Pattern (499T247), then check the quality.
nostic Mode). 2. If there is a problem in copy quality, perform the applicable RAP in Section 3 Image Qual-
When the last error code is displayed, press the [Start] key to return to the Function ity.
input screen.
1.3.4 TRIM Servicing
Pressing the [Stop] key during the display will stop it and return you to the Function
Perform TRIM servicing during the maintenance call.
input screen.
5. Repair all the secondary problems.
1. Perform the necessary TRIM items using the TRIM Checklist.
6. Perform TRIM servicing.
2. Check for parts that require periodic cleaning/replacement by referring to the TRIM
1.2.3 Actions to Take During SM (Scheduled Maintenance) Checklist and the Periodic Replacement Parts/Consumables List. Clean them if neces-
1. Check the copy quality. sary. If replaced, always clear the counters of the corresponding items in the Chain Func-
Make several copies using the Test Pattern (499T247), then check the quality. tion.
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.

1.2, 1.3 1-4 WorkCentre 5016, 5020
1.4 TRIM Checklist 1.5 Periodic Replacement Parts/Consumables List
A: Check. Clean, replace, or replenish if necessary. When servicing the machine, check the number of copies and the replacement interval for the
consumables and parts that require periodical cleaning/replacement. Clean or replace them if
B: Always check and clean. 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
*: Always replace at the specified interval. RAPs). For items that cannot be checked in the Diagnostic Mode, clean or replace them
according to the replacement intervals (standard PV).
Table 1
CAUTION
Every
No. Service Items time Service Details Do not keep toner and drum cartridges in your car for long periods of time.
1.1 Check before servicing A Turn on the machine, and make sure that there are
Table 1
(check machine operation) no abnormal sounds.
Parts/Consumables Replacement
1.2 Check before Servicing A Make several copies using the Test Pattern
(copy the Test Pattern) No Name/PL No. Interval (copies) Counters Check
(499T247), then check the image quality.
2 Clean the interior of the A Clean the paper dust and toner residue in the paper 1 Tray 1 Feed Roll/ 50,000 [29/34] [29/24] [29/14] [29/4]
machine (paper transport path and on the jam sensor. Retard Pad Count up 1 for every feed. Replace both at the
system) same time.
3 Clean the IIT A Clean the Platen Glass surface and the Platen 2 Tray 2 Feed Roll/ 100,000 [29/25] [29/15] [29/5]
Cushion with the optical cleaning cloth. Retard Roll Count up 1 for every feed. Replace both at the
same time.
Clean the Reflector, back of the Platen Glass,
mirrors and lens with the optical cleaning cloth. 3 MSI Feed Roll/ 50,000 [29/39] [29/29] [29/19] [29/9]
5 Safety Precautions B Make sure that the power cord is plugged in Retard Pad Count up 1 for every feed. Replace both at the
same time.
properly.
4 Fuser Unit 100,000 [21/39] [21/29] [21/19] [21/9]
Make sure that there are no cracks in the
Count up 1 for every feed.
power plug and no holes or cuts in the power
cord insulation. 5 Toner Cartridge 6,000
If an extension cord or power strip is used, 6 Drum Cartridge 36,000 31,000 (Warning)
make sure it is of sufficient capacity to handle 36,000 (Machine Stops)
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 A Make several copies using the Test Pattern
(copy quality check) (499T247), then check the image quality.
6.2 Check after servicing A Check the paper feed.
(check machine operation) Make sure that there are no abnormal sounds.
6.3 Check after servicing A Create the Service Log and Service Report.
(check the meter)
CAUTION
Do not touch the Drum of the Drum Cartridge.

WorkCentre 5016, 5020 1-5 1.4, 1.5
1.4, 1.5 1-6 WorkCentre 5016, 5020
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
Reissue June, 2008 Status Indicator RAPS

Status Indicator RAPS June, 2008 Reissue
Fault Repair Overview and List of Error Codes .
Fault Repair Overview

The fault repair operation proceeds in the following flow. After performing the pre-check, verify
the symptoms and refer to the Error Code List and Section 7 Wiring Data to effectively repair
the fault:
Check the status of Installation
Check the problem status

Diagnostic Mode
Operating Principles
Wiring Data
Perform RAP
Reference
Information
Check if the fault is repaired
Completed
Figure 1 Troubleshooting Procedure

Check the Status of Installation Descriptions related to connectors are expressed as follows: P/J12" -> The connector (P/
Before starting to troubleshoot, always check the following items: 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
The voltage of the power supply (measure the voltage at the power outlet to see if it is side when the connector (P/J12) is in the disconnected state (except when it is directly
within specification). connected to a board).
The power cord for damage, short circuits, open circuits, and wrong internal connections. In a RAP, "P/J1 <=> P/J2" means that all the opposing pins between "P/J1" and "P/J12"
The machine for proper grounding. (refer to Section 7, Wiring Data) should be measured.
The voltages on small connectors are measured using a special tool. Handle the tool
The machine is not installed in a place with high temperature, high humidity, low tempera-
carefully because it has a sharp tip.
ture, low humidity, or a place with drastic changes in temperature.
The numerical values described in the RAPs are for reference only. Approximate values
The machine is not installed near a water outlet, humidifier, heater or fire source, dusty
are considered to be the same.
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. Note that for the checks specified in the RAP, you must check the references for the parts
that must be removed and their procedures.
The machine is not installed in a place exposed to direct sunlight.
"Replacement" in the RAPs indicates the parts that are considered to be the cause of the
The machine is installed in a well-ventilated place.
problem. Check by replacing the parts and, if necessary, the assembly that contains those
The machine is installed on a stable level surface. parts.
The paper is within specification (standard paper is recommended). In the RAPs, the highest level paper supply is called "Tray 1," and the one below it is
The machine for any improper handling. called "Tray 2."
The Periodic Replacement Parts are replaced at the proper intervals. In the RAPs, some procedures are described separately for each specification. Follow the
Safety Considerations instructions for your model to repair the faults.
Before servicing, always unplug the power cord unless required otherwise. When the RAP Flow
power is turned ON, never touch a current-carrying part unless required otherwise. Also, RAPs are a good place to start in diagnosing a failure. RAPs guide you through the trouble-
since current is carried in the LVPS power switch/inlet even when the power is turned shooting process by checking for the presence of error codes and other types of problematic
OFF, never touch this area. symptoms. To troubleshoot problems related to image quality, refer to Section 3 Image Quality
When turning the power ON to perform a check while the Interlock Switch or Security Troubleshooting.
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.

Ask the operator about the problem
Did the operator operate the machine correctly? No
Yes
Turn the Power Switch OFF then ON Explain how to operate the
machine
Does the error recur when operating the

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

Does the Control Panel display an Error relevant troubleshooting
Code?
Figure 2 RAP Flow

Error Code List
NOTE: In the Record in Error Log column, O = yes and X = no.
Error Record in
Code Error Name/Explanation/I/O Diagnostic Codes/Check Items Error Log RAP BSD
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 CH8.1
C1-1 Paper damaged, not within specification, or not loaded correctly O -
Figure 1
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.

Error Record in
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
Tray1 Feed Sensor dirty and Sensor Actuator deformed or damaged
Paper damaged, not within specification, or not loaded correctly
CH8.1
Foreign matter, burrs, or paper in the paper path Figure 1
C1-2 Drive gear worn or damaged O -
CH8.4
IOT Registration Clutch faulty Figure 4
(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.

Error Record in
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
Paper damaged, not within specification, or not loaded correctly CH8.2
C2-1 O -
Figure 2
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.

Error Record in
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 Sensor dirty and Sensor Actuator deformed or damaged
Foreign matter, burrs, or paper in the paper path CH8.1
Drive gear worn or damaged Figure 1
C2-2 O -
CH8.2
STM Feed Clutch faulty
Figure 2
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.

Error Record in
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
Foreign matter, burrs, or paper in the paper path CH8.1
C2-3 O -
CH8.4
IOT Registration Clutch faulty
Figure 4
(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.
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. CH7.1
C5-0 X -
Check the tray to see if it is empty; if it is, add paper specified by the job. Figure 1
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).

2-10 WorkCentre 5016, 5020
Error Record in
Error Name
Tray1 Paper Size Mismatch
Explanation
Paper that is different from the one in the Tray Settings is detected when feeding.
C5-1 X - -
Or, paper size setting in Tray1 is different from the paper size specification of the job when Tray1 is selected during a print job.
Check Items
Press the [Stop] button on the Control Panel.
Change the paper size of Tray 1 to the one specified by the job.
Error Name
No paper in the selected paper tray (Tray2)
Explanation
No paper is detected in the STM when ATS function is disabled and STM is selected during a copy job.
No paper is detected in the STM when STM is selected during a print job (the paper size setting matches the one specified for the job).
[07-08] STM No Paper Sensor
Check Items
Press the [Stop] button on the Control Panel. CH7.2
C6-0 X -
Load the correct paper into the STM. Figure 2
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).
Error Name
Tray2 Paper Size Mismatch
Explanation
C6-1 X - -
Or, paper size setting in the STM is different from the paper size specification of the job when STM is selected during a print job.
Check Items
Change the paper size of STM to the one specified by the job.
Error Name
MSI Paper Size Mismatch
Explanation
C7-1 X - -
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.

WorkCentre 5016, 5020 2-11
Error Record in
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.
CH3.2
C0-1 Or, either Tray 1 or STM is "set with paper size that is different from the one specified for the job" when Auto Tray is selected during a print X -
Figure 2
job.
Check Items
Change the paper size of Tray 1 or STM to the one specified by the job.
Error Name
MSI Regi SNR on JAM
Explanation
Timeout between Bypass Solenoid ON and IOT Registration Sensor ON.
[08-17] Bypass Solenoid
Check Items
Bypass Feed Roll, Retard Pad, or Bypass Take Away Roll dirty, contaminated with paper dust, worn, or faulty
IOT Registration Sensor dirty and Sensor Actuator deformed or damaged
CH8.3
Paper damaged, not within specification, or not loaded correctly Figure 3
C9-3 Foreign matter, burrs, or paper in the paper path O -
CH8.4
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).

2-12 WorkCentre 5016, 5020
Error Record in
Error Name
F/O#1 SNR Static JAM
Explanation
Tray1 Feed Sensor ON is detected during standby.
Check Items
Tray1 Feed Sensor dirty and Sensor Actuator deformed or damaged CH8.1
C8-1 O -
(PL 2.5) (REP 2.5.1).
Wire between Tray 1 Feed Sensor J158-3 ( P/J158) and STM PWB J501-6 ( P/J501)
Error Name
F/O#2 SNR Static JAM
Explanation
STM Feed Sensor ON is detected during standby.
Check Items
STM Feed Sensor dirty and Sensor Actuator deformed or damaged CH8.2
C8-2 O -
Figure 2
11.5) (REP 11.5.1).
Wire between STM Feed Sensor J172-3 ( P/J172) and STM PWB J542-6 ( P/J542)
Replace the STM PWB (PL 11.5) (REP 11.5.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Error Name
CPM Image Lost
Explanation
E0-1 O - -
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

WorkCentre 5016, 5020 2-13
Error Record in
Error Name
Regi SNR Static JAM
Explanation
IOT Registration Sensor ON is detected during standby.
Check Items
Sensor dirty CH8.4
E1-6 O -
sor (PL 2.9).
Replace the AIOC PWB (PL 8.1)(REP 8.1.1).
Error Name
Exit SNR JAM
Explanation
Fuser Exit Sensor ON is detected during standby.
[10-23] Fuser Exit Sensor
Check Items
Fuser Exit Sensor dirty and Sensor Actuator deformed or damaged CH10.2
E3-6 O -
Figure 2
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

2-14 WorkCentre 5016, 5020
Error Record in
Error Name
IOT L/H Cover open
Explanation
The Left Hand Cover is open.
[01-01] LH Cover Interlock Switch
Check Items CH1.2
E5-1 Check that the Left Hand Cover closes correctly. X -
Figure 2
Check that the LH Cover Interlock Switch is correctly installed and that the electrical connection is good.
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the LH Cover Interlock
Switch (PL 8.2).
Wire between LH Cover Interlock Switch FS151 ( FS151) and LVPS J506-4 ( P/J506)
Wire between LH Cover Interlock Switch FS152 ( FS152) and LVPS J506-3
Replace the LVPS (PL 8.1) (REP 8.1.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Error Name
IOT Front Cover open
Explanation
The Front Cover is open.
[01-12] Front Cover Interlock Switch
Check Items CH1.2
E5-2 Check that the Front Cover closes correctly. X -
Figure 2
Check that the Front Cover Interlock Switch is correctly installed and that the electrical connection is good.
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the Front Cover Interlock
Switch (PL 8.2).
Wire between Front Cover Interlock Switch FS153 ( FS153) and LVPS J506-2 ( P/J506)
Wire between Front Cover Interlock Switch FS154 ( FS154) and LVPS J506-1
Error Name
L/H Low Cover open
Explanation
Access Cover 1 is open.
[01-11] Tray1 Interlock Switch
Check Items CH7.1
E6-1 Check that Access Cover 1 closes correctly. X -
Figure 1
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

WorkCentre 5016, 5020 2-15
Error Record in
Error Name
STM L/H Cover open
Explanation
Access Cover 2 is open.
[01-10] STM Interlock Switch
Check Items CH7.2
E6-2 Check that Access Cover 2 closes correctly. X -
Figure 2
Check that the STM Interlock Switch is correctly installed and that the electrical connection is good.
Check that the following wires are connected securely with good electrical contact. If there is no problem, replace the STM Interlock Switch
(PL 11.5).
Wire between STM Interlock Switch J173-2 ( P/J173) and STM PWB J542-9 ( P/J542)
Wire between STM Interlock Switch J173-1 and STM PWB J542-10
Replace the STM PWB (PL 11.5) (REP 11.5.2), the LVPS (PL 8.1) (REP 8.1.2), and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Error Name
Nup NG Out Of Range
Explanation
The magnification is not within the range of 50 to 200% during Nup.
Check Items CH3.2
E8-1 Press the [Stop] button on the Control Panel. X -
Figure 2
Press the [Paper Supply] button on the Control Panel.
Press the [Special Copy] button on the Control Panel.
Press the [Original Size Input] button on the Control Panel.
Press the [Clear All] button on the Control Panel.
Error Name
Nup Paper direction mismatch
Explanation
The paper orientation of the document and the tray are not aligned during Nup.
Check Items CH3.2
E8-2 Press the [Stop] button on the Control Panel. X -
Figure 2
Press the [Paper Supply] button on the Control Panel.
Press the [Special Copy] button on the Control Panel.
Press the [Original Size Input] button on the Control Panel.
Press the [Clear All] button on the Control Panel.

2-16 WorkCentre 5016, 5020
Error Record in
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
Fuser Exit Sensor dirty and Sensor Actuator deformed or damaged
Paper damaged or not within specification CH10.2
E1-2 Foreign matter, burrs, or paper in the paper path O -
Figure 2
IOT Registration Clutch faulty
Check that the IOT Registration Clutch and the LVPS J503-4/5 ( P/J503) pins are connected securely with good electrical contact. If there is
no problem, replace the IOT Registration Clutch (PL 2.9).
6.2).
Error Name
Exit SNR off JAM
Explanation
Timeout between Fuser Exit Sensor ON and Fuser Exit Sensor OFF.
Check Items
Fuser Exit Sensor dirty and Sensor Actuator deformed or damaged
Paper damaged or not within specification CH10.2
E3-1 O -

6.2).

WorkCentre 5016, 5020 2-17
Error Record in
Error Name
MCU-STM comm. error
Explanation
A communication failure has occurred between the MCU and the Tray Module. CH3.1
H9-7 O -
Check Items Figure 1
Turn the power OFF then ON.
Check for any open circuit or short circuit between the STM connectors.
Replace the STM PWB (PL 11.5) (REP 11.5.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Error Name
Copy Counter Full
Explanation CH3.2
L9-0 X -
The user that is logged in has reached the allotted copy limit in the Account Mode. Figure 2
Check Items
Error Name
Toner Cartridge was PRENEAR empty
Explanation
The toner cartridge is low.
Check Items
J1-0 X - -
Refill the toner.
Foreign matter on the sensor.
Check that the Toner Empty Sensor and the LVPS J509-1-4 ( P/J509) pins are connected securely with good electrical contact. If there is no
problem, replace the Toner Empty Sensor (PL 4.2).
Error Name
Toner Empty
Explanation
The Toner Cartridge is empty.
[09-07] Toner Empty Sensor CH9.2
J1-2 O -
Check Items Figure 2
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).

2-18 WorkCentre 5016, 5020
Error Record in
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 CH9.2
J3-1 O -
4.1) (REP 4.1.1). Figure 2
Wire between Drum Cartridge P610-7 ( P610) and AIOC PWB J402-1 ( P/J402)
Wire between Drum Cartridge P610-3 and AIOC PWB J402-4
Replace the Drum Cartridge (PL 4.1) (REP 4.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Error Name
Drum near end of life
Explanation
J6-0 X - -
The Drum Cartridge is near the end of its life.
Check Items
Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).
Error Name
Drum cartridge life end
Explanation
J6-1 O - -
The Drum Cartridge has reached the end of its life.
Check Items

WorkCentre 5016, 5020 2-19
Error Record in
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 CH9.2
J7-1 O -
4.1) (REP 4.1.1). Figure 2
Wire between Drum Cartridge P610-7 ( P610) and AIOC PWB J402-1 ( P/J402)
Replace the Drum Cartridge (PL 4.1) (REP 4.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Error Name
Drum CRUM Market Identity Mismatch
Explanation
The AIOC PWB has detected that the Drum CRUM destination does not match. CH9.2
J7-2 O -
Figure 2
Check Items
Error Name
Drum CRUM ID error
Explanation
The AIOC PWB has detected that the Drum CRUM ID is incorrect. CH9.2
J7-3 O -
Figure 2
Check Items
Error Name
EPC Memory Full
Explanation
N1-1 During a copy job in Collate Mode, the EPC memory is full. O - -
Or, the machine has reached a state where it is unable to scan in any more documents.
Check Items

2-20 WorkCentre 5016, 5020
Error Record in
Error Name
No Response from USB-Host
Explanation
Either "USB disconnected" or "Communication timed-out" is detected during a print job. CH3.2
N4-0 O -
Or, either "USB disconnected" or "Communication timed-out" is detected during a scan job. Figure 2
Check Items
Cancel the print job.
Reconnect the USB cable correctly.
Error Name
HBPL or XPJL Syntax Error
Explanation
CH3.2
N4-1 An abnormal command that cannot be ignored is received from the USB-Host during a print job. O -
Figure 2
Check Items
Cancel the print job.
Reconnect the USB cable correctly.
Error Name
Download File Error
Explanation
N4-2 -
There is an abnormal Product ID or there is a checksum error in the download file.
Check Items
Error Name
Download Flash Write Error
Explanation
N4-3 -
Unable to write the downloaded file into flash memory.
Check Items
Error Name
CPM Image Lost
Explanation
E0-1 O - -
During a copy job in CPM Priority Mode, the paper containing an image cannot be output after the image is deleted.
Check Items
Error Name
Push Scan TimeOut
Explanation
N5-0 Push scan notification failed during a scan job. O - -
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.

WorkCentre 5016, 5020 2-21
Error Record in
Error Name
Controller Logic fail
Explanation CH3.2
N9-0 O -
A software defect that cannot be ignored is found in the Controller software. Figure 2
Check Items
Error Name
IOT Communication Error
Explanation CH3.2
N9-1 O -
The AIOC PWB has detected a Type-Di communication error. Figure 2
Check Items
Error Name
Main Motor stop error CH4.1
U0-1 O U0-1
Explanation Figure 1
The motor runs for over 120 seconds without any paper being fed.
Error Name
Main Motor rotation error CH4.1
U1-1 O U1-1
500ms after the IOT has started, the Main Motor Lock signal is "Low."
Error Name
Carriage Module Fail CH6.2
U2-1 O U2-1
An abnormality was detected in the Carriage Module.
Error Name
Laser Power or ROS Motor Fail
CH6.3
U3-5 Explanation O U3-5
Figure 3
The ROS Motor is unable to rotate.
Or, the laser output is not normal.
Error Name
Fuser On Time Fail
CH10.1
Figure 1
The lamp did not turn OFF within the specified time after turning ON.
Or, Warm Up was not completed within the specified time after power ON.
Error Name
Over Heat Temp Fail CH10.1
U4-2 O U4-2
A temperature above 250C is continuously detected for 480ms.
Error Name
FS1 thermistor defect CH10.1
U4-3 O U4-3
FS1 cannot be monitored any more.

2-22 WorkCentre 5016, 5020
Error Record in
Error Name
Fuser Fan defect CH10.3
U4-9 O U4-9
After the start of Fan Fail Signal monitoring, the signal level was Low not more than 30 times.
Error Name
RAM read/write check error CH3.2
U6-2 O U6-2
When the MCU runs the overall Read/Write check for RAM during startup, the Read Data and Write Data do not match.
Error Name
NVM data defect
Explanation CH3.2
U6-3 O U6-3
The NVM Header data ERROR and NVM 3 page data do not match. Figure 2
Or, unable to find the NVM Write & Read area.
The NVM or Counter areas are full.
Error Name
NVM read/write cannot be executed
CH3.2
Figure 2
An NVM Ack NG is detected during NVM Read.
An NVM Write Error is detected 5 times during NVM Recovery.
Error Name
CPU Power to access NVM is not enough CH3.2
U6-5 O U6-5
NVM queue full is detected during NVM Write.
Error Name
UI Communication TimeOut CH2.1
U7-0 X U7-0
At the Power On Sequence, the AIOC PWB did not communicate with the User Interface PWB.
Error Name
UI Communication Error CH2.1
U7-1 X U7-1
The User Interface PWB has detected a communication failure.
Error Name
Billing Counter Defect
CH3.2
Figure 2
It is detected that the Billing Counter Value is incorrect.
Or, the AOIC PWB has failed to read the Billing Counter.
Error Name
HVPS fail CH9.1
U9-0 O U9-0
A 500 msec cycle of the signal HVPS#ERR=High was detected twice in a row.

WorkCentre 5016, 5020 2-23
Display Priority in Case of Multiple Errors Priority Error
When multiple errors occur simultaneously, they will be shown on the Control Panel display in Order Code Error Name Error Characteristic
the following priority order. Always begin troubleshooting with the highest-priority error.
36 A1-1 Doc Misfeed Jam
37 A2-2 No Supported Doc Size
Priority Error Document Jam
38 A4-1 Short Length Detect
Order Code Error Name Error Characteristic
39 A4-2 Long Length Detect
1 U7-0 UI Communication TimeOut Unable to control the 40 C1-1 Tray1 F/O#1 SNR on JAM
(Highest) display at the Control-
41 C1-2 Tray1 Regi SNR on JAM
2 U7-1 UI Communication Error ler
42 C2-1 STM F/O#2 SNR on JAM
3 H9-7 MCU-STM comm. error
43 C2-2 Tray1 F/O#1 SNR on JAM from STM feed
4 N9-1 IOT Communication Error
44 C2-3 STM Regi SNR on JAM
5 N9-0 Controller Logic fail
6 U0-1 Main Motor stop error
46 C9-3 MSI Regi SNR on JAM Paper Jam
7 U1-1 Main Motor rotation error
47 E1-2 Exit SNR on JAM
8 U2-1 Carriage Module Fail
48 E3-1 Exit SNR off JAM
9 U3-5 Laser Power or ROS Motor Fail
49 C8-1 F/O#1 SNR Static JAM
10 U4-1 Fuser On Time Fail
50 C8-2 F/O#2 SNR Static JAM
11 U4-2 Over Heat Temp Fail Fatal Error
51 E1-6 Regi SNR Static JAM
12 U4-3 FS1 thermistor defect
52 E3-6 Exit SNR JAM
13 U4-9 Fuser Fan defect
53 E0-1 CPM Image Lost
14 U6-2 RAM read/write check error
54 C0-1 APS NG Unselected
15 U6-3 NVM data defect
16 U6-4 NVM read/write cannot be executed
56 C5-1 Tray1 Paper Size Mismatch
17 U6-5 RAM read/write check error
57 C6-1 Tray2 Paper Size Mismatch Tray-related errors
18 U8-1 Billing Counter Defect
58 C7-1 MSI Paper Size Mismatch
19 U9-0 HVPS fail
59 C5-0 No paper in the select paper tray (Tray1)
20 E9-1 AMS NG Out Of Range
60 C6-0 No paper in the select paper tray (Tray2)
21 E9-2 Paper direction mismatch
61 J1-2 Toner Empty
22 E8-1 Nup NG Out Of Range
62 J3-1 No Drum cartridge
23 E8-2 Nup Paper direction mismatch
63 J6-1 Drum cartridge life end Resolvable by replac-
24 L9-0 Copy Counter Full Dynamic Error
64 J7-1 Drum CRUM comm. Error ing parts
25 N4-0 No Response from USB-Host (Job Cancel)
65 J7-2 Drum CRUM Market Identity Mismatch
26 N4-1 HBPL or XPJL Syntax Error
66 J7-3 Drum CRUM ID error
27 N4-2 Download File Error
67 N1-1 EPC Memory Full An error that only
27 N4-3 Download Flash Write Error
stops scanning
29 N5-0 Push Scan TimeOut
30 A5-1 Platen Cover Open Document Cover
Open
32 E5-1 IOT L/H Cover open
33 E5-2 IOT Front Cover open
Paper Cover Open
34 E6-1 L/H Low Cover open
35 E6-2 STM L/H Cover open

2-24 WorkCentre 5016, 5020
U0-1 Main Motor Stop Error U1-1 Main Motor Rotation Error
BSD-Reference: CH4.1 (Figure 1) BSD-Reference: CH4.1 (Figure 1)
Explanation Explanation
The motor runs for over 120 seconds without any paper being fed. 500 ms after the IOT Motor starts, the IOT Motor Lock signal is Low.
Procedure Procedure
The problem can be solved according to RAP U1- 1 Main Motor Rotation Error (U1-1). Close the Left Hand Cover and the Front Cover. Execute diagnostics [04--01 Main Motor On].
Y N (How to Enter the Diagnostic Mode) The IOT Motor can be heard rotating.
Execute diagnostics [29-49] (How to Enter the Diagnostic Mode) to check the ROM ver- Y N
sion. The ROM is the latest version. Check P/J504 and P/J201. Both P/J504 and P/J201 are connected securely.
Y N Y N
Upgrade the ROM to the latest version. Connect P/J504 and P/J201 securely.
Replace the IOT Motor (PL 1.1) (REP 1.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in Measure the voltage between LVPS PWB P504-1 ( P/J504) (+) and GND (-). The volt-
that order. age is approximately +24VDC.
Y N
Completed 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.

WorkCentre 5016, 5020 2-25 U0-1, U1-1
U2-1 Carriage Module Fail U3-5 Laser Power Or ROS Motor Fail
A carriage fault was detected. The ROS Motor does not turn, or the laser output is not normal.
Procedure Procedure
Execute diagnostics [05-22 Move scanner to home position] and [05-23 Move scanner to main- Execute diagnostics [6-15 ROS Motor ON]. (How to Enter the Diagnostic Mode) The ROS
tenance position]. (How to Enter the Diagnostic Mode) The carriage moves. Motor can be heard rotating.
Y N Y N
Check each IIT Carriage connector. Each connector is connected securely. Measure the voltage between the AIOC PWB P403-7 ( P/J403) (+) and GND (-). The
Y N voltage is approximately +24VDC.
Connect each connector securely. Y N
Replace the AIOC PWB (PL 8.1) (REP 8.1.1) and the LVPS (PL 8.1) (REP 8.1.2) in
Check for foreign substances and deformed parts in the carriage. None is found. that order.
Y N
Remove the foreign substances and repair the deformed parts. Replace the ROS (PL 3.1) (REP 3.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that
order.
Replace the IIT Carriage (PL 10.3)(REP 10.3.1).
Measure the voltage between the AIOC PWB P403-1 ( P/J403) (+) and GND (-). The volt-
Execute diagnostics [05-23 Move scanner to maintenance position]. When the IIT Carriage age is approximately +5VDC.
has moved to the leftmost position, press the [Stop] button to put the Carriage Sensor into the Y N
blocked state. Execute diagnostics [5-11 Home Sensor], and "H" is displayed. Replace the AIOC PWB (PL 8.1) (REP 8.1.1).
Y N
Check each IIT Carriage and Carriage Sensor connector. Each connector is con- Check the AIOC PWB P/J403 ( P/J403), LD PWB P/J140 ( P/J140), and P/J130 ( P/J130) con-
nected securely. nectors. The P/J403, P/J140, and P/J130 connectors are connected securely.
Y N Y N
Connect each connector securely. Connect the AIOC PWB P/J403 ( P/J403), LD PWB P/J140 ( P/J140), and P/J130 ( P/
J130) connectors securely.
Replace the Carriage Sensor (PL 10.6) and the IIT Carriage (PL 10.3) (REP 10.3.1) in
that order. 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.
Check the Carriage Sensor (PL 10.6 ). The Carriage Sensor is installed properly. Y N
Y N Repair the wire(s).
Install the Carriage Sensor (PL 10.6) properly.
Replace the ROS (PL 3.1) (REP 3.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Replace the IIT Carriage (PL 10.3) (REP 10.3.1).

U2-1, U3-5 2-26 WorkCentre 5016, 5020
U4-1 Fuser On Time Fail U4-2 Over Heat Temp Fail
The lamp did not turn OFF within the specified time after turning ON. A temperature of 250C or higher was detected continuously for 480 ms.
Or, Warm Up was not completed within the specified time after power ON.
Procedure Procedure
When U4-2 occurs, [NVM 50-20 FSR Reset FuserOverTemp] becomes "1." Run [NVM 50-20
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
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
to see if there is paper in the Fuser. The Fuser is normal and there is no paper in it.
J601-2, and the resistance is a minimum of 228k ohms (cold).
Y N
Remove the paper. Y N
Replace the Fuser (PL 5.1) (REP 5.1.1).
Check the condition of the Fuser. The Fuser is installed properly.
Y N Check the wire between J408 ( P/J408) and P601 ( P/J601). The wire between J408 and
Install the Fuser properly. P601 is not shorted or open.
Y N
Remove the Fuser. Check the conductivity between the Thermostat contacts. The contacts Repair the wire.
are conductive.
Replace the Fuser (PL 5.1) (REP 5.1.1), the LVPS (PL 8.1) (REP 8.1.2), and the AIOC PWB
Y N
(PL 8.1) (REP 8.1.1) in that order.
Check the Heater Rod for an open circuit. There is no open circuit between J600-1 ( P/
J600) and J600-2.
Y N
Check the resistance of the Thermistor. There is no open circuit between J601-1 ( P/J601)
and J601-2, and the resistance is a minimum of 228k ohms (cold).
Y N
Immediately after Main Switch ON, the voltage between J3-3 ( P/J3) (ACH) and J3-1
(ACN) is approximately 200VAC.
Y N
Replace the LVPS (PL 8.1) (REP 8.1.2).
Check the wire between J408 ( P/J408) and P601 ( P/J601). 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.

