WC5020

WorkCentre 5020 CAUTION
This equipment generates, uses and can radiate radio frequency energy, and if not installed
Service Documentation 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-
WorkCentre 5020 Service Documentation ing device pursuant to subpart B of part 15 of FCC rules, which are designed to provide rea-
sonable protection against such interference when operated in a commercial environment.
701P47442 Operation of this equipment in a residential area is likely to cause interference in which case
the user, at his own expense, will be required to correct the interference.
Initial Issue
July, 2007
***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 from 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.
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respective companies
July, 2007
WorkCentre 5020 i
July, 2007
WorkCentre 5020 ii
Introduction
How To Use This Manual................................................................................................ iii
Initial Issue July, 2007 Introduction

WorkCentre 5020 i
Introduction July, 2007 Initial Issue
ii WorkCentre 5020
How To Use This Manual Chain 3 Machine Run Control
Chain 4 Start Print Power
Chain 6 Imaging
This manual is used as the standard service manual for the WorkCentre 5020.
Chain 7 Paper Supplying
Enter any comments and/or corrections regarding the WorkCentre 5020 service manual on the Chain 8 Paper Transportation
Publication Comment Sheet, and send it to the Technical Support Center SDEG. Chain 9 Marking
Chain 10 Fusing and Copy Transportation
This manual describes the standard procedures for servicing the WorkCentre 5020. Refer to
Section 1 Service Call Procedure for efficient and effective servicing during maintenance calls.
Description of Terminology and Symbols
Contents of Manual
The terminology and symbols used throughout this service manual are described as follows:
This manual is divided into nine sections as described below.
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.
Reference:
Section 3 Image Quality RAPs
Used when other explanations are given.
This section contains the Repair Analysis Procedures (RAPs) that are used to diagnose image
Purpose:
quality defect problems.
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 5020.
ADJ:
Section 5 Parts List Indicates the adjustment procedure for reference.
This section contains a list of spare parts list for the WorkCentre 5020. PL:
Indicates the parts list for reference.
Section 6 General Procedures/Information
ASSY:
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 Means Assembly.
part 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 FUJI
This section contains the wiring information for the WorkCentre 5020. It contains a connector XEROX Co., Ltd.
list/locator, wirenet diagrams, and Block Schematic Diagrams (BSDs) for the following chains:
Chain 1 Standby Power

Chain 2 Mode Selection
Initial Issue July, 2007 Introduction

WorkCentre 5020 iii
Introduction July, 2007 Initial Issue
iv WorkCentre 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
Initial Issue July, 2007 Service Call Procedures

WorkCentre 5020 1-1
Service Call Procedures July, 2007 Initial Issue
1-2 WorkCentre 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 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 machine’s condition. 1. Ask the operator(s) about the machine’s 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.
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 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 5020 1-5 1.4, 1.5
1.4, 1.5 1-6 WorkCentre 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
Initial Issue July, 2007 Status Indicator RAPS

WorkCentre 5020 2-1
Status Indicator RAPS July, 2007 Initial Issue
2-2 WorkCentre 5020
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

WorkCentre 5020 2-3
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.

2-4 WorkCentre 5020
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

WorkCentre 5020 2-5
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.

2-6 WorkCentre 5020
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.

WorkCentre 5020 2-7
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.

2-8 WorkCentre 5020
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.
• [08-06] STM Feed Sensor
• [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.

WorkCentre 5020 2-9
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 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 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).

Error Record in
Error Name
F/O#1 SNR Static JAM
Explanation
Tray1 Feed Sensor ON is detected during standby.
[08-07] Tray1 Feed Sensor
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.
[08-06] STM Feed Sensor
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
Press the [Stop] button on the Control Panel.

Error Record in
Error Name
Regi SNR Static JAM
Explanation
IOT Registration Sensor ON is detected during standby.
[08-05] IOT Registration Sensor
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

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

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.

Error Record in
Error Name
Exit SNR on JAM
Explanation
Timeout between IOT Registration Clutch ON and Fuser Exit Sensor ON.
• [10-23] Fuser Exit Sensor
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.
[10-23] Fuser Exit Sensor
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).

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).

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
Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).

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
• Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).
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
• Replace the Drum Cartridge (PL 4.1) (REP 4.1.1).
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

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.

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
Turn the power OFF then ON.
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
Turn the power OFF then ON.
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 250°C is continuously detected for 480ms.
Error Name
FS1 thermistor defect CH10.1
U4-3 O U4-3
FS1 cannot be monitored any more.

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.

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

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 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 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 250°C 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 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 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
Replace the AIOC PWB (PL 8.1) (REP 8.1.1).

WorkCentre 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 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 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 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
Initial Issue July, 2007 Image Quality

WorkCentre 5020 3-1
Image Quality July, 2007 Initial Issue
3-2 WorkCentre 5020
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 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 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 can’t 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).

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 can’t 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 can’t 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 can’t, replace the Fuser (PL 5.1) (REP 5.1.1). Y N
Completed

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 can’t 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 can’t 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).

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 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
Table 3 Copy Alignment: Specification

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%)

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).

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.

Figure 2 Image Quality Measurement Positions (Test Pattern 499T247)
Image Quality Specification

Total System

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

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)

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.

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).

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).

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.

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.

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.

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.

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).

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.

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.

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.

4 Repairs and Adjustments
Introduction REP 9.2.2 Right Cover .................................................................................................... 4-64
Introduction ..................................................................................................................... 4-3
10. IIT
Repairs REP 10.1.1 IIT Platen Cover ........................................................................................... 4-65
REP 10.2.1 IIT Upper Cover (SCC) ................................................................................ 4-66
1. Drive REP 10.3.1 IIT Carriage (SCC) ....................................................................................... 4-67
REP 1.1.1 IOT Motor (SCC)............................................................................................ 4-5 REP 10.3.2 Flexible Print Cable (SCC)........................................................................... 4-73
REP 10.6.1 Exposure Lamp............................................................................................ 4-75
2. Paper Transport
REP 10.7.1 Carriage Cable and Drum ............................................................................ 4-76
REP 2.2.1 Tray 1 Feed Clutch (SCC) ............................................................................. 4-7
REP 10.7.2 Inverter PWB................................................................................................ 4-79
REP 2.3.1 Tray 1 Feed Roll (SCC) ................................................................................. 4-9
REP 2.5.1 Tray 1 Feed Sensor ...................................................................................... 4-10 11. Single Tray Module
REP 2.7.1 Tray 1 No Paper Sensor ............................................................................... 4-12 REP 11.1.1 Tray 2........................................................................................................... 4-83
REP 2.8.1 Registration (SCC)......................................................................................... 4-13 REP 11.1.2 Single Tray Module (Separation from IOT) .................................................. 4-83
REP 11.4.1 Tray 2 Feed Roll .......................................................................................... 4-85
3. ROS
REP 11.4.2 Tray 2 Retard Roll........................................................................................ 4-87
REP 3.1.1 ROS (SCC) .................................................................................................... 4-17
REP 11.5.1 STM Feed Sensor........................................................................................ 4-90
4. CRU REP 11.5.2 STM PWB (SCC) ......................................................................................... 4-91
REP 4.1.1 Drum Cartridge .............................................................................................. 4-19 REP 11.6.1 STM Feed Clutch ......................................................................................... 4-92
REP 4.2.1 Toner Empty Sensor...................................................................................... 4-20 REP 11.6.2 STM Feed Motor .......................................................................................... 4-93
REP 4.2.2 Erase Lamp ................................................................................................... 4-21 REP 11.7.1 STM No Paper Sensor................................................................................. 4-94
REP 4.3.1 Transfer Module............................................................................................. 4-23
Adjustments
REP 4.4.1 Corotron Wire ................................................................................................ 4-27
ADJ 8.1.1 Edge Erase Adjustment.................................................................................. 4-95
5. Fuser ADJ 8.1.2 Controller Firmware Version Upgrade ............................................................ 4-95
REP 5.1.1 Fuser (SCC)................................................................................................... 4-29 ADJ 10.3.1 IIT Lead Edge/Side Edge Registration ......................................................... 4-96
REP 5.1.2 Temperature Control Sensor Assembly......................................................... 4-31 ADJ 11.1.1 Carriage Assembly Alignment (Parallelism) ................................................. 4-97
REP 5.1.3 Fuser Lamp.................................................................................................... 4-32
REP 5.1.4 Fuser Roll ...................................................................................................... 4-35
REP 5.1.5 Fuser Pressure Roll ....................................................................................... 4-38
6. Exit
REP 6.1.1 Exit Transport ................................................................................................ 4-39
7. Simplex Module and Bypass Tray

