Xerox 5016 сервисный мануал

701P48365June 2008

Work Center 5016, 5020Service Documentation

CAUTIONCertain components in the Work Center 5016/ 5020 are
susceptible to damage from electrostatic dis-charge. Observe all
ESD procedures to avoid com-ponent damage.

AcknowledgementsPrepared by Global Knowledge & Llanguage
Services — North America800 Phillips Road — Building
0218-01AWebster, New York 14580-9791ISO9001 AND ISO27001 Certified
Copyright 2007-2008 by Xerox Corporation. All rights reserved.Xerox
and all product names and number names are trademarks of Xerox
Corporation.Printed in the USA

While Xerox has tried to make this documentation accurate, Xerox
will haveno 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.

WorkCentre 5016, 5020Reissue

mentioned in this publication are trademarks of rademarks are
also acknowledged.

tone, Inc.

ument. Changes, technical inaccuracies, and typo-nt
editions.

AUTIONradiate radio frequency energy, and if not installed ns
documentation, may cause interference to radio und to comply with
the limits for a Class A comput- of FCC rules, which are designed
to provide rea-ce when operated in a commercial environment. l area
is likely to cause interference in which case d to correct the
interference.June, 2008i

Front Matter

WorkCentre 5016, 5020

Service Documentation

WorkCentre 5016, 5020 Service Documentation

701P48365

Reissue

June, 2008

***Xerox Private Data***

All service documentation is supplied to Xerox external
customers for informational purposes only. Xerox service
documentation is intended for use by certified, product-trained
service per-sonnel only. Xerox does not warrant or represent that
it will notify or provide to such customer any future change to
this documentation. Customer performed service of equipment, or
mod-ules, components, or parts of such equipment may affect whether
Xerox is responsible to fix machine defects under the warranty
offered by Xerox with respect to such equipment. You should consult
the applicable warranty for its terms regarding customer or
third-party provided service.

If the customer services such equipment, modules, components or
parts thereof, the customer releases Xerox from any and all
liability for the customer actions, and the customer agrees to
indemnify, defend and hold xerox harmless from any third party
claims which arise directly or indirectly for such service.

While Xerox has tried to make the documentation accurate, Xerox
will have no liability arising out of any inaccuracies or
omissions. Changes are periodically made to this document. Changes,
technical inaccuracies, and typographical errors will be corrected
in subsequent edi-tions.

Prepared by:

Xerox Corporation

Global Knowledge and Language Services

800 Phillips Road, Bldg. 0218-01A

Webster, New York 14580-9791

USA

2007 — 2008 by Xerox Corporation. All rights reserved.

Copyright protection claimed includes all forms and matters of
copyrightable material and infor-mation now allowed by statutory
judicial law or hereinafter granted, including without limitation,
material generated from the software programs which are displayed
on the screen such as icons, screen displays, looks, etc.

Printed in the United States of America.

XEROX and all Xerox product names XEROX CORPORATION. Other
company t

PANTONE is a registered trademark of Pan

Changes are periodically made to this docgraphic errors will be
corrected in subseque

CThis equipment generates, uses and can and used in accordance
with the instructiocommunications. It has been tested and foing
device pursuant to subpart B of part 15sonable protection against
such interferenOperation of this equipment in a residentiathe user,
at his own expense, will be require

WorkCentre 5016, 5020Reissue June, 2008

iiFront Matter

Introduction

IntroductionJune, 2008iWorkCentre 5016, 5020

Reissue

How To Use This
Manual……………………………………………………………………………………
iii

WorkCentre 5016, 5020ReissueJune, 2008

iiIntroduction

Introduction

tion

Symbolsout this service manual are described as follows:

ARNINGrating or maintenance procedure, practice, or ould result
in personal injury or loss of life.AUTION

g or maintenance procedure, practice, or condition damage to, or
destruction of, equipment.

ating or maintenance procedure, practice, or
condi-efficiently.

nt and troubleshooting.

re for reference.

rence.

ic-sensitive IC chips, which could be damaged if not arding
Safety Critical Components set by XEROX June, 2008iiiWorkCentre
5016, 5020

Reissue

How To Use This Manual

This manual is used as the standard service manual for the
WorkCentre 5016, 5020.

Enter any comments and/or corrections regarding the WorkCentre
5016, 5020 Service Docu-mentationl on the Publication Comment
Sheet, and send it to the Technical Support Center SDEG.

This manual describes the standard procedures for servicing the
WorkCentre 5016, 5020. Refer to Section 1 Service Call Procedure
for efficient and effective servicing during mainte-nance
calls.

Contents of ManualThis manual is divided into nine sections as
described below.

Section 1 Service Call Procedures

This section describes the structured process for determining
the type and sequence of actions that are performed during a
service call.

Section 2 Status Indicator RAPs

This section contains the Repair Analysis Procedures (RAPs)
necessary to repair all faults other than image quality faults.

Section 3 Image Quality RAPs

This section contains the Repair Analysis Procedures (RAPs) that
are used to diagnose image quality defect problems.

Section 4 Removal/Replacement and Adjustment Procedures

This section contains the removal, replacement, and adjustment
procedures for components of WorkCentre 5016, 5020.

Section 5 Parts List

This section contains a list of spare parts list for the
WorkCentre 5016, 5020.

Section 6 General Procedures/Information

This section contains frequently used procedures that relate to
the diagnosis, setup, or opera-tion of the machine. It also
contains pertinent information that will not be found in any other
part of the service documentation.

Section 7 Wiring Data

This section contains the wiring information for the WorkCentre
5016, 5020. It contains a con-nector list/locator, wirenet
diagrams, and Block Schematic Diagrams (BSDs) for the following
chains:

Chain 1 Standby PowerChain 2 Mode SelectionChain 3 Machine Run
ControlChain 4 Start Print PowerChain 6 ImagingChain 7 Paper
SupplyingChain 8 Paper TransportationChain 9 MarkingChain 10 Fusing
and Copy Transporta

Description of Terminology and The terminology and symbols used
through

WA Warning statement indicates an opecondition that, if not
strictly observed, c

CA Caution statement indicates an operatinthat, if not strictly
observed, could result in

NOTE: A Note statement indicates an opertion that is necessary
to accomplish a task

Reference:Used when other explanations are given.

Purpose:Used to describe the purposes of adjustme

REP:Indicates the removal/replacement procedu

ADJ:Indicates the adjustment procedure for refe

PL:Indicates the parts list for reference.

ASSY:Means Assembly.

Safety Critical Components (SCC):These are components, such as
electrostathandled properly. Follow the regulations regCorp.

WorkCentre 5016, 5020ReissueJune, 2008

ivIntroduction

Service Call Procedures

vice Call ProceduresJune, 20081-1WorkCentre 5016, 5020

Reissue

1 Ser1.1 Before Starting Service
…………………………………………………………………………………
1-31.2 Service Call Procedure
…………………………………………………………………………………
1-41.3 Service Call Details
………………………………………………………………………………………
1-41.4 TRIM Checklist
…………………………………………………………………………………………….
1-51.5 Periodic Replacement Parts/Consumables List
……………………………………………….. 1-5

WorkCentre 5016, 5020ReissueJune, 2008

1-2Service Call Procedures

1.1Service Call Procedures

ing Customer Dataata.the purpose of investigation/analysis,
always obtain ure you assure them that the data will not be
used

changed during diagnostics.ch as polling, were set for test
purposes, make sure s after the test.stomer data.ed within the OpCo
and ensure that customer data e.

service, observe the following:

on, so that you can take a systematic approach.

dition of the machine before removing parts or dis-

omplete, check that no parts or tools are left inside

ables consumables, as well as the packaging materials,

WARNINGridges into a fire. Always keep them away from gniting
and causing a fire.

methods for replaced parts or consumables, refer 2-138 for all
machines.

g consumables, affix the «U-TAG» so that the recy-priately.

essary items on the «U-TAG.»

mer’s daily work.to a trash bag and bring it to the service
office.ation in the Machine Service Log:

lacedJune, 20081-3WorkCentre 5016, 5020

Reissue

1.1 Before Starting Service1.1.1SafetyTo prevent any accident
that may occur during maintenance service, any warning or any
cau-tion regarding the service must be strictly observed. Do not
perform any hazardous operation.

1. Power SupplyTo prevent electrical shocks, burns, or injury,
etc., be sure to switch OFF the machine and disconnect the plug
before starting the maintenance service. If the machine has to be
switched ON, such as when measuring a voltage, take extra care to
avoid an electrical shock.

2. Drive AreaNever inspect, clear or lubricate the drive
components, such as chain belts, chain wheels or gears, when the
machine is in operation.

3. Heavy PartsWhen removing or installing heavy parts, keep your
back straight and lift with your legs. Some parts should not be
lifted by one person:

IOT (Platen): 31.5kg (requires 3 persons)2 Tray Modules: 8.6kg
(requires 2 persons)

Take extra care of your working posture to prevent backache.4.
Safety Devices

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

5. Installing and Removing PartsThe edges of parts and covers
may be sharp, so take care not to touch them. Be careful not to
touch those parts, and wipe off any oil that may have adhered to
your fingers or hands before servicing. When pulling out parts,
cables, etc., do it gently. Do not use excessive force.

6. Specified ToolsFollow the instructions when a particular tool
is specified.

7. Cleaning Up Toner SpillsSince toner can be explosive, sweep
or brush any spilled toner into a container to collect it. To clean
away the remaining toner using a vacuum cleaner, always use an FX
standard vacuum cleaner that is toner-tolerant. Never use the
customer’s vacuum cleaner.

8. Earthquake Preparedness MeasuresIf the customer requests
earthquake proofing, an earthquake preparedness kit is
avail-able.Check the Service Guide for more information on the
earthquake preparedness kit.