WorkCentre 5016, 5020 2-27 U4-1, U4-2
U4-3 FS1 Thermistor Defect U4-9 Fuser Fan Defect
Thermistor FS1 cannot be monitored any more. After the start of Fan Fail Signal monitoring, the signal level was Low not more than 30 times.
Procedure Procedure
Check the condition of the Fuser. The Fuser is installed properly. Turn the power ON. Visually check the NOHAD Fan (PL 9.2). The NOHAD Fan is rotating.
Y N Y N
Install the Fuser properly. Measure the voltage between the AIOC PWB P405-3 ( P/J405) (+) and GND (-). The
voltage is approximately +24VDC.
Check the resistance of the Thermistor. There is no open circuit between J601-1 ( P/J601) Y N
and J601-2, and the resistance is a minimum of 228k ohms (cold). Replace the AIOC PWB (PL 8.1) (REP 8.1.1).
Y N
Replace the Fuser (PL 5.1) (REP 5.1.1). Replace the NOHAD Fan (PL 9.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Check the wire between J408 ( P/J408) and P601 ( P/J601). The wire is not shorted or Measure the voltage between the AIOC PWB P405-2 P/J405 (+) and GND (-). The voltage
open. is 0.
Y N Y N
Repair the wire. Replace the NOHAD Fan (PL 9.2) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.
Replace the Fuser (PL 5.1) (REP 5.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order. Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

U4-3, U4-9 2-28 WorkCentre 5016, 5020
U6-2 RAM Read/Write Check Error U6-3 NVM Data Defect
When the AIOC PWB checked RAM read/write at activation, a mismatch of read and write data NVM Header data and NVM 3 page data are mismatched.
was detected. Or, the NVM Write & Read area is not found.
Or, the NVM or Counter area is full.
Procedure
Procedure
Check each AIOC PWB connector. Each connector is connected securely
Y N Check each AIOC PWB connector. Each connector is connected securely.
Y N
Connect each connector securely.
Turn the power OFF and ON. U6-2 recurs.
Y N
Y N
Completed
Completed

WorkCentre 5016, 5020 2-29 U6-2, U6-3
U6-4 NVM Read/Write Cannot Be Executed U6-5 CPU Power To Access NVM Is Not Enough
During NVM read/write, the NVM Ack NG state was detected. At NVM write, the NVM queue full state was detected.
Or, during NVM repairs, an NVM write error was detected five times.
Procedure Procedure
Execute diagnostics [29-49] to check the ROM version. (How to Enter the Diagnostic
Check each AIOC PWB connector. Each connector is connected securely.
Mode) The ROM is the latest version.
Y N
Y N
Upgrade the ROM to the latest version.
Y N
Completed

U6-4, U6-5 2-30 WorkCentre 5016, 5020
U7-0 UI Communication TimeOut U7-1 UI Communication Error
At Power ON, the AIOC PWB does not communicate with the User Interface PWB. The User Interface PWB detected a communication failure.
Procedure Procedure
Measure each voltage between AIOC PWB J401-1 ( P/J401) (+), J401-2 (+), and GND (-). Check each User Inferface PWB connector. Each connector is connected securely.
The voltages are approximately +5VDC. Y N
Y N Connect each connector securely.
Check the wire between J401 ( P/J401) and J710 ( P/J710). The wire is neither shorted nor Y N
open. Completed
Y N
Repair the wire. Replace the User Interface PWB (PL 8.4) (REP 8.4.1).
Replace the User Interface PWB (PL 8.4) (REP 8.4.1) and the AIOC PWB (PL 8.1) (REP 8.1.1)
in that order.

WorkCentre 5016, 5020 2-31 U7-0, U7-1
U8-1 Billing Counter Defect U9-0 HVPS Fail
An illegal Billing Counter value was detected. A 500 ms cycle of HVPS#ERR=High was detected twice in a row.
Or, the AIOC PWB failed to read the Billing Counter.
Procedure Procedure
Close the Left Hand Cover and the Front Cover. Make sure that the Drum Cartridge and the
TBD
Transfer Corotron are properly seated. Measure the voltages between P406-2 ( P/J406) (+)/
P406-4(+)/P406-5(+) on the AIOC PWB and ground (-). The voltages are approximately
+5VDC.
Y N
Replace the AIOC PWB (PL 8.1) (REP 8.1.1) and the HVPS (PL 8.2) (REP 8.2.1) in that
order.
Execute diagnostics [09-04 HVPS ON (Low Voltage)]. (How to Enter the Diagnostic Mode)
The voltages at P406-2 ( P/J406) (+)/P406-4 (+)/P406-5 (+) become 0.
Y N
Replace the HVPS (PL 8.2) (REP 8.2.1). The problem is solved.
Y N
Measure the voltage between P406-1 ( P/J406) (+) on the AIOC PWB and ground (-).
The voltage is approximately +5VDC.
Y N
Check between J520-1 ( P/J520) and J406-1 ( P/J406) on the HVPS PWB for a
short circuit.
If there is no short, replace the HVPS (PL 8.2) (REP 8.2.1).
Completed

U8-1, U9-0 2-32 WorkCentre 5016, 5020
062-300 Platen Interlock Open 062-345 IISS EEPROM Failure
BSD-Reference: CH 5.6 BSD-Reference: CH 3.1
Detected the opened Platen Interlock. Error in writing on or communicatiing with the EEPROM.
Procedure Procedure
Ensure that the DADF can be closed normally. The DADF can be closed normally. Switch off the machine power then switch on the power. The problem is solved.
Y N Y N
Remove obstructions or repair the DADF Counter Balances. (REP 13.3.2, REP 13.3.3) Replace the SLCC PWB (AIOC/Network PWB). (REP 8.1.3) (PL 8.1)
Check that the Platen Interlock is functioning properly. The Platen Interlock is functioning Problem is resolved.
properly.
Y N
Replace the Platen Interlock Sensor.
Replace the SLCC PWB (AIOC/Network PWB). (REP 8.1.3) (PL 8.1)

WorkCentre 5016, 5020 2-33 062-300, 062-345
062-360 Carriage Position Fail 062-371 Lamp Illumination Fail
Detected no input of Regi Sensor when carriage was working or detected the failure of the Detected incufficient light provided from the Lamp to the CCD.
Regi Sensor position, or detected the failure of the IIT Regi Sensor level.
Procedure
Procedure Check for any obstructions in the optical path between the lamp, the lens or the mirror. The
Check that the Lamp Carriage can move freely and has no loose cables. The Lamp Carriage optical path is clear of any obstructions.
and cables are good. Y N
Y N Remove the obstuctions.
Repair the Lamp Carriage. (REP 10.3.1)
Check that the White Color Correction Plate (Reflector) is in place and not deterioarated. (PL
Enter the Diagnostic Mode. Enter Component Control Code [62-212]. Check the operation of 10.6) The White Color Correction Tape is good.
the IIT Regi Sensor. The Regi Sensor is good. Y N
Y N Clean or replace the White Color Correction Plate. (PL 10.6)
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 [62-02]. The Illumination Lamp
is good.
Enter the Diagnostic Mode. Enter Component Control Code [05-22]. The Carriage moves in Y N
the scan direction. Check that the Lamp harness is properly connected and repair if necessary. Replace the
Y N Illumination Lamp. (REP 10.6.1)
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)
Replace the SLCC PWB (AIOC/Network PWB). (PL 8.1) (REP 8.1.3)

062-360, 062-371 2-34 WorkCentre 5016, 5020
062-380 AGC Failure 062-386 AOC Failure
Control logic has detected insufficient light from the Illumination Lamp during AGC (Automatic Control logic has detected an output defect of the CCD at AOC (Automatic Offset Control) of
Gain Congrol) of the auto IIT Calibration at Start. the auto IIT Calibration at Start.
Procedure Procedure
Check for any obstructions in the optical path. Clean the Mirror, lens and the white balance Check the connector P/J410 for proper connection. The problem has been resolved.
strip. Switch off the power then switch it on again. The problem has been resolved. Y N
Y N Replace the SLCC PWB and (3) EEPROMS (AIOC/Network PWB). (PL 8.1) (REP 8.1.3)
Enter the Diagnostic Mode. Enter Component Control Code [62-02]. The lamp is good.
Y N POPO the machine and retry.
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.

WorkCentre 5016, 5020 2-35 062-380, 062-386
062-392 IPS PWB Memory Fail 062-393 IPS PWB Fail
Control logic has detected RAM malfunction of IISS PWB. Control logic has detected a test error or a writing error to the SLCC EEPROMs.
Procedure Procedure
Switch off the power then switch it on again. If the problem is not solved, replace the SLCC 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) PWB (AIOC/Network) and the 3 EEPROMs. (REP 8.1.3)

062-392, 062-393 2-36 WorkCentre 5016, 5020
A B C
005-170 DADF Feed Failure Replace the Document Feed Clutch (PL 13.9)
BSD-Reference: CH 5.2 Replace the Pick Up Roller and Feed Roller. (REP 13.9.1)
Explanation Replace the Document Feed Sensor (PL 13.9).

The control logic has detected the failure of paper to reach the Document Feed Sensor after
the Feed Clutch has energized.
Procedure
Check for obstructions in the Document Tray. Clean the Feed Roll. Confirm that a document is
feeding into the document handler. The Feed Roller feeds paper into the document 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).
A B C
WorkCentre 5016, 5020 2-37 005-170
A B C
005-171 DADF Regi / Exit Failure Replace the Document Feed Clutch (PL 13.9)
BSD-Reference: CH 5.8 Replace the Pick Up Roller and Feed Roller. (REP 13.9.1)
Explanation Enter the Diagnostic Mode. Enter Component Control Code [05-206]. Actuate the Document
Control logic has detected no paper at the Registration Sensor after turning on the Registration Registration Sensor acutator. The display changes from High to Low.
Clutch or detected no paper at the Exit/Invert Sensor after turning on the Registration Clutch. Y N
Replace the Document Registration Sensor. (PL 13.7)
Procedure
Enter the Diagnostic Mode. Enter Component Control Code [05-205]. Actuate the Exit/Invert
Check for obstructions in the Document Tray. Clean the Feed Roll. Confirm that a document is
Sensor actuator. The display changes from High to Low.
Y N
dler.
Replace the Exit/Invert Sensor. (PL 13.7)
Y N
The Document Drive Motor operates.
Replace the DADF PWB (REP 13.2.4), or replace the SLCC PWB (AIOC/Network) (REP 8.1.3)
Y N
Y N
Y N
connections
nection.
open circuit.
13.2.4)

Y N
Y N

Y N
Y N
A B C
005-171 2-38 WorkCentre 5016, 5020
A B
005-172 DADF Inverted Document Jam Y N
BSD-Reference: CH 5.8
Explanation Replace the Document Feed Clutch (PL 13.9)

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 Replace the Pick Up Roller and Feed Roller. (REP 13.9.1)
turning on the Document Registration Sensor.
Enter the Diagnostic Mode. Enter Component Control Code [05-204]. Actuate the Document
Procedure Feed Sensor acutator. The display changes from High to Low.
Check for obstructions in the Document Tray. Clean the Feed Roll. Confirm that a document is Y N
Replace the Document Feed Sensor. (PL 13.9)
dler.
Y N Enter the Diagnostic Mode. Enter Component Control Code [05-205]. Actuate the Exit/Invert
The Document Drive Motor operates. Sensor actuator. The display changes from High to Low.
Y N
Y N
Enter the Diagnostic Mode. Enter Component Control Code [05-01]. The Docu- 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)
Y N
Y N
connections
nection.
open circuit.
13.2.4)

Y N
Y N

Y N
A B
WorkCentre 5016, 5020 2-39 005-172
005-198 Short Scan Jam 005-199 Long Scan Jam
The control logic has found that the length of slow scan is less than 80mm. The control logic has detected that the length of slow scan is 450mm or more.
Procedure Procedure
Choose a document size equal to or larger than A4 paper or 208mm SEF or larger, in the Doc- Choose a document size equal to or less than A3 paper or 294mm SEF or less in the Docu-
ument Tray. The problem is solved. ment Tray. The problem is solved.
Y N Y N
Replace the Document Registration Sensor. (PL 13.7) Replace the Document Registration Sensor. (PL 13.7)
Inform the customer of the minimum size limitation of documents used in the DADF Document Inform the customer of the maximum size limitation of documents used in the DADF Document
Tray. Tray.

005-198, 005-199 2-40 WorkCentre 5016, 5020
005-305 Feeder Top Cover Open 005-920 Static Jam
The control logic has detected that the Feeder Top Cover is open. At power on, the control logic detected either the Platen Interlock is close when the Feeder
Cover is open or the Feeder Cover Interlock is close when the Platen Interlock is open.
Procedure
Close the Feeder Top Cover. The problem continues. Procedure
Y N If this occurs frequently, confirm if there is any interferance with the Feed Sensor (PL 13.9),
Adjust or repair the Feeder Top Cover latch. (REP 13.4.1) 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
Replave the Feeder Top Cover Switch. (PL 13.9) solved.

WorkCentre 5016, 5020 2-41 005-305, 005-920
005-305, 005-920 2-42 WorkCentre 5016, 5020
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
Reissue June, 2008 Image Quality

Image Quality June, 2008 Reissue
IQ1 IOT Image Quality Entry RAP IQ2 IIT Image Quality Entry RAP
Initial Actions Initial Actions
Determine whether the image quality problem occurs in Copy Mode or Print Mode. If the prob- Clean the IIT Upper Cover (PL 10.2) (REP 10.2.1).
lem occurs in Copy Mode, go to IQ2.
Clean the mirrors and lens with a lint-free cloth.
Procedure
Determine the image quality problem and go to the relevant RAP. Determine the image quality problem and go to the relevant RAP.
Table 1 IOT Image Quality Problems Table 1 IIT Image Quality Problems
Image Quality Problem Symptom RAP Image Quality Problem Symptom RAP
Low image density Overall low density of images. IQ3 Low image density Overall low density of images. IQ3
Wrinkled images The printed paper is creased, folded or torn. IQ4 Background contamination The whole page or part of the page is contami- IQ6
nated by toner. The contamination appears as a
Ghost images Ghost images appear on the paper. Parts of the IQ5
very light grayish color.
previous page or current page appear as ghost
images on the paper. Black lines, blank areas, or Black lines or white streaks running parallel to IQ9
Background contamination The whole page or part of the page is contami- IQ6 smears in the process direction. the direction of paper transport.
nated by toner. The contamination appears as a Black lines, blank areas, or Black lines or white streaks running at right IQ11
very light grayish color. smears at right angles to the angles to the direction of paper transport.
process direction.
Deletion Part of the image is missing. IQ7
Skew/Misregistration Printed images are not parallel to the edges of IQ8 Spotted blanks Toner spots and blank areas are spread irregu- IQ13
larly over the whole page.
the paper.
Black lines, blank areas, or Black lines or white streaks running parallel to IQ9 Solid black copy The output is completely black. IQ14
smears in the process direction the direction of paper transport.
Improper fusing, offset Printed images are not properly fused onto the IQ10
paper.
When rubbed, the image comes off easily.
Black lines, blank areas, or Black lines or white streaks running at right IQ11
smears at right angles to the angles to the direction of paper transport.
process direction.
Mottle Uneven printed image density. IQ12
Spotted blanks Toner spots and blank areas are spread irregu- IQ13
larly over the whole page.
Solid black copy The output is completely black. IQ14
Blank copy The output is completely white. IQ15

WorkCentre 5016, 5020 3-3 IQ1, IQ2
IQ3 Low Image Density RAP IQ4 Wrinkled Image RAP
Overall low density of images. The output is creased, folded or torn.
Procedure Procedure
Check for dirt on the Platen Glass. The Platen Glass is clean. Check the paper type. The paper used is within specifications.
Y N Y N
Clean any dirt on the Platen. Use paper that is within specifications.
If unable to clean the dirt, replace the IIT Upper Cover (PL 10.2) (REP 10.2.1).
Use paper from a freshly opened packet. The problem recurs.
Check the drum ground contact. The drum ground contact is clean and not damaged. Y N
Y N Completed
Clean the drum ground contact. If necessary, restore it to its proper shape.
Remove the Fuser (PL 5.1) (REP 5.1.1) and reinstall it properly. Turn the power OFF then ON
Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF and make a print. The problem recurs.
then ON and make a print. The problem recurs. Y N
Y N Completed
Completed
Check for foreign substances and damaged components in the paper transport path. No for-
Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a eign substances or damaged components are found in the paper transport path.
print. The problem recurs. Y N
Y N Remove the foreign substances. Reshape or replace any damaged components.
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).

IQ3, IQ4 3-4 WorkCentre 5016, 5020
IQ5 Residual Image (Ghosting) RAP IQ6 Background RAP
Ghost images appear on the paper. Parts of the previous page or current page appear as ghost The whole page or part of the page is contaminated by toner. The contamination appears as a
images on the paper. very light grayish color.
Procedure Procedure
Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF Check for dirt on the Platen Glass. The Platen Glass is clean.
Y N Remove any dirt from the Platen Glass. If you cannot clean the Platen Glass, replace the
Completed IIT Upper Cover (PL 10.2) (REP 10.2.1).
Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF
print. The problem recurs. then ON and make a print. The problem recurs.
Y N Y N
Completed Completed
Remove the Fuser (PL 5.1) (REP 5.1.1), lower the green levers on both sides, turn the Drive Install a new Drum Cartridge (PL 4.1) (REP 4.1.1) and install it properly. Turn the power OFF
Gear of the Heat Roll and check the Heat Roll surface for dirt and/or contamination. The sur- then ON and make a print.
face of the Heat Roll is clean. The problem recurs.
Y N Y N
Remove any dirt and/or contamination. If you cant clean the surface of the Heat Roller, Completed
replace the Fuser (PL 5.1) (REP 5.1.1).
Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron (PL 4.3) (REP
Replace the AIOC PWB (PL 8.1) (REP 8.1.1). 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).

IQ7 Deletion RAP IQ8 Skew/Misregistration RAP
Part of the image is missing. Printed images are not parallel to the edges of the paper.
Procedure Procedure
Check the paper type. The paper used is within specifications. Check the location where the machine is installed. The machine is installed on a stable,
Y N level surface.
Use paper that is within specifications. Y N
Install the machine on a stable, level surface.
Use paper from a freshly opened packet. The problem recurs.
Y N Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF
Completed then ON and make a print. The problem recurs.
Y N
Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF Completed
then ON and make a print. The problem recurs.
Y N Check the Paper Cassette. The Paper Cassette is installed properly.
Completed Y N
Install it properly.
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. Check the paper transport path. There are no obstructions or damaged parts in the paper
Y N transport path.
Completed Y N
Remove any obstructions. Reshape or replace any damaged parts.
Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron is not damaged.
Y N Replace the AIOC PWB (PL 8.1) (REP 8.1.1).
Replace the Transfer Corotron (PL 4.3) (REP 4.3.1).

IQ7, IQ8 3-6 WorkCentre 5016, 5020
IQ9 Process Direction Bands, Streaks, and Smears RAP IQ10 Unfused Copy/Toner Offset RAP
Black lines or white streaks running parallel to the direction of paper transport. Printed images are not properly fused onto the paper. When rubbed, the image comes off eas-
ily.
Procedure
Check the IIT Carriage Mirrors. The mirrors are not dirty, scratched, or damaged. Procedure
Y N Check the paper type. The paper used is within specifications.
Clean the mirrors. If the mirrors cant be cleaned, have scratches, or are damaged, Y N
replace the IIT Carriage (PL 10.3) (REP 10.3.1). Use paper that is within specifications.
Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF Use paper stored under room conditions. The problem recurs.
Y N Completed
Completed
Check the power supply voltages. The voltages are within the specified range.
Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a Y N
print. The problem recurs. Connect a power supply with voltages within the specified range.
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.
Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron is clean and not Y N
damaged. Completed
Y N
Clean the Transfer Corotron (PL 4.3) (REP 4.3.1). If it is damaged, replace it. Check the fusing temperature using the Diagnostics. A normal fusing temperature is set.
Y N
Check for dirt in the paper transport path. The paper transport path is clean. Set a normal fusing temperature using the Diagnostics.
Y N
Clean away the dirt. Replace the Fuser (PL 5.1) (REP 5.1.1).
Check the IIT Carriage Mirror. The mirror is clean and not damaged.
Y N
Clean the IIT Carriage Mirror (PL 10.3) (REP 10.3.1). If it is damaged, replace it.
Remove the Fuser (PL 5.1) (REP 5.1.1), and check the Heat Roll. The surface of the Heat
Roll is clean.
Y N
Remove any dirt. If you cant clean the surface of the Heat Roll, replace the Fuser (PL
5.1) (REP 5.1.1).
Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron is clean and not
damaged.
Y N
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).

IQ11 Repeating Bands, Streaks, Spots, and Smears RAP IQ12 Mottle RAP
Black lines or white streaks running at right angles to the direction of paper transport. Procedure
Check the paper type. The paper used is within specifications.
Procedure Y N
Check the IIT Carriage. The carriage has no foreign substances or damaged parts. Use paper that is within specifications.
Y N
Remove any foreign substances. If any parts of the IIT Carriage (Capstan Pulley, Capstan Use paper from a freshly opened packet. The problem recurs.
Shaft, Carriage Cable, etc.) are damaged, replace them. Y N
Completed
Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF
then ON and make a print. The problem recurs. Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF
Y N then ON and make a print. The problem recurs.
Completed Y N
Completed
print. The problem recurs. Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a
Y N print. The problem recurs.
Completed Y N
Completed
damaged. Check the Transfer Corotron (PL 4.3) (REP 4.3.1). The Transfer Corotron is clean and not
Y N damaged.
Clean the Transfer Corotron (PL 4.3) (REP 4.3.1). If it is damaged, replace it. 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 ). Remove the HVPS (PL 8.2) (REP 8.2.1) and reinstall it properly. Turn the power OFF then ON
Y N and make a print. The problem recurs.
Clean the surface of the Heat Roll. If you cant, replace the Fuser (PL 5.1) (REP 5.1.1). Y N
Completed

IQ11, IQ12 3-8 WorkCentre 5016, 5020
IQ13 Spots RAP IQ14 Black Prints RAP
Toner spots and blank areas are spread irregularly over the whole page. The paper is printed completely black.
Procedure Procedure
Check for dirt on the Platen Glass. The Platen Glass is clean. Check the IIT Carriage for foreign substances and damaged parts. The carriage has no for-
Y N eign substances or damaged parts.
Remove any dirt on the Platen. If you cant remove the dirt, replace the IIT Upper Cover Y N
(PL 10.2) (REP 10.2.1). Remove any foreign substances. If any parts of the IIT Carriage Assembly (cable, cap-
stan, etc.) (PL 10.3) are damaged, replace them.
then ON and make a print. The problem recurs. Remove the Drum Cartridge (PL 4.1) (REP 4.1.1) and reinstall it properly. Turn the power OFF
Y N then ON and make a print. The problem recurs.
Completed Y N
Completed
print. The problem recurs. Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a
Y N print. The problem recurs.
Completed Y N
Completed
damaged. Remove the HVPS (PL 8.2) (REP 8.2.1) and reinstall it properly. Turn the power OFF then ON
Y N and make a print. The problem recurs.
Clean the Transfer Corotron (PL 4.3) (REP 4.3.1). If it is damaged, replace it. Y N
Completed
Check for dirt in the paper transport path. The paper transport path is clean.
Y N Check the connectors of the HVPS (P/J520) and AIOC PWB (P/J406). The connectors are
Clean away the dirt. connected securely.
Y N
Remove the Fuser (PL 5.1) (REP 5.1.1) and check the surface of the Heat Roll. The surface Connect the connectors securely.
of the Heat Roll is clean.
Y N Check the wire between J460-4 and J520-2. The wire between J460-4 and J520-2 is not
Clean away the dirt. If you cant remove the dirt, replace the Fuser (PL 5.1) (REP 5.1.1). shorted or open.
Y N
Check the paper type. The paper used is within specifications. Repair the wire.
Y N
Use paper that is within specifications. 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
Use paper from a freshly opened packet. The problem recurs. (ROS) and J403 (AIOC PCB), are not shorted or open.
Y N Y N
Completed Repair the wire(s).
Replace the AIOC PWB (PL 8.1) (REP 8.1.1). 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).

WorkCentre 5016, 5020 3-9 IQ13, IQ14
IQ15 Blank Image RAP Copy Quality Specification
The paper is printed completely white. 1. Copy Alignment
How to measure
Procedure Make a copy of the Test Pattern STP3600 (A3) (Figure 1) and measure.
Check the ROS (PL 3.1) (REP 3.1.1). The ROS is installed correctly.
Y N Table 1 Copy Alignment: Measurement
Install the ROS (PL 3.1) (REP 3.1.1) correctly.
Item How to measure (Refer to Figure 1)
Check the drum ground contact. The drum ground contact is clean and not damaged. Lead Edge Registration (mm) (P1~P2) Standard Value *1
Y N Side Edge Registration (mm) (P7~P19) Standard Value *1: A3S
Clean the drum ground contact. If it is damaged, reshape or replace it.
Lead Skew (mm) (P5~P6) (P3~P4)
Vertical Ratio (%) ((P2~P14) - 200) / 200 x 100: A3S
then ON and make a print. The problem recurs. Horizontal Ratio (%) ((P8~P13) - 280) / 280 x 100
Y N Perpendicularity (mm) Difference between the perpendicular line of the intersection
Completed point between the line that connects P4 and P6, and P14.
Linearity (Vertical) (mm) Maximum difference between the [Intersection point of the
Install a new Drum Cartridge (PL 4.1) (REP 4.1.1). Turn the power OFF then ON and make a 400mm vertical line A and each vertical line] and the line that con-
print. The problem recurs. nects P2 and P14.
Y N
Linearity (Horizontal) (mm) Maximum difference between the [Intersection point of the
Completed
280mm horizontal line C and each horizontal line] and the line that
connects P10 and P15.
Print a page that is entirely black. During the print cycle, turn OFF the power after you hear the
Linearity (Skew) (mm) 280mm Maximum difference between the [Intersection point of the
paper feed (to force a stop during the image transfer) and check the surface of the Drum.
skew line D and each line] and the line that connects P17
There is a considerable amount of toner left on the surface of the Drum.
and P13.
Y N
Check the P/J140, P/J406, J403, and J140 connectors. The connectors are connected Or
Maximum difference between the [Intersection point of the
securely.
skew line E and each line] and the line that connects P8 and
Y N
P18.
Connect the connectors securely.
Parallelism (mm) (P10~P12) (P15~P16)
Check the ROS (PL 3.1) (REP 3.1.1). The ROS is installed correctly. *1: Measure the length of the position of FX STP#3600 and use it as the Standard Value
Y N in the table.
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).

IQ15, 3-10 WorkCentre 5016, 5020
Specification
[System] IOT + IIT
Table 2 Copy Alignment: Specification

Specification
Item 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
[DC] IOT + IIT

Item Specification Measurement Length
Simplex MSI
Skew H +/-1.9 +/-2.2 200mm
Perpendicularity +/-2.8 +/-3.0 400mm
Linearity: V 1.4 -- 400mm
Linearity: H 1.4 -- 280mm
Linearity: D 1.4 -- 283mm
Registration: Lead +/-2.4 +/-3.1
Registration: Side +/-3.0 +/-3.2
Magnification: V (%) +/-0.95 (100%) -- 400mm
+/-1.16 (50%-99%)
+/-1.47 (101%-200%)
Magnification: H (%) +/-0.95 (100%) -- 280mm
+/-1.16 (50%-99%)
+/-1.47 (101%-200%)

WorkCentre 5016, 5020 3-11
Figure 1 Copy Alignment Measurement Positions (Test Pattern STP3600)
2. Image Quality Make a copy of the Test Pattern 499T247 (A3) and measure. See Table 5 for specifications.
How to measure
Table 4
Text/Image Density Measure the 0.7G line image (10) at 3 locations.
(100%/Normal mode only) Determine the maximum and minimum mean value measured
(within the same copy).

3-12 WorkCentre 5016, 5020
Table 4
Low Contrast Normal mode: Check that the 0.2G line image 13 can be read.
(100% only) Darker mode: Measure the 0.2G line image 13 at 3 locations.
Determine the maximum and minimum mean value measured
Reproducibility of the blue Normal mode: Check that the 0.2B line image 14 can be read.
color density Darker mode: Measure the 0.2B line image 14 at 3 locations.
(100% only) Determine the maximum and minimum mean value measured
Solid Density Reproduc- Measure the 1.0G solid 16 at 3 locations.
ibility Determine the maximum and minimum mean value measured
(100%/Normal mode only) (within the same copy).
Background Measure the margin.
Resolution 70.7, 100%: Measure the resolution target 17 at 3 locations.
141.4%: Measure the resolution target 17 at 2 locations.
Skip and Smear 100%: Check that the 2.5lp/mm ladder 18 is resolving across the
entire page.
70.7~99%: Check that the 1.8lp/mm ladder 19 is resolving across
the entire page.

WorkCentre 5016, 5020 3-13
Figure 2 Image Quality Measurement Positions (Test Pattern 499T247)
Image Quality Specification

Total System

3-14 WorkCentre 5016, 5020
Table 5
OUTPUT OUTPUT OUTPUT OUTPUT
(Density (Density (Density (Density
Reduce/ Settings Settings Settings Settings
Enlarge Button) Button) Button) Button)
Item (%) INPUT Lighter 3 Normal Darker 3 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- 100 0.2 Blue - >=0.17 >=0.57 >=0.22
sity
Blue Color Density Evenness 100 0.2 Blue - - 0.4 (Max) -
Reproducibility of the blue color den- 100 0.1 Blue Does not - - -
sity 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 100 NBS Target - - - 4.3 Lo/mm
(Excluding Skip/Smear) (Min)
(Excluding Skip/Smear)
Depth of Focus 100 NBS Target - - - 3 Lo/mm
(Min)*1
Skip/Smear 100 Ladder A3 Entire - - - 2.5 Lo/mm
Page (Min)*1
Page (Min)
Page (Min)
Page (Min)*1

WorkCentre 5016, 5020 3-15
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)

3-16 WorkCentre 5016, 5020
Auger Marks
Figure 1 Auger Marks
Cause Action
1. Magnetic field failure in the Developer Magnetic Roll. 1. Replace the Drum Cartridge (PL 4.1) (REP 4.1.1). The problem may occur immediately
2. There was a drop in the level of developer material. after you install a new Drum Cartridge. This can be corrected by feeding a few sheets of
paper.