REP 7.1.1 Simplex Module ............................................................................................. 4-43
REP 7.5.1 Bypass Feed Roll........................................................................................... 4-45
8. Electrical
REP 8.1.1 AIOC PWB (SCC).......................................................................................... 4-47
REP 8.1.2 LVPS (SCC)................................................................................................... 4-50
REP 8.2.1 HVPS (SCC) .................................................................................................. 4-53
REP 8.3.1 Control Panel (SCC) ...................................................................................... 4-56
REP 8.4.1 User Interface PWB (SCC) ............................................................................ 4-58
9. Cover
REP 9.1.1 Output Tray.................................................................................................... 4-61
REP 9.1.2 Front Left Cover............................................................................................. 4-62
REP 9.2.1 Rear Cover .................................................................................................... 4-63
Initial Issue July, 2007 Repairs and Adjustments

WorkCentre 5020 4-1
Repairs and Adjustments July, 2007 Initial Issue
4-2 WorkCentre 5020
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 5020 4-3
4-4 WorkCentre 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 5020 4-5 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 4-6 WorkCentre 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

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 2.3.1 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

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 4-10 WorkCentre 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

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 2.8.1 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

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

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

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

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 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

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

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 5020 4-21 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

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

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

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

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 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

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 5.1.2 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

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

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 5.1.4 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

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

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

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 6.1.1 Exit Transport 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

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).
2 Remove the Connector Cover.
Figure 3
Figure 2

6. Remove the Exit Transport (Figure 4). Replacement
1 Remove the Tapping Screws (3). 1. To install, do the removal steps in reverse order.
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

REP 7.1.1 Simplex Module 3. Open the Left Side Cover.
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

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

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
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 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

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

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

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

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

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 8.2.1 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


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

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 8.3.1 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

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

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

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

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 9.2.1 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

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 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

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 10.3.1 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

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

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

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

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

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

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 10.6.1 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

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

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 10.7.2 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

6. Remove the Inverter PWB (Figure 4).
2 Remove the Inverter PWB.
Figure 4
Replacement

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

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 11.4.2 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

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

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

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 11.5.2 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

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 11.6.2 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

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

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 5020 4-95 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 4-96 WorkCentre 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 5020 4-97 ADJ 11.1.1
ADJ 11.1.1 4-98 WorkCentre 5020
5 Parts Lists
Overview PL 8.3 Control Panel Accessory...................................................................................... 5-31
Introduction ..................................................................................................................... 5-3 PL 8.4 Control Panel Component.................................................................................... 5-32
Subsystem Information ................................................................................................... 5-4
Symbology ...................................................................................................................... 5-5
Cover
PL 9.1 Front / Top Cover................................................................................................. 5-33
Parts Lists PL 9.2 Rear / Right Cover and NOHAD Fan ................................................................... 5-34
Drive IIT
PL 1.1 IOT Motor............................................................................................................. 5-7 PL 10.1 IIT Accessory ..................................................................................................... 5-35
PL 10.2 IIT Component (1 OF 2)..................................................................................... 5-36
Paper Transport PL 10.3 IIT Component (2 OF 2)..................................................................................... 5-37
PL 2.1 Tray 1................................................................................................................... 5-8 PL 10.4 IIT Upper Cover Cover Component ................................................................... 5-38
PL 2.2 Tray 1 Frame Accessory...................................................................................... 5-9 PL 10.5 IIT Under Cover Component.............................................................................. 5-39
PL 10.6 IIT Carriage Component .................................................................................... 5-40
Paper Tray
PL 10.7 Center Plate Component ................................................................................... 5-41
PL 2.3 Tray 1 Components (1 OF 2) ............................................................................... 5-10
Single Tray Module
Paper Transport
PL 11.1 Single Tray Module ............................................................................................ 5-42
PL 2.4 Tray 1 Components ( 2 OF 2).............................................................................. 5-11
PL 11.2 Tray 2 Component (1 OF 3)............................................................................... 5-43
PL 2.5 Tray 1 Frame Components.................................................................................. 5-12
PL 2.6 Tray 1 Frame Components (2 OF 2) ................................................................... 5-13
PL 2.7 No Paper Sensor Housing ................................................................................... 5-14
PL 11.5 Single Tray Frame Component (1 OF 2) ........................................................... 5-46
PL 2.8 Registration.......................................................................................................... 5-15
PL 11.6 Single Tray Frame Component (2 OF 2) ........................................................... 5-47
PL 2.9 Registration Component ...................................................................................... 5-16
PL 11.7 STM No Paper Sensor....................................................................................... 5-48
ROS
Stand
PL 3.1 ROS ..................................................................................................................... 5-17
PL 12.1 Stand Component .............................................................................................. 5-49
CRU
Common Hardware
PL 4.1 Drum Cartridge .................................................................................................... 5-18
Common Hardware ......................................................................................................... 5-50
PL 4.2 Toner Empty Sensor and Erase Lamp ................................................................ 5-19
Part Number Index .......................................................................................................... 5-51
PL 4.3 Transfer ............................................................................................................... 5-20
PL 4.4 Transfer Corotron Housing Component............................................................... 5-21
Fuser
PL 5.1 Fuser.................................................................................................................... 5-22
Exit Transport
PL 6.1 Exit Transport ...................................................................................................... 5-23
PL 6.2 Exit Transport Component (Simplex)................................................................... 5-24
Simplex / Duplex Module and Bypass Tray

PL 7.1 Simplex Module ................................................................................................... 5-25
PL 7.2 Left Hand Cover Assembly .................................................................................. 5-26
PL 7.5 Bypass Tray Accessory ....................................................................................... 5-27
PL 7.6 Bypass Tray Component ..................................................................................... 5-28
Electrical
PL 8.1 AIOC PWB, LVPS, Power Switch........................................................................ 5-29
PL 8.2 HVPS, Interlock Switch, Duplex PWB ................................................................. 5-30
Initial Issue July, 2007 Parts Lists

WorkCentre 5020 5-1
Parts Lists July, 2007 Initial Issue
5-2 WorkCentre 5020
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 illus-
tration. All the parts in a given subsystem of the machine will be located in the same illustration Table 2
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 informa-
tion 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
07/26/2007 Parts List