9. Modifications to the MachineBefore altering the machine,
submit an irregular use license application.

10. Other Safety PrecautionsFollow the recommendations in
WORKING PRACTICES FOR ENGINEERS issued by FXAP EH&S
(Environmental Health and Safety).

1.1.2Things to Note When Handl1. Handling of copied/printed
customer d

Before you bring back any sample for permission from the
customer. Make sfor any other purpose.

2. Security-related NVM values that wereIf any security-related
NVM values, suyou restore them to their original value

3. Other things to note when handling cuFollow the safety
guidelines establishdo not get compromised during servic

1.1.3 Other PrecautionsTo avoid performing wrong or
unnecessary

1. Reference MaterialsRead all relevant service documentati

2. DisassemblingMake sure to note the assembled conassembling
it.

3. Installation and AdjustmentAfter the installation or
adjustment is cthe machine.

4. Handling of replaced parts and consumMake sure that any
replaced parts orare taken back to the Service Center.

Never discard the Drum/Toner Cartopen flames to prevent them
from i

NOTE: For separation and processingto Common Technical
Information No.

If you have replaced the followinclable parts will be handled
approa. Drum Cartridgeb. Toner Cartridge

For recyclable parts, fill in the nec5. General Precautions

Take care not to disturb the custo Place any service-related
trash in Clearly record the following inform

Details of the service call Parts and consumables rep

WorkCentre 5016, 5020Reissue

1.2 Service Call Procedure 1.3 Service Call Details

s condition. paper jams

he machine.e Log from the last call.f Problemtatus Indicator
RAPs. 2 Status Indicator RAPs.leshoot by referring to the BSD in
Section 7 Wiring

ttern (499T247), then check the quality.rform the applicable RAP
in Section 3 Image Qual-

ance call.

ing the TRIM Checklist.c cleaning/replacement by referring to
the TRIM ent Parts/Consumables List. Clean them if neces-nters of
the corresponding items in the Chain Func-June, 20081-41.2, 1.3

Service Call Procedures

1.2.1 Initial Actions1. Ask the operator(s) about the machines
condition.2. Record the billing meter readings.3. Inspect any
faulty copies, then check the machine.4. Check the Service
Log.1.2.2 Actions to Take During UM (Unscheduled Maintenance)1.
Perform the service flow in Section 2 Status Indicator RAPs.2.
Perform the applicable RAP in Section 2 Status Indicator RAPs.

If there are no applicable RAPs, troubleshoot by referring to
the BSD in Section 7 Wiring Data.

3. Check the copy quality.Make several copies using the Test
Pattern (499T247), then check the quality.

4. Look at the last 20 error codes in order to understand the
machine status. Enter Diagnostic Mode. Enter [40-01] (Display Error
History How to Enter the Diag-

nostic Mode). When the last error code is displayed, press the
[Start] key to return to the Function

input screen. Pressing the [Stop] key during the display will
stop it and return you to the Function

input screen.5. Repair all the secondary problems.6. Perform
TRIM servicing.1.2.3 Actions to Take During SM (Scheduled
Maintenance)1. Check the copy quality.

Make several copies using the Test Pattern (499T247), then check
the quality.2. Look at the last 20 error codes in order to
understand the machine status.

Enter Diagnostic Mode. Enter [40-01] (Display Error History How
to Enter the Diag-nostic Mode).

When the last error code is displayed, press the [Start] key to
return to the Function input screen.

Pressing the [Stop] key during the display will stop it and
return you to the Function input screen.

3. Perform TRIM servicing.1.2.4 Final Actions1. Check overall
machine operation/features.2. Check the machine exterior and
consumables.3. Train the operator as required.4. Complete the
Service Log and Service Report.5. Keep the copy samples with the
Service Log.

1.3.1 Initial Actions1. Ask the operator(s) about the
machine

Frequency and location of recent Copy quality

2. Record the billing meter readings.3. Inspect any faulty
copies, then check t4. Check the copy sample and the Servic1.3.2
Checking Reproducibility o1. Perform the service flow in Section 2
S2. Perform the applicable RAP in Section3. If there are no
applicable RAPs, troub

Data.1.3.3 Checking Copy Quality1. Make several copies using the
Test Pa2. If there is a problem in copy quality, pe

ity.1.3.4 TRIM ServicingPerform TRIM servicing during the
mainten

1. Perform the necessary TRIM items us2. Check for parts that
require periodi

Checklist and the Periodic Replacemsary. If replaced, always
clear the coution.

1.4, 1.5Service Call Procedures

arts/Consumables Listmber of copies and the replacement interval
for the ical cleaning/replacement. Clean or replace them if d at
Chain-Function > NVRAM R/W, while the IIT er to Diagnostic Mode
in Section 2 Status Indicator in the Diagnostic Mode, clean or
replace them dard PV).

AUTIONour car for long periods of time.

Table 1 nt pies) Counters Check

[29/34] [29/24] [29/14] [29/4]Count up 1 for every feed. Replace
both at the same time. [29/25] [29/15] [29/5]Count up 1 for every
feed. Replace both at the same time. [29/39] [29/29] [29/19]
[29/9]Count up 1 for every feed. Replace both at the same
time.[21/39] [21/29] [21/19] [21/9]Count up 1 for every feed.

31,000 (Warning)36,000 (Machine Stops)June, 20081-5WorkCentre
5016, 5020

Reissue

1.4 TRIM ChecklistA: Check. Clean, replace, or replenish if
necessary.

B: Always check and clean.

*: Always replace at the specified interval.

CAUTIONDo not touch the Drum of the Drum Cartridge.

1.5 Periodic Replacement PWhen servicing the machine, check the
nuconsumables and parts that require periodnecessary. The IOT
history can be checkehistory can be checked in the Counters
(refRAPs). For items that cannot be checkedaccording to the
replacement intervals (stan

CDo not keep toner and drum cartridges in y

Table 1

No. Service ItemsEvery time Service Details

1.1 Check before servicing(check machine operation)

A Turn on the machine, and make sure that there are no abnormal
sounds.

1.2 Check before Servicing(copy the Test Pattern)

A Make several copies using the Test Pattern (499T247), then
check the image quality.

2 Clean the interior of the machine (paper transport system)

A Clean the paper dust and toner residue in the paper path and
on the jam sensor.

3 Clean the IIT A Clean the Platen Glass surface and the Platen
Cushion with the optical cleaning cloth.

Clean the Reflector, back of the Platen Glass, mirrors and lens
with the optical cleaning cloth.

5 Safety Precautions B Make sure that the power cord is plugged
in properly.

Make sure that there are no cracks in the power plug and no
holes or cuts in the power cord insulation.

If an extension cord or power strip is used, make sure it is of
sufficient capacity to handle the power requirements of the
machine.

Make sure that no more than one power plug is connected to a
single socket.

6.1 Check after servicing(copy quality check)

A Make several copies using the Test Pattern (499T247), then
check the image quality.

6.2 Check after servicing(check machine operation)

A Check the paper feed. Make sure that there are no abnormal
sounds.

6.3 Check after servicing(check the meter)

A Create the Service Log and Service Report.

NoParts/Consumables Name/PL No.

ReplacemeInterval (co

1 Tray 1 Feed Roll/ Retard Pad

50,000

2 Tray 2 Feed Roll/Retard Roll

100,000

3 MSI Feed Roll/Retard Pad

50,000

4 Fuser Unit 100,000

5 Toner Cartridge 6,0006 Drum Cartridge 36,000

WorkCentre 5016, 5020ReissueJune, 2008

1-61.4, 1.5Service Call Procedures

Status Indicator RAPS

tatus Indicator RAPSJune, 20082-1WorkCentre 5016, 5020

Reissue

2 S Error CodesFault Repair Overview and List of Error
Codes………………………………………………………
2-3

RAPsU0-1 Main Motor Stop Error
………………………………………………………………………………..
2-25U1-1 Main Motor Rotation Error
…………………………………………………………………………..
2-25U2-1 Carriage Module Fail
………………………………………………………………………………….
2-26U3-5 Laser Power Or ROS Motor Fail
…………………………………………………………………
2-26U4-1 Fuser On Time
Fail……………………………………………………………………………………
2-27U4-2 Over Heat Temp Fail
…………………………………………………………………………………
2-27U4-3 FS1 Thermistor Defect
………………………………………………………………………………
2-28U4-9 Fuser Fan
Defect………………………………………………………………………………………
2-28U6-2 RAM Read/Write Check Error
…………………………………………………………………….
2-29U6-3 NVM Data Defect
……………………………………………………………………………………..
2-29U6-4 NVM Read/Write Cannot Be Executed
………………………………………………………..
2-30U6-5 CPU Power To Access NVM Is Not Enough
………………………………………………… 2-30U7-0
UI Communication TimeOut
……………………………………………………………………….
2-31U7-1 UI Communication
Error…………………………………………………………………………….
2-31U8-1 Billing Counter
Defect………………………………………………………………………………..
2-32U9-0 HVPS Fail
………………………………………………………………………………………………..
2-32062-300 Platen Interlock Open
……………………………………………………………………………
2-33062-345 IISS EEPROM
Failure……………………………………………………………………………
2-33062-360 Carriage Position
Fail…………………………………………………………………………….
2-34062-371 Lamp Illumination Fail
……………………………………………………………………………
2-34062-380 AGC Failure
…………………………………………………………………………………………
2-35062-386 AOC Failure
…………………………………………………………………………………………
2-35062-392 IPS PWB Memory Fail
…………………………………………………………………………..
2-36062-393 IPS PWB Fail
……………………………………………………………………………………….
2-36005-170 DADF Feed Failure
……………………………………………………………………………….
2-37005-171 DADF Regi / Exit
Failure……………………………………………………………………….
2-38005-172 DADF Inverted Document Jam
……………………………………………………………….
2-39005-198 Short Scan Jam
……………………………………………………………………………………
2-40005-199 Long Scan Jam
…………………………………………………………………………………….
2-40005-305 Feeder Top Cover Open
………………………………………………………………………..
2-41005-920 Static Jam
……………………………………………………………………………………………
2-41

WorkCentre 5016, 5020ReissueJune, 2008

2-2Status Indicator RAPS

Status Indicator RAPSJune, 20082-3WorkCentre 5016, 5020

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Fault Repair Overview and List of Error CodesFault Repair
OverviewThe fault repair operation proceeds in the following flow.
After performing the pre-check, verify the symptoms and refer to
the Error Code List and Section 7 Wiring Data to effectively repair
the fault:

.