WorkCentre 5016, 5020 3-17
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).

3-18 WorkCentre 5016, 5020
White Streaks (Process Direction)
Figure 3 White Streaks (Process Direction)
Cause Action
1. Foreign substances are blocking the ROS Laser. 1. Clean the optical path between the ROS (PL 3.1) (REP 3.1.1) and the Drum Cartridge (PL
2. Developer material clogging on the Developer Magnetic Roll due to foreign substances. 4.1) (REP 4.1.1), and clean the seal glass.
2. Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).

WorkCentre 5016, 5020 3-19
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.

3-20 WorkCentre 5016, 5020
Toner Contamination
Figure 5 Toner Contamination
Cause 2. Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).

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.

WorkCentre 5016, 5020 3-21
Toner Splattering
Figure 6 Toner Splattering
Cause Action
1. Paper size mismatch (tray settings and paper size are different). 1. Check the tray settings.
2. Increased paper resistance due to dry conditions. 2. Use paper from a freshly opened packet.

3-22 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.

WorkCentre 5016, 5020 3-23
Regular Deletions in the Process Direction (Spots, Streaks, Bands,
etc.)
Figure 8 Regular Deletions in the Process Direction (Spots, Streaks, Bands, etc.)
Cause 4. 80mm Pitch (Fuser Heat Roll): Scratches or foreign substances.

1. 94mm Pitch (Drum): Scratches or foreign substances. Action
2. 57mm Pitch (Developer Roll): Developer material clogging on the Magnetic Roll. 1. 1,4: Clean or replace the Drum Cartridge (PL 4.1) (REP 4.1.1)/Fuser (PL 5.1) (REP
3. 44mm Pitch (Charger): Scratches or foreign substances. 5.1.1).
2. 2,3: Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).

3-24 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 Action
1. 94mm Pitch (Drum): Scratches or foreign substances. 1. 1,4,5,6: Clean or replace the Drum Cartridge (PL 4.1) (REP 4.1.1)/Fuser (PL 5.1) (REP
2. 57mm Pitch (Magnetic Roll): Developer material clogging on the Magnetic Roll. 5.1.1).
3. 44mm Pitch (Charger): Scratches or foreign substances. 2. 2,3: Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).
4. 80mm Pitch (Heat Roll): Scratches or foreign substances.
5. 19mm Pitch (Fuser Roll-Exit): Dirt.
6. 44mm Pitch (Registration): Dirt.

WorkCentre 5016, 5020 3-25
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.

3-26 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 Action
[Auto] performs background detection of images at a distance of up to 10mm from the Lead Select [Off] for [Auto].
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.

WorkCentre 5016, 5020 3-27
3-28 WorkCentre 5016, 5020
4 Repairs and Adjustments
Introduction REP 9.1.1 Output Tray .................................................................................................... 4-67
Introduction ..................................................................................................................... 4-3 REP 9.1.2 Front Left Cover ............................................................................................. 4-68
REP 9.2.1 Rear Cover..................................................................................................... 4-69
Repairs REP 9.2.2 Right Cover .................................................................................................... 4-70
1. Drive 10. IIT
REP 1.1.1 IOT Motor (SCC)............................................................................................ 4-5 REP 10.1.1 IIT Platen Cover ........................................................................................... 4-71
REP 10.2.1 IIT Upper Cover (SCC) ................................................................................ 4-72
2. Paper Transport
REP 10.3.1 IIT Carriage (SCC) ....................................................................................... 4-73
REP 2.2.1 Tray 1 Feed Clutch (SCC) ............................................................................. 4-7
REP 10.3.2 Flexible Print Cable (SCC)........................................................................... 4-79
REP 2.3.1 Tray 1 Feed Roll (SCC) ................................................................................. 4-9
REP 10.6.1 Exposure Lamp............................................................................................ 4-81
REP 2.5.1 Tray 1 Feed Sensor ...................................................................................... 4-10
REP 10.7.1 Carriage Cable and Drum ............................................................................ 4-82
REP 2.7.1 Tray 1 No Paper Sensor ............................................................................... 4-12
REP 10.7.2 Inverter PWB................................................................................................ 4-85
REP 2.8.1 Registration (SCC)......................................................................................... 4-13
11. Single Tray Module
3. ROS
REP 11.1.1 Tray 2........................................................................................................... 4-89
REP 3.1.1 ROS (SCC) .................................................................................................... 4-17
REP 11.1.2 Single Tray Module (Separation from IOT) .................................................. 4-89
4. CRU REP 11.4.1 Tray 2 Feed Roll .......................................................................................... 4-91
REP 4.1.1 Drum Cartridge .............................................................................................. 4-19 REP 11.4.2 Tray 2 Retard Roll........................................................................................ 4-93
REP 4.2.1 Toner Empty Sensor...................................................................................... 4-20 REP 11.5.1 STM Feed Sensor........................................................................................ 4-96
REP 4.2.2 Erase Lamp ................................................................................................... 4-21 REP 11.5.2 STM PWB (SCC) ......................................................................................... 4-97
REP 4.3.1 Transfer Module............................................................................................. 4-23 REP 11.6.1 STM Feed Clutch ......................................................................................... 4-98
REP 4.4.1 Corotron Wire ................................................................................................ 4-27 REP 11.6.2 STM Feed Motor .......................................................................................... 4-99
REP 11.7.1 STM No Paper Sensor................................................................................. 4-100
5. Fuser
REP 5.1.1 Fuser (SCC)................................................................................................... 4-29 13. ADF
REP 5.1.2 Temperature Control Sensor Assembly......................................................... 4-31 REP 13.1.1 ADF Assembly ............................................................................................. 4-101
REP 5.1.3 Fuser Lamp.................................................................................................... 4-32 REP 13.1.2 ADF/DADF Platen Cushion.......................................................................... 4-102
REP 5.1.4 Fuser Roll ...................................................................................................... 4-35 REP 13.2.1 Document Tray Assembly (ADF) ................................................................. 4-104
REP 5.1.5 Fuser Pressure Roll ....................................................................................... 4-38 REP 13.2.2 ADF Feeder Assembly................................................................................. 4-106
REP 13.2.3 Front Cover .................................................................................................. 4-109
6. Exit REP 13.2.4 Rear Cover................................................................................................... 4-110
REP 6.1.1 Exit Transport (Simplex) ................................................................................ 4-39 REP 13.2.5 DADF Eject Roller Solenoid......................................................................... 4-111
REP 6.1.2 Exit Transport (Duplex).................................................................................. 4-42 REP 13.2.6 DADF Assembly........................................................................................... 4-112
REP 13.2.7 Document Tray Assembly (DADF)............................................................... 4-113
7. Simplex Module and Bypass Tray REP 13.2.8 DADF Feeder Assembly .............................................................................. 4-116
REP 7.1.1 Simplex, Duplex Module ................................................................................ 4-45 REP 13.3.1 ADF Control PWB ........................................................................................ 4-119
REP 7.5.1 Bypass Feed Roll........................................................................................... 4-47 REP 13.3.2 Left Counter Balance (SCC) ........................................................................ 4-121
8. Electrical REP 13.3.3 Right Counter Balance (SCC)...................................................................... 4-122
REP 8.1.1 AIOC PWB (SCC).......................................................................................... 4-49 REP 13.3.4 DADF PWB .................................................................................................. 4-124
REP 8.1.2 LVPS (SCC)................................................................................................... 4-52 REP 13.4.1 Top Cover .................................................................................................... 4-125
REP 8.1.3 AIOC/Network PWB (DADF/Network Only)................................................... 4-55 REP 13.8.1 Retard Roll ................................................................................................... 4-126
REP 8.2.1 HVPS (SCC) .................................................................................................. 4-58 REP 13.9.1 Pickup Roll, Feed Roll.................................................................................. 4-128
REP 8.2.2 Duplex PWB (SCC) ....................................................................................... 4-61 Adjustments
REP 8.3.1 Control Panel (SCC) ...................................................................................... 4-62
ADJ 8.1.1 Edge Erase Adjustment.................................................................................. 4-131
REP 8.4.1 User Interface PWB (SCC) ............................................................................ 4-64 ADJ 8.1.2 Controller Firmware Version Upgrade ............................................................ 4-131
9. Cover ADJ 10.3.1 IIT Lead Edge/Side Edge Registration ......................................................... 4-132
Reissue June, 2008 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 June, 2008 Reissue

Introduction Terms and Symbols
This section contains procedures required for parts replacement and adjustment. Terms and symbols used throughout this section are explained here.
How to Use the Replacement and Adjustment Section WARNING

For installation procedures, only NOTEs are described here since installation procedures are A Warning statement indicates an operating or maintenance procedure, practice, or
the reverse of removal ones. condition that, if not strictly observed, could result in personal injury or loss of life.
CAUTION
1. (Figure X) at the beginning of a procedure indicates that its detailed steps are shown in A Caution statement indicates an operating or maintenance procedure, practice, or condition
the illustration. Numbers in the illustration indicate the sequence of the steps. that, if not strictly observed, could result in damage to, or destruction of, equipment.
2. (REP X.X.X) at the end of a procedure indicates the replacement procedure to be referred
NOTE: A Note statement indicates an operating or maintenance procedure, practice, or condi-
to.
tion that is necessary to accomplish a task efficiently.
3. Item numbers of replacement and adjustment procedures (i.e. REP/ADJ No.) correlate to
Reference: Used when other explanations are given.
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- Purpose: Used to describe the purpose of the Adjustment.
ment or adjustment procedure of Component PL 1.1 is REP 1.1.X or ADJ 1.1.X. Safety Critical Components (SCC):
4. When replacement/adjustment procedures or title items vary by modification or model, Safety Critical Components are components, such as static-sensitive integrated circuit chips,
the modification number or the model is indicated at the beginning or the end of the that require special precautions to prevent them from being damaged. Follow the regulations
respective titles or procedures. regarding Safety Critical Components set by FUJI XEROX Co., Ltd.
Example 1: REP X.X.X Main PWB [Models with 1V] indicates that the entire procedure Important Information Stored Component (ISC):
under this title applies to machines with Tag 1V. This component stores all the important customer information that is input after the installation.
Example 2: See Table 1. When replacing this component, follow the procedures in Section 4 Repairs and Adjustments.
Make absolutely sure that no customer information gets revealed.
Table 1
Symbol Description
Illustration 1: Indicates that a specific part has been modified by the
tag number within the circle.
Figure 1 Illustration 1
Illustration 2: Indicates that the configuration of the part shown is the
configuration before the part was modified by the number within the
circle.
Figure 2 Illustration 2
5. Positions or directions are defined as follows:

a. Front: Front of the machine.
b. Right: Right-hand side facing the machine.
c. Left: Left-hand side facing the machine.
d. Rear: Rear of the machine.

WorkCentre 5016, 5020 4-29
4-30 WorkCentre 5016, 5020
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

WorkCentre 5016, 5020 4-31 REP 1.1.1
4. Remove the IOT Motor (Figure 2).
1 Remove the Tapping Screws (4).
2 Remove the IOT Motor.
Figure 2
Replacement
1. To install, do the removal steps in reverse order.

REP 1.1.1 4-32 WorkCentre 5016, 5020
REP 2.2.1 Tray 1 Feed Clutch (SCC) 3. Remove the screws (3) that secure the Clutch Bracket (Figure 2).
1 Remove the screws (3).
Removal
WARNING
1 Disconnect the connector.
2 Release the wire harness from the clamp.
Figure 2
Figure 1

WorkCentre 5016, 5020 4-33 REP 2.2.1
4. Remove the Tray 1 Feed Clutch (Figure 3). Replacement
1 Remove the Clutch Bracket. 1. To install, do the removal steps in reverse order.
2 Remove the bearing. 2. When installing the Tray 1 Feed Clutch, place the tab of Clutch Bracket in the notch of
3 Remove the Tray 1 Feed Clutch. Tray 1 Feed Clutch (Figure 4).
4 Pull out the wire harness through the hole.
Figure 3 Figure 4

REP 2.2.1 4-34 WorkCentre 5016, 5020
REP 2.3.1 Tray 1 Feed Roll (SCC) 4. Remove the Tray 1 Feed Roll (Figure 2).
1 Gently lift up the tab to remove the Tray 1 Feed Roll.
Removal
WARNING
1. Remove all paper from Tray 1.
2. Remove Tray 1.
3. Remove the Feed Shaft (Figure 1).
1 Lower the Bottom Plate.
2 Release the Feed Shaft from the bearing by pressing down on the white tab.
3 Remove the Feed Shaft by pulling it in the direction of the arrow.
Figure 2
Figure 1

WorkCentre 5016, 5020 4-35 REP 2.3.1
Replacement REP 2.5.1 Tray 1 Feed Sensor
1. To install, do the removal steps in reverse order. Parts List on PL 2.5
2. When installing the Tray 1 Feed Roll, align the pin of the Feed Shaft with the slot in the
Tray 1 Feed Roll (Figure 3).
Removal
WARNING
1. Remove Tray 1.
2. Remove Tray 2 (REP 11.1.1).
3. Remove the Sensor Housing of the Tray 1 No Paper Sensor (REP 2.7.1).
4. Open the Tray 1 Access Cover on the left side of the machine.
Figure 3

REP 2.3.1, REP 2.5.1 4-36 WorkCentre 5016, 5020
5. Remove the Tray 1 Feed Sensor (Figure 1). Replacement
1 Remove the Tapping Screw. 1. To install, do the removal steps in reverse order.
2 Remove the cable bands (2). 2. Insert the Connector Housing of the Tray 1 Interlock Switch into the square hole of the
3 Release the wire harness from the clamps (2). frame (Figure 2).
4 Move the wire harness toward you and disconnect the connector. A Square hole
5 Remove the Tray 1 Feed Sensor.
Figure 2
Figure 1

WorkCentre 5016, 5020 4-37 REP 2.5.1
REP 2.7.1 Tray 1 No Paper Sensor 4. Remove the Tray 1 No Paper Sensor (Figure 2).
1 Remove the Actuator.
2 Release the tabs to remove the 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 2
Replacement
Figure 1

REP 2.7.1 4-38 WorkCentre 5016, 5020
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

WorkCentre 5016, 5020 4-39 REP 2.8.1
5. Remove the Connector Housing (Figure 2). 6. Remove the Front Stopper (Figure 3).
1 Remove the wire harness from the guide. 1 Remove the Front Stopper.
2 Slide the Connector Housing through the hole.
Figure 3
Figure 2

REP 2.8.1 4-40 WorkCentre 5016, 5020
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

WorkCentre 5016, 5020 4-41 REP 2.8.1
REP 2.8.1 4-42 WorkCentre 5016, 5020
REP 3.1.1 ROS (SCC) 1. Open the Front Cover.
2. Remove the Output Tray (REP 9.1.1).
Removal 4. Remove the HVPS and Contact Block (REP 8.2.1).
WARNING 5. Remove the Laser Housing (Figure 2).
To avoid personal injury or electrical shock, ensure that the machine is completely off 1 Remove the Tapping Screw.
before disassembling or adjusting. Turn OFF the power and unplug the machine. 2 Remove the Laser Housing.
NOTE: Attach the attachment in the ROS Replacement Kit to a Stubby Driver to remove the
screws (Figure 1).
Figure 2
Figure 1

WorkCentre 5016, 5020 4-43 REP 3.1.1
6. Disconnect the ROS connectors (Figure 3). 7. Remove the ROS (Figure 4).
1 Disconnect the Ground connectors (2). 1 Remove the Tapping Screws (5).
2 Disconnect the connectors (2). 2 Remove the ROS.
4 Remove the wire harness from the hook.
Figure 4
Figure 3 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.

REP 3.1.1 4-44 WorkCentre 5016, 5020
REP 4.1.1 Drum Cartridge 2. When installing the Drum Cartridge, align the protruding end of the Drum Cartridge with
the cavity in the frame (Figure 2).
Removal
WARNING
1. Open the Simplex/Duplex Module.
2. Open the Front Cover.
3. Remove the Drum Cartridge (Figure 1).
1 Release the tab.
2 Remove the Drum Cartridge.
Figure 2
Figure 1
Replacement

WorkCentre 5016, 5020 4-45 REP 4.1.1
REP 4.2.1 Toner Empty Sensor 5. Remove the Toner Empty Sensor (Figure 2).
1 Release the tabs (2) to remove the Toner Empty Sensor.
Removal
WARNING
2. Remove Tray 1.
Figure 2
Figure 1

REP 4.2.1 4-46 WorkCentre 5016, 5020
Replacement REP 4.2.2 Erase Lamp
2. Insert the Connector Housing of the Toner Empty Sensor into the square hole of the frame
(Figure 3).
Removal
A Square hole WARNING
5. Remove the HVPS and Contact Block (REP 8.2.1).
Figure 3

WorkCentre 5016, 5020 4-47 REP 4.2.1, REP 4.2.2
6. Release the Erase Lamp tabs (7) (Figure 1). 7. Remove the Erase Lamp (Figure 2).
1 Release the tabs (upper: 3). 1 Remove the Erase Lamp.
2 Release the tabs (lower: 4).
Figure 2
Figure 1

REP 4.2.2 4-48 WorkCentre 5016, 5020
Replacement REP 4.3.1 Transfer Module
2. Insert the Connector Housing of the Erase Lamp into the square hole in the frame (Figure
3).
Removal
A Square hole WARNING
4. Remove the Exit Transport (REP 6.1.1).
5. Remove the Fuser (REP 5.1.1).
Figure 3

6. Remove the Transfer Corotron Housing (Figure 1). 7. Remove the Tapping Screws that secure the Corotron Block (Figure 2).
1 Release the hooks (2). 1 Remove the Tapping Screws (2).
2 Remove the Transfer Corotron Housing by pulling its front side in the direction of the 2 Move the Fuser Connector Bracket.
arrow. 3 Remove the Tapping Screw.
Figure 1 Figure 2

REP 4.3.1 4-50 WorkCentre 5016, 5020
8. Remove the Corotron Block (Figure 3). 9. Disconnect the Corotron Block cables (Ground/Detack/Transfer) (Figure 4).
1 Press the Spring Plate. 1 Disconnect the Ground Cable (white).
2 Remove the Corotron Block by pulling it in the direction of arrow. 2 Remove the Ground Cable (white) from the guides (2).
3 Remove the Detack Cable (black).
4 Remove the Detack Cable (black) from the guides (2).
5 Disconnect the Transfer Cable (white).
6 Remove the Transfer Cable (white) from the guides (3).
Figure 3
Figure 4

WorkCentre 5016, 5020 4-51 REP 4.3.1
Replacement 3. Attach the cables (Ground/Detack/Transfer) to the Corotron Block hooks as shown in Fig-
1. To install, do the removal steps in reverse order. ure 6.
2. Perform the following steps to install the Corotron Block (Figure 5).
1 Press the Spring Plate.
2 Install the Corotron Block.
Figure 6
Figure 5

REP 4.3.1 4-52 WorkCentre 5016, 5020
4. When installing the Transfer Corotron Housing, insert the tabs of Transfer Corotron Hous- REP 4.4.1 Corotron Wire
ing into the square holes of the Corotron Bracket (Figure 7).
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 7
Figure 1

4. Attach the Corotron Wire (Figure 2). 5. Attach the spring (Figure 3).
1 Attach the Corotron Wire. 1 Attach the spring to the Corotron Wire.
2 Attach the spring.
Figure 2
Figure 3
Replacement

REP 4.4.1 4-54 WorkCentre 5016, 5020
REP 5.1.1 Fuser (SCC) 3. Disconnect the connectors (Figure 2).
1 Disconnect the connectors (2).
Removal
WARNING
WARNING
The Fuser and Exit Transport are hot. Do not work on them until they are cool enough.
1. Open the Left Side Cover.
2. Remove the Connector Cover (Figure 1).
1 Remove the Tapping Screw.
2 Remove the Connector Cover.
Figure 2
Figure 1

WorkCentre 5016, 5020 4-55 REP 5.1.1
4. Remove the Fuser (Figure 3). Replacement
1 Remove the Tapping Screws (2). 1. To install, do the removal steps in reverse order.
2 Remove the Fuser by shifting it in the direction of the arrow. 2. When installing the Connector Cover, do the following (Figure 4):
1 Insert the wire harness into the U-groove of the Fuser Frame.
2 Insert the stud of the Connector Cover into the hole in the frame.
Figure 3
Figure 4

REP 5.1.1 4-56 WorkCentre 5016, 5020
REP 5.1.2 Temperature Control Sensor Assembly 3. Remove the Temperature Control Sensor Assembly (Figure 2).
1 Remove the Screw.
2 Remove the Harness.
Removal
WARNING
WARNING
2. Slide the Cover to the left and remove (Figure 1).
Harness
Screw
Cover
Figure 2 Removing the Temperature Control Sensor Assembly
Figure 1 Removing the Cover

WorkCentre 5016, 5020 4-57 REP 5.1.2
Replacement REP 5.1.3 Fuser Lamp
NOTE: Before tightening the Screw, make sure that the Tab on the Sensor Block is Removal
inserted in the notch of the Frame (Figure 3).
WARNING
WARNING
2. Slide the Cover to the left and remove (Figure 1).
Screw
Sensor Block
Tab Notch
Figure 3 Installing the Temperature Control Sensor Assembly
Cover
Figure 1 Removing the Cover

3. Disconnect the hot side of the Fuser Lamp (Figure 2). 4. Disconnect the neutral side of the Fuser Lamp (Figure 3).
1 Disconnect the Terminal. 1 Disconnect the white wire from theTerminal.
2 Remove the Screw. 2 Remove the Screw.
White Wire
Screw
Terminal
Screw
Terminal
Figure 2 Disconnecting the hot side of the Fuser Lamp
Figure 3 Disconnecting the neutral side of the Fuser Lamp

WorkCentre 5016, 5020 4-59 REP 5.1.3
5. Remove the Fuser Lamp Housing (Figure 4). 6. Remove the Fuser Lamp by pulling it through the Fuser Roll (Figure 5).
1 Remove 2 Screws.
NOTE: Do not lose the Fuser Lamp Mount.
2 Carefully remove the Fuser Lamp Housing.
Fuser Roll
Screws
Fuser Lamp Mount
Fuser Lamp Housing Fuser Lamp
Figure 5 Removing the Fuser Lamp
Replacement
CAUTION
Figure 4 Removing the Fuser Lamp Housing
Do not touch the glass part of the Fuser Lamp unless you are are wearing gloves.

REP 5.1.3 4-60 WorkCentre 5016, 5020
REP 5.1.4 Fuser Roll 3. Remove the Stripper Finger Assembly (Figure 2 and Figure 3).
1 Remove the Screw.
2 Remove the Stripper Finger Assembly.
Removal
WARNING
before disassembling or adjusting. Turn OFF the power and unplug the machine. Cover Mount Stripper Finger Assembly
WARNING
CAUTION
1. Remove the Fuser Lamp (REP 5.1.3).
2. Remove the Fuser Cover (Figure 1).
1 Remove the 2 Screws.
2 Remove the Fuser Cover.
NOTE: Do not lose the Cover Mount (Figure 2). Fuser Cover
Fuser Cover Figure 2 Fuser Cover Removed
Stripper Finger Assembly
Screw
Screws
Figure 1 Removing the Fuser Cover
Figure 3 Removing the Stripper Finger Assembly

WorkCentre 5016, 5020 4-61 REP 5.1.4
4. Remove the Fuser Roll Retaining Rings and Drive Gear (Figure 4). 5. Remove the Fuser Roll by pulling it through the Bushings in the Frame (Figure 5).
1 Remove the Retaining Ring.
2 Remove the Drive Gear.
3 Remove the Retaining Ring from the other end of the Fuser Roll. Bushing
Fuser Roll
Frame
Fuser Roll
Drive Gear
Figure 5 Removing the Fuser Roll
Retaining Ring
Figure 4 Removing the Retaining Rings and Drive Gear

REP 5.1.4 4-62 WorkCentre 5016, 5020
Replacement CAUTION
CAUTION Make sure the stripper fingers are oriented correctly when reinstalling the Stripper Finger
Assembly, as shown in Figure 7.
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 7 Setting the Stripper Fingers
Locating Key
Figure 6 Installing the Drive Gear

WorkCentre 5016, 5020 4-63 REP 5.1.4
REP 5.1.5 Fuser Pressure Roll 3. Remove the Fuser Pressure Roll (Figure 2).
1 Remove the Levers.
2 Remove the Spring Mount Assemblies.
Removal 3 Remove the Fuser Pressure Roll.
WARNING
WARNING
CAUTION
Levers
1. Remove the Fuser Roll (REP 5.1.4).
2. Remove the Bushings (Figure 1).
Fuser Pressure Roll
Spring Mount Assemblies
Bushings
Figure 2 Removing the Fuser Pressure Roll
Replacement
CAUTION
Do not touch the glass part of the Fuser Lamp unless you are wearing gloves.
NOTE: When installing the Fuser Roll, see REP 5.1.4.
Figure 1 Removing the Bushings

REP 5.1.5 4-64 WorkCentre 5016, 5020
REP 6.1.1 Exit Transport (Simplex) 3. Disconnect the connector (Figure 1).
2 Remove the wire harness from the hook.
Removal 3 Remove the wire harness from the guides (2).
WARNING 4 Release the wire harness from the clamps (2).
WARNING
1. Open the Left Side Cover.
Figure 1

WorkCentre 5016, 5020 4-65 REP 6.1.1
4. Remove the Connector Cover (Figure 2). 5. Lower the Fuser levers (2) (Figure 3).
1 Remove the Tapping Screw. 1 Lower the levers (2).
Figure 3
Figure 2

REP 6.1.1 4-66 WorkCentre 5016, 5020
6. Remove the Exit Transport (Figure 4). Replacement
2 Remove the Exit Transport. 2. When installing the Connector Cover, insert the stud of the Connector Cover into the hole
3 Remove the Belt from the Exit Transport Drive Gear, and disconnect J153 from the in the frame (Figure 5).
Fuser Exit Sensor.
4 Remove the J153 wire harness from the Exit Transport.
J153
Figure 5
Figure 4

WorkCentre 5016, 5020 4-67 REP 6.1.1
REP 6.1.2 Exit Transport (Duplex) 3. Disconnect the connectors (Figure 1).
2. Disconnect P/J 551.
Removal 3 Remove the wire harness from the hook.
WARNING 4 Remove the wire harness from the guides (2).
To avoid personal injury or electrical shock, ensure that the machine is completely off 5 Release the wire harness from the clamp.
WARNING
1. Open the Duplex Module.
Figure 1

REP 6.1.2 4-68 WorkCentre 5016, 5020
4. Remove the Connector Cover (Figure 2). 5. Lower the Fuser levers (2) (Figure 3).
1 Remove the Tapping Screw. 1 Lower the levers (2).
Figure 3
Figure 2

WorkCentre 5016, 5020 4-69 REP 6.1.2
6. Remove the Exit Transport (Figure 4). Replacement
2 Remove the Exit Transport. 2. When installing the Connector Cover, insert the stud of the Connector Cover into the hole
3 Remove the Wire Harness through the hole. in the frame (Figure 5).
Figure 4

REP 6.1.2 4-70 WorkCentre 5016, 5020
REP 7.1.1 Simplex, Duplex Module 3. Open the Left Side Cover.
Parts List on PL 7.1, PL 7.3
Removal 2 Remove the wire harness from the hook.
WARNING 3 Remove the wire harness from the groove in the frame.
To avoid personal injury or electrical shock, ensure that the machine is completely off 4 Remove the wire harness from the guides (5).
before disassembling or adjusting. Turn OFF the power and unplug the machine. 5 Remove the wire harness from the groove in the frame.
6 Remove the wire harness from the hooks (3).
2. Tape the Bypass Tray so that it cannot open by itself (Figure 1).
1 Apply 2 pieces of tape as shown.
Figure 2
Figure 1

WorkCentre 5016, 5020 4-71 REP 7.1.1
5. Remove the Front Stopper (Figure 3). 6. Remove the Rear Stopper (Figure 4).
1 Remove the Front Stopper from the Registration. 1 Release the tab to remove the Rear Stopper.
2 Release the tab to remove the Front Stopper.
Figure 4
Figure 3

REP 7.1.1 4-72 WorkCentre 5016, 5020
7. Remove the Simplex Module (Figure 5). REP 7.5.1 Bypass Feed Roll
1 Loosen the Tapping Screws (2).
2 Move the Pivot Retainers (2) in the direction of the arrow.
3 Remove the Simplex Module.
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 5 Removing the Left Hand Cover Assembly
Replacement
Figure 1

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

REP 7.5.1 4-74 WorkCentre 5016, 5020
REP 8.1.1 AIOC PWB (SCC) 3. Remove the Core Clip (Figure 2).
1 Remove the Core Clip.
Removal
WARNING
CAUTION
Static electricity may damage electrical parts. Always wear an anti-static wrist band during 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 2 Removing the Core Clip
Figure 1

WorkCentre 5016, 5020 4-75 REP 8.1.1
4. Disconnect the Flexible Print Cables (2) from the AIOC PWB (Figure 3). 5. Remove the screw of the USB connector (Figure 4).
1 Disconnect the Flexible Print Cables (2). 1 Remove the screw.
2 Remove the Cores (2).
Figure 4
Figure 3

REP 8.1.1 4-76 WorkCentre 5016, 5020
6. Remove the AIOC PWB (Figure 5) Replacement
1 Remove the screws (2). 1. To install, do the removal steps in reverse order.
2 Remove the Tapping Screws (2). 2. When replacing the AIOC PWB, transfer the EP ROM (U2) from the old board to the new
3 Slide the the AIOC PWB up and out of P/J 407. one (Figure 6).
A EP ROM (U2)
Figure 5
Figure 6

WorkCentre 5016, 5020 4-77 REP 8.1.1
REP 8.1.2 LVPS (SCC) 5. Remove the IIT Ground Plate (Figure 2).
1 Remove the Screws (4).
2 Remove the IIT Ground Plate.
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 2 Removing the IIT Ground Plate
Figure 1

REP 8.1.2 4-78 WorkCentre 5016, 5020
6. Move the Inlet Bracket (Figure 3). 7. Disconnect the connectors (Figure 4).
1 Disconnect the connector (wire: blue). 1 Disconnect the connectors (2).
2 Disconnect the connector (wire: brown).
5 Move the Power Inlet Bracket.
Figure 4
Figure 3