WorkCentre 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 list-
ing of the contents of the assembly.
Brackets
A bracket is used when an assembly or kit is spared, but is not shown in the illustration. The
item number of the assembly or kit precedes the bracket; the item numbers of the piece parts
follow the bracket.
Tag
The notation “W/Tag” in the parts description indicates that the part configuration has been
updated. Check the change Tag index in the General Information section of the Service Data
for the name and purpose of the modification.
In some cases, a part or assembly may be spared in two versions: with the Tag and without the
Tag. In those cases, use whichever part is appropriate for the configuration of the machine on
which the part is to be installed. If the machine does not have a particular Tag and the only
replacement part available is listed as “W/Tag”, install the Tag kit or all of the piece parts. The
Change Tag Index tells you which kit or piece parts you need.
Whenever you install a Tag kit or all the piece parts that make up a Tag, mark the appropriate
number on the Tag matrix.
Parts List 07/26/2007

Subsystem Information 5-4 WorkCentre 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 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 draw-
the tag number within the circle (Figure 3). Information on the modification is in the Change Tag ing was the configuration before being changed by the tag number within the circle (Figure 4).
Index.
Figure 4 Entire Drawing Without Tag Symbol

Figure 3 Entire Drawing With Tag Symbol

Symbology 5-6 WorkCentre 5020
PL 1.1 IOT Motor
Item Part Description
1 007K94880 IOT Motor (REP 1.1.1)
2 120E22470 Push Tie
3 – Gear Pulley
4 – Cover
5 – Belt
6 – Traceability Label (Not Spared)

WorkCentre 5020 5-7 PL 1.1
PL 2.1 Tray 1
1 050K57460 Tray 1 Assembly
2 – Tray Stopper
3 – Label (Not Spared)

PL 2.1 5-8 WorkCentre 5020
PL 2.2 Tray 1 Frame Accessory
1 – Tray 1 Frame
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

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 2.4 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)

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 2.6 Tray 1 Frame Components (2
OF 2)
1 – Tray Spacer (Not Spared)
2 – Enclosure Plate (Not Spared)
4 005E18630 Coupling Clutch
5 006K25750 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)

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 2.8 Registration
1 059K48250 Registration Roll Assembly (REP
2.8.1)

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 3.1 ROS
1 062K18161 ROS Assembly (REP 3.1.1)
2 – Laser Housing (Not Spared)
4 – ROS Wire Harness
5 – Ground Harness (Not Spared)

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 604K43850 CRU Blocker Kit

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)

PL 4.3 Transfer
1 – Transfer Module (Not Spared) (REP
4.3.1)
2 125K93751 Transfer Corotron Housing
3 014K83122 Corotron Block Assembly

PL 4.4 Transfer Corotron Housing
Component
1 125K93751 Transfer Corotron Housing
2 604K43810 Corotron Wire Kit (REP 4.4.1)
3 – Spring (P/O Item 2)
4 – Outboard Cover (Not Spared)
5 – Latch (Not Spared)
6 – Corotron Wire (P/O Item 2)

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 6.1 Exit Transport
1 059K48230 Exit Transport (Simplex) (REP
6.1.1)

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)
8 – Bearing (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 7.1 Simplex Module
1 802K99450 Simplex Module (REP 7.1.1)

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

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 (P/O Item 22)
25 022E29860 Nudge Roller
26 604K45750 MSI Assembly No. 2 Repair Kit

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

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
9 960K31862 AIOC PWB (110V) (REP 8.1.1)
– 960K31863 AIOC PWB (220V) (REP 8.1.1)
10 105E17391 LVPS (220V) (REP 8.1.2)
– 105E17411 LVPS (110V)
11 – Choke Coil (Not Spared)
12 – Power Cord (Not Spared)

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)

PL 8.3 Control Panel Accessory
1 – Support Bracket (Not Spared)
2 – Control Panel Cover (Not Spared)
3 962K66150 Control Panel Wire Harness
4 848K04903 Control Panel (110V, 220V) (REP
8.3.1)
5 – Label (Not Spared) (WorkCentre
5020)

PL 8.4 Control Panel Component
1 – Control Panel Panel Case (With
Key) (P/O PL8.4 Item 1)
2 960K32601 UI Platen PWB Assembly (REP
8.4.1)
3 – Middle Panel (P/O PL8.4 Item 1)
4 – Label (P/O PL8.4 Item 1)

PL 9.1 Front / Top Cover
1 848E04480 Exit Cover
2 604K46510 Front Cover Plate Kit
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 9.2 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 127K51631 NOHAD Fan
4 053E93650 Ozone Filter
5 – Data Plate (Not Spared) (Remove
Data Plate and Place on New Rear
Cover)

PL 10.1 IIT Accessory
1 – IIT Right Bracket (Not Spared)
2 – IIT (Not Spared)
4 – Platen Cover (P/O Item 8)
5 004E17510 Platen Cushion
6 – Cap (Not Spared)
7 – Label (Not Spared) (Error Code)
8 604K46500 Platen Cover Kit (REP 10.1.1)

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)

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 10.4 IIT Upper Cover Cover
Component
1 848E18960 IIT Upper Cover
2 090E02380 Small Platen Glass
3 090E91720 Platen Glass
4 815E08650 White Referance
5 815E42250 Sheet (Black and White)

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 10.6 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)

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)
20 – Wire Harness (P/O PL10.3 Item 1)
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 11.1 Single Tray Module
1 050K57701 Tray 2 (REP 11.1.1)
2 – Single Tray Frame (Not Spared)
3 – Label (End Guide) (Not Spared)
4 – Label (Caution) (Not Spared)
5 – Label (Instructon) (Not Spared)

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)
5 – Earth Plate (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)

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)

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 11.5 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
20 809E74030 Feed Sensor Spring
21 – Access Cover 2

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)
14 – Bearing (Not Spared)

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)

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)

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)

Common Hardware 5-50 WorkCentre 5020
Part Number Index Table 1 Part Number Index
Part Number Part List
Table 1 Part Number Index
059K48200 PL 2.6
Part Number Part List 059K48230 PL 6.1
003K15530 PL 11.4 059K48250 PL 2.8
003K15540 PL 11.4 059K48260 PL 7.5
004E17510 PL 10.1 059K48430 PL 11.4
005E18630 PL 2.6 059K48440 PL 11.6
006K25750 PL 2.6 059K48660 PL 11.4
007K94880 PL 1.1 059K53230 PL 2.9
007K97780 PL 2.2 059K54730 PL 7.5
007K97790 PL 2.2 059E99331 PL 6.2
013E25881 PL 2.3 062K18161 PL 3.1
013E25920 PL 2.2 068K53590 PL 11.6
013E30050 PL 6.2 090E02380 PL 10.4
013E32180 PL 11.6 090E91720 PL 10.4
013E32690 PL 2.6 101R00432 PL 4.1
013E90840 PL 11.4 105E12210 PL 9.1
013E90840 PL 11.6 105E17391 PL 8.1
013E90840 PL 2.6 105E17401 PL 8.2
014K83122 PL 4.3 105E17411 PL 8.1
014K83141 PL 8.2 106R01277 PL 4.1
017E12010 PL 12.1 110E11320 PL 8.1
017K93121 PL 12.1 110E11551 PL 10.5
017K93132 PL 12.1 110E11580 PL 11.5
017E98760 PL 12.1 110E11580 PL 2.5
019K07086 PL 2.4 120E22470 PL 1.1
019K08890 PL 7.6 120E23791 PL 2.7
019K09250 PL 11.4 120E28091 PL 11.5
022E29860 PL 7.5 120E29540 PL 2.5
022E30121 PL 5.1 120E29630 PL 11.7
022K74110 PL 5.1 121E20950 PL 7.5
038K89761 PL 11.3 121K39710 PL 2.9
038K89821 PL 11.3 121K40770 PL 2.2
041K95870 PL 10.3 121K41690 PL 10.6
050K57460 PL 2.1 121E93360 PL 12.1
050K57701 PL 11.1 122E92530 PL 5.1
050K58051 PL 7.6 122E92550 PL 5.1
053E93650 PL 9.2 122E92570 PL 10.6
055K31090 PL 11.5 122K94091 PL 4.2
059K32773 PL 2.3 125K93751 PL 4.3
059K33051 PL 2.3 125K93751 PL 4.4
059K43000 PL 6.2 126K23581 PL 5.1