Figure 1 Troubleshooting Procedure

Check the status of Installation

Check the problem status

Perform RAP

Check if the fault is repaired

Completed

Diagnostic ModeOperating PrinciplesWiring Data

Reference Information

WorkCentre 5016, 5020Reissue

Check the Status of Installation Descriptions related to
connectors are expressed as follows: P/J12″ -> The connector
(P/J12) is in the connected state. «P12» -> The plug side when
the connector (P/J12) is in the

directly connected to a board). «J12» -> The jack the
disconnected state (except when it is directly

t all the opposing pins between «P/J1» and «P/J12» d be
measured.e measured using a special tool. Handle the tool

RAPs are for reference only. Approximate values

e RAP, you must check the references for the parts ures.

the parts that are considered to be the cause of the and, if
necessary, the assembly that contains those

supply is called «Tray 1,» and the one below it is

cribed separately for each specification. Follow the e
faults.

ing a failure. RAPs guide you through the trouble-nce of error
codes and other types of problematic d to image quality, refer to
Section 3 Image Quality June, 20082-4

Status Indicator RAPS

Before starting to troubleshoot, always check the following
items:

The voltage of the power supply (measure the voltage at the
power outlet to see if it is within specification).

The power cord for damage, short circuits, open circuits, and
wrong internal connections. The machine for proper grounding. The
machine is not installed in a place with high temperature, high
humidity, low tempera-

ture, low humidity, or a place with drastic changes in
temperature. The machine is not installed near a water outlet,
humidifier, heater or fire source, dusty

areas, or under the direct draft of an air conditioner. The
machine is not installed in a place where volatile or flammable gas
is generated. The machine is not installed in a place exposed to
direct sunlight. The machine is installed in a well-ventilated
place. The machine is installed on a stable level surface. The
paper is within specification (standard paper is recommended). The
machine for any improper handling. The Periodic Replacement Parts
are replaced at the proper intervals.Safety Considerations Before
servicing, always unplug the power cord unless required otherwise.
When the

power is turned ON, never touch a current-carrying part unless
required otherwise. Also, since current is carried in the LVPS
power switch/inlet even when the power is turned OFF, never touch
this area.

When turning the power ON to perform a check while the Interlock
Switch or Security Switch is also turned ON and the covers are
removed, always disconnect the connector ( P/J140) that is
connected to the ROS, unless required otherwise, because a laser
beam might be emitted from the ROS.

When connecting the connector ( P/J520) on the HVPS according to
the instructions in the RAP, never touch the HVPS and high-voltage
output parts.

When performing a high voltage output check using the Input
Diagnostics or Output Diag-nostics in Diagnostic Mode, make sure
that all covers are installed unless specified other-wise. Also,
never touch any high voltage output section when performing the
high voltage output check.

When operating the Drive Section using the Input Diagnostics or
Output Diagnostics in Diagnostic Mode, make sure that all covers
are installed unless specified otherwise. Also, never touch the
Drive Section while operating it.

Be careful not to burn yourself when touching parts that can get
very hot. When servicing, use a grounded wrist band to remove
static electricity from your body.Things to Note When Using RAPs
When troubleshooting using RAPs, prepare normally working parts
such as the AIOC

PWB, LVPS, HVPS and Fuser in advance because they might be
required to identify a failure. In addition, if the fault cannot be
repaired, replace the «parts considered to be the cause» and
related parts in sequence and check the operation.

When servicing, always disconnect the power cord unless required
otherwise. When the power cord is connected, never touch any
current-carrying part unless absolutely neces-sary.

disconnected state (except when it isside when the connector
(P/J12) is inconnected to a board).

In a RAP, «P/J1 P/J2» means tha(refer to Section 7, Wiring Data)
shoul

The voltages on small connectors arcarefully because it has a
sharp tip.

The numerical values described in theare considered to be the
same.

Note that for the checks specified in ththat must be removed and
their proced

«Replacement» in the RAPs indicates problem. Check by replacing
the partsparts.

In the RAPs, the highest level papercalled «Tray 2.»

In the RAPs, some procedures are desinstructions for your model
to repair th

RAP FlowRAPs are a good place to start in diagnosshooting
process by checking for the presesymptoms. To troubleshoot problems
relateTroubleshooting.

Status Indicator RAPS

orm the June, 20082-5WorkCentre 5016, 5020

Reissue

Figure 2 RAP Flow

Ask the operator about the problemDid the operator operate the
machine correctly?

Turn the Power Switch OFF then ON

Does the error recur when operating the machine in the same way
as before (when the problem originally occurred)?

Does the Control Panel display an Error Code?

Explain how to operate the machine

Procedure is complete

Refer to the Error Code List and perfrelevant
troubleshooting

Yes

No

Yes

No

Yes

WorkCentre 5016, 5020Reissue

Error Code List

Record in Error Log RAP BSD

eed Sensor

O — CH8.1Figure 1June, 20082-6

Status Indicator RAPS

NOTE: In the Record in Error Log column, O = yes and X = no.

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check
Items

C1-1

Error NameTray1 F/O#1 SNR on JAM

ExplanationTimeout 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 ClutchCheck Items Feed Roll or
Retard Pad dirty, contaminated with paper dust, worn, or faulty
Tray1 Feed Sensor dirty and Sensor Actuator deformed or damaged
Paper damaged, not within specification, or not loaded correctly
Foreign matter, burrs, or paper in the paper path Drive gear worn
or damaged Tray1 Feed Clutch faulty Check that the following wires
are connected securely with good electrical contact. If there is no
problem, replace the Tray 1 F

(PL 2.5)(REP 2.5.1). Wire between Tray 1 Feed Sensor J158-3 (
P/J158) and LVPS J501-6 ( P/J501) Wire between Tray 1 Feed Sensor
J158-2 and LVPS J501-7 Wire between Tray 1 Feed Sensor J158-1 and
LVPS J501-8

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.

Status Indicator RAPS

eed Sensor

stration Sen-

O —

CH8.1Figure 1CH8.4

Figure 4

Record in Error Log RAP BSDJune, 20082-7WorkCentre 5016,
5020

Reissue

C1-2

Error NameTray1 Regi SNR on JAM

ExplanationTimeout between Tray1 Feed Sensor ON and IOT
Registration Sensor ON.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [08-07]
Tray1 Feed Sensor [08-05] IOT Registration Sensor [08-10] IOT
Registration ClutchCheck 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 Foreign matter, burrs, or
paper in the paper path Drive gear worn or damaged IOT Registration
Clutch faulty Check that the following wires are connected securely
with good electrical contact. If there is no problem, replace the
Tray 1 F

(PL 2.5) (REP 2.5.1). Wire between Tray 1 Feed Sensor J158-3 (
P/J158) and LVPS J501-6 ( P/J501) Wire between Tray 1 Feed Sensor
J158-2 and LVPS J501-7 Wire between Tray 1 Feed Sensor J158-1 and
LVPS J501-8

Check that the following wires are connected securely with good
electrical contact. If there is no problem, replace the IOT Regisor
(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 Code Error Name/Explanation/I/O Diagnostic Codes/Check
Items

WorkCentre 5016, 5020Reissue

Sensor (PL

.5) (REP

O — CH8.2Figure 2

Error Record in Error Log RAP BSDJune, 20082-8

Status Indicator RAPS

C2-1

Error NameSTM F/O#2 SNR on JAM

ExplanationTimeout between STM Feed Motor ON and STM Feed Sensor
ON.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [08-06]
STM Feed Sensor [08-11] STM Feed Clutch [08-13] STM Feed MotorCheck
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 Foreign matter, burrs, or
paper in the paper path Drive gear worn or damaged STM Feed Clutch
faulty STM Feed Motor faulty Check that the following wires are
connected securely with good electrical contact. If there is no
problem, replace the STM Feed

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 1111.5.2 ) in
that order.

Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Status Indicator RAPS

Sensor (PL

eed Sensor

.5) (REP

O —

CH8.1Figure 1CH8.2

Figure 2

Record in Error Log RAP BSDJune, 20082-9WorkCentre 5016,
5020

Reissue

C2-2

Error NameTray1 F/O#1 SNR on JAM from STM feed

ExplanationTimeout between STM Feed Out Sensor ON and Tray 1
Feed Out Sensor ON.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [08-06]
STM Feed Sensor [08-07] Tray1 Feed Sensor [08-11] STM Feed Clutch
[08-13] STM Feed MotorCheck Items Take Away Roll 2 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 Foreign matter, burrs, or
paper in the paper path Drive gear worn or damaged STM Feed Clutch
faulty STM Feed Motor faulty Check that the following wires are
connected securely with good electrical contact. If there is no
problem, replace the STM Feed

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

Check that the following wires are connected securely with good
electrical contact. If there is no problem, replace the Tray 1 F(PL
2.5) (REP 2.5.1). Wire between Tray 1 Feed Sensor J158-3 ( P/J158)
and STM PWB J501-6 ( P/J501) Wire between Tray 1 Feed Sensor J158-2
and STM PWB J501-7 Wire between Tray 1 Feed Sensor J158-1 and STM
PWB J501-8

Replace the STM Feed Clutch (PL 11.6) (REP 11.6.1), the STM Feed
Motor (PL 11.6) (REP 11.6.2), and the STM PWB (PL 1111.5.2) in that
order.