WorkCentre 5016, 5020 4-79 REP 8.1.2
8. Disconnect the connectors (7) (Figure 5). 9. Remove the LVPS (Figure 6).
1 Remove the screw to remove the Ground Wire.
3 Remove the LVPS.
Figure 5
Figure 6
Replacement

REP 8.1.2 4-80 WorkCentre 5016, 5020
REP 8.1.3 AIOC/Network PWB (DADF/Network Only) 3. Remove the EMI Cover (Figure 2).
2 Remove the EMI Cover.
Removal 3 Remove the Cable Clip from the EMI Cover.
NOTE: The following procedure is for the WorkCentre 5020 (DADF/Network) only. If you have
a WorkCentre 5016, or 5020 with Platen only, see REP 8.1.1.
Screw (10) EMI Cover Cable Clip
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
Figure 2 Removing the EMI Cover

WorkCentre 5016, 5020 4-81 REP 8.1.3
4. Remove the SLCC PWB (Figure 3).
a. Disconnect the Flexible Print Cables (2) from the AIOC PWB (Figure 4).
1 Disconnect the Flexible Print Cables (2).
2 Remove the Cores (2).
b. Disconnect all the Connectors from the right side of the SLCC PWB.
c. Remove 6 Screws and disconnect the SLCC PWB from the LVPS.
AIOC PWB Flexible Print Cables Connectors
Figure 4 Disconnecting the Flexible Print Cables
Screw (6) LVPS Connectors
Figure 3 SLCC PWB for DADF/Network

REP 8.1.3 4-82 WorkCentre 5016, 5020
Replacement NOTE: If you do not transfer the EPROMs, the existing NVM values for skew, copy qual-
1. To install, do the removal steps in reverse order. ity, etc. will be lost.
2. When replacing the SLCC PWB, transfer the EPROMs (3) from the old PWB to the new NOTE: If one or more of the EPROMs are damaged during replacement or the informa-
one (Figure 5). 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.
EPROM EPROM
EPROM
Figure 5 Transferring the EPROMs

WorkCentre 5016, 5020 4-83 REP 8.1.3
REP 8.2.1 HVPS (SCC) NOTE: When removing the HVPS, use a Stubby Driver (499T00353).
Parts List on PL 8.2 5. Remove the Tapping Screws that secure the Contact Block (Figure 2).
Removal 1 Release the hook to remove the Harness Block.
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 2
Figure 1


REP 8.2.1 4-84 WorkCentre 5016, 5020
6. Remove the HVPS and Contact Block (Figure 3). 7. Separate the HVPS from the Contact Block (Figure 4).
1 Remove the Tapping Screws (3). 1 Remove the Contact Block in the direction of the arrow.
2 Disconnect the connector at the inner side of the HVPS.
3 Remove the HVPS and Contact Block.
Figure 4
Figure 3

WorkCentre 5016, 5020 4-85 REP 8.2.1
Replacement 3. When installing the HVPS and Contact Block, insert the slot of the Contact Block into the
guide of the frame (Figure 6).
2. Insert the wire harness of the HVPS into the slot of the Laser Housing (Figure 5).
A Slot
Figure 6
Figure 5

REP 8.2.1 4-86 WorkCentre 5016, 5020
REP 8.2.2 Duplex PWB (SCC) 3. Remove the Duplex PWB (Figure 2).
2 Remove the Guide.
Removal 3 Disconnect the Connector.
WARNING 4 Remove the Tapping Screws (2).
To avoid personal injury or electrical shock, ensure that the machine is completely off 5 Remove the Duplex PWB.
2. Disconnect the Connector (Figure 1).
2 Remove the Wire Harness from the Hook.
3 Remove the Wire Harness from the Guides (3).
Replacement

WorkCentre 5016, 5020 4-87 REP 8.2.2
REP 8.3.1 Control Panel (SCC) 3. Remove the screws that secure the Control Panel (Figure 2).
Removal
WARNING
1. Remove the Front Left Cover (REP 9.1.2).
2. Remove the Control Panel Cover (Figure 1).
2 Press the tabs (2) to release them.
3 Remove the Control Panel Cover towards the front.
Figure 2
Figure 1

REP 8.3.1 4-88 WorkCentre 5016, 5020
4. Remove the Control Panel (Figure 3). Replacement
1 Slide the rear of the Control Panel in the direction of the arrow. 1. To install, do the removal steps in reverse order.
2 Disconnect the connectors (2). 2. When installing the Control Panel, attach the Control Panel hooks (3) to the IIT Frame
3 Remove the Cable Band from the Control Panel Hook (Figure 4, B). (Figure 4).
A Spring - On top
B Hook - Below
Figure 3
Figure 4

WorkCentre 5016, 5020 4-89 REP 8.3.1
3. Thread the wire harness of the Control Panel as shown (Figure 5). REP 8.4.1 User Interface PWB (SCC)
Removal
WARNING
1. Remove the Control Panel (REP 8.3.1).
2. Turn the Control Panel upside down.
3. Remove the Support Brackets (Figure 1).
2 Remove the Support Brackets (3).
Figure 5
Figure 1

4. Remove the User Interface PWB (Figure 2).
2 Remove the User Interface PWB.
Figure 2
Replacement

WorkCentre 5016, 5020 4-91 REP 8.4.1
REP 8.4.1 4-92 WorkCentre 5016, 5020
REP 9.1.1 Output Tray Replacement
Parts List on PL 9.1 1. To install, do the removal steps in reverse order.
2. Perform the following steps to install the Output Tray (Figure 2).
Removal
1 Insert the tabs (2) into the square hole of the frame.
WARNING 2 Attach the hook.
2. Remove the Output Tray (Figure 1).
2 Remove the Output Tray by pulling it in the direction of the arrow.
Figure 2
Figure 1

WorkCentre 5016, 5020 4-93 REP 9.1.1
REP 9.1.2 Front Left Cover Replacement
2. When installing the Front Left Cover, attach the hooks (Figure 2).
Removal
A Hooks (3)
WARNING
2. Remove the Front Left Cover (Figure 1).
2 Remove the Front Left Cover by pulling in the direction of the arrow.
Figure 2
Figure 1

REP 9.1.2 4-94 WorkCentre 5016, 5020
REP 9.2.1 Rear Cover 2. Remove the Rear Cover (Figure 2).
2 Remove the 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 2
Replacement
Figure 1

WorkCentre 5016, 5020 4-95 REP 9.2.1
REP 9.2.2 Right Cover Replacement
2. When installing the Right Cover, insert the tabs (Figure 2).
Removal
A Tabs (5)
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 2
Figure 1

REP 9.2.2 4-96 WorkCentre 5016, 5020
REP 10.1.1 IIT Platen Cover Replacement
Parts List on PL 10.1 NOTE: The Platen Cover comes as a kit, consisting of a Platen Cover and a Platen Cushion
Removal (Figure 1).
WARNING 1. Place the Platen Cushion on the Platen Glass, with the adhesive strips facing up.
To avoid personal injury or electrical shock, ensure that the machine is completely off 2. Remove the backing from the adhesive strips.
before disassembling or adjusting. Turn OFF the power and unplug the machine. 3. Position the Platen Cushion against the back left corner of the Platen Glass (Figure 1).
1. Remove the Platen Cover (PL 10.1) (Figure 1) by lifting it straight up. 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
Platen Cover ensure good adhesion.
mounting posts
Platen Cushion
When installing a new Platen

Cushion, place it against this
corner
Figure 1

WorkCentre 5016, 5020 4-97 REP 10.1.1
REP 10.2.1 IIT Upper Cover (SCC) 3. Remove the IIT Upper Cover (Figure 2).
1 Press the tabs (2) to release them.
Removal NOTE: The tabs are visible through the Platen Glass.
WARNING 2 Open the right side of the IIT Upper Cover.

To avoid personal injury or electrical shock, ensure that the machine is completely off 3 Press the tabs (2) to release them, and remove the IIT Upper Cover.
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 2
Replacement
Figure 1

REP 10.2.1 4-98 WorkCentre 5016, 5020
REP 10.3.1 IIT Carriage (SCC) 4. At the right side of the IIT Carriage, secure the Carriage Cable with tape so that it does
not come loose (Figure 2).
Parts List on PL 10.3 1 Secure the Carriage Cable with 2 pieces of tape.
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 2
Figure 1

WorkCentre 5016, 5020 4-99 REP 10.3.1
5. While maintaining tension on the Carriage Cable (silver) at the front left side, disconnect it 6. Use pieces of tape to secure the Carriage Cable (silver) that was disconnected in step 5
(Figure 3). so that it does not get separated from the pulley of the IIT Carriage (Figure 4).
1 Disconnect the Carriage Cable. A Secure the Carriage Cable with tape
2 Remove the Cable Spring. 1 Pulley
3 Remove the Carriage Cable from the pulley.
4 Remove the Carriage Cable from the guide.
Figure 4
Figure 3

REP 10.3.1 4-100 WorkCentre 5016, 5020
7. While maintaining tension on the Carriage Cable (black) at the front right side, disconnect 8. Use pieces of tape to secure the Carriage Cable (black) that was disconnected in step 7
it (Figure 5). so that it does not get separated from the pulley of the IIT Carriage (Figure 6).
1 Disconnect the Carriage Cable (black). A Pulley
2 Remove the Carriage Cable (black) from the guide. 1 Secure the Carriage Cable with tape
3 Remove the Carriage Cable (black) from the guide.
Figure 6
Figure 5

WorkCentre 5016, 5020 4-101 REP 10.3.1
9. While maintaining tension on the Carriage Cable (black) at the rear left side, disconnect it 10. Use tape to secure the Carriage Cable (black) that was disconnected in step 9 so that it
(Figure 7). does not get separated from the Cable Supply Drum (Figure 8).
1 Remove the Cable Spring. 1 Secure the Carriage Cable with tape.
2 Disconnect the Carriage Cable.
3 Remove the Carriage Cable from the pulley.
Figure 8
Figure 7

REP 10.3.1 4-102 WorkCentre 5016, 5020
11. While maintaining tension on the Carriage Cable (silver) at the rear right side, disconnect 12. Use tape to secure the Carriage Cable (silver) that was disconnected in step 11 so that it
it (Figure 9). does not get separated from the Cable Supply Drum (Figure 10).
1 Disconnect the Carriage Cable. 1 Secure the Carriage Cable with tape.
Figure 9 Figure 10

WorkCentre 5016, 5020 4-103 REP 10.3.1
13. Turn the left side of the IIT Carriage face up. Replacement
14. Disconnect the Flexible Print Cable connectors (2) (Figure 11). 1. To install, do the removal steps in reverse order.
2. Do not allow the Rail Contact of the IIT Carriage to bend in the direction of the arrow
(Figure 12).
A Rail Contact
Figure 11
Figure 12

REP 10.3.1 4-104 WorkCentre 5016, 5020
3. Attach the Carriage Cables (black and silver) to the IIT Frame in the sequence shown REP 10.3.2 Flexible Print Cable (SCC)
(Figure 13).
Removal
WARNING
3. Remove the IIT Carriage (REP 10.3.1).
4. Remove the Core Clip (Figure 1).
1 Remove the Core Clip.
Figure 13
Figure 1 Removing the Core Clip

5. Disconnect the Flexible Print Cables (2) from the AIOC PWB (Figure 2). 6. Remove the Flexible Print Cable (Figure 3).
1 Disconnect the Flexible Print Cables (2). 1 Peel off the pieces of tape to remove the Flexible Print Cable.
2 Remove the Cores (2). 2 Slide the Flexible Print Cable through the hole in the IIT Frame.
Figure 2 Figure 3
Replacement

REP 10.3.2 4-106 WorkCentre 5016, 5020
REP 10.6.1 Exposure Lamp 4. Disconnect the connector (Figure 2).
Removal
WARNING
3. Remove the Inverter PWB Bracket 2 (Figure 1).
1 Remove the screw.
2 Remove the Inverter PWB Bracket 2.
Figure 2
Figure 1

WorkCentre 5016, 5020 4-107 REP 10.6.1
5. Remove the Exposure Lamp (Figure 3). REP 10.7.1 Carriage Cable and Drum
1 Remove the screw.
2 Remove the Exposure Lamp from the Lamp Holder.
Removal
WARNING
3. Remove the IIT Carriage (REP 10.3.1).
4. Turn the IIT Carriage upside down.
Figure 3
Replacement

5. Remove the Carriage Cables (black and silver) (Figure 1). Replacement
1 Peel off the pieces of tape to remove the Carriage Cables. 1. To install, do the removal steps in reverse order.
2. Attach the Carriage Cables (black/silver) to the holes in the Drum (Figure 2).
Figure 1
Figure 2

WorkCentre 5016, 5020 4-109 REP 10.7.1
3. Wind the Carriage Cables around the Drum and secure them with tape (Figure 3). 4. Wind the Carriage Cables around the pulleys (Figure 4). See also the Cable Winding
Schematic (Figure 5).
5. Secure the Cables with pieces of tape so that they do not become loose (see Figure 1).
Figure 3
Figure 4

REP 10.7.1 4-110 WorkCentre 5016, 5020
REP 10.7.2 Inverter PWB
Removal
WARNING
3. Remove the Inverter PWB Bracket 2 (Figure 1).
1 Remove the screw.
2 Remove the Inverter PWB Bracket 2.
Figure 5 Cable Winding Schematic
Figure 1

4. Disconnect the connector (Figure 2). 5. Remove the Inverter PWB Bracket 1 (Figure 3).
1 Release the wire harness from the clamp. 1 Remove the screw.
2 Disconnect the connectors (2). 2 Remove the Inverter PWB Bracket 1.
Figure 2 Figure 3

REP 10.7.2 4-112 WorkCentre 5016, 5020
6. Remove the Inverter PWB (Figure 4).
2 Remove the Inverter PWB.
Figure 4
Replacement

WorkCentre 5016, 5020 4-113 REP 10.7.2
REP 10.7.2 4-114 WorkCentre 5016, 5020
REP 11.1.1 Tray 2 REP 11.1.2 Single Tray Module (Separation from IOT)
Parts List on PL 11.1 Parts List on PL 11.1
Removal Removal
WARNING WARNING
To avoid personal injury or electrical shock, ensure that the machine is completely off 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. before disassembling or adjusting. Turn OFF the power and unplug the machine.
1. Remove all paper from Tray 2. WARNING
2. Pull out Tray 2. The IOT is heavy. Do this procedure with 2 persons.
3. Lift the front side of Tray 2 and remove the tray (Figure 1). 1. Disconnect the connector. (Figure 1).
2 Pull out the cable clamp.
Figure 1
Replacement Figure 1
To install, do the removal steps in reverse order.

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

REP 11.1.2 4-116 WorkCentre 5016, 5020
4. Hold onto A (2) and B (2), and remove the IOT from the Single Tray Module (Figure 4). REP 11.4.1 Tray 2 Feed Roll
Removal
WARNING
2. Remove the Feed Shaft (Figure 1).
1 Remove the KL-Clip.
2 Remove the bearing.
3 Slide the Feed Shaft towards the rear to remove it.
Figure 4
Replacement
Figure 1

3. Remove the Tray 2 Feed Roll (Figure 2). Replacement
1 Remove the KL-Clip. 1. To install, do the removal steps in reverse order.
2 Remove the Tray 2 Feed Roll. 2. When installing the Tray 2 Feed Roll, align the pin on the Feed Shaft with the groove in
the Tray 2 Feed Roll (Figure 3).
Figure 2
Figure 3

REP 11.4.1 4-118 WorkCentre 5016, 5020
REP 11.4.2 Tray 2 Retard Roll 3. Remove the Tray 2 Retard Roll Housing (Figure 2).
1 Release the hooks (2).
2 Remove the Tray 2 Retard Roll Housing from the tabs (2).
Removal
WARNING
2. Remove the Tray 2 Feeder (Figure 1).
2 Remove the Tray 2 Feeder.
Figure 2
Figure 1

WorkCentre 5016, 5020 4-119 REP 11.4.2
4. Remove the Retard Shaft (Figure 3). 5. Remove the Tray 2 Retard Roll (Figure 4).
1 Remove the Retard Shaft. 1 Release the tab to remove the Tray 2 Retard Roll.
Figure 3 Figure 4

REP 11.4.2 4-120 WorkCentre 5016, 5020
Replacement 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).
2. When installing the Tray 2 Retard Roll, align the coupling of the Friction Clutch with the A Holder Arm
Tray 2 Retard Roll (Figure 5). B Tray 2 Retard Roll
Figure 5 Figure 6

WorkCentre 5016, 5020 4-121 REP 11.4.2
REP 11.5.1 STM Feed Sensor Replacement
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

REP 11.5.1 4-122 WorkCentre 5016, 5020
REP 11.5.2 STM PWB (SCC) Replacement
Removal
WARNING
1. Remove the STM Rear Cover (PL 11.5).
2. Remove the STM PWB (Figure 1).
1 Disconnect the connectors (3).
3 Remove the STM PWB.
Figure 1

WorkCentre 5016, 5020 4-123 REP 11.5.2
REP 11.6.1 STM Feed Clutch 3. Remove the STM Feed Clutch (Figure 2).
Removal 3 Remove the screws (2).
WARNING 4 Release the tab on the gear, and remove the gear together with the STM Feed Clutch.
To avoid personal injury or electrical shock, ensure that the machine is completely off 5 Slide the wire harness through the hole.
2. Remove the gears (Figure 1).
1 Remove the E-rings.
2 Release the tabs.
Figure 2
Replacement
Figure 1

REP 11.6.1 4-124 WorkCentre 5016, 5020
REP 11.6.2 STM Feed Motor 3. Remove the STM Feed Motor (Figure 2).
Removal 3 Remove the screws (4).
WARNING 4 Remove the STM Feed Motor.
2. Remove the gears (Figure 1).
1 Release the tab, and remove the gear.
2 Release the tab, and remove the gear.
Figure 2
Replacement
Figure 1

WorkCentre 5016, 5020 4-125 REP 11.6.2
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

REP 11.7.1 4-126 WorkCentre 5016, 5020
REP 13.1.1 ADF Assembly 3. Remove the Screws (Figure 2).
1. Remove the Screws (2).
Removal
WARNING
1. Disconnect the Connector.
2. Remove the Cable Band.
Figure 2 (j0hu41302)
Figure 1 (johu41301)

WorkCentre 5016, 5020 4-127 REP 13.1.1
2. Remove the ADF (Figure 3). REP 13.1.2 ADF/DADF Platen Cushion
1. Remove the ADF.
Removal
WARNING
1. Remove the Platen Cushion ([Figure 1]).
1. Remove the Platen Cushion.
Replacement

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.

WorkCentre 5016, 5020 4-129 REP 13.1.2
REP 13.2.1 Document Tray Assembly (ADF) 4. Remove the Support Bracket (Figure 2) .
i. Release the Wire Harness from the Clamp.
ii. Remove the Tapping Screw.
Removal iii. Remove the Tapping Screw.
WARNING iv. Remove the Ground Wire.
To avoid personal injury or electrical shock, ensure that the machine is completely off v. Remove the Support Bracket.
Front Cover (REP 13.2.3)
Rear Cover (REP 13.2.4)
2. Open the Top Cover.
3. Remove the Tapping Screw (Figure 1) .
i. Remove the Screw.

REP 13.2.1 4-130 WorkCentre 5016, 5020
5. Disconnect the Connector (Figure 3) . 6. Remove the Ground Wires (Figure 4) .
i. Disconnect the Connector. i. Remove the Screw to remove the Ground Wires (2).
ii. Remove the Cable Tie.

WorkCentre 5016, 5020 4-131 REP 13.2.1
7. Remove the Document Tray Assembly (Figure 5) . REP 13.2.2 ADF Feeder Assembly
1. Remove the Document Tray Assembly.
Removal
WARNING
1. Remove the following covers.
3. Remove the Document Tray Assembly (REP 13.2.1).
Replacement

4. Remove the Rear Blind Cover (Figure 1). 3. Disconnect the ADF PWB Connectors ([Figure 2]):
1. Remove the Tapping Screw. CN2
2. Remove the Rear Blind Cover. 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).

WorkCentre 5016, 5020 4-133 REP 13.2.2
4. Remove the Screws at the front ([Figure 3]). 3. Remove the Tapping Screw.
1. Remove the Screw (short). 1. Remove the Screws at the rear ([Figure 4]).
2. Remove the Screw (long). 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).

REP 13.2.2 4-134 WorkCentre 5016, 5020
4. Remove the ADF Feeder Assembly ([Figure 5]). REP 13.2.3 Front Cover
1. Remove the ADF Feeder Assembly.
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.
Replacement

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.

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.
1 3 2 4
Disconnect the con- Remove wire clamp Remove the screws Remove the
nector (2) 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.

REP 13.2.6 DADF Assembly 3. Remove the Screws (Figure 2).
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.
Disconnect the con-

nectors (2)
Figure 1 Disconnecting the DADF Cable

REP 13.2.6 4-138 WorkCentre 5016, 5020
2. Remove the DADF (Figure 3). REP 13.2.7 Document Tray Assembly (DADF)
1. Remove the DADF.
Removal
WARNING
3. Loosen the Tapping Screw (Figure 1).
a. Loosen the Screw.
Replacement Loosen the screw

(1)
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.

i. Disconnect the Connector.
ii. Remove the Cable Tie.
Disconnect the connector Remove cable tie
Figure 3 Disconnecting the connecgor

REP 13.2.7 4-140 WorkCentre 5016, 5020
6. Remove the Ground Wires (Figure 4). 7. Remove the Document Tray Assembly (Figure 5).
i. Remove the Screw to remove the Ground Wires (2). 1. Remove the Document Tray Assembly.
Figure 4 (j0hu41309) Figure 5 (j0hu41310)
Replacement

WorkCentre 5016, 5020 4-141 REP 13.2.7
REP 13.2.8 DADF Feeder Assembly 4. Remove the Rear Blind Cover (Figure 1).
i. Remove the Tapping Screw.
ii. Remove the Rear Blind Cover.
Removal
WARNING
1. Remove the following covers.
3. Remove the Document Tray Assembly (REP 13.2.7).

REP 13.2.8 4-142 WorkCentre 5016, 5020
5. Disconnect the ADF PWB Connectors (Figure 2):
CN2 3
CN3 Remove
the Sole-
CN5 noid
CN7 Bracket
i. Disconnect the Connectors (4).
1 2
Disconnect the connector Remove the screws (3)
Figure 3 Removing the Eject Roller Solenoid Bracket
7. Remove the Screws at the front ([Figure 3]).

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

WorkCentre 5016, 5020 4-143 REP 13.2.8
8. Remove the Tapping Screw.
i. Remove the Screws at the rear ([Figure 4]).
ii. Remove the Screw (long).
iii. Remove the Tapping Screw to remove the Ground Wire.

REP 13.2.8 4-144 WorkCentre 5016, 5020
9. Remove the ADF Feeder Assembly ([Figure 5]). REP 13.3.1 ADF Control PWB
1. Remove the ADF Feeder Assembly.
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.
Replacement

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

REP 13.3.1 4-146 WorkCentre 5016, 5020
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.

WorkCentre 5016, 5020 4-147 REP 13.3.2
2. Remove the Left Counter Balance (Figure 2). REP 13.3.3 Right Counter Balance (SCC)
2. Remove the Left Counter Balance.
Removal
WARNING
WARNING
The ADF/DADF must be removed. There is danger when removing a Counter Balance
that is in closed state because the compressed spring may get released suddenly.
1. Remove the ADF/DADF (REP 13.1.1).
2. Remove the Rear Cover (PL 13.2).
Replacement

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

WorkCentre 5016, 5020 4-149 REP 13.3.3
REP 13.3.4 DADF PWB 3. Disconnect the PWB Connectors (Figure 2).
1. Disconnect the PWB Connectors (5).
Removal
Discon-
WARNING nect the
To avoid personal injury or electrical shock, ensure that the machine is completely off connec-
before disassembling or adjusting. Turn OFF the power and unplug the machine. tors
2. Raise the Document Tray Assembly in the direction of the arrow (Figure 1).
i. Raise the Document Tray Assembly in the direction of the arrow.
Disconnect the
connectors

REP 13.3.4 4-150 WorkCentre 5016, 5020
2. Remove the DADF Control PWB (Figure 3). REP 13.4.1 Top Cover
Removal
4. Remove the DADF Control PWB. 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 4 3 2
Remove screws Remove the PWB Remove the screw (1) Remove the screw
(2) (1)
Figure 3 Removing the DADF Control PWB
Replacement

Replacement REP 13.8.1 Retard Roll
Removal
WARNING
2. Open the Retard Roll Assembly (Figure 1).
1. Open the Retard Roll Assembly.

2. Remove the Plate (Figure 2). 3. Remove the Retard Roll together with the Bearings (Figure 3).
a. Remove the Tapping Screws (2). 1. Remove the Retard Roll.
b. Remove the Plate.

WorkCentre 5016, 5020 4-153 REP 13.8.1
2. Remove the Retard Roll (Figure 4). REP 13.9.1 Pickup Roll, Feed Roll
1. Remove the Bearings (2).
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.
Replacement
2. After a replacement, enter the Diagnostic Mode How to Enter the Diagnostic Mode and
clear the simplex and duplex feed counters.

3. Remove the E-Clip and the Bearing. 4. Remove the Feed Roll Assembly (Figure 3).
a. Remove the Spring (Figure 2). 1. Move the Shaft.
b. Remove the E-Clips (2). 2. Remove the Feed Roll Assembly.
c. Remove the Spring.

WorkCentre 5016, 5020 4-155 REP 13.9.1
3. Remove the Feed Roll (Figure 4). 4. Remove the Pickup Roll (Figure 5).
1. Remove the E-Clip. a. Remove the Bearing.
2. Remove the Shaft. b. Remove the Pickup Roll.
3. Remove the Feed Roll.
Replacement
2. After a replacement, enter the Diagnostic Mode and clear the simplex and duplex feed
counters.

REP 13.9.1 4-156 WorkCentre 5016, 5020
ADJ 8.1.1 Edge Erase Adjustment ADJ 8.1.2 Controller Firmware Version Upgrade
Purpose Purpose
To set the right amount of edge erase at the lead edge and trail edge, as well as at both sides To upgrade the version of the Controller.
(left/right) of the image.
Check
NOTE: Do the IOT Lead Edge/Side Edge Registration adjustment first.
Check the current version:
Check
Enter the Diagnostic Mode and check the Controller Firmware version xxx using Chain-Func-
1. Specify a tray that contains paper, leave the platen cover open, and make a completely
tion [29-50].
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 Adjustment
2mm wide.
[USB Connection]
Adjustment
1. Enter the Diagnostic Mode and adjust the following NVM. Increasing the value will 1. Download the Firmware from our home page.
increase the amount of edge erase. 2. Decompress the Firmware.
3. Connect the PC to the USB connector at the Right Cover.
Table 1
4. Turn the power ON, and the Add USB Device window will appear on the PC. Click the
Chain Func Name Min Initial Max Step [Cancel] button when the New Hardware Detected Wizard window is displayed.
6 59 Normal Side Edge Erase Adjust- 0 16 32 0.254mm 5. Double-click the executable file of the decompressed Firmware to run it.
ment 6. The [Firmware Update Tool (Printer Model And File Selection)] is displayed. Select the
6 60 Normal Lead Edge Erase Adjust- 0 16 32 0.145mm machine model and the downloaded Firmware file, and then click [Next].
ment 7. The [Firmware Update Tool (Communication Interface Selection)] is displayed. Select
6 63 Normal Trail Edge Erase Adjust- 0 16 32 0.145mm [USB Port] and click [Next].
ment 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.

WorkCentre 5016, 5020 4-157 ADJ 8.1.1, ADJ 8.1.2
ADJ 10.3.1 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.
Purpose
To obtain the home position in the IIT lead edge (slow scan)/IIT side edge (fast scan) direction. Table 1 Specification
Item Simplex MSI
Check
Lead edge (A) 10 1.6mm 10 2.2mm
1. Set the Test Pattern 499T247 (A3) on the platen, so that there is no gap between it and
Side edge (B) 5 2.1mm 5 3.0mm
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 Adjustment
Side edge: part B in the figure 1. Enter the Diagnostic Mode, and use the following Chain Functions to perform adjustments
until the measured values for lead edge (A) and side edge (B) registration are within the
specifications.
When the measured value is short, reduce the setting value.
When the measured value is long, increase the setting value.
Table 2
Chain Func Sub Name Value Initial 1 Count
System Min. Max. Value
20 1 PH REGI ADJUSTMENT - ALL 0 60 30 0.146mm
20 41 PH TRAY 1 for Normal LEAD REGI 0 60 30 0.146mm
ADJ
20 42 PH TRAY 2 for Normal LEAD REGI 0 60 30 0.146mm
ADJ
20 43 PH MSI for Normal LEAD REGI 0 60 30 0.146mm
ADJ
6 20 ROS ALL TRAY - LASER SIDE REGI 1 99 50 0.254mm
ADJUSTMENT
6 21 ROS TRAY 1 - LASER SIDE REGI 1 99 50 0.254mm
ADJUSTMENT
6 22 ROS TRAY 2 - LASER SIDE REGI 1 99 50 0.254mm
ADJUSTMENT
6 26 ROS MSI - LASER SIDE REGI 1 99 50 0.254mm
ADJUSTMENT
2. After the adjustment, again set the Test Pattern 499T247 (A3) on the platen so that there
is no gap between it and the Rear Registration Guide. Make a copy using 100% R/E and
A3 SEF paper.
3. Repeat the procedure until the measured values for lead edge (A) and side edge (B) are
within the specifications.
Figure 1 IIT Lead Edge/Side Edge Registration

ADJ 10.3.1 4-158 WorkCentre 5016, 5020
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.