WorkCentre 5020 5-51 Part Number Index
Table 1 Part Number Index Table 1 Part Number Index
Part Number Part List Part Number Part List
126K24411 PL 5.1 807E18410 PL 11.6
127K51631 PL 9.2 807E19430 PL 2.2
127K52180 PL 11.6 807E19440 PL 2.2
127K57140 PL 10.6 807E19450 PL 2.6
130K71230 PL 2.9 807E19460 PL 2.6
130K71361 PL 5.1 809E54170 PL 2.4
130K71400 PL 4.2 809E54180 PL 2.6
130E87090 PL 11.5 809E73520 PL 2.2
130E87090 PL 6.2 809E74030 PL 11.5
130E87090 PL 11.7 809E76520 PL 6.2
130E87090 PL 2.7 809E79910 PL 10.3
130E87090 PL 2.5 809E79920 PL 10.3
140E88751 PL 10.7 815E08650 PL 10.4
413W77559 PL 2.6 815E42250 PL 10.4
604K43810 PL 4.4 848K01660 PL 2.2
604K43820 PL 7.5 848K02140 PL 11.6
604K43830 PL 7.6 848E04451 PL 9.2
604K43840 PL 6.2 848E04480 PL 9.1
604K43850 PL 4.1 848E04501 PL 9.2
604K43860 PL 7.2 848E04511 PL 9.1
604K43870 PL 7.2 848K04903 PL 8.3
604K44330 PL 10.2 848K07410 PL 10.2
604K45740 PL 7.6 848E18960 PL 10.4
604K45750 PL 7.5 868E12730 PL 10.6
604K45760 PL 7.6 960K28562 PL 11.5
604K45770 PL 7.5 960K31862 PL 8.1
604K45780 PL 7.5 960K31863 PL 8.1
604K45790 PL 7.5 960K32601 PL 8.4
604K46500 PL 10.1 962K59950 PL 10.3
604K46510 PL 9.1 962K66150 PL 8.3
801E04660 PL 9.1
801E05970 PL 10.5
801K25570 PL 8.2
801K25580 PL 2.2
801K30780 PL 10.5
802K99450 PL 7.1
807E17870 PL 7.5
807E18360 PL 11.6
807E18380 PL 11.6
807E18390 PL 11.6
807E18400 PL 11.6

Part Number Index 5-52 WorkCentre 5020
6 General Procedures
Diagnostics
Diagnostic Mode ............................................................................................................. 6-3
Basic Operations of the Diagnostic Mode ....................................................................... 6-4
IOT Diagnostics............................................................................................................... 6-5
General Procedures
GP1 Serial Number Locations......................................................................................... 6-31
General Information
Specifications .................................................................................................................. 6-33
Tools ............................................................................................................................... 6-38
Consumables .................................................................................................................. 6-39
Glossary of Terms........................................................................................................... 6-39
Initial Issue July, 2007 General Procedures

WorkCentre 5020 6-1
General Procedures July, 2007 Initial Issue
6-2 WorkCentre 5020
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 5020 6-3 Diagnostic Mode
Basic Operations of the Diagnostic Mode How to Input the Chain and Function
The following shows the Chain and Function input method in the Diagnostic Mode.
A Chain/Function Code must be input as 2 digits. If the Chain/Function Code is "1,"

it must be input as "01." Any input value that goes beyond the 2nd digit will be ignored.
To clear the Chain/Function Code that was input, press the "C" button.
Both digits will be cleared, and you will be returned to the Code input screen.
When inputting the Function Code, pressing the [Start] button after inputting a Function Code
that is out of the specified range will transfer you to the initial screen of Function input.
Enter the Diagnostic Mode and check that the "C_ " (Chain Code input screen) is shown on the
display. The "_" should be blinking.
Display: Displays the menus and their results.
Keypad: Inputs Chain Function Codes.
[Start] button: Displays the Diagnostics Menu.

C _
[Stop] button: Pauses/Stops the diagnostic.
Use the keypad to enter the 2-digit Chain Code.
The first number will appear in the first digit space, and the "_" will move to the right.
How to Enter the Diagnostic Mode

Press and hold down the [0] button on the keypad for 4 seconds or longer, and then press (and
quickly release) the [Start] button while still keeping the [0] button pressed. C 1 _
Once in the Diagnostic Mode, "C_ " (Chain Code input screen) is shown on the display.
The "_" is blinking.
Input the next number, and it will appear in the second digit space.
C _
C 1 2
How to Exit the Diagnostic Mode

Switch the machine OFF and then ON again.

6-4 WorkCentre 5020
Pressing the [Start] button will show the "F_ " (Function Code input screen) on the display. IOT Diagnostics
An "F" and the blinking "_" are shown on the Function Code input screen.
Input Diagnostics
The Input Diagnostics can be used to check the status of the various sensors in the engine, IIT,
F _ and Trays.
Pressing the [Stop] button will stop the monitoring and return you to the Function Code input
screen. To resume the monitoring, press the [Start] button again.
Use the keypad to enter the 2-digit Function Code.
Chain Func Sub Contents of Data Meaning
01 01 PH L/H (Left Side) L: Cover is closed

COVER H: Cover is open
F 2 _ 01 10 TRAY STM (Tray 2) L/H
COVER
L: Cover is closed
H: Cover is open
01 11 PH L/H (Tray 1) LOW L: Cover is closed
Pressing the [Start] button will then run the specified Diagnostic Code. COVER H: FCover is open
01 12 PH FRONT COVER L: Cover is closed
H: Cover is open
F 2 3 05 10 IIT Platen COVER Open L: Cover is closed

H: Cover is open
05 11 IIT Carriage Home Sensor L: Sensor is exposed
How to Interrupt a Diagnostic H: Sensor is blocked
Press the [Stop] button when the diagnostic is still running. 07 07 TRAY Tray1 No Paper Sensor L: Paper present
Stopping a diagnostic that is running will return you to the Function Code input screen.
H: No paper
07 08 TRAY STM No Paper Sensor L: Paper present
Pressing the [AC] button will return you to the Chain Code input screen (“C_”).
H: No paper
08 05 PH IOT Regi Sensor L: No paper
H: Paper present
08 06 TRAY STM Feed Sensor L: No paper
H: Paper present
08 07 TRAY Tray1 Feed Sensor L: No paper
H: Paper present
08 47 TRAY FEED READY Level is high
SIGNAL Hot-Line Control
09 02 XERO Drum Cartridge L: No Drum Cartridge
Detected H: Cartridge present