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check
Items

WorkCentre 5016, 5020Reissue

eed Sensor

stration Sen-

O —

CH8.1Figure 1CH8.4

Figure 4

e job).

Paper Sen-

X — CH7.1Figure 1

Error Record in Error Log RAP BSDJune, 20082-10

Status Indicator RAPS

C2-3

Error NameSTM Regi SNR on JAM

Explanation When feeding paper from the STM, timeout between
Tray1 Feed Sensor ON and IOT Registration Sensor ON.I/O Diagnostic
Codes (How to Enter the Diagnostic Mode) [08-05] IOT Registration
Sensor [08-10] IOT Registration Clutch Check Items Take Away Roll 1
dirty, contaminated with paper dust, worn, or faulty IOT
Registration Sensor dirty and Sensor Actuator deformed or damaged
Paper damaged, not within specification, or not loaded correctly
Foreign matter, burrs, or paper in the paper path Drive gear worn
or damaged IOT Registration Clutch faulty Check that the following
wires are connected securely with good electrical contact. If there
is no problem, replace the Tray 1 F

(PL 2.5) (REP 2.5.1). Wire between Tray 1 Feed Sensor J158-3 (
P/J158) and LVPS J501-6 ( P/J502) Wire between Tray 1 Feed Sensor
J158-2 and LVPS J501-7 Wire between Tray 1 Feed Sensor J158-1 and
LVPS J501-8

Check that the following wires are connected securely with good
electrical contact. If there is no problem, replace the IOT Regisor
(PL 2.9). Wire between Tray 1 Feed Sensor J156-3 ( P/J156) and LVPS
J503-1 ( P/J503) Wire between Tray 1 Feed Sensor J156-2 and LVPS
J503-2 Wire between Tray 1 Feed Sensor J156-1 and LVPS J503-3

Replace the IOT Registration Clutch (PL 2.9) and the AIOC PWB
(PL 8.1) (REP 8.1.1) in that order.

C5-0

Error NameNo 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 thI/O Diagnostic
Codes

[07-07] Tray1 No Paper SensorCheck Items Press the [Stop] button
on the Control Panel. Check the tray to see if it is empty; if it
is, add paper specified by the job. Tray1 No Paper Sensor dirty and
Sensor Actuator deformed or damaged Check that the following wires
are connected securely with good electrical contact. If there is no
problem, replace the Tray 1 No

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).

Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Status Indicator RAPS

X — —

the job).

Paper Sen-

X — CH7.2Figure 2

b. X — —

. X — —

Record in Error Log RAP BSDJune, 20082-11WorkCentre 5016,
5020

Reissue

C5-1

Error NameTray1 Paper Size Mismatch

Explanation Paper that is different from the one in the Tray
Settings is detected when feeding. Or, paper size setting in Tray1
is different from the paper size specification of the job when
Tray1 is selected during a print job.Check Items Press the [Stop]
button on the Control Panel. Change the paper size of Tray 1 to the
one specified by the job.

C6-0

Error NameNo 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 forI/O Diagnostic
Codes (How to Enter the Diagnostic Mode)

[07-08] STM No Paper SensorCheck Items Press the [Stop] button
on the Control Panel. Load the correct paper into the STM. STM No
Paper Sensor dirty and Sensor Actuator deformed or damaged. Check
that the following wires are connected securely with good
electrical contact. If there is no problem, replace the STM No

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).

C6-1

Error NameTray2 Paper Size Mismatch

Explanation Paper that is different from the one in the Tray
Settings is detected when feeding. Or, paper size setting in the
STM is different from the paper size specification of the job when
STM is selected during a print joCheck Items Press the [Stop]
button on the Control Panel. Change the paper size of STM to the
one specified by the job.

C7-1

Error NameMSI Paper Size Mismatch

Explanation Paper that is different from the one in the Tray
Settings is detected when feeding. Or, paper size setting in the
MSI is different from the paper size specification of the job when
MSI is selected during a print jobCheck Items Press the [Stop]
button on the Control Panel. Change the paper size of Bypass to the
one specified by the job.

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check
Items

WorkCentre 5016, 5020Reissue

g a copy job.uring a print X — CH3.2Figure 2

stration Sen-

there is no

O —

CH8.3Figure 3CH8.4

Figure 4

Error Record in Error Log RAP BSDJune, 20082-12

Status Indicator RAPS

C0-1

Error NameAPS 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 durin 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 d

job.Check Items Press the [Stop] button on the Control Panel.
Change the paper size of Tray 1 or STM to the one specified by the
job.

C9-3

Error NameMSI Regi SNR on JAM

ExplanationTimeout between Bypass Solenoid ON and IOT
Registration Sensor ON.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [08-05]
IOT Registration Sensor [08-17] Bypass SolenoidCheck 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 Paper damaged, not within
specification, or not loaded correctly Foreign matter, burrs, or
paper in the paper path Drive gear worn or damaged Bypass Solenoid
faulty Check that the following wires are connected securely with
good electrical contact. If there is no problem, replace the IOT
Regi

sor (PL 2.9). Wire between Tray 1 Feed Sensor J156-3 ( P/J156)
and LVPS J503-1 ( P/J503) Wire between Tray 1 Feed Sensor J156-2
and LVPS J503-2 Wire between Tray 1 Feed Sensor J156-1 and LVPS
J503-3

Check that the Bypass Solenoid and the LVPS J502-1/3 ( P/J502)
pins are connected securely with good electrical contact. If
problem, replace the Bypass Solenoid (PL 7.5).

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

Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Status Indicator RAPS

eed Sensor

O — CH8.1Figure 1

Sensor (PL

O — CH8.2Figure 2

eleted. O — —

Record in Error Log RAP BSDJune, 20082-13WorkCentre 5016,
5020

Reissue

C8-1

Error NameF/O#1 SNR Static JAM

ExplanationTray1 Feed Sensor ON is detected during standby.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)[08-07]
Tray1 Feed Sensor

Check Items Tray1 Feed Sensor dirty and Sensor Actuator deformed
or damaged Foreign matter, burrs, or paper in the paper path Check
that the following wires are connected securely with good
electrical contact. If there is no problem, replace the Tray 1
F

(PL 2.5) (REP 2.5.1). Wire between Tray 1 Feed Sensor J158-3 (
P/J158) and STM PWB J501-6 ( P/J501) Wire between Tray 1 Feed
Sensor J158-2 and STM PWB J501-7 Wire between Tray 1 Feed Sensor
J158-1 and STM PWB J501-8

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

C8-2

Error NameF/O#2 SNR Static JAM

ExplanationSTM Feed Sensor ON is detected during standby.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)[08-06]
STM Feed Sensor

Check Items STM Feed Sensor dirty and Sensor Actuator deformed
or damaged Foreign matter, burrs, or paper in the paper path Check
that the following wires are connected securely with good
electrical contact. If there is no problem, replace the STM
Feed

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 PWB (PL 11.5) (REP 11.5.2) and the AIOC PWB (PL
8.1) (REP 8.1.1) in that order.

E0-1

Error NameCPM Image Lost

ExplanationDuring a copy job in CMP Priority Mode, it is
detected that the paper containing an image cannot be output after
the image is d

Check ItemsPress the [Stop] button on the Control Panel.

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check
Items

WorkCentre 5016, 5020Reissue

stration Sen-

O — CH8.4Figure 4

t Sensor (PL

O — CH10.2Figure 2

Error Record in Error Log RAP BSDJune, 20082-14

Status Indicator RAPS

E1-6

Error NameRegi SNR Static JAM

ExplanationIOT Registration Sensor ON is detected during
standby.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)[08-05]
IOT Registration Sensor

Check Items Sensor dirty Foreign matter, burrs, or paper in the
paper path Check that the following wires are connected securely
with good electrical contact. If there is no problem, replace the
IOT Regi

sor (PL 2.9). Wire between Tray 1 Feed Sensor J156-3 ( P/J156)
and LVPS J503-1 ( P/J503) Wire between Tray 1 Feed Sensor J156-2
and LVPS J503-2 Wire between Tray 1 Feed Sensor J156-1 and LVPS
J503-3

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

E3-6

Error NameExit SNR JAM

ExplanationFuser Exit Sensor ON is detected during standby.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)[10-23]
Fuser Exit Sensor

Check Items Fuser Exit Sensor dirty and Sensor Actuator deformed
or damaged Foreign matter, burrs, or paper in the paper path Check
that the following wires are connected securely with good
electrical contact. If there is no problem, replace the Fuser
Exi

6.2). Wire between Fuser Exit Sensor J153-3 ( P/J153) and LVPS
J505-1 ( P/J505) Wire between Fuser Exit Sensor J153-2 and LVPS
J505-2 Wire between Fuser Exit Sensor J153-1 and LVPS J505-3

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

Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Status Indicator RAPS

r Interlock

X — CH1.2Figure 2

ver Interlock

X — CH1.2Figure 2

terlock

X — CH7.1Figure 1

Record in Error Log RAP BSDJune, 20082-15WorkCentre 5016,
5020

Reissue

E5-1

Error NameIOT L/H Cover open

ExplanationThe Left Hand Cover is open.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)[01-01]
LH Cover Interlock Switch

Check Items Check that the Left Hand Cover closes correctly.
Check that the LH Cover Interlock Switch is correctly installed and
that the electrical connection is good. Check that the following
wires are connected securely with good electrical contact. If there
is no problem, replace the LH Cove

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.