WorkCentre 5016, 5020 4-159 ADJ 11.1.1
ADJ 13.1.1 ADF/DADF Positional Adjustment Result when the ADF/DADF is moved in direction A (Figure 2):
Purpose
To correct the alignment of the ADF/DADF and correct the movement of the document.
Adjustment
1. Remove the ADF/DADF Rear Cover (PL 13.2).
2. Change the position of the Right Counter Balance to adjust the skew amount (Figure 1).
1. Loosen the Screws (4).
2. Move the DADF/ADF in direction of A or B.
3. Tighten the Screws (4).
Figure 2 ADF Adjustment - Direction A (j0hu41335)
Figure 1 ADF Adjustment - 1 (j0hu41334)

ADJ 13.1.1 4-160 WorkCentre 5016, 5020
Result when the ADF/DADF is moved in direction B (Figure 3):
Figure 3 ADF Adjustment - Direction B (j0hu41336)

WorkCentre 5016, 5020 4-161 ADJ 13.1.1
ADJ 13.1.1 4-162 WorkCentre 5016, 5020
5 Parts List
Overview PL 8.4 Control Panel Component.................................................................................... 5-35
Introduction ..................................................................................................................... 5-3
Subsystem Information ................................................................................................... 5-4
Cover
PL 9.1 Front / Top Cover................................................................................................. 5-36
Symbology ...................................................................................................................... 5-5
PL 9.2 Rear / Right Cover and NOHAD Fan ................................................................... 5-37
Parts Lists
IIT
Drive PL 10.1 IIT Accessory ..................................................................................................... 5-38
PL 1.1 IOT Motor............................................................................................................. 5-7 PL 10.2 IIT Component (1 OF 2)..................................................................................... 5-39
PL 10.3 IIT Component (2 OF 2)..................................................................................... 5-40
Paper Transport PL 10.4 IIT Upper Cover Cover Component ................................................................... 5-41
PL 2.1 Tray 1................................................................................................................... 5-8 PL 10.5 IIT Under Cover Component.............................................................................. 5-42
PL 2.2 Tray 1 Frame Accessory...................................................................................... 5-9 PL 10.6 IIT Carriage Component .................................................................................... 5-43
PL 2.3 Tray 1 Components (1 OF 2) ............................................................................... 5-10 PL 10.7 Center Plate Component ................................................................................... 5-44
PL 2.4 Tray 1 Components ( 2 OF 2).............................................................................. 5-11
PL 2.5 Tray 1 Frame Components.................................................................................. 5-12 Single Tray Module
PL 2.6 Tray 1 Frame Components (2 OF 2) ................................................................... 5-13 PL 11.1 Single Tray Module ............................................................................................ 5-45
PL 2.7 No Paper Sensor Housing ................................................................................... 5-14 PL 11.2 Tray 2 Component (1 OF 3)............................................................................... 5-46
PL 2.8 Registration.......................................................................................................... 5-15 PL 11.3 Tray 2 Component (2 OF 3)............................................................................... 5-47
PL 2.9 Registration Component ...................................................................................... 5-16 PL 11.4 Tray 2 Component (3 OF 3)............................................................................... 5-48
PL 11.5 Single Tray Frame Component (1 OF 2) ........................................................... 5-49
ROS PL 11.6 Single Tray Frame Component (2 OF 2) ........................................................... 5-50
PL 3.1 ROS ..................................................................................................................... 5-17 PL 11.7 STM No Paper Sensor....................................................................................... 5-51
CRU Stand
PL 4.1 Drum Cartridge .................................................................................................... 5-18 PL 12.1 Stand Component .............................................................................................. 5-52
PL 4.2 Toner Empty Sensor and Erase Lamp ................................................................ 5-19
PL 4.3 Transfer ............................................................................................................... 5-20 ADF/DADF
PL 4.4 Transfer Corotron Housing Component............................................................... 5-21 PL 13.1 ADF/DADF Accessory ....................................................................................... 5-53
PL 13.2 Component, Cover............................................................................................. 5-54
Fuser PL 13.3 Base Cover Component..................................................................................... 5-55
PL 5.1 Fuser.................................................................................................................... 5-22 PL 13.4 Feeder Component ............................................................................................ 5-56
PL 13.5 Lower Feeder Component ................................................................................. 5-57
Exit Transport
PL 13.6 Retard Roll Component ..................................................................................... 5-58
PL 6.1 Exit Transport ...................................................................................................... 5-23
PL 13.7 Lower Feeder Assembly .................................................................................... 5-59
PL 6.2 Exit Transport Component (Simplex)................................................................... 5-24
PL 13.8 Retard Roll Assembly ........................................................................................ 5-60
PL 6.3 Exit Transport Component (Duplex) .................................................................... 5-25
PL 13.9 Upper Feeder Assembly .................................................................................... 5-61
Simplex / Duplex Module and Bypass Tray PL 13.10 Document Tray ................................................................................................ 5-62
PL 7.1 Simplex Module ................................................................................................... 5-26
Common Hardware
PL 7.2 Left Hand Cover Assembly .................................................................................. 5-27
Common Hardware ......................................................................................................... 5-63
PL 7.3 Duplex Module Component (1 OF 2)................................................................... 5-28
Part Number Index .......................................................................................................... 5-64
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
Reissue June, 2008 Parts Lists

Parts Lists June, 2008 Reissue
Introduction Table 1
Overview Abbreviation Meaning
The Parts List section identifies all part numbers and the corresponding location of all spared R/E Reduction/Enlargement
subsystem components. REF: Refer to
SCSI Small Computer Systems Interface
Organization W/ With
Parts Lists W/O Without
Each item number in the part number listing corresponds to an item number in the related
illustration. All the parts in a given subsystem of the machine will be located in the same Table 2
illustration or in a series of associated illustrations.
Operating Companies
Electrical Connectors and Fasteners Abbreviation Meaning
This section contains the illustrations and descriptions of the plugs, jacks, and fasteners used
AO Americas Operations
in the machine. A part number listing of the connectors is included.
NASG - US North American Solutions Group - US
Common Hardware NASG - North American Solutions Group -
The common hardware is listed in alphabetical order by the letter or letters used to identify Canada Canada
each item in the part number listing and in the illustrations. Dimensions are in millimeters XE Xerox Europe
unless otherwise identified.
Symbology
Part Number Index
Symbology used in the Parts List section is identified in the Symbology section.
This index lists all the spared parts in the machine in numerical order. Each number is followed
by a reference to the parts list on which the part may be found. Service Procedure Referencing
If a part or assembly has an associated repair or adjustment procedure, the procedure number
Other Information will be listed at the end of the part description in the parts lists e.g. (REP 5.1, ADJ 5.3)
Abbreviations
Abbreviations are used in the parts lists and the exploded view illustrations to provide
information in a limited amount of space. The following abbreviations are used in this manual:
Table 1
Abbreviation Meaning
A3 297 x 594 Millimeters
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

WorkCentre 5016, 5020 5-3 Introduction
Subsystem Information
Use of the Term Assembly
The term assembly will be used for items in the part number listing that include other itemized
parts in the part number listing. When the word assembly is found in the part number listing,
there will be a corresponding item number on the illustrations followed by a bracket and a
listing of the contents of the assembly.
Brackets
A bracket is used when an assembly or kit is spared, but is not shown in the illustration. The
item number of the assembly or kit precedes the bracket; the item numbers of the piece parts
follow the bracket.
Tag
The notation W/Tag in the parts description indicates that the part configuration has been
updated. Check the change Tag index in the General Information section of the Service Data
for the name and purpose of the modification.
In some cases, a part or assembly may be spared in two versions: with the Tag and without the
Tag. In those cases, use whichever part is appropriate for the configuration of the machine on
which the part is to be installed. If the machine does not have a particular Tag and the only
replacement part available is listed as W/Tag, install the Tag kit or all of the piece parts. The
Change Tag Index tells you which kit or piece parts you need.
Whenever you install a Tag kit or all the piece parts that make up a Tag, mark the appropriate
number on the Tag matrix.

Subsystem Information 5-4 WorkCentre 5016, 5020
Symbology 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
A Tag number within a circle pointing to an item number shows that the part has been changed number within the circle (Figure 2).
by the tag number within the circle (Figure 1). Information on the modification is in the Change
Tag Index.
Figure 2 Without Tag Symbol
Figure 1 With Tag Symbol

WorkCentre 5016, 5020 5-5 Symbology
A tag number within a circle with no apex shows that the entire drawing has been changed by A tag number within a circle with no apex and having a shaded bar shows that the entire
the tag number within the circle (Figure 3). Information on the modification is in the Change Tag drawing was the configuration before being changed by the tag number within the circle
Index. (Figure 4).
Figure 3 Entire Drawing With Tag Symbol Figure 4 Entire Drawing Without Tag Symbol

Symbology 5-6 WorkCentre 5016, 5020
Overview PL 9.2 Rear / Right Cover and NOHAD Fan ................................................................... 5-37
Introduction ..................................................................................................................... 5-3
Subsystem Information ................................................................................................... 5-4
IIT
PL 10.1 IIT Accessory ..................................................................................................... 5-38
Symbology ...................................................................................................................... 5-5
PL 10.2 IIT Component (1 OF 2)..................................................................................... 5-39
Parts Lists PL 10.3 IIT Component (2 OF 2)..................................................................................... 5-40
PL 10.4 IIT Upper Cover Cover Component ................................................................... 5-41
Drive PL 10.5 IIT Under Cover Component.............................................................................. 5-42
PL 1.1 IOT Motor............................................................................................................. 5-7 PL 10.6 IIT Carriage Component .................................................................................... 5-43
PL 10.7 Center Plate Component ................................................................................... 5-44
Paper Transport
PL 2.1 Tray 1................................................................................................................... 5-8 Single Tray Module
PL 2.2 Tray 1 Frame Accessory...................................................................................... 5-9 PL 11.1 Single Tray Module ............................................................................................ 5-45
PL 2.3 Tray 1 Components (1 OF 2) ............................................................................... 5-10 PL 11.2 Tray 2 Component (1 OF 3)............................................................................... 5-46
PL 2.4 Tray 1 Components ( 2 OF 2).............................................................................. 5-11 PL 11.3 Tray 2 Component (2 OF 3)............................................................................... 5-47
PL 2.5 Tray 1 Frame Components.................................................................................. 5-12 PL 11.4 Tray 2 Component (3 OF 3)............................................................................... 5-48
PL 2.6 Tray 1 Frame Components (2 OF 2) ................................................................... 5-13 PL 11.5 Single Tray Frame Component (1 OF 2) ........................................................... 5-49
PL 2.7 No Paper Sensor Housing ................................................................................... 5-14 PL 11.6 Single Tray Frame Component (2 OF 2) ........................................................... 5-50
PL 2.8 Registration.......................................................................................................... 5-15 PL 11.7 STM No Paper Sensor....................................................................................... 5-51
PL 2.9 Registration Component ...................................................................................... 5-16
Stand
ROS PL 12.1 Stand Component .............................................................................................. 5-52
PL 3.1 ROS ..................................................................................................................... 5-17
ADF/DADF
CRU PL 13.1 ADF/DADF Accessory ....................................................................................... 5-53
PL 4.1 Drum Cartridge .................................................................................................... 5-18 PL 13.2 Component, Cover............................................................................................. 5-54
PL 4.2 Toner Empty Sensor and Erase Lamp ................................................................ 5-19 PL 13.3 Base Cover Component..................................................................................... 5-55
PL 4.3 Transfer ............................................................................................................... 5-20 PL 13.4 Feeder Component ............................................................................................ 5-56
PL 4.4 Transfer Corotron Housing Component............................................................... 5-21 PL 13.5 Lower Feeder Component ................................................................................. 5-57
PL 13.6 Retard Roll Component ..................................................................................... 5-58
Fuser
PL 13.7 Lower Feeder Assembly .................................................................................... 5-59
PL 5.1 Fuser.................................................................................................................... 5-22
PL 13.8 Retard Roll Assembly ........................................................................................ 5-60
Exit Transport PL 13.9 Upper Feeder Assembly .................................................................................... 5-61
PL 6.1 Exit Transport ...................................................................................................... 5-23 PL 13.10 Document Tray ................................................................................................ 5-62
PL 6.2 Exit Transport Component (Simplex)................................................................... 5-24
Common Hardware
PL 6.3 Exit Transport Component (Duplex) .................................................................... 5-25
Common Hardware ......................................................................................................... 5-63
Simplex / Duplex Module and Bypass Tray Part Number Index .......................................................................................................... 5-64
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 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)

WorkCentre 5016, 5020 5-3 PL 1.1
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)

PL 2.1 5-4 WorkCentre 5016, 5020
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

WorkCentre 5016, 5020 5-5 PL 2.2
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)

PL 2.3 5-6 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-7 PL 2.4
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)

PL 2.5 5-8 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-9 PL 2.6
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)

PL 2.7 5-10 WorkCentre 5016, 5020
PL 2.8 Registration
1 059K48250 Registration Roll Assembly (REP
2.8.1)

WorkCentre 5016, 5020 5-11 PL 2.8
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)

PL 2.9 5-12 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-13 PL 3.1
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

PL 4.1 5-14 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-15 PL 4.2
PL 4.3 Transfer
1 Transfer Module (Not Spared) (REP
4.3.1)
2 125K93751 Transfer Corotron Housing
3 014K83123 Corotron Block Assembly

PL 4.3 5-16 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-17 PL 4.4
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)

PL 5.1 5-18 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-19 PL 6.1
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

PL 6.2 5-20 WorkCentre 5016, 5020
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

WorkCentre 5016, 5020 5-21 PL 6.3
PL 7.1 Simplex Module
1 802K99450 Simplex Module (REP 7.1.1)

PL 7.1 5-22 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-23 PL 7.2
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)

PL 7.3 5-24 WorkCentre 5016, 5020
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

WorkCentre 5016, 5020 5-25 PL 7.4
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

PL 7.5 5-26 WorkCentre 5016, 5020
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

WorkCentre 5016, 5020 5-27 PL 7.6
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

PL 8.1 5-28 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-29 PL 8.2
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)

PL 8.3 5-30 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-31 PL 8.4
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

PL 9.1 5-32 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-33 PL 9.2
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)

PL 10.1 5-34 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-35 PL 10.2
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)

PL 10.3 5-36 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-37 PL 10.4
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

PL 10.5 5-38 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-39 PL 10.6
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)

PL 10.7 5-40 WorkCentre 5016, 5020
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

WorkCentre 5016, 5020 5-41 PL 11.1
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)

PL 11.2 5-42 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-43 PL 11.3
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)

PL 11.4 5-44 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-45 PL 11.5
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)

PL 11.6 5-46 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-47 PL 11.7
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)

PL 12.1 5-48 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-49 PL 13.1
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)

PL 13.2 5-50 WorkCentre 5016, 5020
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

WorkCentre 5016, 5020 5-51 PL 13.3
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)

PL 13.4 5-52 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-53 PL 13.5
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)

PL 13.6 5-54 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-55 PL 13.7
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)

PL 13.8 5-56 WorkCentre 5016, 5020
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

WorkCentre 5016, 5020 5-57 PL 13.9
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)

PL 13.10 5-58 WorkCentre 5016, 5020
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)

WorkCentre 5016, 5020 5-59 Common Hardware
Part Number Index Table 1 Part Number Index
Part Number Part List
Table 1 Part Number Index
038K89761 PL 11.3
Part Number Part List 038K89821 PL 11.3
003K13560 PL 13.3 041K95870 PL 10.3
003K15530 PL 11.4 050K57701 PL 11.1
003K15540 PL 11.4 050K58051 PL 7.6
003K15950 PL 13.3 050K60800 PL 13.2
003K86760 PL 13.3 050K62940 PL 2.1
004E17510 PL 13.1 050K63270 PL 13.2
005E26740 PL 2.6 053E93650 PL 9.2
006K25751 PL 2.6 055K31090 PL 11.5
006K86440 PL 7.4 059E03090 PL 7.3
007K94880 PL 1.1 059E03650 PL 7.4
007K97780 PL 2.2 059E04080 PL 13.8
007K97790 PL 2.2 059K32773 PL 2.3
013E25881 PL 2.3 059K33051 PL 2.3
013E25920 PL 2.2 059K43000 PL 6.2
013E30050 PL 6.2 059K43000 PL 6.3
013E30050 PL 6.3 059K48200 PL 2.6
013E32180 PL 11.6 059K48230 PL 6.1
013E32690 PL 2.6 059K48240 PL 6.1
013E33260 PL 7.3 059K48250 PL 2.8
013E33260 PL 7.4 059K48260 PL 7.5
013E90840 PL 11.4 059K48430 PL 11.4
013E90840 PL 2.6 059K48440 PL 11.6
013E90840 PL 11.6 059K48660 PL 11.4
014K83123 PL 4.3 059K53230 PL 2.9
014K83141 PL 8.2 059K54730 PL 7.5
016E93560 PL 13.3 059K55590 PL 13.2
017E12010 PL 12.1 059K55600 PL 13.3
017K93121 PL 12.1 059K55610 PL 13.7
017K93132 PL 12.1 059K55620 PL 13.7
017E98760 PL 12.1 059K55630 PL 13.7
019K07086 PL 2.4 059K55640 PL 13.9
019K08890 PL 7.6 059K55860 PL 13.3
019K09250 PL 11.4 059E99331 PL 6.2
022E29860 PL 7.5 059E99331 PL 6.3
022E30121 PL 5.1 059E99690 PL 13.9
022K74110 PL 5.1 062K18161 PL 3.1
022K74860 PL 13.1 068K53590 PL 11.6
022K75730 PL 13.2 090E02380 PL 10.4
023E26660 PL 7.3 090E91720 PL 10.4

Part Number Index 5-60 WorkCentre 5016, 5020
Table 1 Part Number Index Table 1 Part Number Index
Part Number Part List Part Number Part List
101R00432 PL 4.1 130K71230 PL 2.9
105E12210 PL 9.1 130K71361 PL 5.1
105E17391 PL 8.1 130K71400 PL 4.2
105E17401 PL 8.2 130E87090 PL 11.5
105E17411 PL 8.1 130E87090 PL 11.7
105E18010 PL 8.1 130E87090 PL 6.3
105E18020 PL 8.1 130E87090 PL 6.2
106R01277 PL 4.1 130E87090 PL 2.7
110E11320 PL 8.1 130E87090 PL 2.5
110E11551 PL 10.5 140E88751 PL 10.7
110E11570 PL 13.9 413W77559 PL 2.6
110E11580 PL 11.5 423W06555 PL 6.3
110E11580 PL 2.5 604K43810 PL 4.4
120E22470 PL 1.1 604K43820 PL 7.5
120E23791 PL 2.7 604K43830 PL 7.6
120E28091 PL 11.5 604K43840 PL 6.2
120E29540 PL 2.5 604K43840 PL 6.3
120E29630 PL 11.7 604K43851 PL 4.1
121E20950 PL 7.5 604K43860 PL 7.2
121K39710 PL 2.9 604K43860 PL 7.3
121K40770 PL 2.2 604K43870 PL 7.2
121K41600 PL 13.9 604K43870 PL 7.4
121K41650 PL 13.9 604K44330 PL 10.2
121K41660 PL 13.9 604K44340 PL 13.3
121K41670 PL 13.9 604K44350 PL 13.3
121K41690 PL 10.6 604K45740 PL 7.6
121E93360 PL 12.1 604K45750 PL 7.5
122E92530 PL 5.1 604K45760 PL 7.6
122E92550 PL 5.1 604K45770 PL 7.5
122E92570 PL 10.6 604K45780 PL 7.5
122K94091 PL 4.2 604K45790 PL 7.5
125K93751 PL 4.3 604K46500 PL 10.1
125K93751 PL 4.4 604K47130 PL 10.1
126K23581 PL 5.1 801E04660 PL 9.1
126K24411 PL 5.1 801E05970 PL 10.5
127K51590 PL 6.3 801K25570 PL 8.2
127K51632 PL 9.2 801K25580 PL 2.2
127K52180 PL 11.6 801K30780 PL 10.5
127K57120 PL 13.5 802K71882 PL 10.4
127K57140 PL 10.6 802K97500 PL 7.3
127K58700 PL 13.5 802K97694 PL 8.3

WorkCentre 5016, 5020 5-61 Part Number Index
Table 1 Part Number Index Table 1 Part Number Index
Part Number Part List Part Number Part List
802K99450 PL 7.1 960K32783 PL 8.4
807E17870 PL 7.5 960K38300 PL 8.4
807E18360 PL 11.6 960K42980 PL 13.3
807E18380 PL 11.6 960K43421 PL 8.1
807E18390 PL 11.6 960K44250 PL 8.1
807E18400 PL 11.6 962K59950 PL 10.3
807E18410 PL 11.6 962K60840 PL 13.3
807E19430 PL 2.2 962K66150 PL 8.3
807E19440 PL 2.2
807E19450 PL 2.6
807E19460 PL 2.6
807E21180 PL 7.4
809E54170 PL 2.4
809E54180 PL 2.6
809E56440 PL 13.8
809E73520 PL 2.2
809E74030 PL 11.5
809E76520 PL 6.2
809E76520 PL 6.3
809E76630 PL 7.4
809E79910 PL 10.3
809E79920 PL 10.3
815E08650 PL 10.4
815E42250 PL 10.4
848K01660 PL 2.2
848K02140 PL 11.6
848E04451 PL 9.2
848E04480 PL 9.1
848E04501 PL 9.2
848E04511 PL 9.1
848K04904 PL 8.3
848K07410 PL 10.2
848K17300 PL 9.1
868E12730 PL 10.6
896E41981 PL 11.1
896E42140 PL 11.1
896E58070 PL 8.3
960K28562 PL 11.5
960K28611 PL 8.1
960K32370 PL 13.3
960K32602 PL 8.4

Part Number Index 5-62 WorkCentre 5016, 5020
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
Reissue June, 2008 General Procedures

General Procedures June, 2008 Reissue
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 This is used to check and change the values of the various parameters in NVM.
and changing the settings

WorkCentre 5016, 5020 6-3 Diagnostic Mode
Basic Operations of the Diagnostic Mode Once in the Diagnostic Mode, "C_ " (Chain Code input screen) is shown on the display.
The "_" is blinking.
C _
How to Exit the Diagnostic Mode
Switch the machine OFF and then ON again.
Display: Displays the menus and their results. 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.
Keypad: Inputs Chain Function Codes.
A Chain/Function Code must be input as 2 digits. If the Chain/Function Code is "1,"
[Start] button: Displays the Diagnostics Menu. it must be input as "01." Any input value that goes beyond the 2nd digit will be ignored.
[Stop] button: Pauses/Stops the diagnostic. To clear the Chain/Function Code that was input, press the "C" button.
Both digits will be cleared, and you will be returned to the Code input screen.
When inputting the Function Code, pressing the [Start] button after inputting a Function Code
that is out of the specified range will transfer you to the initial screen of Function input.
How to Enter the Diagnostic Mode Enter the Diagnostic Mode and check that the "C_ " (Chain Code input screen) is shown on the
There are 2 ways to enter the diagnostic mode depending on the model of the IOT. display. The "_" should be blinking.
The procedure below entitled WC 5016, 5020 (with platen or ADF) Entering the Diagnostic
Mode is for IOT models with a platen, or with an ADF.
The procedure following entitled WC 5020 is for IOT models with a DADF.
C _
WC 5016, 5020 (with Platen or ADF) Entering the Diagnostic Mode
Press and hold down the [0] button on the keypad for 4 seconds or longer, and then press (and Use the keypad to enter the 2-digit Chain Code.
quickly release) the [Start] button while still keeping the [0] button pressed. The first number will appear in the first digit space, and the "_" will move to the right.
C 1 _

Input the next number, and it will appear in the second digit space. Once in the Diagnostic Mode, "C_ " (Chain Code input screen) is shown on the display.
The "_" is blinking.
C 1 2
Pressing the [Start] button will show the "F_ " (Function Code input screen) on the display.
An "F" and the blinking "_" are shown on the Function Code input screen. How to Exit the Diagnostic Mode
Switch the machine OFF and then ON again.
How to Input the Chain and Link (WC 5020 w/DADF)
F _ The following shows the Chain and Link input method in the Diagnostic Mode.
A Chain/Link Code can be up to 3 digits. If the Chain/Function Code is "1,"

it must be input as "1." Do necessary to 0 fill. Any input value that goes beyond the 3rd digits
Use the keypad to enter the 2-digit Function Code. 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
F 2 _ 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.
Pressing the [Start] button will then run the specified Diagnostic Code.
F 2 3
Use the keypad to enter the Chain Code.
WC 5020 Entering the Diagnostic Mode The first number will appear in the right hand digit space, and the "_" will move to the left and
Press and hold down the [0] button on the keypad for 4 seconds or longer, and then press (and the C will disappear.
quickly release) the [Start] button while still keeping the [0] button pressed.
Enter 6, 7, 8, and 9 then press the Start button.

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.
Input the next number and it will appear in the right hand digit space. Pressing the [Start] button will then run the specified Diagnostic Code.
NOTE: If in NVM, the value of that NVM location will flash waiting for a new input. After inputing
a new NVM code press the START button and the Link Code input screen will appear on the
display waiting for a new Lind Code.
How to Interrupt a Diagnostic

Press the [Stop] button when the diagnostic is still running.
Stopping a diagnostic that is running will return you to the Link Code input screen.
Pressing the [Start] button will show the "L_ " (Link Code input screen) on the display.
An "L" and the blinking "_" are shown on the Link Code input screen. Pressing the [AC] button will return you to the Chain Code input screen (C_).
Use the keypad to enter the Link Code first digit.
Input the next number and it will appear in the right hand digit space.

IOT Diagnostics Input Component Control Codes
Func
or
Input Diagnostics Chain Link Sub Contents of Data Meaning
The Input Diagnostics can be used to check the status of the various sensors in the engine, IIT,
and Trays. 05 33 ADF Document Tray Width L: No document
Sensor 2 H: Document present
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.
05 34 ADF Document Tray Length L: No document
For DADF model machines; Pressing the [Stop] button will stop the operation of the component Sensor 1 H: Document present
and return to the Link Code inpit screen.
05 35 ADF Document Tray Length L: No document
Input Component Control Codes Sensor 2 H: Document present
Func 05 36 ADF Document Feed Sensor L: No document
or H: Document present
Chain Link Sub Contents of Data Meaning
07 07 TRAY Tray1 No Paper Sensor L: Paper present
01 01 PH L/H (Left Side) L: Cover is closed H: No paper
COVER H: Cover is open
07 08 TRAY STM No Paper Sensor L: Paper present
01 10 TRAY STM (Tray 2) L/H L: Cover is closed H: No paper
COVER H: Cover is open
08 05 PH IOT Regi Sensor L: No paper
01 11 PH L/H (Tray 1) LOW L: Cover is closed H: Paper present
COVER H: FCover is open
08 06 TRAY STM Feed Sensor L: No paper
01 12 PH FRONT COVER L: Cover is closed H: Paper present
H: Cover is open
08 07 TRAY Tray1 Feed Sensor L: No paper
05 10 IIT Platen COVER Open L: Cover is closed H: Paper present
H: Cover is open
08 47 TRAY FEED READY Level is high
05 11 IIT Carriage Home Sensor L: Sensor is exposed SIGNAL Hot-Line Control
H: Sensor is blocked
09 02 XERO Drum Cartridge L: No Drum Cartridge
05 29 ADF ADF Top Cover Open L: Cover is open Detected H: Cartridge present
H: Cover is closed
09 07 XERO Toner Empty Sensor L: Toner available
05 30 ADF Document Set Sensor L: No document H: Toner depleted
H: Document present
10 23 PH Fuser Exit Sensor L: No paper
05 31 ADF Document Feeder L: No document H: Paper present
Width Sensor H: Document present
10 60 FUSER Nohad Fan Fail Monitor L: Able to monitor FUSER
05 32 ADF Document Tray Width L: No document FAN FAIL
Sensor 1 H: Document present H: Unable to monitor
FUSER FAN FAIL

Input Component Control Codes Output Diagnostics
The Output Diagnostics can be used to operate and check the status of the various motors,
Func solenoids and clutches in the engine, IIT, and Trays. The operation can be enabled for every
or component, and whether or not the component is operating properly can be determined by
Chain Link Sub Contents of Data Meaning checking the operation from outside.
05 217 DADF Document Width Sen- L: When a component is operating, "run" is displayed.
sor H:
62 212 IIT Regi Sensor L:
H:
62 272 IIT Scan Start L:
r u n
H:
For Platen and ADF model machines; Pressing the [Stop] button will stop the operation of the
62 300 IIT Platen I/L Switch L: component and return you to the Function Code input screen.
H:
5 212 DADF Feeder Cover Switch L:
H:
5 102 DADF Document Set Sensor L: F 2 3
H:
5 215 DADF Doc Feeder Width Sen- L: For DADF model machines; Pressing the [Stop] button will stop the operation of the component
and return to the Link Code inpit screen.
sor H:
5 216 DADF Doc Tray Width Sensor L:
1 H:
5 217 DADF Doc Tray Width Sensor L:
2 H:
5 218 DADF Doc Tray Length Sen- L: To resume the operation of the specified component, press the [Start] button again.
sor 1 H:
Output Component Control Codes
5 219 DADF Doc Tray Length Sen- L:
Chain Func Sub Contents of Data Meaning
sor 2 H:
04 01 PH IOT Motor ON
5 204 ADF/ Document Feed Sensor L:
DADF H: 04 02 FUSER Nohad Fan Motor Fuser Fan changes from
(HIGH SPEED) Low to High speed
5 206 ADF/ Doc Regi Sensor L:
DADF H:
5 205 ADF/ Doc Feedout Sen sor/ L:
DADF Exit Invert Sensor H:

Output Component Control Codes Output Component Control Codes
Chain Func Sub Contents of Data Meaning Chain Func Sub Contents of Data Meaning
05 20 IIT Carriage Motor High Move the Carriage in the 08 11 TRAY STM Feed Clutch
Speed scan scan direction at 80mm/
08 12 TRAY Tray1 Feed Clutch
sec. NOTE: After the
scan, the Carriage stops 08 13 TRAY STM Feed Motor
beyond the end position.
08 17 PH Bypass Solenoid
Pressing the [Start] but-
ton again returns the Car- 09 04 XERO HVPS ON (LOW
riage to the home VOLTAGE)
position. After another
09 05 XERO HVPS ON (HIGH
scan, the Carriage stops
VOLTAGE)
beyond the end position.
Turn the power off and on 09 06 XERO Pre-Charge Erase
to return the Carriage to Lamp
the home position.
10 08 PH Exit Motor Forward NOTE: Ejects paper.
05 21 IIT Carriage Motor High Move the Carriage
Speed return toward home position at 10 09 PH Exit Motor Reverse
80mm/sec. NOTE: See 05 62 DADF Paper Feed Clutch
05-20.
05 63 DADF Registration Clutch
05 22 IIT Carriage Motor Low Move the Carriage in the
Speed scan scan direction at 40mm/ 05 64 DADF Output Inverting
sec. NOTE: See 05-20. Clutch
05 23 IIT Carriage Motor Low Move the Carriage 05 65 DADF Output Spacing Sole-
Speed return toward home position at noid
40mm/sec. NOTE: See
05-20. 62 05 IIT Scan Motor, Scan Used with locking posi-
Direction tion
05 40 ADF Document Drive Motor Run the Document Drive
High Speed Motor at 80 mm/sec. 62 06 IIT Scan Motor Return Used with locking posi-
Direction tion
05 41 ADF Document Drive Motor Run the Document Drive
Low Speed Motor at 40 mm/sec. 62 07 IIT Scan Locking Position
05 42 ADF Document Feed Clutch Turn the Document Feed 05 01 DADF DADF Motor
Clutch on. 62 2 IIT Exposure Lamp
06 15 ROS ROS Motor ON ROS Motor Start & Stop.
62 86 IIT Image Area H8_PS
08 10 PH IOT Registration
Clutch

Program Function Clearing the error will return you to the Function Code input screen.
The Program Function can access the NVM (the EEPROM on the AIOC PWB) to perform the
following functions:
Test Print
Initialize NVM
Check Error History
F _
Check Print Count
Display Version To resume the test print, press the [Start] button again.
Clear Error History
Pressing the [Stop] button in the middle of a test print will stop the feeding of additional paper,
Display Serial Number, Product Number
output any paper that was already fed, and return you to the Function Code input screen.
Initialize NVM [20-58]

Test Print [23-10], [23-01]
This will return the NVM settings to their default values.
There are two test print modes: one that outputs the Controller built-in pattern, and another that
outputs the MCU built-in pattern. While the NVM is being initialized, "run" is displayed.
NOTE: Before running either of these test prints, you must check and make sure that the appli-
cable NVM settings are correct. See Summary of Program Functions.
During a test print, "run" is displayed.

r u n
r u n When NVM initialization is complete, you will be returned to the Function Code input screen.
Once the test print starts, an error code will be displayed if an error occurs while printing.
C 1

6-10 WorkCentre 5016, 5020
Display Error History [40-01] Display Firmware Version [29-49]
This can be used to check for the last 20 errors. This can be used to check the firmware versions of the Controller and the MCU.
Pressing the [Start] button will display the error codes, starting with the most recent error. Pressing the [Start] button will display the firmware version, starting from the highest order (left-
most) digit.
Once everything has been displayed, you will be returned to the Function Code input screen.
E 1
J 6 6
1
When the last error is displayed, press the [Start] key to return to the Function Code input F 1
a
2
screen.
Clear Error History [20-59]
This can be used to clear the Error History.
F _ While the Error History is being cleared, "run" is displayed.
Pressing the [Stop] key during the display will stop it and return you to the Function Code input
screen.
Check Print Count [25-01] r u n

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

WorkCentre 5016, 5020 6-11
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 _

6-12 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.