WorkCentre 5020 6-5
Chain Func Sub Contents of Data Meaning Chain Func Sub Contents of Data Meaning
09 07 XERO Toner Empty Sensor L: Toner available 05 20 IIT Carriage Motor High Move the Carriage in the
H: Toner depleted Speed scan scan direction at 80mm/
sec. NOTE: After the
10 23 PH Fuser Exit Sensor L: No paper
scan, the Carriage stops
H: Paper present
beyond the end position.
10 60 FUSER Nohad Fan Fail Monitor L: Able to monitor FUSER Pressing the [Start] but-
FAN FAIL ton again returns the Car-
H: Unable to monitor riage to the home
FUSER FAN FAIL position. After another
scan, the Carriage stops
Output Diagnostics beyond the end position.
Turn the power off and on
The Output Diagnostics can be used to operate and check the status of the various motors,
solenoids and clutches in the engine, IIT, and Trays. The operation can be enabled for every to return the Carriage to
component, and whether or not the component is operating properly can be determined by the home position.
checking the operation from outside.
05 21 IIT Carriage Motor High Move the Carriage
When a component is operating, "run" is displayed. Speed return toward home position at
80mm/sec. NOTE: See
05-20.
05 22 IIT Carriage Motor Low Move the Carriage in the
r u n Speed scan scan direction at 40mm/
sec. NOTE: See 05-20.
05 23 IIT Carriage Motor Low Move the Carriage
Pressing the [Stop] button will stop the operation of the component and return you to the Func- Speed return toward home position at
tion Code input screen.
40mm/sec. NOTE: See
05-20.
06 15 ROS ROS Motor ON ROS Motor Start & Stop
F 2 3 08 10 PH IOT Registration
Clutch
08 11 TRAY STM Feed Clutch
To resume the operation of the specified component, press the [Start] button again.
08 12 TRAY Tray1 Feed Clutch
08 13 TRAY STM Feed Motor
04 01 PH IOT Motor ON 08 17 PH Bypass Solenoid
04 02 FUSER Nohad Fan Motor Fuser Fan changes from 09 04 XERO HVPS ON (LOW
(HIGH SPEED) Low to High speed VOLTAGE)

6-6 WorkCentre 5020
Clearing the error will return you to the Function Code input screen.
09 05 XERO HVPS ON (HIGH

VOLTAGE)
09 06 XERO Pre-Charge Erase
Lamp
F _
To resume the test print, press the [Start] button again.
Program Function
The Program Function can access the NVM (the EEPROM on the AIOC PWB) to perform the Pressing the [Stop] button in the middle of a test print will stop the feeding of additional paper,
following functions: output any paper that was already fed, and return you to the Function Code input screen.
• Test Print Initialize NVM [20-58]

• Initialize NVM
• Check Error History This will return the NVM settings to their default values.
• Check Print Count
While the NVM is being initialized, "run" is displayed.
• Display Version
• Clear Error History
• Display Serial Number, Product Number
Test Print [23-10], [23-01]

r u n
There are two test print modes: one that outputs the Controller built-in pattern, and another that
outputs the MCU built-in pattern. When NVM initialization is complete, you will be returned to the Function Code input screen.
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
Once the test print starts, an error code will be displayed if an error occurs while printing.
C 1

WorkCentre 5020 6-7
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

6-8 WorkCentre 5020
Display Product Code [25-21]
This can be used to display the product code of the machine.
Pressing the [Start] button will display the product code, starting from the highest order (left-
most) digit.
Once the whole product code has been displayed, you will be returned to the Function Code
input screen.
F _

WorkCentre 5020 6-9
Summary of Program Functions
Chain Function Sub Contents of Data Meaning
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.

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.

List of NVM Settings
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: 11”x17” SEF
2: A3 SEF
3: 8K SEF*1
5: B4SEF
6: 8.5”x14” SEF(Legal)
7: 8.5”x13.4” SEF(Mexico Folio)
8: 8.5”x13” (Folio)
10: A4 SEF
11: 8.5”x11” SEF(Letter)
12: 16K SEF*1
15: B5 SEF
17: 8.5”x11” LEF(Letter)

CE
Access
Func Initial
07 47 TRAY Tray2-paper size 0~254 1mm 2 O O O value paper type

1: 11”x17” SEF
2: A3 SEF
3: 8K SEF*1
5: B4SEF
8: 8.5”x13” (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: 11”x17” SEF
2: A3 SEF
3: 8K SEF*1
5: B4SEF
8: 8.5”x13” (Folio)
10: A4 SEF
12: 16K SEF*1
15: B5 SEF
18: 5.5”x8.5” 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.

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

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.)

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)

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.)

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

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)

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

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

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

CE
Access
Func Initial

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

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

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

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

CE
Access
Func Initial


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

CE
Access
Func Initial

60 36 Product Product code 1 0~254 1 0 O X X

GP1 Serial Number Locations
The Serial Number is located in three places on the machine:
NOTE: If the Rear cover has to be replaced, do not worry about saving the data plate (which
has the machine serial number), since the serial number can be found in two other locations.
• On the Data Plate on the Rear Cover.

• In software on the machine. The serial number can be displayed by accessing Diagnos-
tics (How to Enter the Diagnostic Mode) and entering NVM code [25-20].
• On a bar code sticker at the left rear of the machine, which can be seen by opening the
Left Side Cover and looking toward the back.

WorkCentre 5020 6-31 GP1
GP1 6-32 WorkCentre 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 Ternimal)
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, out- Standard memory SDRAM 64M TBD --
puts image data to the computer. Serial EEPROM 4Mbit TBD --
Extended slot Not supported TBD --
Standard Specification of Host
Table 3
Item Description GDI
Host I/F USB (2.0) x 1 Yes
Product Codes
Table 4
Product XJ IOT Prt/
Code Code CODE Model speed Scan Dup IIT Platen ADF FINAL ASSY

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
Warmup Time – Paper size and feeding orientation: A4 or 8.5x11 LEF
In an ambient environment of 22°C 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. Read Rate

After a certain amount of time in Standby Mode, the machine enters Low Power Mode. This TBD
time can be changed by a software program (setting range: 0-240 minutes). The factory
default is 5 minutes. Software Download
Controller Part: User can upgrade the software by downloading the object from the PC.
Low Power Mode is cancelled when a button is pressed on the Control Panel or when a printer
job is received. IOT Engine Part
MCU: Replacing the board. Optional Tray: Replacing the board.
Sleep Mode (Off Mode)
The machine operates as follows to save power when the machine is in Low Power Mode for a Count-up for Print/Copy jobs: GDI
specified time:
The purpose of the Count-up Meter is to categorize the number of sheets of print output by
print job, copy job, and test prints (Diagnostic Mode). The NLM Count-up Meter is not guaran-
• Control Panel: LED: OFF, Power Save Button: ON teed as a meter for billing purposes. The Count-up Meter is managed by the device unit and
• Device Control: Power is turned off (except for warmup). can be confirmed with device UI.
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 The Count-up Meter has only one total counter.
minutes.
Table 6
Sleep mode is cancelled when a button is pressed on the Control Panel or when a printer job is
Job type Counter type Description
received. When Sleep Mode is cancelled, the machine returns to Standby Mode.
Copy Total Counter Counter of copy job
Time to transfer to Standby Mode shall be 45 seconds or less (on standard configuration). Print Counter of print job
Diag Test print in Diag mode
FCOT (Warm Start) (It doesn't contain the Diag test print with Type-Di.)
FCOT: First Copy Output Time
Report: One (Printer).