E5-2

Error NameIOT Front Cover open

ExplanationThe Front Cover is open.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)[01-12]
Front Cover Interlock Switch

Check Items Check that the Front Cover closes correctly. Check
that the Front Cover Interlock Switch is correctly installed and
that the electrical connection is good. Check that the following
wires are connected securely with good electrical contact. If there
is no problem, replace the Front Co

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

Replace the LVPS (PL 8.1) (REP 8.1.2) and the AIOC PWB (PL 8.1)
(REP 8.1.1) in that order.

E6-1

Error NameL/H Low Cover open

ExplanationAccess Cover 1 is open.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)[01-11]
Tray1 Interlock Switch

Check Items Check that Access Cover 1 closes correctly. Check
that the Tray 1 Interlock Switch is correctly installed and that
the electrical connection is good. Check that the following wires
are connected securely with good electrical contact. If there is no
problem, replace the Tray 1 In

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

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 Code Error Name/Explanation/I/O Diagnostic Codes/Check
Items

WorkCentre 5016, 5020Reissue

rlock Switch

t order.

X — CH7.2Figure 2

X — CH3.2Figure 2

X — CH3.2Figure 2

Error Record in Error Log RAP BSDJune, 20082-16

Status Indicator RAPS

E6-2

Error NameSTM L/H Cover open

ExplanationAccess Cover 2 is open.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)[01-10]
STM Interlock Switch

Check Items Check that Access Cover 2 closes correctly. Check
that the STM Interlock Switch is correctly installed and that the
electrical connection is good. Check that the following wires are
connected securely with good electrical contact. If there is no
problem, replace the STM Inte

(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 tha

E8-1

Error NameNup NG Out Of Range

ExplanationThe magnification is not within the range of 50 to
200% during Nup.

Check Items Press the [Stop] button on the Control Panel. Press
the [Paper Supply] button on the Control Panel. Press the [Special
Copy] button on the Control Panel. Press the [Original Size Input]
button on the Control Panel. Press the [Clear All] button on the
Control Panel.

E8-2

Error NameNup Paper direction mismatch

ExplanationThe paper orientation of the document and the tray
are not aligned during Nup.

Check Items Press the [Stop] button on the Control Panel. Press
the [Paper Supply] button on the Control Panel. Press the [Special
Copy] button on the Control Panel. Press the [Original Size Input]
button on the Control Panel. Press the [Clear All] button on the
Control Panel.

Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Status Indicator RAPS

ct. If there is

t Sensor (PL

O — CH10.2Figure 2

t Sensor (PL

O — CH10.2Figure 2

Record in Error Log RAP BSDJune, 20082-17WorkCentre 5016,
5020

Reissue

E1-2

Error NameExit SNR on JAM

ExplanationTimeout between IOT Registration Clutch ON and Fuser
Exit Sensor ON.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [08-10]
IOT Registration Clutch [10-23] Fuser Exit SensorCheck Items
Registration Roll dirty, contaminated with paper dust, worn, or
faulty Fuser Exit Sensor dirty and Sensor Actuator deformed or
damaged Paper damaged or not within specification Foreign matter,
burrs, or paper in the paper path Drive gear worn or damaged IOT
Registration Clutch faulty Check that the IOT Registration Clutch
and the LVPS J503-4/5 ( P/J503) pins are connected securely with
good electrical conta

no problem, replace the IOT Registration Clutch (PL 2.9). Check
that the following wires are connected securely with good
electrical contact. If there is no problem, replace the Fuser
Exi

6.2). Wire between Fuser Exit Sensor J153-3 ( P/J153) and LVPS
J505-1 ( P/J505) Wire between Fuser Exit Sensor J153-2 and LVPS
J505-2 Wire between Fuser Exit Sensor J153-1 and LVPS J505-3

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

E3-1

Error NameExit SNR off JAM

ExplanationTimeout between Fuser Exit Sensor ON and Fuser Exit
Sensor OFF.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)[10-23]
Fuser Exit Sensor

Check Items Fuser Exit Sensor dirty and Sensor Actuator deformed
or damaged Paper damaged or not within specification Foreign
matter, burrs, or paper in the paper path Drive gear worn or
damaged Check that the following wires are connected securely with
good electrical contact. If there is no problem, replace the Fuser
Exi

6.2). Wire between Fuser Exit Sensor J153-3 ( P/J153) and LVPS
J505-1 ( P/J505) Wire between Fuser Exit Sensor J153-2 and LVPS
J505-2 Wire between Fuser Exit Sensor J153-1 and LVPS J505-3

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 Code Error Name/Explanation/I/O Diagnostic Codes/Check
Items

WorkCentre 5016, 5020Reissue

O — CH3.1Figure 1

X — CH3.2Figure 2

If there is no

X — —

t. If there is

O — CH9.2Figure 2

Error Record in Error Log RAP BSDJune, 20082-18

Status Indicator RAPS

H9-7

Error Name MCU-STM comm. errorExplanation

A communication failure has occurred between the MCU and the
Tray Module.Check Items Turn the power OFF then ON. Check for any
open circuit or short circuit between the STM connectors. Replace
the STM PWB (PL 11.5) (REP 11.5.2) and the AIOC PWB (PL 8.1) (REP
8.1.1) in that order.

L9-0

Error NameCopy Counter Full

ExplanationThe user that is logged in has reached the allotted
copy limit in the Account Mode.

Check ItemsPress the [Stop] button on the Control Panel.

J1-0

Error NameToner Cartridge was PRENEAR empty

ExplanationThe toner cartridge is low.

Check Items Refill the toner. Foreign matter on the sensor.
Check that the Toner Empty Sensor and the LVPS J509-1-4 ( P/J509)
pins are connected securely with good electrical contact.

problem, replace the Toner Empty Sensor (PL 4.2). Replace the
AIOC PWB (PL 8.1) (REP 8.1.1).

J1-2

Error NameToner Empty

ExplanationThe Toner Cartridge is empty.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)[09-07]
Toner Empty Sensor

Check Items Refill the toner. Foreign matter on the sensor.
Check that the Toner Empty Sensor and the LVPS J509 ( P/J509) 1-4
pins are connected securely with good electrical contac

no problem, replace the Toner Empty Sensor (PL 4.2). Replace the
AIOC PWB (PL 8.1) (REP 8.1.1).

Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Status Indicator RAPS

rtridge (PL O — CH9.2Figure 2

X — —

O — —

Record in Error Log RAP BSDJune, 20082-19WorkCentre 5016,
5020

Reissue

J3-1

Error NameNo Drum Cartridge

ExplanationUnable to detect the Drum Cartridge.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode)[09-02]
Drum Cartridge

Check Items Turn the power OFF then ON. Check that the following
wires are connected securely with good electrical contact. If there
is no problem, replace the Drum Ca

4.1) (REP 4.1.1). Wire between Drum Cartridge P610-7 ( P610) and
AIOC PWB J402-1 ( P/J402) Wire between Drum Cartridge P610-3 and
AIOC PWB J402-4 Wire between Drum Cartridge P610-2 and AIOC PWB
J402-5 Wire between Drum Cartridge P610-5 and AIOC PWB J402-2 Wire
between Drum Cartridge P610-4 and AIOC PWB J402-3 Wire between Drum
Cartridge P610-1 and AIOC PWB J402-6

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.

J6-0

Error NameDrum near end of life

ExplanationThe Drum Cartridge is near the end of its life.

Check ItemsReplace the Drum Cartridge (PL 4.1) (REP 4.1.1).

J6-1

Error NameDrum cartridge life end

ExplanationThe Drum Cartridge has reached the end of its
life.

Check ItemsReplace the Drum Cartridge (PL 4.1) (REP 4.1.1).

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check
Items

WorkCentre 5016, 5020Reissue

rtridge (PL O — CH9.2Figure 2

O — CH9.2Figure 2

O — CH9.2Figure 2

O — —

Error Record in Error Log RAP BSDJune, 20082-20

Status Indicator RAPS

J7-1

Error NameDrum CRUM comm. Error

ExplanationThe AIOC PWB is unable to communicate with the Drum
Cartridge.

I/O Diagnostic Codes (How to Enter the Diagnostic Mode) [09-02]
Drum CartridgeCheck Items Turn the power OFF then ON. Check that
the following wires are connected securely with good electrical
contact. If there is no problem, replace the Drum Ca

4.1) (REP 4.1.1). Wire between Drum Cartridge P610-7 ( P610) and
AIOC PWB J402-1 ( P/J402) Wire between Drum Cartridge P610-3 and
AIOC PWB J402-4 Wire between Drum Cartridge P610-2 and AIOC PWB
J402-5 Wire between Drum Cartridge P610-5 and AIOC PWB J402-2 Wire
between Drum Cartridge P610-4 and AIOC PWB J402-3 Wire between Drum
Cartridge P610-1 and AIOC PWB J402-6

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.

J7-2

Error NameDrum CRUM Market Identity Mismatch

ExplanationThe AIOC PWB has detected that the Drum CRUM
destination does not match.

Check Items Turn the power OFF then ON. Replace the Drum
Cartridge (PL 4.1) (REP 4.1.1).

J7-3

Error NameDrum CRUM ID error

Explanation The AIOC PWB has detected that the Drum CRUM ID is
incorrect.Check Items Turn the power OFF then ON. Replace the Drum
Cartridge (PL 4.1) (REP 4.1.1).

N1-1

Error NameEPC Memory Full

Explanation During a copy job in Collate Mode, the EPC memory is
full. Or, the machine has reached a state where it is unable to
scan in any more documents.Check Items

Press the [Stop] button on the Control Panel.

Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Status Indicator RAPS

O — CH3.2Figure 2

O — CH3.2Figure 2

—

—

O — —

O — —

Record in Error Log RAP BSDJune, 20082-21WorkCentre 5016,
5020

Reissue

N4-0

Error NameNo Response from USB-Host

Explanation Either «USB disconnected» or «Communication
timed-out» is detected during a print job. Or, either «USB
disconnected» or «Communication timed-out» is detected during a
scan job. Check Items Cancel the print job. Reconnect the USB cable
correctly.