WorkCentre 5016, 5020 6-13
NVM Settings Mode
Basic Operations of the NVM Settings Mode
The NVM Settings Mode allows you to check or change the value of each NVM setting.
Initially, the current value of the specified NVM item is shown as blinking.
3
Using the keypad to input a value shows the value as blinking.
3 1
3
Pressing the [C] button clears the value that was input and leaves the current value as blinking.
3
Pressing the [Start] button sets the value that was input, stops the blinking, and returns you to
the Function Code input screen after 2 seconds has passed.
3
If the [Start] button is pressed when "_" is displayed, or when the input value is outside the
range of possible settings, the input value is treated as invalid while the current value is shown
as blinking. You will then be returned to the Function Code input screen after 4 seconds has
passed.
See List of NVM Settings (WC 5016, 5020 ADF).

6-14 WorkCentre 5016, 5020
List of NVM Settings (WC 5016, 5020 ADF)
NOTE: In the CE Access columns, O = yes and X = no.
CE
Access
Func Initial
Chain tion Sub Contents of Data Range Unit Value R W Init Remarks
06 20 ROS ALL TRAY-LASER SIDE 1~99 0.254 50 O O O

REGI ADJUSTMENT mm
06 21 ROS TRAY1-LASER SIDE REGI 1~99 0.254 50 O O O
ADJUSTMENT mm
06 22 ROS TRAY2-LASER SIDE REGI 1~99 0.254 50 O O O
ADJUSTMENT mm
06 26 ROS MSI-LASER SIDE REGI 1~99 0.254 50 O O O
ADJUSTMENT mm
06 28 ROS DUP ALL TRAY-LASER 1~99 0.254 50 O O O
SIDE REGI ADJUSTMENT mm
06 29 ROS DUP TRAY1-LASER SIDE 1~99 0.254 50 O O O
REGI ADJUSTMENT mm
06 30 ROS DUP TRAY2-LASER SIDE 1~99 0.254 50 O O O
REGI ADJUSTMENT mm
06 34 ROS DUP MSI-LASER SIDE 1~99 0.254 50 O O O
REGI ADJUSTMENT mm
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)

WorkCentre 5016, 5020 6-15
CE
Access
Func Initial
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 0~60 0.146 30 O O O Image input is delayed when Set Value is
- ALL TRAY mm increased.
Min(0)=-4.46mm, Max(66)=4.46mm,
Initial(33)=0mm
20 41 PH TRAY1 for Normal LEAD 0~60 0.146 30 O O O Image input is delayed when Set Value is
REGI ADJ mm increased.
20 42 PH TRAY2 for Normal LEAD 0~60 0.146 30 O O O Image input is delayed when Set Value is
REGI ADJ mm increased.

6-16 WorkCentre 5016, 5020
CE
Access
Func Initial
20 43 PH SMH for Normal LEAD REGI 0~60 0.146 30 O O O Image input is delayed when Set Value is
ADJ mm increased.
20 45 PH DUP ALL SIZE for Normal 0~60 0.146 30 O O O Image input is delayed when Set Value is
LEAD REGI ADJ mm increased.
20 46 PH ALL TRAY - REGI LOOP 0~66 0.438 33 O O O Loop increases when Set Value is
TIMER mm increased.
20 47 PH TRAY1 for Normal Paper - 0~66 0.438 33 O O O Loop increases when Set Value is
REGI LOOP TIMER mm increased.
20 48 PH TRAY2 for Normal Paper - 0~66 0.438 33 O O O Loop increases when Set Value is
REGI LOOP TIMER mm increased.
20 49 PH SMH for Normal Paper - REGI 0~66 0.438 11 O O O Loop increases when Set Value is
LOOP TIMER mm increased.
20 51 PH DUP for Normal Paper - REGI 0~66 0.438 33 O O O Loop increases when Set Value is
LOOP TIMER mm increased.
21 09 HFSI Last 2 of Fuser discharging 0~99 1 0 O O X Only 0 clearance is possible in the write
Number mode.
("0 clearance" means all bytes change to 0
at the same time.)
21 19 HFSI 5th & 6th Fuser discharging 0~99 1 0 O O X Only 0 clearance is possible in the write
Number mode.
at the same time.)
21 29 HFSI 3rd & 4th Fuser discharging 0~99 1 0 O O X Only 0 clearance is possible in the write
Number mode.
at the same time.)
21 39 HFSI 1st 2 of Fuser discharging 0~3 1 0 O O X Only 0 clearance is possible in the write
Number mode.
at the same time.)
23 20 PH Simplex/Duplex 0~1 1 O O O 0: Simplex
1: Duplex

WorkCentre 5016, 5020 6-17
CE
Access
Func Initial
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 0~99 1 O O O Number of Test Prints
Byte
23 27 PH Test Print Run Length High 0~99 0 O O O Number of Test Prints
Byte
29 01 Billing Last 2 Dig Total Copy 0~99 0 O X X
Counter(8 Digits)
29 11 Billing 3rd & 4th Dig Total Copy 0~99 0 O X X
Counter(8 Digits)
29 21 Billing 1st 2 Dig Total Copy 0~99 0 O X X
Counter(8 Digits)
29 04 HFSI Tray1 Last 2 Digits of Feed 0~99 1 0 O O X Only 0 clearance is possible in the write
Capacity (8 Digits) mode.
at the same time.)
29 14 HFSI Tray1 5th & 6th Digits of Feed 0~99 1 0 O O X Only 0 clearance is possible in the write
at the same time.)
29 24 HFSI Tray1 3rd & 4th Digits of 0~99 1 0 O O X Only 0 clearance is possible in the write
Feed Capacity (8 Digits) mode.
at the same time.)
29 34 HFSI Tray1 1st 2 Digits of Feed 0~3 1 0 O O X Only 0 clearance is possible in the write
at the same time.)

6-18 WorkCentre 5016, 5020
CE
Access
Func Initial
29 05 HFSI Tray2 Last 2 Digits of Feed 0~99 1 0 O O X Only 0 clearance is possible in the write
at the same time.)
29 15 HFSI Tray2 5th & 6th Digits of Feed 0~99 1 0 O O X Only 0 clearance is possible in the write
at the same time.)
29 25 HFSI Tray2 3rd & 4th Digits of 0~99 1 0 O O X Only 0 clearance is possible in the write
Feed Capacity (6 Digits) mode.
at the same time.)
29 09 HFSI MSI Last 2 Digits of Feed 0~99 1 0 O O X Only 0 clearance is possible in the write
at the same time.)
29 19 HFSI MSI 5th & 6th Digits of Feed 0~99 1 0 O O X Only 0 clearance is possible in the write
at the same time.)
29 29 HFSI MSI 3rd & 4th Digits of Feed 0~99 1 0 O O X Only 0 clearance is possible in the write
at the same time.)
29 39 HFSI MSI 1st 2 Digits of Feed 0~3 1 0 O O X Only 0 clearance is possible in the write
at the same time.)
30 04 Recycle Last 2 Digits of MSI Feed 0~99 1 0 O X X
Capacity (8 Digits)
30 14 Recycle 5th & 6th Digits of MSI Feed 0~99 1 0 O X X
Capacity (8 Digits)
30 24 Recycle 3rd & 4th Digits of MSI Feed 0~99 1 0 O X X
Capacity (8 Digits)

WorkCentre 5016, 5020 6-19
CE
Access
Func Initial
30 34 Recycle 1st 2 Digits of MSI Feed 0~3 1 0 O X X

Capacity (8 Digits)
30 05 Recycle Last 2 of IOT Starting Number 0~99 1 0 O X X
30 15 Recycle 3rd & 4th IOT Starting 0~99 1 0 O X X
Number
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 0~99 1 0 O X X
Capacity (8 Digits)
30 16 Recycle Tray1 5th & 6th Digits of Feed 0~99 1 0 O X X
Capacity (8 Digits)
30 26 Recycle Tray1 3rd & 4th Digits of 0~99 1 0 O X X
Feed Capacity (8 Digits)
30 36 Recycle Tray1 1st 2 Digits of Feed 0~3 1 0 O X X
Capacity (8 Digits)
30 07 Recycle Tray2 Last 2 Digits of Feed 0~99 1 0 O X X
Capacity (6 Digits)
30 17 Recycle Tray2 5th & 6th Digits of Feed 0~99 1 0 O X X
Capacity (6 Digits)
30 27 Recycle Tray2 3rd & 4th Digits of 0~99 1 0 O X X
Feed Capacity (6 Digits)
30 37 Recycle Tray2 1st 2 Digits of Feed 0~3 1 0 O X X
Capacity (8 Digits)
30 41 HFSI Last 2 Digits of the number of 0~99 1 0 O O X Only 0 clearance is possible in the write
Sheets Reaching BIAS transfer mode.
Roll (8 Digits) ("0 clearance" means all bytes change to 0
at the same time.)
30 42 HFSI 5th & 6th Digits of the number 0~99 1 0 O O X Only 0 clearance is possible in the write
of Sheets Reaching BIAS mode.
transfer Roll (8 Digits) ("0 clearance" means all bytes change to 0
at the same time.)

6-20 WorkCentre 5016, 5020
CE
Access
Func Initial
30 43 HFSI 3rd & 4th Digits of the number 0~99 1 0 O O X Only 0 clearance is possible in the write
at the same time.)
30 44 HFSI 1st Two Digits of the number 0~3 1 0 O O X Only 0 clearance is possible in the write
at the same time.)
30 61 Recycle Tray Feed Capacity MAX 0~1 1 0 O X X It is shown whether the Recycle Tray
Over Feed Capacity NVM was written more
than 4000000 times.
0: not exceed
1: exceeded.
30 62 Recycle IOT Starting Number MAX 0~1 1 0 O X X It is shown whether the IOT Starting
Over 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

WorkCentre 5016, 5020 6-21
CE
Access
Func Initial
33 09 ESS IF Default Reduction / 0~4 - 0 O O O 0=100%

Enlargement 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 50~200 - 82 O O O China 82=82%(=82)
Reduction / Enlargement XC 64=64%(=64)
33 14 ESS IF Sharpness Adjustment for 0~4 - 2 O O O 0=Weakest
Copy Job 1=Weaker
2=Normal
3=Stronger
4=Strongest
33 15 ESS IF Sharpness Adjustment for 0~4 - 2 O O O 0=Weakest
Scan Job 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)

6-22 WorkCentre 5016, 5020
CE
Access
Func Initial
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 0~5 - 2 O O O 0=OFF
COPY 1=Level1
2=Level2
3=Level3
4=Level4
5=Level5
33 20 ESS IF Background removal for 0~5 - 2 O O O 0=OFF
SCAN 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 0~60 1sec 8 O O O 0- 60sec
Clear
33 25 ESS IF Carriage Return Default 0~60 1sec 7 O O O 0- 60sec
Position

WorkCentre 5016, 5020 6-23
CE
Access
Func Initial
33 26 ESS IF Platen Fast Scan REGI 0~144 1dot 72 O O O 0-71=-72 to -1dot

Adjustment (600dpi) 72=0dot
73-144=1 to 72dot
33 27 ESS IF Platen Slow scan REGI 0~151 1dot 24 O O O 0-23=-24 to -1dot
25-144=1 to 151dot
33 28 ESS IF ADF Fast Scan REGI 0~144 1dot 72 O O O 0-71=-72 to -1dot
73-144=1 to 72dot
33 29 ESS IF ADF Slow scan REGI 0~79 0.1mm 40 O O O 0-39=-4.0 to -0.1mm
Adjustment 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 0~20 0.10% 10 O O O 0-9=-1.0% to -0.1%
Adjustment 10=0%
11-20=0.1% to 1.0%
33 35 ESS IF ADF Slow Scan scale 0~20 0.10% 10 O O O 0-9=-1.0% to -0.1%
Adjustment 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

6-24 WorkCentre 5016, 5020
CE
Access
Func Initial
34 01 ESS IF Administrator User Login 48~57 - 49 O O O 48-57

Password Low byte
34 11 ESS IF Administrator User Login 48~57 - 49 O O O
Password Mid byte
34 21 ESS IF Administrator User Login 48~57 - 49 O O O
Password High Byte
34 02 ESS IF User1 Login Password Low 48~57 - 48 O O O
Byte
34 12 ESS IF User1 Login Password Mid 48~57 - 48 O O O
byte
34 22 ESS IF User1 Login Password High 48~57 - 48 O O O
byte
Byte
byte
byte
Byte
byte
byte
Byte
byte
byte

WorkCentre 5016, 5020 6-25
CE
Access
Func Initial

Byte
byte
byte
Byte
byte
byte
Byte
byte
byte
Byte
byte
byte
Byte
byte
byte

6-26 WorkCentre 5016, 5020
CE
Access
Func Initial

Byte
byte
byte
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

WorkCentre 5016, 5020 6-27
CE
Access
Func Initial

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

6-28 WorkCentre 5016, 5020
CE
Access
Func Initial
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

WorkCentre 5016, 5020 6-29
CE
Access
Func Initial


6-30 WorkCentre 5016, 5020
CE
Access
Func Initial

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

WorkCentre 5016, 5020 6-31
CE
Access
Func Initial

60 36 Product Product code 1 0~254 1 0 O X X
Reprograming the DADF EPROMS on the SLCC PWB when replacing them with new ones.
Table 1 Reprogaming the EPROMS on the SLCC PWB (DADF)

XC(DMO-W) XC(DMO-W) XC(DMO-E)
110 V 220 V 220 V
100S12656 100S12657 100S12655
Serial No. Serial No. Serial No.
KMA469001- KMX484001- 331494001x-
Chain Link MMA484000 KMX494000 331524000x NVM Destination Remarks Reference
700 339
700 340
700 341
700 342 Get the information from the latest
700 343 soft ware version.
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 This list
0x04:AP
700 700 6 6 6 Machine serial number format 6 This list

6-32 WorkCentre 5016, 5020
Table 1 Reprogaming the EPROMS on the SLCC PWB (DADF)
XC(DMO-W) XC(DMO-W) XC(DMO-E)
110 V 220 V 220 V
100S12656 100S12657 100S12655
Serial No. Serial No. Serial No.
KMA469001- KMX484001- 331494001x-
Chain Link MMA484000 KMX494000 331524000x NVM Destination Remarks Reference
700 329 75 75 75 Product Code #1
700 330 77 77 76 Product Code #2
700 331 65 88 66 Procuct Code #3
700 332 0 0 o Product Code #4
Refer to this list or the Serial Number
700 333 0 0 0 Product Code #5 Plate.
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
709 12 67 67 67 XJ Code #2
This list
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- 0:none specified, 1:LEF, This list
tion 2:SEF
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- This list
tion
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 This list
1: -
2: Duplex M/C
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- Initial Value: 6 This list
ment

WorkCentre 5016, 5020 6-33
List of NVM Settings (WC 5020 DADF)
NOTE: In the CE Access columns, O = yes and X = no.
Table 2
Initial CE Access
Chain Link Name of data Range Unit Value 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.

6-34 WorkCentre 5016, 5020
Table 2
Initial CE Access
715 32 CVT FS OFFset Side 2 0~240 1 dot 120 O O O CVT FS Registration Correction Value for Side 2 (back
side) NVM value 120 is Adjustment Value 0. Adjust by 1
dot.
715 40 FS Magnification Adjustment 0~100 0.1% 50 O O O Fine Adjustment Value of FS magnification. Shows =/-
5% (by 0.1%) fine adjustment value with 50 for 0%, ) for
-5% and 100 for 5%.
715 41 Platen SS Magnification Adjustment 40~60 0.1% 50 O O O Fine Adjustment Value of Platen SS Magnification.
Shows +/- 1% (by 0.1%) fine adjustment value with 50
for 0%, 40 for -1% and 60 for +1%/
715 42 CVT SS Magnification Adjustment 40~60 0.1% 50 O O O Fine Adjustment Value of CVT SS Magnification.
Shows +/- 1% (by 0.1%) fine adjustment value with 50
for 0%, 40 for -1% and 60 for +1%.
715 90 Fail Bypass 0~1 - 0 O O O 0: With out Fail Bypass
1: With Fail Bypass
715 91 Error Information 0~65535 - 0 O O O Debug information
715 92 Size detection: Sensor Information of Cus- 0~65535 - 0 O O O Sensor information in the case of the size detection
tom Size 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

WorkCentre 5016, 5020 6-35
Table 2
Initial CE Access
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

6-36 WorkCentre 5016, 5020
Table 2
Initial CE Access
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

WorkCentre 5016, 5020 6-37
Table 2
Initial CE Access
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

6-38 WorkCentre 5016, 5020
Table 2
Initial CE Access
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- 0~4000 0.1% 4000 O O O Maximum SS detection length (1 step=0.1%) For RAE.
ing
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)

WorkCentre 5016, 5020 6-39
Table 2
Initial CE Access
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 0~3 0 O O O Select the job type applying the corrective LUT of
Job Type 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 0~7 0 O O O Select the document mode applying the corrective LUT
Org Type 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 0~31 0 O O O Select the density level applying the corrective LUT of
Density 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.

6-40 WorkCentre 5016, 5020
Table 2
Initial CE Access
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)

WorkCentre 5016, 5020 6-41
6-42 WorkCentre 5016, 5020
GP1 Serial Number Locations GP 2 Viewing the Six Digit Error Code
The Serial Number is located in three places on the machine: If an error occurs, the two-digit error code, such as C1 and E2, appears in the display on the
Control Panel. To view the six digit error code in the display, use the following procedudre.
NOTE: If the Rear cover has to be replaced, do not worry about saving the data plate (which
1. When the two digit error code appears in the Display, press the Display Button.
has the machine serial number), since the serial number can be found in two other locations.
a. The first three digits of the six digit error code appears in the display.
On the Data Plate on the Rear Cover. 2. Press the Display Button.
In software on the machine. The serial number can be displayed by accessing Diagnos- a. The second half of the six digit error code appears in the display.
tics (How to Enter the Diagnostic Mode) and entering NVM code [25-20].
3. Press the Display Button.
On a bar code sticker at the left rear of the machine, which can be seen by opening the
a. The display switches back to the two digit error codes.
Left Side Cover and looking toward the back.

WorkCentre 5016, 5020 6-43 GP1, GP 2
GP1, GP 2 6-44 WorkCentre 5016, 5020
Specifications Standard Specification of IIT, IOT, and Control UI
This subsection contains the performance specifications of the WorkCentre 5020, the multi-
functional machine that has copier, printer, and scanner functions. Table 1
IIT CCD Image Sensor capable of scanning
System Overview at multi-level 600 dpi
IOT 20 PPM
The WorkCentre 5020 consists of IIT, IOT, PANEL, Controller, and Printer I/F. The summary of
600 dpi
each system is as follows:
Paper Feeding:
1 tray 250 sheets
1. IIT (Image Input Terminal)
MSI 50 sheets
Scans documents for copying and scanning. The IIT resolution is 600 dpi at multi-level.
Paper Output:
2. IOT (Image Output Terminal) Face down tray (250 sheet capacity)
Writes video data on paper for copying and printing. A laser xerography system is applied. PANEL LED
Images can be written at 600dpi on paper up to 11"x17"/ A3 size.
3. UI (User Interface)
Standard Specification of Controller
Displays various settings, errors.
4. Controller Table 2
Controls the whole machine. Processes and stores input from IIT, printer I/F, and images Item GDI Controller NW Controller Notes
to be output to IOT. Controls UI as well.
5. Printer I/F (GDI) CPU OTI4110 MPC8311E --
Receives data from the computer and passes it to the IOT (printer). In scan mode, outputs Standard memory SDRAM 64M --
image data to the computer. Serial EEPROM 4Mbit --
6. I/F (NetWork) Extended slot Not supported --
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. Standard Specification of Host
7. User Registration and Department Management
Administrators can register users who can use a machine, so that only limited users can Table 3
use the machine and that each users operation history can be managed and recorded. Item Description GDI
GDI Host I/F USB (2.0) x 1 Yes
Number of Account: 10 users
Password: 3 digits, Numerical only Product Codes
Network
Number of Account: 99 Table 4
Password: 4-12 columns digits, Numerical only, ommissible Product XJ IOT Prt/
8. Duplex Copy Code Code CODE Model speed Scan Dup IIT Platen ADF FINAL ASSY
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)

WorkCentre 5016, 5020 6-45
Options FCOT shall be 7.5 sec or less. FCOT (Warm Start) is measured from the time the Start button
is pressed (when the engine receives a START command in the "STAND-BY" state) till the trail
Table 5 edge of the first sheet is fed out, under the following conditions:
Product name Installation
Code Documents are placed on Platen
User
Power is on
STM (500sheets) O EL200735
Engine motor is not running
Stand O EL200736
Fuser is ready
Laser scanner motor (ROS: Raster Output Scanner) is ready
Warm-up Time Paper size and feeding orientation: A4 or 8.5x11 LEF
In an ambient environment of 22C and 55% R.H. and in the power off or power save mode,
Paper tray: Tray 1
the machine will reach a "ready to copy" condition within 45 seconds.
Low Power Mode FPOT

When the machine is not operated for a certain period of time, the machine enters Low Power FPOT: First Print Output Time
Mode automatically.
FPOT shall be 12sec or less
Control Panel: LED: ON
Resolution
Device Control: The fuser reduces its temperature. Copy print: 600 X 600 dpi. Printer print: 600 X 600 dpi.
Printer I/F: Activated status. Software Download

After a certain amount of time in Standby Mode, the machine enters Low Power Mode. This Controller Part: User can upgrade the software by downloading the object from the PC.
time can be changed by a software program (setting range: 0-240 minutes). The factory default
is 5 minutes. IOT Engine Part
MCU: Replacing the board. Optional Tray: Replacing the board.
Low Power Mode is cancelled when a button is pressed on the Control Panel or when a printer
job is received.
Sleep Mode (Off Mode)

The machine operates as follows to save power when the machine is in Low Power Mode for a
specified time:
Control Panel: LED: OFF, Power Save Button: ON

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

FCOT: First Copy Output Time

6-46 WorkCentre 5016, 5020
Count-up for Print/Copy jobs: GDI Electrical/Mechanical Characteristics
The purpose of the Count-up Meter is to categorize the number of sheets of print output by Electrical Characteristics
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 Table 8
can be confirmed with device UI. Input Voltage Frequency Rated input cur- Power Con- Sleep Mode
(VAC) (Hz) rent Max (A) sumption* (Off Mode)
The Count-up Meter has only one total counter. Spec (VA) Reference
220 - 240V 240+10% 50/60+/-3 Hz 6A 1320VA (Max) 6 W (Max)
Table 6
220-10%
Job type Counter type Description
110 - 127V 110+10% 50/60 +/-3 Hz 12A 1320VA (Max) 6 W (Max)
Copy Total Counter Counter of copy job 110-10%
Print Counter of print job
Diag Test print in Diag mode *Power consumption is specified assuming full configuration.
(It doesn't contain the Diag test print with Type-Di.)
Rated Power Consumption
Report: One (Printer). [GDI]
GDI: not supported. Table 9 GDI

Mode Power consumption Configuration
Timing of Count-up
In Low Power Mode CP: 107W or less 20cpm
MCU increments the billing counter when the trail edge of the paper passes the Exit Sensor. 91W or less 16cpm
In Sleep Mode (Off Mode) DC: 6W or less
The number of counter increments is as follows:
CP: 20W or less
Table 7 At operation 110V Full configuration
(During printing operation) 12A, 1320VA (Max)
Paper size Number of counter increments 220/240V
Billing Life 6A, 1320VA (Max)
A3, B4, 8K, 11x17, Non-fixed 1 2
A4 or less (A4, Letter, ....) 1 1 Network
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 110V Full configuration
(During printing operation) 12A, 1320VA (Max)
220/240V
6A, 1320VA (Max)

WorkCentre 5016, 5020 6-47
TEC Method (New E-Star) Machine Size/Weight
The machine specified below does not include a drum and toner cartridge.
Table 11
Config TEC 1. Size
GDI Network
Table 12
DC20 3.0Kwh -
CP20 6.0Kwh - Type Width (mm) Depth (mm) Height (mm)
IOT 595+/-5 532+/-5 505+/-5
IOT+IIT (Platen Glass) 595+/-5 532+/-5 528+/-5
IOT+IIT+ADF/DADF/DUP 595+/-5 532+/-5 605+/-5
[Optional Devices]
Table 13
Width (mm) Depth (mm) Height (mm)
STM (500 Sheets) 551+/-5 522+/-5 130+/-5
Stand 551+/-5 506+/-5 385+/-5
Size of Package:
DC: 710x660x716 (mm)
IBG ADF, DADF: 710x660x840 (mm)
2. Weight
Table 14
Main body Configuration
Platen model: Net weight 33.02 Kg Platen/IIT/MSI/Std Tray (250sheets) including
(including toner cartridge) 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- 38.0 Kg TBD IIT/MSI/Std Tray (250sheets) including toner car-
tion) tridge
Stand 18 Kg TBD

6-48 WorkCentre 5016, 5020
Storage Environment (According to Egret) Copy Speed
A machine (without CRU and Toner Cartridge)which has been stored in the following environ- Continuous copy speed at 100% magnification.
ment shall attain the specified performance when installed in the environment specified.
Measurement method: Make 11 continuous copies. Measure the time (T, in seconds) from the
1. In operation (guaranteed copy quality environment): 10 - 32 degrees C @ 15 - 85% RH output of the trail edge of the first sheet of paper to the output of the trail edge of 11th sheet of
2. Shipping and storage conditions: paper, and convert into copies per 60 seconds: CPM = T/60 (normal paper mode).
Table 15 Table 18
Paper Size Paper Tray
Type Transit (48 hrs) Storage (18 mo) Comments
and Tray 1 STM (Add 1 Tray) MSI
Temperature -29 to 66 degrees C -29 to 66 degrees C After storage or transit, Paper Orientation Plain Paper Plain Paper Fixed Mode
(-20 to 150 degrees F) (-20 to 150 degrees F) the machine must normal-
ize to the operating envi- A4 LEF 20 20 10
ronment before power is 8.5" x 11" LEF
applied (this could take up 16K LEF
to 4 hours maximum at
B5 LEF
extreme values).
A4 SEF 15 15 10
Humidity 10 - 95% RH 20 - 80% RH
8.5" x 11" SEF
Altitude Up to 12,000 m Up to 3,000 m
16K SEF
B5 SEF
Noise (Sound Power Level: LWAd) 8.5"x13"SEF 8.5"x14" 12 12 10
Unit: B SEF
Mexico Folio
Table 16
(8.5" x13.4")
Standby Mode Operation Mode A3 SEF 10 10 10
11" x 17" SEF
Base Machine 4.0 6.8 8K SEF
B4 SEF
Full System 4.0 6.8
A5 SEF Not supported 10
5.5" ( 8.5" SEF) 10
Impulse Sound Power (FX) Impulse Sound Power Level (LWAI)
A5 LEF Not supported
LWAI B(A)
5.5" x 8.5" LEF
Table 17
Base Machine 6.6
Full system 7.1
Chemical Substances
1. Levels of Ozone:
Ozone formed from this product: less than 0.02 mg/m3 (according to C11-705)
Eco-Mark Requirement: 0.02 mg/m3
2004 Version Green Target A Limit: 0.015 mg/m3
2. Airborne Dust Concentration:
Inhaled airborne dust from this product: less than 0.08 mg/m3 (according to C11-705)
Eco-Mark Requirement: 0.075 mg/m3
2004 Version Green Target A Limit: 0.04 mg/m3

WorkCentre 5016, 5020 6-49
Alignment Paper Supply
1. [Full System] IOT + IIT + ADF + DADF All paper trays (excluding MSI) are universal trays, which are front-loading trays.
Table 19 Copy Alignment: Specification 1. Capacity

Specification Specification Tray 1: 250 sheets (Business 80gsm/sheet).
SYSTEM SYSTEM The height of a stack of paper shall be 27mm or less.
Item 1 Sided 2 Sided Application STM (optional): 500 sheets (Busines 70gsm/sheet).
Lead Edge Registra- +/- 2.90 +/- 3.80 450 sheets (Business 80gsm/sheet).
tion (mm) The height of a stack of paper shall be 54mm or less.
Side Edge Registra- +/- 3.40 +/- 3.90 2. Standard paper
tion (mm)
Standard paper is indicated by "Standard Paper" on "Paper List."
Lead Skew (mm) +/- 2.30 +/- 2.70 280 mm
3. Weight
Vertical Ratio (%) +/- 1.40 -1.72 400 mm
Tray 1: 60gsm to 90gsm
100%
STM: 60gsm to 90gsm
Horizontal Ratio (%) +/- 1.40 -1.72 280 mm
4. Size
100%
Perpendicularity (mm) +/- 3.40 +/- 4.00 400 mm 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
Linearity (Vertical) +/- 2.00 - 400 mm
(mm)
5. Usage rate
Linearity (Horizontal) +/- 1.40 - 280 mm
(mm) Tray 1: 60%
Linearity (Skew) (mm) +/- 1.42 - 280 mm STM: 30%
Parallelism +/- 3.70 -4.00 400 mm
2. [DC] IOT+IIT

Item Specification Measurement
SYSTEM Length
Simplex Duplex
Skew H +/-2.3 +/-2.7 200mm
Perpendicularity +/-3.7 +/-4.0 400mm
Linearity: V 2.3 -- 400mm
Linearity: H 2.3 -- 280mm
Linearity: D 2.3 -- 283mm
Registration: Lead +/-2.9 +/-3.8
Registration: Side +/-3.4 +/-3.9
Magnification: V (%) +/-1.4 (100%) +/-1.72 (100%) 400mm
+/-1.56 (50%-99%) +/-1.89 (50%-99%)
+/-1.8 (101%-200%) +/-2.42 (101%-
200%)
Magnification: H (%) +/-1.4 (100%) +/-1.72 (100%) 280mm
+/-1.56 (50%-99%) +/-1.89 (50%-99%)
+/-1.8 (101%-200%) +/-2.42 (101%-
200%)

6-50 WorkCentre 5016, 5020
Bypass Tray(MSI) Paper List
1. Capacity
50 sheets of paper (70 gsm) Table 21
2. Paper size and paper orientation Media Type Paper Code CIM Bypass
Size and orientation of paper set on MSI shall be as follows: A4L/S, A3, B5L/S, B4, 8K, Flag Ship (80 gsm) O O
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
Baseline Paper Xerox Business Multipurpose 4200
3. Paper weight
20 lb O O
Weight of paper that can be supplied from MSI is 60g/m2 to 110g/m2.
Xerox Xcite (80 gsm) O O
4. Usage rate
10%
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
Standard Paper 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
Plain 3R96002 O
Transparency Removable Bar Stripe 3R96023 0
Xerox 3R12050 O O
(TBD)
Label O O
Recycle Paper O O
Business 80 gsm-4 Hole (Hole on TE) 3R91823 O
Other Primier A4 80 gsm-4 Hole (Hole on 3R91723 O
TE)
3- Hole (hole on TE) 3R2193 O
Paperbacked OHP is out of quality assurance.
Paper Selection
There are two methods of Paper Tray selection:
1. Direct selection
User selects the paper tray that contains the required type of paper (size and orientation).
2. APS (Automatic Paper Selection) (ADF/DADF only)
MC automatically selects the paper that matches the image size.