GDI: not supported. TEC Method (New E-Star)
Timing of Count-up Table 10

MCU increments the billing counter when the trail edge of the paper passes the Exit Sensor. Config TEC
GDI Network
The number of counter increments is as follows:
DC20 3.0Kwh -
Table 7 CP20 6.0Kwh -
Paper size Number of counter increments

Machine Size/Weight
Billing Life
The machine specified below does not include a drum and toner cartridge.
A3, B4, 8K, 11x17, Non-fixed 1 2
A4 or less (A4, Letter, ....) 1 1 1. Size
Electrical/Mechanical Characteristics Table 11
Electrical Characteristics Type Width (mm) Depth (mm) Height (mm)

IOT 595+/-5 532+/-5 505+/-5
Table 8 IOT+IIT (Platen Glass) 595+/-5 532+/-5 528+/-5
Input Voltage Frequency Rated input cur- Power Con- Sleep Mode
(VAC) (Hz) rent Max (A) sumption* (Off Mode)
[Optional Devices]
Spec (VA) Reference
220 - 240V 240+10% 50/60+/-3 Hz 6A 1320VA (Max) 6 W (Max) Table 12
220-10%
Width (mm) Depth (mm) Height (mm)
110 - 120V TBD TBD TBD TBD TBD
STM (500 Sheets) 551+/-5 522+/-5 130+/-5
*Power consumption is specified assuming full configuration. Stand 551+/-5 506+/-5 385+/-5
Rated Power Consumption Size of Package: 710x660x716 (mm)

[GDI]
2. Weight
Table 9
Mode Power consumption Table 13
Main body Configuration
In Low Power Mode DC: 43W or less
CP: 107W or less Platen: Net weight (includ- 33.02 Kg Platen/IIT/MSI/Std Tray (250sheets) including
In Sleep Mode (Off Mode) DC: 6W or less ing toner cartridge) toner cartridge
CP: 20W or less (TBD) Gross weight (with Pack- 48.5Kg
At operation 110V age) (Reference)
(During printing operation) 12A, 1320VA (Max) STM 8.8 Kg Optional tray: 500sheets
220/240V Toner cartridge 1.2 Kg
6A, 1320VA (Max)
Net weight (full configura- 38.0 Kg TBD IIT/MSI/Std Tray (250sheets) including toner car-
tion) tridge
Stand 18 Kg TBD

Noise (Sound Power Level: LWAd) Table 16
Unit: B 8.5"x13"SEF 8.5"x14" 12 12 10
SEF
Table 14 Mexico Folio
(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
Full System 4.0 6.8 B4 SEF
A5 SEF Not supported 10
Impulse Sound Power (FX) Impulse Sound Power Level (LWAI) 5.5" ( 8.5" SEF) 10
LWAI B(A) A5 LEF Not supported
5.5" x 8.5" LEF
Table 15
Base Machine 6.6
Full system 7.1 Alignment
1. Full system] IOT+IIT+ADF
Chemical Substances
1. Levels of Ozone: Table 17
Ozone formed from this product: less than 0.02 mg/m3 (according to C11-705) Item Specification Measurement Length
Eco-Mark Requirement: 0.02 mg/m3
2004 Version Green Target A Limit: 0.015 mg/m3
2. Airborne Dust Concentration: Skew H [mm] +/-2.3 200mm
Inhaled airborne dust from this product: less than 0.08 mg/m3 (according to C11-705) Perpendicularity [mm] +/-3.7 400mm
Eco-Mark Requirement: 0.075 mg/m3 Linearity: V [mm] 2.3 400mm
2004 Version Green Target A Limit: 0.04 mg/m3 Linearity: H [mm] 2.3 280mm
Copy Speed Linearity: D [mm] 2.3 280mm
Registration: Lead [mm] +/-2.9
Continuous copy speed at 100% magnification.
Registration: Side [mm] +/-3.4
Measurement method: Make 11 continuous copies. Measure the time (T, in seconds) from the Magnification: V (%) +/-1.4 (100%) 400mm
output of the trail edge of the first sheet of paper to the output of the trail edge of 11th sheet of +/-1.56 (50%-99%)
paper, and convert into copies per 60 seconds: CPM = T/60 (normal paper mode). +/-1.8 (101%-200%)
Magnification: H (%) +/-1.4 (100%) 280mm
Table 16 +/-1.56 (50%-99%)
Paper Size Paper Tray +/-1.8 (101%-200%)
and Tray 1 STM (Add 1 Tray) MSI
Paper Orientation Fixed Mode
Plain Paper Plain Paper 2. [DC] IOT+IIT (TBD)
A4 LEF 20 20 10
Table 18
8.5" x 11" LEF
Item Specification Measurement Length
16K LEF
B5 LEF
Simplex MSI
A4 SEF 15 15 10
8.5" x 11" SEF Skew H +/-2.0 +/-2.3 200mm
16K SEF Perpendicularity +/-3.1 +/-3.3 400mm
B5 SEF Linearity: V 1.6 -- 400mm

Table 18 Bypass Tray(MSI)
Linearity: H 1.6 -- 280mm 1. Capacity
Linearity: D 1.6 -- 280mm 50 sheets of paper (70 gsm)
Registration: Lead +/-2.5 +/-3.2 2. Paper size and paper orientation
Registration: Side +/-3.1 +/-3.3 Size and orientation of paper set on MSI shall be as follows: A4L/S, A3, B5L/S, B4, 8K,
Magnification: V (%) +/-1.0 (100%) -- 400mm 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
+/-1.2 (50%-99%) 3. Paper weight
+/-1.5 (101%-
Weight of paper that can be supplied from MSI is 60g/m2 to 110g/m2.
200%)
4. Usage rate
Magnification: H (%) +/-1.0 (100%) -- 280mm
10%
+/-1.2 (50%-99%)
+/-1.5 (101%-
200%)
Paper Supply
All paper trays (excluding MSI) are universal trays, which are front-loading trays.
1. Capacity
Tray 1: 250 sheets (Business 80gsm/sheet).
The height of a stack of paper shall be 27mm or less.
STM (optional): 500 sheets (Busines 70gsm/sheet).
450 sheets (Business 80gsm/sheet).
The height of a stack of paper shall be 54mm or less.
2. Standard paper
Standard paper is indicated by "Standard Paper" on "Paper List."
3. Weight
Tray 1: 60gsm to 90gsm
STM: 60gsm to 90gsm
4. Size
Standard paper sizes: A4L/S, A3, B5L/S, B4, 8K, 16KL/S, 8.5 x11L/S, 8.5 x 13, 8.5 x 13.4
(Mexico Folio), 8.5 x 14, 11 x 17
5. Usage rate
Tray 1: 60%
STM: 30%

Paper List Tools
Most maintenance procedures can be done with the following standard tools:
Table 19
Media Type Paper Code CIM Bypass Table 1
Flag Ship (80 gsm) O O No. TOOL NO. /TOOL NAME No. TOOL NO. /TOOL NAME
Baseline Paper Xerox Business Multipurpose 4200 1 499T 1423 BOX DRIVER 5.5 8 499T 247 TEST PATTERN (A3)
20 lb O O 2 499T 355 SCREWDRIVER (+) 9 499T 301 MINI DRIVER
Xerox Xcite (80 gsm) O O 3 499T 2004 ROUND NOSE PLIERS 10 499T 1901 SIDE CUTTING NIPPER
4 499T 2320 S/E TESTER SET
Xerox Xplore (70 gsm) O O 5 499T 2601 SILVER SCALE (ISO M/N) 12 499T 9507 TESTER LEAD WIRE
(Red)
Xerox Premier (80 gsm) O O
6 499T 8104 FLASHLIGHT (UM-2) 13 499T 9508 TESTER LEAD WIRE
Xerox Business (80 gsm) O O
(Black)
Flag Ship (70/80 gsm) O O
7 499T 8902 BRUSH 14 499T 353 * STUBBY DRIVER
Standard Paper Canary (70/80 gsm) O O

* 499T 353 STUBBY DRIVER should be used when replacing the ROS ASSEMBLY.
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 O
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
User selects the paper tray that contains the required type of paper (size and orientation).