N4-1

Error NameHBPL or XPJL Syntax Error

ExplanationAn abnormal command that cannot be ignored is
received from the USB-Host during a print job.

Check Items Cancel the print job. Reconnect the USB cable
correctly.

N4-2

Error NameDownload File Error

ExplanationThere is an abnormal Product ID or there is a
checksum error in the download file.

Check ItemsPress the [Stop] button on the Control Panel.

N4-3

Error NameDownload Flash Write Error

ExplanationUnable to write the downloaded file into flash
memory.

Check ItemsPress the [Stop] button on the Control Panel.

E0-1

Error NameCPM Image Lost

ExplanationDuring a copy job in CPM Priority Mode, the paper
containing an image cannot be output after the image is
deleted.

Check ItemsPress the [Stop] button on the Control Panel.

N5-0

Error NamePush Scan TimeOut

Explanation Push scan notification failed during a scan job. Or,
there is no scan job request from the PC after a push scan
notification.Check Items

The error will clear itself after a set amount of time has
passed.

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check
Items

WorkCentre 5016, 5020Reissue

O — CH3.2Figure 2

O — CH3.2Figure 2

O U0-1 CH4.1Figure 1

O U1-1 CH4.1Figure 1

O U2-1 CH6.2Figure 2

O U3-5 CH6.3Figure 3

O U4-1 CH10.1Figure 1

O U4-2 CH10.1Figure 1

O U4-3 CH10.1Figure 1

Error Record in Error Log RAP BSDJune, 20082-22

Status Indicator RAPS

N9-0

Error NameController Logic fail

ExplanationA software defect that cannot be ignored is found in
the Controller software.

Check ItemsTurn the power OFF then ON.

N9-1

Error NameIOT Communication Error

ExplanationThe AIOC PWB has detected a Type-Di communication
error.

Check ItemsTurn the power OFF then ON.

U0-1

Error NameMain Motor stop error

ExplanationThe motor runs for over 120 seconds without any paper
being fed.

U1-1

Error NameMain Motor rotation error

Explanation500ms after the IOT has started, the Main Motor Lock
signal is «Low.»

U2-1

Error NameCarriage Module Fail

ExplanationAn abnormality was detected in the Carriage
Module.

U3-5

Error NameLaser Power or ROS Motor Fail

Explanation The ROS Motor is unable to rotate. Or, the laser
output is not normal.

U4-1

Error NameFuser On Time Fail

Explanation The lamp did not turn OFF within the specified time
after turning ON. Or, Warm Up was not completed within the
specified time after power ON.

U4-2

Error NameOver Heat Temp Fail

ExplanationA temperature above 250C is continuously detected for
480ms.

U4-3

Error NameFS1 thermistor defect

ExplanationFS1 cannot be monitored any more.

Code Error Name/Explanation/I/O Diagnostic Codes/Check Items

Status Indicator RAPS

O U4-9 CH10.3Figure 3

O U6-2 CH3.2Figure 2

O U6-3 CH3.2Figure 2

O U6-4 CH3.2Figure 2

O U6-5 CH3.2Figure 2

X U7-0 CH2.1Figure 1

X U7-1 CH2.1Figure 1

O U8-1 CH3.2Figure 2

O U9-0 CH9.1Figure 1

Record in Error Log RAP BSDJune, 20082-23WorkCentre 5016,
5020

Reissue

U4-9

Error NameFuser Fan defect

ExplanationAfter the start of Fan Fail Signal monitoring, the
signal level was Low not more than 30 times.

U6-2

Error NameRAM read/write check error

ExplanationWhen the MCU runs the overall Read/Write check for
RAM during startup, the Read Data and Write Data do not match.

U6-3

Error NameNVM data defect

Explanation The NVM Header data ERROR and NVM 3 page data do not
match. Or, unable to find the NVM Write & Read area. The NVM or
Counter areas are full.

U6-4

Error NameNVM read/write cannot be executed

Explanation An NVM Ack NG is detected during NVM Read. An NVM
Write Error is detected 5 times during NVM Recovery.

U6-5

Error NameCPU Power to access NVM is not enough

ExplanationNVM queue full is detected during NVM Write.

U7-0

Error NameUI Communication TimeOut

ExplanationAt the Power On Sequence, the AIOC PWB did not
communicate with the User Interface PWB.

U7-1

Error NameUI Communication Error

ExplanationThe User Interface PWB has detected a communication
failure.

U8-1

Error NameBilling Counter Defect

Explanation It is detected that the Billing Counter Value is
incorrect. Or, the AOIC PWB has failed to read the Billing
Counter.

U9-0

Error NameHVPS fail

ExplanationA 500 msec cycle of the signal HVPS#ERR=High was
detected twice in a row.

Error Code Error Name/Explanation/I/O Diagnostic Codes/Check
Items

WorkCentre 5016, 5020Reissue

Display Priority in Case of Multiple Errors

Document Jamize

t

n JAM

Paper Jam

JAM JAMn JAM from STM feedAM

AM

AMAMM

Tray-related errorsismatchismatchmatchct paper tray (Tray1)ct
paper tray (Tray2)

Resolvable by replac-ing parts

nd. Errort Identity Mismatchr

An error that only stops scanning

Priority Error Error CharacteristicJune, 20082-24

Status Indicator RAPS

When multiple errors occur simultaneously, they will be shown on
the Control Panel display in the following priority order. Always
begin troubleshooting with the highest-priority error.

Priority Order

Error Code Error Name Error Characteristic

1 (Highest)

U7-0 UI Communication TimeOut Unable to control the display at
the Control-

ler2 U7-1 UI Communication Error3 H9-7 MCU-STM comm. error

Fatal Error

4 N9-1 IOT Communication Error5 N9-0 Controller Logic fail6 U0-1
Main Motor stop error7 U1-1 Main Motor rotation error8 U2-1
Carriage Module Fail9 U3-5 Laser Power or ROS Motor Fail10 U4-1
Fuser On Time Fail11 U4-2 Over Heat Temp Fail12 U4-3 FS1 thermistor
defect13 U4-9 Fuser Fan defect14 U6-2 RAM read/write check error15
U6-3 NVM data defect16 U6-4 NVM read/write cannot be executed17
U6-5 RAM read/write check error18 U8-1 Billing Counter Defect19
U9-0 HVPS fail20 E9-1 AMS NG Out Of Range

Dynamic Error(Job Cancel)

21 E9-2 Paper direction mismatch22 E8-1 Nup NG Out Of Range23
E8-2 Nup Paper direction mismatch24 L9-0 Copy Counter Full25 N4-0
No Response from USB-Host26 N4-1 HBPL or XPJL Syntax Error27 N4-2
Download File Error27 N4-3 Download Flash Write Error29 N5-0 Push
Scan TimeOut30 A5-1 Platen Cover Open Document Cover

Open32 E5-1 IOT L/H Cover open

Paper Cover Open33 E5-2 IOT Front Cover open34 E6-1 L/H Low
Cover open35 E6-2 STM L/H Cover open

36 A1-1 Doc Misfeed Jam37 A2-2 No Supported Doc S38 A4-1 Short
Length Detec39 A4-2 Long Length Detect40 C1-1 Tray1 F/O#1 SNR o41
C1-2 Tray1 Regi SNR on42 C2-1 STM F/O#2 SNR on43 C2-2 Tray1 F/O#1
SNR o44 C2-3 STM Regi SNR on J

46 C9-3 MSI Regi SNR on J47 E1-2 Exit SNR on JAM48 E3-1 Exit SNR
off JAM49 C8-1 F/O#1 SNR Static J50 C8-2 F/O#2 SNR Static J51 E1-6
Regi SNR Static JA52 E3-6 Exit SNR JAM53 E0-1 CPM Image Lost54 C0-1
APS NG Unselected

56 C5-1 Tray1 Paper Size M57 C6-1 Tray2 Paper Size M58 C7-1 MSI
Paper Size Mis59 C5-0 No paper in the sele60 C6-0 No paper in the
sele61 J1-2 Toner Empty62 J3-1 No Drum cartridge63 J6-1 Drum
cartridge life e64 J7-1 Drum CRUM comm65 J7-2 Drum CRUM Marke66
J7-3 Drum CRUM ID erro67 N1-1 EPC Memory Full

Order Code Error Name

U0-1, U1-1Status Indicator RAPS

rror

otor Lock signal is Low.

over. Execute diagnostics [04—01 Main Motor On]. OT Motor can
be heard rotating.

504 and P/J201 are connected securely.

urely.

WB P504-1 ( P/J504) (+) and GND (-). The volt-

8.1.2).

04) and J201-3 ( P/J201). The wire is not

1.1.1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in

1.1 ) (REP 1.1.1). The IOT Motor is installed

.1.1) properly.

unterclockwise by hand. It rotates smoothly,

t obstruct the drive and for any incorrectly installed or
incorrectly installed parts.

REP 1.1.1).

ix any installation errors.

nd J201-3 ( P/J201). The wire is not shorted

1) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that June,
20082-25WorkCentre 5016, 5020

Reissue

U0-1 Main Motor Stop ErrorBSD-Reference: CH4.1 (Figure 1)

ExplanationThe motor runs for over 120 seconds without any paper
being fed.

ProcedureThe problem can be solved according to RAP U1- 1 Main
Motor Rotation Error (U1-1).Y N

Execute diagnostics [29-49] (How to Enter the Diagnostic Mode)
to check the ROM ver-sion. The ROM is the latest version.Y N

Upgrade the ROM to the latest version.

Replace the IOT Motor (PL 1.1) (REP 1.1.1) and the AIOC PWB (PL
8.1) (REP 8.1.1) in that order.