WorkCentre 5016, 5020 6-51
Tools Consumables
Most maintenance procedures can be done with the following standard tools: Machine CRU Strategy
Machine LCB is designed to interface with a CRUM and Billing Counter on all configurations.
Table 1
The CRUM can be used to provide a "hard stop" capability for markets requiring this feature.
No. TOOL NO. /TOOL NAME No. TOOL NO. /TOOL NAME 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
1 499T 1423 BOX DRIVER 5.5 8 499T 247 TEST PATTERN (A3)
end-of-life point. The primary uses of the Counter are to indentify the machine's market loca-
2 499T 355 SCREWDRIVER (+) 9 499T 301 MINI DRIVER tion, electronically store the machine's serial number, and store the number of copies made on
3 499T 2004 ROUND NOSE PLIERS 10 499T 1901 SIDE CUTTING NIPPER the machine.
4 499T 2320 S/E TESTER SET
5 499T 2601 SILVER SCALE (ISO M/N) 12 499T 9507 TESTER LEAD WIRE Consumable Replacement Intervals (TBD)
(Red)
6 499T 8104 FLASHLIGHT (UM-2) 13 499T 9508 TESTER LEAD WIRE Table 1
(Black) ITEM YIELD/LIFE STRATEGY/REPLACEMENT
7 499T 8902 BRUSH 14 499T 353 * STUBBY DRIVER
Toner 6K @ 5% area coverage of A4 size Warning/Hard Stop
Test pattern - Warning with approximately 100
* 499T 353 STUBBY DRIVER should be used when replacing the ROS ASSEMBLY. copies of toner remaining.
Drum Car- Hard Stop: 22K @ 5% A4 area cover- End of life Warning/Hard Stop
tridge age for XC - Warning at 16K
Job Size = 4 pages Hard Stop at 22K (XC)
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)

6-52 WorkCentre 5016, 5020
Glossary of Terms Table 1
Term Description
Table 1
Hz Hertz (Cycles per second)
Term Description IIT Image Input Terminal - the Scanner/CCD portion of the machine
A3 Paper size 297 millimeters (11.69 inches) x 420 millimeters (16.54 inches). IOT Image Output Terminal - the ROS/Xero/paper handling/ fusing portion of the
A4 Paper size 210 millimeters (8.27 inches) x 297 millimeters (11.69 inches). machine
AC Alternating Current is type of current available at power source for machine. IQ Image Quality
ACT Advanced Customer Training: teaches customers to perform some of service that is KC 1000 copies
normally performed by Xerox Service Representative. LCD Liquid Crystal Display
A/D Analog to Digital refers to conversion of signal LE Lead Edge of copy or print paper, with reference to definition of term TE
ADF Automatic Document Feeder LED Light Emitting Diode
ADJ Adjustment Procedure LEF Long Edge Feed
Bit Binary digit, either 1 or 0, representing an electrical state. LTR Letter size paper (8.5 x 11 inches)
CCD Charge Coupled Device (Photoelectric Converter) LUT Look Up Table - array of NVM locations that store process control data
CD 1: Circuit Diagram; 2: Compact Disc LVPS Low Voltage Power Supply
CF Copier Fax MF Multi-Function
CP Copier Printer MN Multinational
CPF Copier Printer Fax MPT Multi Purpose Tray
Chip Integrated Circuit (IC) NBCR New Book Scanner Control Relay
CRU Customer Replaceable Unit NIC Network Interface Card
CVT Constant Velocity Transport NSC New Scanner Controller
DADF Duplexing Automatic Document Feeder NVM Non Volatile Memory
DC Direct Current is type of power for machine components. Machine converts AC OEM Original equipment manufacturer
power from power source to DC power. OGM On-going Maintenance
DC Digital Copier PC Personal Computer
DMM Digital Multimeter is generic name for meter that measures voltage, current, or elec- PL Parts List
trical resistance. PO Part of (Assembly Name)
Duplex 2-sided printing or copying PS Post Script
EME Electromagnetic Emissions are emitted from machine during normal operation and PSW Portable Standard Workstation
power of these emissions are reduced by machine design features.
PWB Printed Wiring Board
ERU Engineer Replaceable Unit
PWS Portable Workstation for Service
ESD Electrostatic Discharge. A transfer of charge between bodies at different electrostatic
PJ Plug Jack (electrical connections)
potential.
FS Fax Scanner RAM Random Access Memory
FS Fast Scan (direction) - Inboard - to - Outboard RAP Repair Analysis Procedure for diagnosis of machine status codes and abnormal con-
ditions
ESS Electronic Sub-System
R/E Reduction/Enlargement refers to features selection or components that enable
ENG English
reduction or enlargement
2TM Two Tray Module
REP Repair Procedure for disassembly and reassembly of component on machine
FAX Facsimile
RIS Raster Input Scanner
FIC Final Integration Center
ROM Read Only Memory
GND Ground
ROS Raster Output Scanner - Device that transfers digitally processed image, using laser
HFSI High Frequency Service Item light, to photoreceptor.
HVPS High Voltage Power Supply SAD Solid Area Density

WorkCentre 5016, 5020 6-53 Glossary of Terms
Table 1
Term Description
SCP Service Call Procedure
SEF Short Edge Feed
Self- An automatic process that is used to check Control Logic circuitry. Any fault that is
test 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

Glossary of Terms 6-54 WorkCentre 5016, 5020
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
Reissue June, 2008 Wiring Data

Wiring Data June, 2008 Reissue
Chain 1 Standby Power
A B C D E F G H J
1.1 MAIN POWER GENERATION ADF PWB

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

A B C D E F G H J
1.2 INTERLOCK SWITCHING
1 LVPS LH COVER LVPS FRONT COVER LVPS AIOC PWB

PL8.1 INTERLOCK PL8.1 INTERLOCK PL8.1 PL8.1
SWITCH 1-1 1 SWITCH 1-12 1
PL8.2 PL8.2
LH COVER FRONT COVER
INTERLOCK SWITCH INTERLOCK SWITCH 4.1 10.1
J506FS151 FS152 COVER OPEN(L) +24VDC J506 J506FS153 FS154 COVER OPEN(L) +24VDC J506 J416
4 ORN ORN
3 2 ORN ORN
1 1 BLU
F2
+24VDC
(1.1)
2
AIOC PWB
PL8.1 P/J407
A1 E5-2
P/J407 B1
A2 E5-1
INTLK INTLK
+24VDC +24VDC
Fail Code
E5-1 LH Cover Open

DUPLEX PWB
PL8.2
4 E5-2 Front Cover Open
10.2
INTLK +24VDCJ550
BLU
9
1 The actual H/L level is displayed inversely on the UI display.

5
LH COVER INTERLOCK SWITCH
FRONT COVER INTERLOCK SWITCH
Figure 2 1.2 Interlock Switching

Chain 2 Mode Selection
A B C D E F G H J
2.1 CONTROL PANEL

Fail
Code
AIOC PWB USER INTERFACE PWB
1 PL8.1 PL8.4 U7-0 UI Communication
Timeout
U7-1 UI Communication
J401 WAKE J710 Error
8 UP 1
BLU BLU AIOC PWB
PL8.1
UI
7 RESET 2
BLU BLU
2
UI J710 J401 U7-0
UI RXD
5 TXD 4 3 6
BLU BLU BLU BLU
U7-1
4 5
BLU BLU
6.1
3 6
BLU BLU
3
DC COM DC COM
(1.1)
2 7
BLU BLU
1 8
BLU BLU
+5VDC +5VDC
(1.1)
4
1 2 3
4 5 6
7 8 9
1
6 2 C 0
Figure 1 2.1 Control Panel

Chain 3 Machine Run Control
A B C D E F G H J
3.1 PWB COMMUNICATION (STM PWB)
1 AIOC PWB LVPS STM PWB

PL8.1 PL8.1 PL11.5
LVPS AIOC PWB
PL8.1 PL8.1
P/ J407 J508 J540
B19 STM IIC SCL
9 6
YEL YEL
J540 J508 P/ J407

STM IIC SDA STM REQ
B20 7 4 3 6 B21 H9-7
YEL YEL YEL YEL
2
Fail Code
3 H9-7 MCU (AIOC PWB) - STM PWB Communication Error
Figure 1 3.1 PWB Communication (STM PWB)

A B C D E F G H J
3.2 BILLING AND MACHINE CONTROL

Fail Code
1
U8-1 Billing Counter Defect
AIOC PWB
PL8.1 U6-2 RAM Read/Write Check Error
U6-3 NVM Data Defect
9.2 BILLING U6-4 NVM Read/Write Cannot be Excuted

J401 BILL ID J630 P630 COUNTER
U8-1 9 BLU BLU
2 1 PL8.1
U6-5 CPU Power to access NVM is not enough
2
N9-0 Controller Logic Fail
U6-2 RAM 10 BLU BLU
1 2
DC COM N9-1 IOT Communication Error
(1.1)
U6-3 E9-1 AMS NG Out Of Range
U6-4 NVM E9-2 Paper Direction Mismatch
3 U6-5 E8-1 Nup NG Out Of Range
E8-2 Paper Direction Mismatch

N9-0
L9-0 Copy Counter Full
N9-1 P/J411
1,2,3 USB 2.0
,4,5 N4-0 No Response from USB-Host
E9-1
N4-1 HBPL or XPJL Syntax Error
E9-2
4
N4-2 CPM Image Lost
E8-1
C0-1 APS NG Unselected
E8-2
C0-2 ADF NG out of range
L9-0
N4-0
5 N4-1
N4-2
C0-1
C0-2
Figure 2 3.2 Billing and Machine Control

Chain 4 Start Power
A B C D E F G H J
4.1 MAIN DRIVE
1 AIOC PWB LVPS IOT MOTOR

PL8.1 PL8.1 PL1.1
4-1
P/J407 IOT MOTOR Fuser CRU
J504 ON(H) +5VDC J201
B2 4 BLU 4
BLU
F3 J201 IOT MOTOR LOCK(H) +5VDC

1 RED 1 MOT 3 YEL
RED
2 INTLK
+24VDC
(1.2)
2 BLK BLK
2
DC COM
(1.1)
GN/YL LVPS AIOC PWB

3 Regi
T82 T81 PL8.1 PL8.1
INLET FRAME DRV ESD GND +5VDC

U0-1
J504 P/J407
GRN YEL
3 B3 U1-1
T30 F155
4
DRV ESD GND IOT ESD GND
Duplex
Dupulex
Fail Code
U0-1 IOT Motor Stop Error
5
U1-1 IOT Motor Rotation Error
Tray
Figure 1 4.1 Main Drive

Chain 5 ADF/DADF
A B C D E F G H J
5.1 DOCUMENT SIZE SENSING

ADF PWB AIOC PWB
PL13.3 PL8.1
DOCUMENT 5-34 1
1 TRAY LENGTH
DOCUMENT TRAY +3.3VDC
SENSOR 1
PL13.10 LENGTH SENSOR 1
DF4 DOCUMENT SENSED(H) +3.3VDC CN4 J731 ADF SEL0 J414
2 BLU
7 A3 YEL YEL
A10
ADF PWB
PL13.3 DOCUMENT 5-35 1
TRAY LENGTH +3.3VDC
SENSOR 2 DOCUMENT TRAY
PL13.10 LENGTH SENSOR 2
DF5 DOCUMENT SENSED(H) +3.3VDC ADF SEL1
CN4 DF4 2 BLK
8 B5 YEL YEL
B8 A2-2
5 WHT 1
2
+5VDC
(1.1)
6 WHT 3
DC COM
DF5 ADF SEL2
(1.1) B6 YEL YEL
B7
WHT
1
WHT
3
3 DOCUMENT 5-32 1
TRAY WIDTH +3.3VDC Fail Code
PL13.10 WIDTH SENSOR 1
DF3 DOCUMENT SENSED(H) +3.3VDC
2 RED
3 A2-2 Not Supported Doc Size
DOCUMENT 5-33 1
TRAY WIDTH +3.3VDC
PL13.10 WIDTH SENSOR 2
DF3 2 4
YEL
4 1 WHT 1
DOCUMENT TRAY WIDTH SENSOR 2
+5VDC DOCUMENT 5-31 1
(1.1) FEEDER +3.3VDC
2 WHT 3 WIDTH DOCUMENT FEEDER DOCUMENT TRAY
SENSOR WIDTH SENSOR LENGTH SENSOR 2
DC COM DF8 DOCUMENT SENSED(H) +3.3VDC
CN5
(1.1) DF2 PL13.9 2 5
1 YEL
WHT
WHT
3
5
CN5 DF8
3 WHT 1 DOCUMENT FEEDER WIDTH SENSOR
+5VDC
(1.1)
4 WHT 3
DC COM
(1.1)
6
1 A combination of H and L levels of these five sensors determines a document size. DOCUMENT TRAY WIDTH SENSOR 1
For the relation between H/L of each sensor and document size,
see the marginal table under 5.4 DOCUMENT PATH.
DOCUMENT TRAY LENGTH SENSOR 1
Figure 1 Document Size Sensing

A B C D E F G H J
5.2 DOCUMENT SETTING AND TRANSPORT
1
ADF PWB AIOC PWB
PL13.3 PL8.1
ADF PWB ADF TOP

PL13.3 COVER 5-29 +3.3VDC +3.3VDC
SWITCH
PL13.9 ADF TOP COVER SWITCH
CN5 DF14 DF14 COVER OPEN(L) +3.3VDC CN5 J731 J414
2 WHT WHT
1 2 WHT WHT
1 A5 YEL YEL
A8 A5-2
2 DC COM
DOCUMENT
(1.1)
SET SENSOR 5-30 +3.3VDC +3.3VDC
PL13.9
DOCUMENT SET SENSOR
2 BLU BLU
8 A4 YEL YEL
A9
DOCUMENT
FEED SENSOR 5-36 +3.3VDC +3.3VDC
PL13.9
DOCUMENT FEED SENSOR A1-1
DF10 DOCUMENT SENSED(L) +3.3VDC
3 DF9 2 WHT 10 A6 YEL A7
6 WHT 1 WHT YEL A4-1
+5VDC
(1.1) A4-2
7 WHT 3
DC COM
(1.1) DF10
WHT
1
9 WHT 3 ADF TOP COVER SWITCH

WHT
4
DC COM
(1.1)
DOCUMENT FEED SENSOR
Fail Code
5 A5-2 ADF Cover Open

DOCUMENT SET SENSOR
A1-1 Doc Misfeed Jam
A4-1 Short Length Detect
A4-2 Long Length Detect

6
Figure 2 Document Setting and Transport

7-10 WorkCentre 5016, 5020
A B C D E F G H J
5.3 DOCUMENT FEED AND TRANSPORT MECHANISM
1 AIOC PWB ADF PWB

PL8.1 PL13.3
5-42 DOCUMENT
DOCUMENT FEED CLUTCH
FEED CLUTCH DOCUMENT FEED CLUTCH
J414 J731 CN3 ON(L) +24VDCDF13 DF13 PL13.9 Feed Roller
A6 YEL YEL
A7 2 WHT 1 2
DC COM
1 WHT 2 1
2 +24VDC
DOCUMENT
DRIVE MOTOR
5-40 High Speed

DOCUMENT
5-41 Low Speed DRIVE MOTOR
PL13.5 DOCUMENT SET SENSOR
DOCUMENT DRIVE MOTOR
MOT M1 CN2 ON +24V CLOCK
A1 YEL YEL
A12 2 ORN
3
DC COM DOCUMENT FEEDER
MOT M2 DOCUMENT DRIVE MOTOR WIDTH SENSOR
B12 YEL YEL
B1 ON +24V CLOCK
3 YEL
MOT M3 DC COM
A2 YEL YEL
A11 DOCUMENT DRIVE MOTOR
ON +24V CLOCK Exit Roller
5 BRN
MOT CLOCK
B11 YEL YEL
B2 DC COM MOT
DOCUMENT DRIVE MOTOR
ON +24V CLOCK
4 MOT ON 6 BLK
A3 YEL YEL
A10
DC COM
MOT CURR1 Regi Roll
B10 YEL YEL
B3 1 WHT
MOT CURR2 Reed Out

Out Roll
Roll
A4 YEL YEL
A9 Feed
4 BLK
Reed In
Feed In Roll
Roll
MOT RST +24VDC
B9 YEL YEL
B4 (1.1)
5
MOT CW/CCW
A5 YEL YEL
A8
DOCUMENT LEAD EDGE SENSOR
Figure 3 Document Feed and Transport Mechanism

WorkCentre 5016, 5020 7-11
A B C D E F G H J
5.4 DOCUMENT PATH

DOCUMENT TRAY WIDTH SENSOR 1
Feed Roll
1 DOCUMENT TRAY LENGTH SENSOR 1
DOCUMENT SET SENSOR DOCUMENT TRAY WIDTH SENSOR 2
DOCUMENT FEEDER WIDTH SENSOR DOCUMENT TRAY LENGTH SENSOR 2
Regi Roll
2 DOCUMENT FEED SENSOR
Read In Roll
Read Out Roll
3 Exit Roller
DOCUMENT DOCUMENT DOCUMENT DOCUMENT DOCUMENT

The table at the right shows the relationship between High/Low FEEDER WIDTH TRAY WIDTH TRAY WIDTH TRAY LENGTH TRAY LENGTH
of each document size sensor and document size . Document Size
SENSOR SENSOR 1 SENSOR 2 SENSOR 1 SENSOR 2
The standard size of a document is sensed at the tim e the
DOCUMENT FEEDER WIDTH SENSOR detects it after it is fed.
4 5.5"x8.5"SEF L L L L L
A5 SEF L H L L L
B5 SEF L H L H L
A4 SEF L H H H L
A5 LEF L H H L L
5.5"x8.5"LEF L L H L L
8.5"x11"SEF (Letter) L L H H L
5 8.5"x13"SEF (Legal) L L H H H
8.5"x14"SEF (Legal) L L H H H
B5 LEF H H H L L
B4 SEF H H H H H
Executive LEF H L H L L
16K LEF H L H L L
8K SEF H L H H H
6 8.5"x11"LEF (Letter) H H L L L
11"x17"SEF(Ledger) H H L H H
A4 LEF H L L L L
A3 SEF H L L H H
Figure 4 Document Path

7-12 WorkCentre 5016, 5020
Figure 5 BSD 5.5 Document Size Sensing - DADF/Network Configuration

WorkCentre 5016, 5020 7-13
Figure 6 BSD 5.6 Document Setting & Transport - DADF/Network Configuration

7-14 WorkCentre 5016, 5020
Figure 7 BSD 5.7 Document Feed & Transport Mechanism- DADF/Network Configuration

WorkCentre 5016, 5020 7-15
Figure 8 BSD 5.8 Document Inversion - DADF/Network Configuration

7-16 WorkCentre 5016, 5020
Figure 9 BSD 5.9 Document Path - DADF/Network Configuration

WorkCentre 5016, 5020 7-17
Chain 6 Imaging
A B C D E F G H J
6.1 IMAGE INPUT
1 AIOC PWB LENS ASSEMBLY AIOC PWB

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

28 7
CCD TRNSF CLK

30 5
3 PLATEN OPEN SWITCH
USER INTERFACE PLATEN OPEN USER INTERFACE PWB

PWB SWITCH PL8.4
PL8.4 PL10.5
4
5-10 +5VDC
MAGNET
PLATEN OPEN SWITCH
J711 COVER CLOSED(L) +5VDC J711
1 2 A5-1
BLK BLK
DC COM
(2.1)
Fail Code
A5-1 Platen Cover Open

6
Figure 1 6.1 Image Input

7-18 WorkCentre 5016, 5020
A B C D E F G H J
6.2 CARRIAGE SCAN

5-20 High speed scan CARRIAGE MOTOR
AIOC PWB LENS 5-21 CARRIAGE SENSOR
PL8.1 ASSEMBLY High speed return
1 PL10.7 5-22 Low speed scan CARRIAGE
5-23 Low speed return MOTOR
IIT PWB PL10.6 EXPOSURE LAMP
CARRIAGE MOTOR
J409 CLOCK A J721 CN4 ON +24V CLOCK IIT5
12 10 1 1
YEL
CLOCK A
13 9
CARRIAGE MOTOR
CLOCK /A ON +24V CLOCK
2 14 8 2 2
ORN
CLOCK /A
15 7
CARRIAGE MOTOR
CLOCK /B ON +24V CLOCK MOT
16 6 3 3 Fail Code
BRN
CLOCK /B
17 5 U2-1 Carriage Module Fail
CARRIAGE MOTOR
CLOCK B ON +24V CLOCK
18 4 4 4
BLK
3 CLOCK B 1
19 3 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.
5 5 Run DC [5-23] to move the carriage until it reaches the left side,
RED and then stop it. It can then be detected that CARRIAGE SENSOR turns High.
+24VDC
(1.1)
INVERTER PWB EXPOSURE

PL10.7 LAMP
EXPOSURE PL10.6
J410 J720 CN3 LAMP ON INV CN1 INV CN2
4 32 3 2
GRY
2
DC COM
1 1
GRY
+24VDC LENS AIOC PWB
(1.1) ASSEMBLY PL8.1
3 3 PL10.7
GRY
DC COM
(1.1) CARRIAGE IIT PWB 5-11 1
SENSOR +3.3VDC
x PL10.6 CARRIAGE SENSOR
5 CAUTION IIT4 CN3 J720 J410
High Voltage BLOCKED(H) +5VDC
2 4 2 33 U2-1
GRY
IIT4
6 1
GRY
+5VDC
(1.1)
6 5
GRY
3
DC COM
(1.1)
Figure 2 6.2 Carriage Scan

WorkCentre 5016, 5020 7-19
A B C D E F G H J
6.3 LASER CONTROL AND SCANNING
1 AIOC PWB ROS

PL8.1 PL3.1
LD PWB SOS PWB LD PWB AIOC PWB
PL8.1
J404 J160 J201 J2011 SOS
2 2 3 1 SENSOR
RED RED LD INTLK
+5VDC +5VDC
LD INTLK
+5VDC SOS SENSED
J2011 J201 J140 SIGNAL J403
1 1 1 3 2 2 6 3 U3-5
BLU BLU
2 DC COM
LD INTLK
+5VDC
LASER DIODE
J403 ENABLE ON(L) +5VDC J140
6 1
BLU BLU LASER DIODE GRN GRN
T24 F171 F156 F170
LD INTLK
+5VDC
PD
POWER CONTROL
ON(L) +5VDC INLET FRAME ROS GND IIT GND ROS GND
4 5 LD
BLU BLU
3 6-16
ROS VREF 6-17
5
OUT SIGNAL
4 Fail Code U3-5 Laser Power or ROS Motor
BLU BLU COM Fail
9.2
1 8
BLU BLU
LD INTLK
+5VDC
4 2
BLU BLU
7
LD PWB
DC COM
(1.1)
6-15 ROS MOTOR
ROS MOTOR
ON(L) +5VDC P620 J620 J130
9 2 3 3
BLU BLU
ROS MOTOR
5 CLOCK
10 1 4 1 MOT
BLU BLU
7 4 1 5
BLU BLU
+24VDC
(1.1)
8 3 2 4
BLU BLU
DC COM
6 (1.1) ROS MOTOR
SOS PWB
Figure 3 6.3 Laser Control and Scanning

7-20 WorkCentre 5016, 5020
Chain 7 Paper Supplying
A B C D E F G H J
7.1 TRAY1 PAPER STACKING
1 LVPS AIOC PWB

PL8.1 PL8.1
TRAY1 NO PAPER
SENSOR 7-7
PL2.7 +5VDC
J157 J203 P203

TRAY1 NO PAPER SENSOR
J501 P/ J407
LVPS PAPER SENSED(L) +5VDC
1 3 1 5 A19 C5-0
PL8.1 BLU BLU
+5VDC
(1.1)
2
J501 P203 J203 J157
3 3 1 3
BLU BLU
4 2 2 2
BLU BLU
DC COM
(1.1)
TRAY1
INTERLOCK
3 SWITCH 1-11 +5VDC
PL2.5
TRAY1 INTERLOCK SWITCH
J161 J161 COVER OPEN(H) +5VDC
9 2 1 10 B22 E6-1
BLU BLU BLU BLU
DC COM
(1.1)
4 Fail Code
TRAY1 NO PAPER SENSOR C5-0 No paper in the selected paper tray (Tray1)
TRAY1 INTERLOCK SWITCH
E6-1 L/H Lower Cover open
Figure 1 7.1 Tray 1 Paper Stacking

WorkCentre 5016, 5020 7-21
A B C D E F G H J
7.2 STM PAPER STACKING
1 STM PWB
PL11.5
STM NO PAPER
SENSOR 7-8
PL11.7 +5VDC
STM NO PAPER SENSOR
J171 PAPER SENSED(L) +5VDC J542
STM PWB 1 5 C6-0
PL11.5 BLU BLU
+5VDC
(1.1)
2
J542 J171
3 3
BLU BLU
4 2
BLU BLU
DC COM
(1.1)
STM INTERLOCK
SWITCH
3 PL11.5 1-10 +5VDC
STM INTERLOCK SWITCH
J173 J173 COVER OPEN(H) +5VDC
9 2 1 10 E6-2
BLU BLU BLU BLU
DC COM
(1.1)
4 Fail Code
C6-0 No paper in the selected paper tray (Tray2)
E6-2 STM L/H Cover open
STM NO PAPER SENSOR

STM INTERLOCK SWITCH
5
Figure 2 7.2 STM Paper Stacking

7-22 WorkCentre 5016, 5020
Chain 8 Paper Transportation
A B C D E F G H J
8.1 TRAY1 PAPER FEEDING

LVPS AIOC PWB
PL8.1 PL8.1
1 TRAY1 FEED
SENSOR 8-7 1 +5VDC
PL2.5
TRAY1 FEED SENSOR P/J407
1 BLU BLU
8 A20 C1-1
AIOC PWB LVPS
PL8.1 PL8.1 C2-2
+5VDC
(1.1)
C8-1
2 J501 J158
6 BLU BLU
3
7 BLU BLU
2
DC COM
(1.1)
TRAY1 FEED
8-12 CLUTCH
PL2.2
P/J407 TRAY1 FEED CLUTCH
ON(L) +24VDC P202 J202
3 A18 2 BLU 2 1
BLU
DC COM
1 BLU BLU
1 2 IOT Motor
+24VDC
(1.1)
4 Fail Code 1 The actual H/L level is displayed inversely on the UI display.
TRAY1 FEED CLUTCH
C1-1 Tray1 Feed Sensor on JAM
TRAY1 FEED SENSOR

C2-2 Tray1 Feed Sensor on JAM from STM Feed
Take Away Roll 1

C8-1 Tray1 Feed Sensor Static JAM
Tray 1 Feed Roll
5
Figure 1 8.1 Tray 1 Paper Feeding

WorkCentre 5016, 5020 7-23
A B C D E F G H J
8.2 STM PAPER FEEDING

STM PWB
PL11.5
1 STM FEED
SENSOR 8-6 1 +5VDC
PL11.5
STM FEED SENSOR
1 BLU BLU
8 C2-1
STM PWB
PL11.5 C8-2
+5VDC
(1.1)
2 J542 J172
6 BLU BLU
3
7 BLU BLU
2
DC COM
(1.1)
STM FEED
8-11 CLUTCH
PL11.6
STM FEED CLUTCH
ON(L) +24VDC P212 J212
3 2 BLU BLU
2 1
STM FEED CLUTCH
DC COM
1 BLU BLU
1 2
STM FEED MOTOR
+24VDC
(1.1)
8-13 STM FEED

MOTOR
STM FEED MOTOR PL11.6 Take Away Roll 2
J541 ON +24V CLOCK
4 1 YEL
STM FEED MOTOR STM FEED SENSOR
ON +24V CLOCK
2 RED
STM FEED MOTOR MOT
ON +24V CLOCK
3 ORN
STM FEED MOTOR
ON +24V CLOCK
4 BRN
5
Tray 2 Feed Roll
Fail Code 1 The actual H/L level is displayed inversely on the UI display.
C2-1 STM Feed Sensor on JAM
6 C8-2 STM Feed Sensor Static JAM
Figure 2 8.2 STM Paper Feeding