Consumables Glossary of Terms
Machine CRU Strategy
Table 1
Machine LCB is designed to interface with a CRUM and Billing Counter on all configurations.
The CRUM can be used to provide a "hard stop" capability for markets requiring this feature. Term Description
The primary uses of the CRUM are to ensure that the CRU being used is correct for the market A3 Paper size 297 millimeters (11.69 inches) x 420 millimeters (16.54 inches).
& service/warranty agreements, store the number of copies made on the CRU, and enforce the
A4 Paper size 210 millimeters (8.27 inches) x 297 millimeters (11.69 inches).
end-of-life point. The primary uses of the Counter are to indentify the machine's market loca-
tion, electronically store the machine's serial number, and store the number of copies made on AC Alternating Current is type of current available at power source for machine.
the machine. ACT Advanced Customer Training: teaches customers to perform some of service that is
normally performed by Xerox Service Representative.
Consumable Replacement Intervals (TBD) A/D Analog to Digital refers to conversion of signal
ADF Automatic Document Feeder
Table 1 ADJ Adjustment Procedure
ITEM YIELD/LIFE STRATEGY/REPLACEMENT Bit Binary digit, either 1 or 0, representing an electrical state.
Toner 6K @ 5% area coverage of A4 size Warning/Hard Stop CCD Charge Coupled Device (Photoelectric Converter)
Test pattern - Warning with approximately 100 CD 1: Circuit Diagram; 2: Compact Disc
copies of toner remaining. CF Copier Fax
Drum Car- Hard Stop: 22K @ 5% A4 area cover- End of life Warning/Hard Stop CP Copier Printer
tridge age for XC - Warning at 16K CPF Copier Printer Fax
Job Size = 4 pages Hard Stop at 22K (XC)
Chip Integrated Circuit (IC)
CRU Customer Replaceable Unit
This specification is applied when the machine is operated under the following conditions:
CVT Constant Velocity Transport
– Paper: A4 LEF DADF Duplexing Automatic Document Feeder
– Paper Tray: Tray 1 DC Direct Current is type of power for machine components. Machine converts AC
power from power source to DC power.
– Copy Mode (not Print Mode)
DC Digital Copier
DMM Digital Multimeter is generic name for meter that measures voltage, current, or elec-
trical resistance.
Duplex 2-sided printing or copying
EME Electromagnetic Emissions are emitted from machine during normal operation and
power of these emissions are reduced by machine design features.
ERU Engineer Replaceable Unit
ESD Electrostatic Discharge. A transfer of charge between bodies at different electrostatic
potential.
FS Fax Scanner
FS Fast Scan (direction) - Inboard - to - Outboard
ESS Electronic Sub-System
ENG English
2TM Two Tray Module
FAX Facsimile
FIC Final Integration Center
GND Ground
HFSI High Frequency Service Item
HVPS High Voltage Power Supply

WorkCentre 5020 6-39 Glossary of Terms
Table 1 Table 1
Term Description Term Description
Hz Hertz (Cycles per second) SCP Service Call Procedure
IIT Image Input Terminal - the Scanner/CCD portion of the machine SEF Short Edge Feed
IOT Image Output Terminal - the ROS/Xero/paper handling/ fusing portion of the Self- An automatic process that is used to check Control Logic circuitry. Any fault that is
machine test detected during self-test is displayed by fault code or by LEDs on PWB.
IQ Image Quality SIMM Single Inline Memory Module used to increase printing capacity
KC 1000 copies Simplex Single sided copies
LCD Liquid Crystal Display FS Fast Scan (direction) - LE - to - TE
LE Lead Edge of copy or print paper, with reference to definition of term TE TE Trail Edge of copy or print paper, with reference to definition of term LE
LED Light Emitting Diode UM Unscheduled Maintenance
LEF Long Edge Feed UI User Interface
LTR Letter size paper (8.5 x 11 inches) USB Universal Serial Bus
LUT Look Up Table - array of NVM locations that store process control data W/ With - indicates machine condition where specified condition is present
LVPS Low Voltage Power Supply W/O Without - indicates machine condition where specified condition is not present
MF Multi-Function XBRA Xerox Brazil
MN Multinational XC Xerox Corporation
MPT Multi Purpose Tray XE Xerox Europe - also referred to as ESG (European Solutions Group)
NBCR New Book Scanner Control Relay XLA Xerox Latin America
NIC Network Interface Card XMEX Xerox Mexico
NSC New Scanner Controller
NVM Non Volatile Memory
OEM Original equipment manufacturer
OGM On-going Maintenance
PC Personal Computer
PL Parts List
PO Part of (Assembly Name)
PS Post Script
PSW Portable Standard Workstation
PWB Printed Wiring Board
PWS Portable Workstation for Service
PJ Plug Jack (electrical connections)
RAM Random Access Memory
RAP Repair Analysis Procedure for diagnosis of machine status codes and abnormal con-
ditions
R/E Reduction/Enlargement refers to features selection or components that enable
reduction or enlargement
REP Repair Procedure for disassembly and reassembly of component on machine
RIS Raster Input Scanner
ROM Read Only Memory
ROS Raster Output Scanner - Device that transfers digitally processed image, using laser
light, to photoreceptor.
SAD Solid Area Density

Glossary of Terms 6-40 WorkCentre 5020
7 Wiring Data
BSDs
Chain 1 Standby Power ................................................................................................. 7-3
Chain 2 Mode Selection ................................................................................................. 7-6
Chain 3 Machine Run Control ........................................................................................ 7-8
Chain 4 Start Power ....................................................................................................... 7-11
Chain 6 Imaging ............................................................................................................. 7-13
Chain 7 Paper Supplying ............................................................................................... 7-17
Chain 8 Paper Transportation ........................................................................................ 7-20
Chain 9 Marking ............................................................................................................. 7-26
Chain 10 Fusing and Copy Transportation .................................................................... 7-30
Wirenets
Wirenets .......................................................................................................................... 7-35
P/J Locations
7.1 P/J Locations............................................................................................................ 7-45
Initial Issue July, 2007 Wiring Data

WorkCentre 5020 7-1
Wiring Data July, 2007 Initial Issue
7-2 WorkCentre 5020
Chain 1 Standby Power

WorkCentre 5020 7-3
A B C D E F G H J
1.1 MAIN POWER GENERATION

AIOC PWB
PL8.1 ALL
J414
1 B6
B5
B3,B4
B1,B2
LVPS
2 PL8.1
A11,A12
CHOKE COIL
PL8.1 DC POWER
J5 GENERATION
2
BLK
J416
3
1
BLK
4
3 LENS ASSEMBLY
POWER 2 PL10.7
POWER CORD SWITCH
PL8.1 PL8.1 10.1 IIT PWB
FS11 FS31 FS32 AC P/J407
ACH ALL
H A16,A17,B J409 +3.3VDC J721
BLK BLK +3.3VDC 4,5 18,17
FS60 BRN 1 16,B17
ACH J410 J720
GN/YL ALL
10.1 1,6,11,15,17, 34,29,24,20,1
AC A14,A15,B DC COM
FS12 ACN FS33 FS34 DC COM 14,B15 19,21,23,25,27 8,16,14,12,10
N ,29,31,34 ,8,6,4,1
T21 WHT WHT
ALL
BLU 2 ALL
4 +5VDC A11,B11 J409 J721
DC COM
1,2 21,20
ALL ALL
AIOC PWB A12,A13,B +5VDC
PL8.1 DC COM 12,B13 6,7 16,15
1.2 ALL ALL
P/J407
ON/ +24VDC A7,A8, +24VDC
B18 9,10,11 13,12,11
OFF B7,B8
F1
ALL
A9,A10, DC COM
DC COM B9,B10 20,21 2,1
5 ALL
STM PWB
Wire Color PL11.5 ALL
1 J508 J540
BLK:100V M/C, BRN:200V M/C +5VDC
1 1
GRY GRY
2 Wire Color ALL
WHT:100V M/C, BLU:200V M/C DC COM
3 2
VIO VIO
ALL
24VRTN
8 5
6 VIO VIO
ALL
+24V
10 7
ORN ORN
Figure 1 1.1 Main Power Generation