Completed

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

Explanation500 ms after the IOT Motor starts, the IOT M

ProcedureClose the Left Hand Cover and the Front C(How to Enter
the Diagnostic Mode) The IY N

Check P/J504 and P/J201. Both P/JY N

Connect P/J504 and P/J201 sec

Measure the voltage between LVPS Page is approximately +24VDC.Y
N

Replace the LVPS (PL 8.1) (REP

Check the wire between J504-3 ( P/J5shorted or open.Y N

Repair the wire.

Replace the IOT Motor (PL 1.1) (REPthat order.

Check the installation of the IOT Motor (PL properly.Y N

Install the IOT Motor (PL 1.1 ) (REP 1

Turn the rotor of the IOT Motor (PL 1.1 ) cowithout any abnormal
load.Y N

Check for any foreign substances thaparts. There are foreign
substancesY N

Replace the IOT Motor (PL 1.1) (

Remove any foreign substances and f

Check the wire between J504-3 ( P/J504) aor open.Y N

Repair the wire.

Replace the IOT Motor (PL 1.1) (REP 1.1.order.

WorkCentre 5016, 5020Reissue

U2-1 Carriage Module Fail U3-5 Laser Power Or ROS Motor Fail

output is not normal.

(How to Enter the Diagnostic Mode) The ROS

C PWB P403-7 ( P/J403) (+) and GND (-). The

(REP 8.1.1) and the LVPS (PL 8.1) (REP 8.1.2) in

) and the AIOC PWB (PL 8.1) (REP 8.1.1) in that

B P403-1 ( P/J403) (+) and GND (-). The volt-

8.1.1).

PWB P/J140 ( P/J140), and P/J130 ( P/J130) con- connectors are
connected securely.

403), LD PWB P/J140 ( P/J140), and P/J130 ( P/

d J140 ( P/J140) and between J403 and J130 ( P/.

the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.June,
20082-26U2-1, U3-5

Status Indicator RAPS

BSD-Reference: CH6.2 (Figure 2)

ExplanationA carriage fault was detected.

ProcedureExecute diagnostics [05-22 Move scanner to home
position] and [05-23 Move scanner to main-tenance position]. (How
to Enter the Diagnostic Mode) The carriage moves.Y N

Check each IIT Carriage connector. Each connector is connected
securely.Y N

Connect each connector securely.

Check for foreign substances and deformed parts in the carriage.
None is found.Y N

Remove the foreign substances and repair the deformed parts.

Replace the IIT Carriage (PL 10.3)(REP 10.3.1).

Execute diagnostics [05-23 Move scanner to maintenance
position]. When the IIT Carriage has moved to the leftmost
position, press the [Stop] button to put the Carriage Sensor into
the blocked state. Execute diagnostics [5-11 Home Sensor], and «H»
is displayed.Y N

Check each IIT Carriage and Carriage Sensor connector. Each
connector is con-nected securely.Y N

Connect each connector securely.

Replace the Carriage Sensor (PL 10.6) and the IIT Carriage (PL
10.3) (REP 10.3.1) in that order.

Check the Carriage Sensor (PL 10.6 ). The Carriage Sensor is
installed properly.Y N

Install the Carriage Sensor (PL 10.6) properly.

Replace the IIT Carriage (PL 10.3) (REP 10.3.1).

BSD-Reference: CH6.3 (Figure 3)

ExplanationThe ROS Motor does not turn, or the laser

ProcedureExecute diagnostics [6-15 ROS Motor ON].Motor can be
heard rotating.Y N

Measure the voltage between the AIOvoltage is approximately
+24VDC.Y N

Replace the AIOC PWB (PL 8.1)that order.

Replace the ROS (PL 3.1) (REP 3.1.1order.

Measure the voltage between the AIOC PWage is approximately
+5VDC.Y N

Replace the AIOC PWB (PL 8.1) (REP

Check the AIOC PWB P/J403 ( P/J403), LDnectors. The P/J403,
P/J140, and P/J130Y N

Connect the AIOC PWB P/J403 ( P/JJ130) connectors securely.

Check the wires between J403 ( P/J403) anJ130) The wires are not
shorted or openY N

Repair the wire(s).

Replace the ROS (PL 3.1) (REP 3.1.1) and

U4-1, U4-2Status Indicator RAPS

cted continuously for 480 ms.

t FuserOverTemp] becomes «1.» Run [NVM 50-20 set it. (How to
Enter the Diagnostic Mode) Check o open circuit between J601-1 (
P/J601) and of 228k ohms (cold).

).

P601 ( P/J601). The wire between J408 and

e LVPS (PL 8.1) (REP 8.1.2), and the AIOC PWB June,
20082-27WorkCentre 5016, 5020

Reissue

U4-1 Fuser On Time FailBSD-Reference: CH10.1 (Figure 1)

Explanation The lamp did not turn OFF within the specified time
after turning ON. Or, Warm Up was not completed within the
specified time after power ON.ProcedureWhen U4-1 occurs, [NVM 50-20
FSR Reset FuserOverTemp] becomes «3.» Run [NVM 50-20 FSR Reset
FuserOverTemp] using «0» to reset it. (How to Enter the Diagnostic
Mode) Check to see if there is paper in the Fuser. The Fuser is
normal and there is no paper in it.Y N

Remove the paper.

Check the condition of the Fuser. The Fuser is installed
properly.Y N

Install the Fuser properly.

Remove the Fuser. Check the conductivity between the Thermostat
contacts. The contacts are conductive. Y N

Replace the Fuser (PL 5.1) (REP 5.1.1).

Check the Heater Rod for an open circuit. There is no open
circuit between J600-1 ( P/J600) and J600-2.Y N

Replace the Fuser (PL 5.1) (REP 5.1.1).

Check the resistance of the Thermistor. There is no open circuit
between J601-1 ( P/J601) and J601-2, and the resistance is a
minimum of 228k ohms (cold).Y N

Replace the Fuser (PL 5.1) (REP 5.1.1).

Immediately after Main Switch ON, the voltage between J3-3 (
P/J3) (ACH) and J3-1 (ACN) is approximately 200VAC.Y N

Replace the LVPS (PL 8.1) (REP 8.1.2).

Check the wire between J408 ( P/J408) and P601 ( P/J601). The
wire between J408 and P601 is not shorted or open.Y N

Repair the wire.

Check the wire between J3 ( P/J3) and P600 ( P/J600). The wire
between J3 and P600 is not shorted or open.Y N

Repair the wire.

Replace the Fuser (PL 5.1) (REP 5.1.1), the LVPS (PL 8.1) (REP
8.1.2), and the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

U4-2 Over Heat Temp FailBSD-Reference: CH10.1 (Figure 1)

ExplanationA temperature of 250C or higher was dete

ProcedureWhen U4-2 occurs, [NVM 50-20 FSR ReseFSR Reset
FuserOverTemp] using «0» to rethe resistance of the Thermistor.
There is nJ601-2, and the resistance is a minimumY N

Replace the Fuser (PL 5.1) (REP 5.1.1

Check the wire between J408 ( P/J408) andP601 is not shorted or
open.Y N

Repair the wire.

Replace the Fuser (PL 5.1) (REP 5.1.1), th(PL 8.1) (REP 8.1.1)
in that order.

WorkCentre 5016, 5020Reissue

U4-3 FS1 Thermistor Defect U4-9 Fuser Fan Defect

, the signal level was Low not more than 30 times.

HAD Fan (PL 9.2). The NOHAD Fan is rotating.

C PWB P405-3 ( P/J405) (+) and GND (-). The

(REP 8.1.1).

the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

B P405-2 P/J405 (+) and GND (-). The voltage

the AIOC PWB (PL 8.1) (REP 8.1.1) in that order.

1). June, 20082-28U4-3, U4-9

Status Indicator RAPS

BSD-Reference: CH10.1 (Figure 1)

ExplanationThermistor FS1 cannot be monitored any more.

ProcedureCheck the condition of the Fuser. The Fuser is
installed properly.Y N

Install the Fuser properly.

Check the resistance of the Thermistor. There is no open circuit
between J601-1 ( P/J601) and J601-2, and the resistance is a
minimum of 228k ohms (cold).Y N

Replace the Fuser (PL 5.1) (REP 5.1.1).

Check the wire between J408 ( P/J408) and P601 ( P/J601). The
wire is not shorted or open.Y N

Repair the wire.

Replace the Fuser (PL 5.1) (REP 5.1.1) and the AIOC PWB (PL 8.1)
(REP 8.1.1) in that order.

BSD-Reference: CH10.3 (Figure 3)

ExplanationAfter the start of Fan Fail Signal monitoring

ProcedureTurn the power ON. Visually check the NOY N

Measure the voltage between the AIOvoltage is approximately
+24VDC.Y N

Replace the AIOC PWB (PL 8.1)

Replace the NOHAD Fan (PL 9.2) and

Measure the voltage between the AIOC PWis 0.Y N

Replace the NOHAD Fan (PL 9.2) and

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

U6-2, U6-3Status Indicator RAPS

ta are mismatched. found.

onnector is connected securely.

.

1).June, 20082-29WorkCentre 5016, 5020

Reissue

U6-2 RAM Read/Write Check ErrorBSD-Reference: CH3.2 (Figure
2)

ExplanationWhen the AIOC PWB checked RAM read/write at
activation, a mismatch of read and write data was detected.

ProcedureCheck each AIOC PWB connector. Each connector is
connected securelyY N

Connect each connector securely.

Turn the power OFF and ON. U6-2 recurs.Y N

Completed

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

U6-3 NVM Data DefectBSD-Reference: CH3.2 (Figure 2)

Explanation NVM Header data and NVM 3 page da Or, the NVM Write
& Read area is not Or, the NVM or Counter area is
full.ProcedureCheck each AIOC PWB connector. Each cY N

Connect each connector securely.