7-24 WorkCentre 5016, 5020
A B C D E F G H J
8.3 MANUAL BYPASS
1
AIOC PWB LVPS
PL8.1 PL8.1
BYPASS
8-17 SOLENOID
PL7.5
P/ J407 J502
BYPASS SOLENOID
A5 ON(L) +24VDC
3
RED
2
DC COM
1
RED
+24VDC
(1.1)
BYPASS SOLENOID
Bypass Feed Roll
Bypass Take Away Roll
Figure 3 8.3 Manual Bypass

WorkCentre 5016, 5020 7-25
A B C D E F G H J
8.4 PAPER REGISTRATION

LVPS AIOC PWB
PL8.1 PL8.1
1 IOT REGI.
SENSOR 8-5 1 +5VDC
PL2.9
IOT REGI. SENSOR P/J407
1 BLU BLU
3 A4 C1-2
AIOC PWB LVPS
PL8.1 PL8.1 C2-3
+5VDC
(1.1)
C6-2
2 J503 J156
1 BLU BLU
3 C9-3
E1-6
2 BLU BLU
2
DC COM
(1.1)
IOT REGI.
8-10 CLUTCH
IOT REGI. CLUTCH PL2.9
P/J407 ON(L) +24VDC P640 J640
3 A6 4 BLU 1 2
BLU
DC COM
5 BLU BLU
2 1
+24VDC
(1.1)
IOT Motor
4 Fail Code 1 The actual H/L level is displayed inversely on the UI display.
C1-2 Tray1 Regi. Sensor on JAM
IOT REGI. CLUTCH

C2-3 STM IOT Regi. Sensor on JAM
C6-2 Duplex IOT Regi. Sensor on JAM
5 Manual Bypass IOT Regi. Sensor on JAM

IOT REGI. SENSOR
C9-3
E1-6 IOT Regi. Sensor Static JAM
Regi. Roll
6
Figure 4 8.4 Paper Registration

7-26 WorkCentre 5016, 5020
A B C D E F G H J
8.5 PAPER PATH
2
ExitExit
RollRoll
EXIT MOTOR
FUSER EXIT SENSOR
Duplex Roll 1
3 Fuser
Regi. Roll IOT MOTOR
Duplex Roll 2
Drum
IOT REGI. SENSOR
4
Bypass Feed Roll
TRAY1 FEED SENSOR

Bypass Take Away Roll
TRAY1 NO PAPER SENSOR

Take Away Roll 1
5 Tray 1 Feed Roll
STM NO PAPER SENSOR

Take Away Roll 2
STM FEED SENSOR STM FEED MOTOR
6 Tray 2 Feed Roll
Figure 5 8.5 Paper Path

WorkCentre 5016, 5020 7-27
Chain 9 Marking
A B C D E F G H J
9.1 XEROGRAPHICS
ChargeCorotron
1 Drum
AIOC PWB HVPS PWB DRUM CARTRIDGE Paper

PL8.1 PL8.2 PL4.1
9-4
CHARGE
9-5
J406 CHARGE ON(L) +5VDC J520 GRID

2 2
BLU BLU
GND Detack Saw
2 DC COM Grid
DEVE BIAS AC/DC ON(L) +5VDC DEVE
4 4 BIAS
BLU BLU
DC COM
TRANSFER COROTRON
TRANSFER ON(L) +5VDC HOUSING
5 5
BLU BLU PL4.3
DC COM
DETACK Transfer Corotron
TRANSFER S/D ON
3 3
BLU BLU
3
DC COM TRANSFER
9.3
Deve Bias
9 9
BLU BLU
Magnet Roll
INTLK INTLK
+24VDC +24VDC GND
7 7
BLU BLU
4 8
BLU BLU
8
AIOC PWB
DC COM PL8.1
(1.1)
+5VDC
J520 HVPS ERROR(L) +5VDC J406

1 1 U9-0
RED RED
Fail Code
U9-0 HVPS fail
Figure 1 9.1 Xerographics

7-28 WorkCentre 5016, 5020
A B C D E F G H J
9.2 TONER SENSE AND CRUM

TONER EMPTY LVPS AIOC PWB
1 LVPS
SENSOR PL8.1 PL8.1
PL4.2
PL8.1
J509 P110 J110 J110 P110 J509
1 BLU BLU
4 1 RED WHT
2 3 BLU BLU
2
9-7 +5VDC
+24VDC
(1.1) TONER EMPTY SENSOR P/J407
TONER SENSED(L) +5VDC
3 BLU BLU
2 3 BLK GRN
4 1 BLU BLU
4 B4 J1-2
DC COM
(1.1)
2
AIOC PWB DRUM CARTRIDGE

PL8.1 PL4.1
CRUM
+12VDC J6-1
3.2
J402 CRU ID P610 J610
1 BLU BLU
7 1 2
J7-1
3
J7-2
4 BLU BLU
3 5 1
9-2 1 +5VDC
DC COM J7-3
(1.1) DRUM CARTRIDGE
J610 P610 SENSED(L) +5VDC J402
INTLK 5 BLU BLU
2 6 4 4 BLU BLU
3 J3-1
+5VDC +24VDC
(1.2)
6.3
INTLK +5VDC INTLK +5VDC
2 BLU BLU
5 3 7 1 BLU BLU
6
4 DC COM INTLK
+5VDC
Fail Code 1 The actual H/L level is displayed inversely on the UI display.
J1-2 Toner Empty
5 CRUM
J3-1 No Drum cartridge
J6-1 Drum cartridge life end
J7-1 Drum CRUM communication error TONER EMPTY SENSOR
J7-2 Drum CRUM Market identity mismatch

6 DRUM CARTRIDGE
J7-3 Drum CRUM ID error
Figure 2 9.2 Toner Sense and CRUM

WorkCentre 5016, 5020 7-29
A B C D E F G H J
9.3 ERASE LAMP
1
AIOC PWB HVPS PWB
PL8.1 PL8.2
ERASE LAMP
+24VDC PL4.2
9-6
J406 ERASE LAMP ON(L) +5VDC J520 J521 J210
6 6 1 1
BLU BLU BLU
2 DC COM DC COM
3 3
BLU
DC COM
2 2
BLU ERASE LAMP
INTLK
+24VDC
(9.1)
3
Figure 3 9.3 Erase Lamp

7-30 WorkCentre 5016, 5020
Chain 10 Fusing and Copy Transportation
A B C D E F G H J
10.1 FUSER TEMPERATURE CONTROL
1 AIOC PWB LVPS FUSER

PL8.1 PL8.1 PL5.1
THERMOSTAT
+5VDC
P/ J407 J3 J600 F28 F25
B6 FUSER LAMP ON ACH
3 2
BLK BLK BLK
DC COM
2
ACH
SWITCHED
(1.1) FUSER LAMP
F26
B5
AIOC PWB
PL8.1
DC COM
F27
1 1
WHT WHT
3 +24VDC
INTLK ACN U4-1
(1.2) (1.1)
10-20 +5VDC
THERMISTOR U4-2
FUSER THERMISTOR
J408 P601 J601 J601 P601 SENSED SIGNAL J408
2 2 1 2 1 1 U4-3
BLU BLU BLU BLU
DC COM
(1.1)
4
Fail Code
U4-1 Fuser On Time Fail
U4-2 Over Heat Temp Fail
FUSER LAMP U4-3 FS1 thermistor defect

5
THERMISTOR
THERMOSTAT
Figure 1 10.1 Fuser Temperature Control

WorkCentre 5016, 5020 7-31
A B C D E F G H J
10.2 EXIT AND DUPLEX

LVPS AIOC PWB
10-8 PL8.1 PL8.1
AIOC PWB 10-9 DUPLEX PWB
1 PL8.1 PL8.2 FUSER EXIT 10-23 1 +5VDC
EXIT MOTOR SENSOR E1-2
J416 CURR J550 PL6.3 FUSER EXIT SENSOR P/J407
9 BLU 1 EXIT MOTOR J153 J505
PAPER SENSED(L) +5VDC
BLU 1 BLU 3 A3 E3-1
PL6.3 BLU
EXIT MOTOR EXIT MOTOR LVPS
ON CLOCK J551 ON +24V CLOCK PL8.1
8 BLU BLU
2 6 YEL E3-6
EXIT MOTOR EXIT MOTOR +5VDC
ON CLOCK ON +24V CLOCK
7 BLU BLU
3 5 BLK
J505J153
EXIT MOTOR EXIT MOTOR 1 BLU BLU 3
2 ON CLOCK ON +24V CLOCK
6 BLU BLU
4 4 ORN
EXIT MOTOR EXIT MOTOR MOT 2 BLU 2
BLU
ON CLOCK ON +24V CLOCK
5 BLU BLU
5 3 BRN DC COM
(1.1)
2 RED
F1
1 RED
3
INTLK
+24VDC
(1.2)
Simplex Transport: Duplex (Side 2) Transport: Fail Code
Exit Roll is driven by IOT Motor. Exit Roll is driven by EXIT Motor.
E1-2
4 Fuser Exit Sensor on JAM
E3-1
Fuser Exit Sensor off JAM
EXIT MOTOR E3-6

Exit Roll Fuser Exit Sensor Static JAM
Exit Roll
5
1
The actual H/L level is displayed

inversely on the UI display.
IOT Motor IOT Motor
6
FUSER EXIT SENSOR FUSER EXIT SENSOR
Figure 2 10.2 Exit

7-32 WorkCentre 5016, 5020
A B C D E F G H J
10.3 MACHINE COOLING
1 AIOC PWB
PL8.1
NOHAD FAN AIOC PWB
4-2 1 PL9.2 PL8.1
+24VDC
J405 NOHAD FAN ON(H) +24VDC
3
RED
+5VDC
MOT 10-60
NOHAD FAN FAIL(H) +5VDC J405

2 1 U4-9
BLK BLU
2 DC COM
(1.1)
Fail Code 1
NOHAD FAN rotates at low speed when Diag is off,
and at high speed when Diag is on.
3 U4-9 Nohad Fan defect Voltage levels are as follows:
Low Speed: approx. 15VDC
High Speed: approx. 24VDC
4
NOHAD FAN
Figure 3 10.3 Machine Cooling

WorkCentre 5016, 5020 7-33
7-34 WorkCentre 5016, 5020
Wirenets
7.2.1 WIRE NET AC POWER (HOT)
POWER CORD POWER SWITCH LOW LOW

VOLTAGE VOLTAGE
POWER POWER
SUPPLY 1.1 SUPPLY
CHOKE COIL
FS11 FS31 FS32 J5 J5
1 2
BLK BLK BLK BLK
FS60 BRN 1
GN/YL
(SEE WIRE NET
WHT AC POWER (NEUT))
FUSER
J3 P600 J600 F28 F25 F26 10.1

THERMOSTAT
3 2 FUSER LAMP
BLK BLK
1 Wire Color
BLK: 100V M/C, BRN: 200V M/C
7.2.2 WIRE NET AC POWER (NEUT)
POWER CORD POWER SWITCH LOW VOLTAGE

POWER SUPPLY
FUSER
FS12 FS33 FS34 J3 P600 J600 F27 10.1

1 1 FUSER LAMP
WHT WHT WHT
FS60 BLU 1
GN/YL
(SEE WIRE NET
BLK AC POWER (HOT)) DC POWER
GENERATION
1 Wire Color
WHT: 100V M/C, BLU: 200V M/C

WorkCentre 5016, 5020 7-35
7.2.3 WIRE NET +3.3VDC
LOW VOLTAGE LENS

POWER SUPPLY ASSEMBLY
AIOC PWB
IIT PWB
P/J407
J409 J721
+3.3VDC A16 4 18
A17 5 17
FLAT
B16 CABLE
B17
ADF PWB
J414 J731
B6 B7
YEL

7-36 WorkCentre 5016, 5020
7.2.4 WIRE NET +5VDC-1
LOW VOLTAGE
POWER SUPPLY
J501 P203 J203 J157 7.1
TRAY1 NO PAPER
3 3 1 3 SENSOR
BLU BLU
J158 8.1
+5VDC 6 3 TRAY1 FEED SENSOR
BLU
J503 J156 8.4

IOT REGISTRATION
1 3 SENSOR
BLU
J505 J153 10.2

1 3 FUSER EXIT SENSOR
BLU
STM PWB
J508 J540 J542 J171 7.2

STM NO PAPER
1 1 3 3 SENSOR
GRY BLU
J172 8.2
6 3 STM FEED SENSOR
BLU
AIOC PWB
USER INTERFACE
P/J407 J401 J710 PWB 2.1
A11 1 8
BLU
B11 2 7
BLU
(SEE WIRE NET +5VDC-2)

WorkCentre 5016, 5020 7-37
(FROM WIRE NET +5VDC-1)
LENS
ASSEMBLY
IIT PWB
J409 J721 CN3 IIT4 CARRIAGE 6.2
6 16 6 1 SENSOR
GRY
7 15
FLAT
CABLE
J416 J550
3 7 DUPLEX PWB
BLU
ADF PWB
J414 J731 CN4 DF3 DOCUMENT TRAY 5.1
B5 B8 1 1 WIDTH SENSOR1
YEL WHT
DF2 DOCUMENT TRAY 5.1

1 WIDTH SENSOR2
WHT

5 1 LENGTH SENSOR1
AIOC PWB WHT

1 LENGTH SENSOR2
WHT
CN5 DF8 DOCUMENT 5.1

3 1 FEEDER WIDTH
WHT SENSOR
DF9 DOCUMENT SET 5.2

6 1 SENSOR
WHT
DF10 DOCUMENT LEAD 5.2

1 EDGE SENSOR
WHT

7-38 WorkCentre 5016, 5020
7.2.6 WIRE NET DC COM (+5V RTN)-1
LOW VOLTAGE
POWER SUPPLY
J501 P203 J203 J157 7.1
TRAY1 NO PAPER
4 2 2 2 SENSOR
BLU BLU
J158 8.1
+5VRTN 7 2 TRAY1 FEED SENSOR
BLU
J161 7.1
TRAY1 INTERLOCK
9 2 SWITCH
BLU
J503 J156 8.4

IOT REGISTRATION
2 2 SENSOR
BLU
J505 J153 10.2

2 2 FUSER EXIT SENSOR
BLU
STM PWB
J508 J540 J542 J171 7.2
STM NO PAPER
3 2 4 2 SENSOR
VIO BLU
J172 8.2
7 2 STM FEED SENSOR
BLU
J173 7.2
STM INTERLOCK
9 2 SWITCH
BLU
J509 P110 J110 9.2

TONER EMPTY
3 2 3 SENSOR
BLU BLK
(SEE WIRE NET

DC COM (+5VRTN)-2)

WorkCentre 5016, 5020 7-39
7.2.7 WIRE NET DC COM(+5V RTN)-2
(FROM WIRE NET
DC COM(+5VRTN)-1)
LOW VOLTAGE
POWER SUPPLY AIOC PWB
DRUM CARTRIDGE
P/J407 9.2
J402 P610 J610
A12 4 3 5 1 CRUM
BLU
5 2 6
A13 BLU
J416 J550 DUPLEX PWB

B12 4 6
BLU
LENS
B13 ASSEMBLY
J409 J721 IIT PWB
1 21
2 20
FLAT
CABLE
+3.3VRTN A14 1 34 5 3 SENSOR
GRY
6 29
A15
11 24
15 20
B14
17 18
B14 19 16
21 14
23 12
25 10
27 8
29 6
31 4
34 1
FLAT
(SEE WIRE NET CABLE
DC COM(+5VRTN)-3)

7-40 WorkCentre 5016, 5020
7.2.8 WIRE NET DC COM(+5V RTN)-3
(FROM WIRE NET
DC COM(+5VRTN)-2)
USER INTERFACE
PWB
J401 J710 J711 PLATEN OPEN 6.1
3 6 2 SWITCH
BLU BLK
4 5
BLU
J630 P630 3.2

10 1 2 BILLING COUNTER
BLU
ROS
J403 J140 6.3
2 7 LD PWB
BLU
FUSER
J408 P601 J601 10.1
2 2 1 THERMISTOR
BLU
ADF PWB
J414 J731 CN4 DF3 DOCUMENT TRAY 5.1
B3 B10 2 3 WIDTH SENSOR1
YEL WHT

3 WIDTH SENSOR2
WHT

B4 B9 6 3 LENGTH SENSOR1
YEL WHT

3 LENGTH SENSOR2
WHT
CN5 DF14 ADF TOP COVER 5.2

2 1 SWITCH
WHT
DF8 DOCUMENT 5.1

4 3 FEEDER WIDTH
WHT SENSOR
DF9 DOCUMENT SET 5.2

7 3 SENSOR
WHT
DF10 DOCUMENT LEAD 5.2

9 3 EDGE SENSOR
AIOC PWB WHT

WorkCentre 5016, 5020 7-41
FRONT
LH COVER LOW VOLTAGE COVER
LOW VOLTAGE INTERLOCK POWER INTERLOCK
POWER SUPPLY SWITCH SUPPLY SWITCH
J506 FS151 FS152 J506 J506 FS153 FS154
4 3 1 3 2 3 1
ORN ORN ORN ORN
F1
+24VDC
J506 F3 J504 J201 4.1

1 1 1 IOT MOTOR
ORN BLU
F2 J508
4 N.C
AIOC PWB HIGH VOLTAGE

POWER
P/J407 J406 P520 SUPPLY J521 J210 9.3
A1 9 9 2 2 ERASE LAMP
BLU BLU
DUPLEX PWB
J416 J550 J551 10.2
B1 1 9 1
BLU RED EXIT MOTOR
2
RED
J501 P202 J202 TRAY1 FEED 8.1

1 1 2 CLUTCH
BLU
J502 BYPASS 8.3

1 SOLENOID
RED
J503 P640 J640 IOT 8.4

5 2 1 REGISTRATION
BLU CLUTCH
STM PWB
J508 J540 J542 P212 J212 STM FEED 8.2
10 7 1 1 2 CLUTCH
ORN BLU
(SEE WIRE NET +24VDC-2)

7-42 WorkCentre 5016, 5020
(FROM WIRE NET +24VDC-1)
J509 P110 J110 TONER EMPTY 9.2

1 4 1 SENSOR
BLU RED
AIOC PWB
ROS
P/J407 6.3
J403 P620 J620 J130
A7 7 4 1 5 ROS MOTOR
BLU
A8
LENS
ASSEMBLY
B7
IIT PWB
9 13 5 5 MOTOR
RED
B8
10 12
CN3 INV CN1 INVERTER 6.2
11 11 1 1PWB
GRY
FLAT
CABLE
ADF PWB
J414 J731 CN3 DF13 DF13 DOCUMENT FEED 5.3
B1 B12 1 2 1 CLUTCH
YEL WHT
CN2 5.3
B2 B11 1
YEL WHT
LOW VOLTAGE
DOCUMENT DRIVE
POWER SUPPLY MOTOR
4
BLK

WorkCentre 5016, 5020 7-43
7.2.11 WIRE NET DC COM(+24V RTN)
LOW VOLTAGE
POWER SUPPLY
J504 J201 4.1

+24VRTN 2 2 IOT MOTOR
BLU
J508 J540
8 5 STM PWB
VIO
AIOC PWB
ROS
P/J407 J403 P620 J620 J130 6.3
A7 8 3 2 4 ROS MOTOR
BLU
J405 10.3
A8 2 NOHAD FAN
BLK
J406 J520 HIGH VOLTAGE 9.1

B1 7 7 POWER SUPPLY
BLU
B7 8 8
BLU
LENS
B8 ASSEMBLY
IIT PWB
J409 J721 CN3 INV CN1 INVERTER PWB 6.2
20 2 3 3
GRY
21 1
FLAT
CABLE
J416 J550
2 8 DUPLEX PWB
BLU
J414 J731 ADF PWB

A11 A2
YEL
A12 A1
YEL

7-44 WorkCentre 5016, 5020
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.

WorkCentre 5016, 5020 7-45
7.1.2 P/J List Table 1
Figure
Table 1 P/J No. No. Item No. Description
Figure INV CN1 Figure 1 2 Inverter PWB
P/J No. No. Item No. Description INV CN2 Figure 1 1 Inverter PWB
CN1 Figure 12 1 DADF Control PWB J333 Figure 13 23 SLCC PWB
CN2 Figure 11 6 ADF PWB J340 Figure 13 22 SLCC PWB
CN2 Figure 12 6 DADF Control PWB J341 Figure 13 21 SLCC PWB
CN3 Figure 11 5 ADF PWB J342 Figure 13 20 SLCC PWB
CN3 Figure 12 5 DADF Control PWB J411 Figure 7 1 AIOC PWB
CN4 Figure 11 2 ADF PWB J508 Figure 6 8 STM
CN4 Figure 12 2 DADF Control PWB J610 Figure 8 2 CRU
CN5 Figure 11 4 ADF PWB NBCR CN6 Figure 1 7 NBCR PWB
CN5 Figure 12 4 DADF Control PWB NSC CN1 Figure 1 8 NSC PWB
CN6 Figure 12 3 DADF Control PWB P412 Figure 7 14 AIOC PWB
CN7 Figure 12 7 DADF Control PWB P417 Figure 7 16 AIOC PWB
DF2 Figure 10 3 Document Tray Width Sensor 2 P418 Figure 7 15 AIOC PWB
DF3 Figure 10 2 Document Tray Width Sensor 1 P419 Figure 7 2 AIOC PWB
DF4 Figure 10 4 Document Tray Length Sensor 1 P508 Figure 9 15 LVPS
DF5 Figure 10 5 Document Tray Length Sensor 2 P610 Figure 8 9 CRU
DF8 Figure 10 6 Document Feeder Width Sensor P/J3 Figure 9 18 Fuser Lamp
DF9 Figure 10 7 Document Tray Set Sensor P/J5 Figure 9 17 Choke Coil
DF10 Figure 10 8 Document Lead Edge Sensor P/J5 Figure 13 3 SLCC PWB
DF13 Figure 10 1 ADF Top Cover Switch P/J110 Figure 3 6 Toner Empty Sensor
DF14 Figure 11 3 ADF Top Cover Switch P/J130 Figure 2 2 ROS MPA
DF14 Figure 12 14 Feeder Cover Switch P/J140 Figure 2 5 ROS
F25 Figure 5 1 Fuser Thermostat P/J153 Figure 4 1 Fuser Exit Sensor
F26 Figure 5 4 Fuser Lamp P/J156 Figure 4 4 IOT Regi. Sensor
F27 Figure 5 3 Fuser Lamp P/J157 Figure 3 7 Tray 1 No Paper Sensor
F28 Figure 5 2 Fuser Thermostat P/J158 Figure 4 6 Tray 1 Feed Sensor
FS11 Figure 9 4 Inlet P/J160 Figure 2 6 ROS, Video
FS12 Figure 9 6 Inlet P/J161 Figure 4 5 Tray 1 Interlock Sensor
FS151 Figure 4 8 LH Cover Interlock Switch P/J171 Figure 6 2 STM No Paper Sensor
FS152 Figure 4 7 LH Cover Interlock Switch P/J172 Figure 6 1 STM Feed Sensor
FS153 Figure 3 4 Front Cover Interlock Switch P/J173 Figure 6 3 STM Interlock Switch
FS154 Figure 3 5 Front Cover Interlock Switch P/J201 Figure 8 6 IOT Motor
FS31 Figure 9 7 Power Switch P/J201 Figure 2 4 ROS, SOS PWB
FS32 Figure 9 1 Power Switch P/J2011 Figure 2 1 ROS, SOS PWB
FS33 Figure 9 3 Power Switch P/J202 Figure 8 7 Tray 1 Feed Clutch
FS34 Figure 9 2 Power Switch P/J203 Figure 8 8 Tray 1 No Paper Sensor
FS60 Figure 9 5 Inlet GND P/J210 Figure 3 1 Erase Lamp
IIT4 Figure 1 5 Carriage Sensor P/J212 Figure 6 4 STM Feed Clutch
IIT5 Figure 1 6 Carriage Motor P/J380 Figure 13 6 SLCC PWB

7-46 WorkCentre 5016, 5020
Table 1 Table 1
Figure Figure
P/J No. No. Item No. Description P/J No. No. Item No. Description
P391 Figure 13 24 SLCC PWB P/J550 Figure 8 3 Duplex PWB
P/J401 Figure 7 6 UI P/J551 Figure 8 4 Duplex PWB
P/J401 Figure 13 7 SLCC PWB P/J600 Figure 4 2 Fuser Lamp
P/J402 Figure 7 11 CRU ID P/J601 Figure 4 3 Fuser Thermistor
P/J402 Figure 13 13 SLCC PWB P/J620 Figure 2 3 ROS MPA
P/J403 Figure 7 12 ROS P/J630 Figure 8 1 Billing ID
P/J403 Figure 13 14 SLCC PWB P/J640 Figure 8 5 IOT Regi Clutch
P/J404 Figure 7 5 ROS, Video P/J710 Figure 1 9 UI
P/J404 Figure 13 19 SLCC PWB P/J711 Figure 1 10 Platen Switch
P/J405 Figure 7 9 Nohad Fan P/J720 Figure 1 4 IIT Data
P/J405 Figure 13 12 SLCC PWB P/J721 Figure 1 3 IIT Power
P/J406 Figure 7 8 HVPS P/J731A/B Figure 11 1 ADF
P/J406 Figure 13 10 SLCC PWB P/J801 Figure 12 11 Document Feed Clutch
P/J407 Figure 9 16 LVPS-AIOC PWB P/J802 Figure 12 12 Exit/Invert Sensor
P/J407 Figure 13 18 LVPS-SLCC PWB P/J803 Figure 12 13 Registration Sensor
P/J408 Figure 7 13 AIOC PWB P/J804 Figure 12 10 Registration Clutch
P/J408 Figure 13 15 SLCC PWB P/J805 Figure 12 9 Exit/Invert Clutch
P/J409 Figure 7 4 AIOC PWB P/J806 Figure 12 8 Exit/Invert Solenoid
P/J409 Figure 13 5 SLCC PWB
P/J410 Figure 7 3 AIOC PWB
P/J414A/B Figure 7 7 AIOC PWB
P/J414A/B Figure 13 8 SLCC PWB
P/J416 Figure 7 10 AIOC PWB
P/J501 Figure 9 13 LVPS
P/J520 Figure 3 3 HVPS
P/J521 Figure 3 2 HVPS
P/J540 Figure 6 7 STM
P/J541 Figure 6 5 STM Feed Motor
P/J542 Figure 6 6 STM (TOTAL CL, SNR, SW)

WorkCentre 5016, 5020 7-47
Figure 1 IIT

7-48 WorkCentre 5016, 5020
Figure 2 ROS

WorkCentre 5016, 5020 7-49
Figure 3 HVPS

7-50 WorkCentre 5016, 5020
Figure 4 LH

WorkCentre 5016, 5020 7-51
Figure 5 Fuser

7-52 WorkCentre 5016, 5020
Figure 6 STM

WorkCentre 5016, 5020 7-53
Figure 7 AIOC PWB

7-54 WorkCentre 5016, 5020
Figure 8 Rear

WorkCentre 5016, 5020 7-55
P/
J503
P/
J505
Figure 9 Inlet & LVPS

7-56 WorkCentre 5016, 5020
Figure 10 ADF/DADF

WorkCentre 5016, 5020 7-57
Figure 11 ADF 2

7-58 WorkCentre 5016, 5020
Figure 12 DADF Control PWB

WorkCentre 5016, 5020 7-59
Figure 13 SLCC PWB

7-60 WorkCentre 5016, 5020

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Xerox WC 5016 5020 Service Manua PDF

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Work Center 5016, 5020

All service documentation is supplied to Xerox external customers for infor-

June, 2008 CAUTION

Global Knowledge and Language Services

800 Phillips Road, Bldg. 0218-01A

Webster, New York 14580-9791

2007 - 2008 by Xerox Corporation. All rights reserved.

Front Matter June, 2008 Reissue

Reissue June, 2008 Introduction

Contents of Manual Description of Terminology and Symbols

Section 1 Service Call Procedures WARNING

Section 3 Image Quality RAPs Reference:

Reissue June, 2008 Introduction

Reissue June, 2008 Service Call Procedures

Reissue June, 2008 Service Call Procedures

Service Call Procedures June, 2008 Reissue

Reissue June, 2008 Service Call Procedures

Reissue June, 2008 Status Indicator RAPS

Fault Repair Overview

Check the status of Installation

Check the problem status

Figure 1 Troubleshooting Procedure

Reissue June, 2008 Status Indicator RAPS

Status Indicator RAPS June, 2008 Reissue

Does the error recur when operating the

Yes Refer to the Error Code List and perform the

Figure 2 RAP Flow

Reissue June, 2008 Status Indicator RAPS

Status Indicator RAPS June, 2008 Reissue

Reissue June, 2008 Status Indicator RAPS

Status Indicator RAPS June, 2008 Reissue

Reissue June, 2008 Status Indicator RAPS

Tray1 No Paper Sensor dirty and Sensor Actuator deformed or damaged

Status Indicator RAPS June, 2008 Reissue

STM No Paper Sensor dirty and Sensor Actuator deformed or damaged.

Reissue June, 2008 Status Indicator RAPS

Status Indicator RAPS June, 2008 Reissue

Reissue June, 2008 Status Indicator RAPS

Status Indicator RAPS June, 2008 Reissue

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Status Indicator RAPS June, 2008 Reissue

Drive gear worn or damaged

Reissue June, 2008 Status Indicator RAPS

Status Indicator RAPS June, 2008 Reissue

Reissue June, 2008 Status Indicator RAPS

Status Indicator RAPS June, 2008 Reissue

Reissue June, 2008 Status Indicator RAPS

Status Indicator RAPS June, 2008 Reissue

Reissue June, 2008 Status Indicator RAPS

Status Indicator RAPS June, 2008 Reissue

Remove any foreign substances and fix any installation errors.

Reissue June, 2008 Status Indicator RAPS

Status Indicator RAPS June, 2008 Reissue

Reissue June, 2008 Status Indicator RAPS

Status Indicator RAPS June, 2008 Reissue

Reissue June, 2008 Status Indicator RAPS

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Status Indicator RAPS June, 2008 Reissue

Reissue June, 2008 Status Indicator RAPS

Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

Status Indicator RAPS June, 2008 Reissue

Reissue June, 2008 Status Indicator RAPS

Status Indicator RAPS June, 2008 Reissue