Turn the power OFF and ON. U6-3 recursY N

Completed

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

WorkCentre 5016, 5020Reissue

U6-4 NVM Read/Write Cannot Be Executed U6-5 CPU Power To Access
NVM Is Not Enough

detected.

OM version. (How to Enter the Diagnostic

.

1). June, 20082-30U6-4, U6-5

Status Indicator RAPS

BSD-Reference: CH3.2 (Figure 2)

Explanation During NVM read/write, the NVM Ack NG state was
detected. Or, during NVM repairs, an NVM write error was detected
five times.ProcedureCheck each AIOC PWB connector. Each connector
is connected securely.Y N

Connect each connector securely.

Turn the power OFF and ON. U6-4 recurs.Y N

Completed

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

BSD-Reference: CH3.2 (Figure 2)

ExplanationAt NVM write, the NVM queue full state was

ProcedureExecute diagnostics [29-49] to check the RMode) The ROM
is the latest version.Y N

Upgrade the ROM to the latest version

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

U7-0, U7-1Status Indicator RAPS

ror

nication failure.

. Each connector is connected securely.

.

REP 8.4.1).June, 20082-31WorkCentre 5016, 5020

Reissue

U7-0 UI Communication TimeOutBSD-Reference: CH2.1 (Figure 1)

ExplanationAt Power ON, the AIOC PWB does not communicate with
the User Interface PWB.

ProcedureMeasure each voltage between AIOC PWB J401-1 ( P/J401)
(+), J401-2 (+), and GND (-). The voltages are approximately
+5VDC.Y N

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

Check the wire between J401 ( P/J401) and J710 ( P/J710). The
wire is neither shorted nor open.Y N

Repair the wire.

Replace the User Interface PWB (PL 8.4) (REP 8.4.1) and the AIOC
PWB (PL 8.1) (REP 8.1.1) in that order.

U7-1 UI Communication ErBSD-Reference: CH2.1 (Figure 1)

ExplanationThe User Interface PWB detected a commu

ProcedureCheck each User Inferface PWB connectorY N

Connect each connector securely.

Turn the power OFF and ON. U7-1 recursY N

Completed

Replace the User Interface PWB (PL 8.4) (

WorkCentre 5016, 5020Reissue

U8-1 Billing Counter Defect U9-0 HVPS Fail

etected twice in a row.

over. Make sure that the Drum Cartridge and the asure the
voltages between P406-2 ( P/J406) (+)/d ground (-). The voltages
are approximately

8.1.1) and the HVPS (PL 8.2) (REP 8.2.1) in that

Voltage)]. (How to Enter the Diagnostic Mode) -4 (+)/P406-5 (+)
become 0.

8.1.1).

he problem is solved.

( P/J406) (+) on the AIOC PWB and ground (-)..

) and J406-1 ( P/J406) on the HVPS PWB for a

VPS (PL 8.2) (REP 8.2.1).

8.1.1). June, 20082-32U8-1, U9-0

Status Indicator RAPS

BSD-Reference: CH3.2 (Figure 2)

Explanation An illegal Billing Counter value was detected. Or,
the AIOC PWB failed to read the Billing Counter.ProcedureTBD

BSD-Reference: CH9.1 (Figure 1)

ExplanationA 500 ms cycle of HVPS#ERR=High was d

ProcedureClose the Left Hand Cover and the Front CTransfer
Corotron are properly seated. MeP406-4(+)/P406-5(+) on the AIOC PWB
an+5VDC.Y N

Replace the AIOC PWB (PL 8.1) (REPorder.

Execute diagnostics [09-04 HVPS ON (LowThe voltages at P406-2 (
P/J406) (+)/P406Y N

Replace the AIOC PWB (PL 8.1) (REP

Replace the HVPS (PL 8.2) (REP 8.2.1). TY N

Measure the voltage between P406-1The voltage is approximately
+5VDCY N

Check between J520-1 ( P/J520short circuit.If there is no short,
replace the H

Replace the AIOC PWB (PL 8.1) (REP

Completed

062-300, 062-345Status Indicator RAPS

re

e EEPROM.

n the power. The problem is solved.

rk PWB). (REP 8.1.3) (PL 8.1)June, 20082-33WorkCentre 5016,
5020

Reissue

062-300 Platen Interlock OpenBSD-Reference: CH 5.6

ExplanationDetected the opened Platen Interlock.

ProcedureEnsure that the DADF can be closed normally. The DADF
can be closed normally.Y N

Remove obstructions or repair the DADF Counter Balances. (REP
13.3.2, REP 13.3.3)

Check that the Platen Interlock is functioning properly. The
Platen Interlock is functioning properly.Y N

Replace the Platen Interlock Sensor.

Replace the SLCC PWB (AIOC/Network PWB). (REP 8.1.3) (PL
8.1)

062-345 IISS EEPROM FailuBSD-Reference: CH 3.1

ExplanationError in writing on or communicatiing with th

ProcedureSwitch off the machine power then switch oY N

Replace the SLCC PWB (AIOC/Netwo

Problem is resolved.

WorkCentre 5016, 5020Reissue

062-360 Carriage Position Fail 062-371 Lamp Illumination
Fail

Lamp to the CCD.

th between the lamp, the lens or the mirror. The

e (Reflector) is in place and not deterioarated. (PL s good.

ection Plate. (PL 10.6)

nt Control Code [62-02]. The Illumination Lamp

rly connected and repair if necessary. Replace the

B). (PL 8.1) (REP 8.1.3)June, 20082-34062-360, 062-371

Status Indicator RAPS

BSD-Reference: CH 6.2

ExplanationDetected no input of Regi Sensor when carriage was
working or detected the failure of the Regi Sensor position, or
detected the failure of the IIT Regi Sensor level.

ProcedureCheck that the Lamp Carriage can move freely and has no
loose cables. The Lamp Carriage and cables are good.Y N

Repair the Lamp Carriage. (REP 10.3.1)

Enter the Diagnostic Mode. Enter Component Control Code
[62-212]. Check the operation of the IIT Regi Sensor. The Regi
Sensor is good.Y N

Reseat the Regi Sensor connector. Check the wiring for proper
operation and repair if necessary. Replace the Regi Sensor. (PL
10.6)

Enter the Diagnostic Mode. Enter Component Control Code [05-22].
The Carriage moves in the scan direction.Y N

Check the connector of the Carriage Motor and repair if
necessary. Replace the Carriage Motor. (PL 10.6)

Replace the SLCC PWB (AIOC/Network PWB). (PL 8.1) (REP
8.1.3)

BSD-Reference: CH 6.1

ExplanationDetected incufficient light provided from the

ProcedureCheck for any obstructions in the optical paoptical
path is clear of any obstructions.Y N

Remove the obstuctions.

Check that the White Color Correction Plat10.6) The White Color
Correction Tape iY N

Clean or replace the White Color Corr

Enter the Diagnostic Mode. Enter Componeis good.Y N

Check that the Lamp harness is propeIllumination Lamp. (REP
10.6.1)

Replace the SLCC PWB (AIOC/Network PW

062-380, 062-386Status Indicator RAPS

t of the CCD at AOC (Automatic Offset Control) of

nection. The problem has been resolved.

OMS (AIOC/Network PWB). (PL 8.1) (REP 8.1.3) June,
20082-35WorkCentre 5016, 5020

Reissue

062-380 AGC FailureBSD-Reference: CH 6.2

ExplanationControl logic has detected insufficient light from
the Illumination Lamp during AGC (Automatic Gain Congrol) of the
auto IIT Calibration at Start.

ProcedureCheck for any obstructions in the optical path. Clean
the Mirror, lens and the white balance strip. Switch off the power
then switch it on again. The problem has been resolved.Y N

Enter the Diagnostic Mode. Enter Component Control Code [62-02].
The lamp is good.Y N

Check that the Lamp harness is properly connected and repair if
necessary. Replace the Illumination Lamp. (REP 10.6.1)

Replace the SLCC PWB and (3) EEPROMS (AIOC/Network PWB). (PL
8.1) (REP 8.1.3)

POPO the machine and retry.

062-386 AOC FailureBSD-Reference: CH 6.1

ExplanationControl logic has detected an output defecthe auto
IIT Calibration at Start.

ProcedureCheck the connector P/J410 for proper conY N

Replace the SLCC PWB and (3) EEPR

POPO the machine and retry.

WorkCentre 5016, 5020Reissue

062-392 IPS PWB Memory Fail 062-393 IPS PWB Fail

writing error to the SLCC EEPROMs.

in. If the problem is not solved, replace the SLCC . (REP 8.1.3)
June, 20082-36062-392, 062-393

Status Indicator RAPS

BSD-Reference: CH 3.1

ExplanationControl logic has detected RAM malfunction of IISS
PWB.

ProcedureSwitch 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)

BSD-Reference: CH 3.1

ExplanationControl logic has detected a test error or a

ProcedureSwitch off the power then switch it on agaPWB
(AIOC/Network) and the 3 EEPROMs

005-170Status Indicator RAPS

tch (PL 13.9)

Roller. (REP 13.9.1)

.9).

A B CJune, 20082-37WorkCentre 5016, 5020

Reissue

005-170 DADF Feed FailureBSD-Reference: CH 5.2

ExplanationThe control logic has detected the failure of paper
to reach the Document Feed Sensor after the Feed Clutch has
energized.

ProcedureCheck 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

connections2. 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)

The Feed Roller rotates.Y N

Enter the Diagnostic Mode. Enter Component Control Code [05-62].
The Docu-ment Feed Clutch operates.Y N

Check the connector of the Document Feed Clutch (PL 13.9) If the
connector is good, replace the Document Feed Clutch (PL 13.9).

Replace the Document Feed Clu

Replace the Pick Up Roller and Feed

Replace the Document Feed Sensor (PL 13

A B C

WorkCentre 5016, 502