7-4 WorkCentre 5020
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
J506 FS151 FS152 COVER OPEN(L) J506 J506 FS153 FS154 COVER OPEN(L) J506 J416
4 +24VDC 3 2 +24VDC 1 1
ORN ORN ORN ORN
F2
+24VDC
(1.1)
2
AIOC PWB
PL8.1 P/J407
A1 E5-2
P/J407 B1
A2 E5-1
INTLK INTLK
+24VDC +24VDC
E5-1 LH Cover
Open
Front Cover
4 E5-2
Open
Fail 1 The H/L level is displayed on the UI

5 Code display.
LH COVER INTERLOCK
SWITCH
FRONT COVER INTERLOCK

SWITCH
Figure 2 1.2 Interlock Switching

WorkCentre 5020 7-5
Chain 2 Mode Selection

7-6 WorkCentre 5020
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

WorkCentre 5020 7-7
Chain 3 Machine Run Control

7-8 WorkCentre 5020
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)

WorkCentre 5020 7-9
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
BILLING U6-4 NVM Read/Write Cannot be

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

Mismatch
Nup NG Out Of
3 U6-5 E8-1
Range
E8-2 Paper Direction

N9-0 Mismatch
L9-0 Copy Counter

N9-1 P/J411 Full
1,2,3, USB
2.0 N4-0 No Response from USB-
E9-1 4,5 Host
N4-1 HBPL or XPJL Syntax

E9-2 Error
4 CPM Image
N4-2
E8-1 Lost
C0-1 APS NG
E8-2 Unselected
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 J504
IOT MOTOR
J201 Fuser CRU
B2 ON(H) +5VDC
4 4
BLU BLU
F3 J201 IOT MOTOR LOCK(H) +5VDC

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

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

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

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

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
‚压Œx 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

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

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
TRAY1 NO PAPER SENSOR P/J407
J157 J203 P203 PAPER SENSED(L) +5VDC J501
LVPS 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

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

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

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

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 BYPASS SOLENOID
J502 ON(L) +24VDC
A5 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

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

C2-3 STM IOT Regi. Sensor on JAM
5 IOT REGI. SENSOR

C9-3 Manual Bypass IOT Regi. Sensor on JAM
E1-6 IOT Regi. Sensor Static JAM
Regi. Roll
6
Figure 4 8.4 Paper Registration

A B C D E F G H J
8.5 PAPER PATH
2
Exit Roll
FUSER EXIT SENSOR
3 Fuser
Regi. Roll IOT MOTOR
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

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

A B C D E F G H J
9.2 TONER SENSE AND CRUM

TONER EMPTY LVPS AIOC PWB
1 SENSOR PL8.1 PL8.1
LVPS PL4.2
PL8.1
J509 P110 J110 J110 P110 J509
1 4 1 2 3 2
BLU BLU RED WHT BLU 9-7 BLU
+5VDC
+24VDC
(1.1) TONER EMPTY SENSOR P/J407
TONER SENSED(L) +5VDC
3 2 3 4 1 4 B4 J1-2
BLU BLU BLK GRN BLU BLU
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 7 1 2
BLU BLU J7-1
3
J7-2
4 3 5 1
BLU BLU 9-2 1 +5VDC
DC COM J7-3
(1.1) DRUM CARTRIDGE
J610 P610 SENSED(L) +5VDC J402
INTLK 5 2 6 4 4 3 J3-1
BLU BLU BLU BLU
+5VDC +24VDC
(1.2)
6.3
INTLK +5VDC INTLK +5VDC
2 5 3 7 1 6
BLU BLU BLU BLU
4 DC COM INTLK
+5VDC
Fail Code 1 The H/L level is displayed 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

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

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

A B C D E F G H J
10.2 EXIT LVPS AIOC PWB

PL8.1 PL8.1
1 FUSER EXIT 10-23 1 +5VDC
SENSOR E1-2
PL6.3 FUSER EXIT SENSOR
J153 J505 P/J407
PAPER SENSED(L) +5VDC
1 3 A3 E3-1
LVPS BLU BLU
PL8.1
E3-6
+5VDC
J505 J153
1 3
2 BLU BLU
2 2
BLU BLU
DC COM
(1.1)
SimplexTransport: Fail Code
Exit Roll is driven by IOT Motor.

E1-2
4 Fuser Exit Sensor on JAM
E3-1
Fuser Exit Sensor off JAM
E3-6
Fuser Exit Sensor Static JAM

Exit Roll
5
1
The H/L level is displayed

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

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

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

7.2.3 WIRE NET +3.3VDC
LOW VOLTAGE LENS ASSEMBLY

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

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)

(FROM WIRE NET +5VDC-1)
LENS ASSEMBLY
IIT PWB
J409 J721 CN3 IIT4 6.2
6 16 6 1 CARRIAGE SENSOR
GRY
7 15
FLAT
CABLE
J416
3
J414
B5
AIOC PWB

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)

(FROM WIRE NET
DC COM (+5VRTN)-1)
LOW VOLTAGE
POWER SUPPLY
AIOC PWB
DRUM CARTRIDGE
P/J407 J402 P610 J610 9.2
A12 4 3 5 1 CRUM
BLU
5 2 6
A13 BLU
J416
B12 4
LENS ASSEMBLY
B13
J409 J721 IIT PWB
1 21
2 20
FLAT
CABLE
J410 J720 CN3 IIT4 6.2

+3.3VRTN A14 1 34 5 3 CARRIAGE 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
CABLE
(SEE WIRE NET
DC COM(+5VRTN)-3)

(FROM WIRE NET
DC COM (+5VRTN)-2)
USER INTERFACE
PWB
J401 J710 J711 6.1
PLATEN OPEN
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
J414
B3
B4
AIOC PWB

FRONT
LH COVER LOW VOLTAGE COVER
LOW VOLTAGE INTERLOCK POWER SUPPLY INTERLOCK
POWER SUPPLY SWITCH SWITCH
J506 FS151 FS152 J506 J506 FS153 FS154
4 3 1 3 2 3 1
ORN ORN ORN ORN
F1
+24VDC
LOW VOLTAGE
POWER SUPPLY
J506 F3 J504 J201 4.1

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

POWER SUPPLY
P/J407 J406 P520 J521 J210 9.3
A1 9 9 2 2 ERASE LAMP
BLU BLU
J416
B1 1
J501 P202 J202 8.1

1 1 2 TRAY1 FEED CLUTCH
BLU
J502 8.3
1 BYPASS SOLENOID
RED
J503 P640 J640 8.4

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

(FROM WIRE NET +24VDC-1)
J509 P110 J110 9.2

TONER EMPTY
1 4 1 SENSOR
BLU RED
AIOC PWB
ROS
P/J407 J403 P620 J620 J130 6.3
A7 7 4 1 5 ROS MOTOR
BLU
A8
LENS ASSEMBLY
B7
IIT PWB
J409 J721 CN4 IIT5 6.2
9 13 5 5 CARRIAGE MOTOR
RED
B8
10 12
CN3 INV CN1 INVERTER PWB 6.2
11 11 1 1
GRY
FLAT
CABLE
J414
B1
B2
LOW VOLTAGE
POWER SUPPLY

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 STM PWB

8 5
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 ASSEMBLY
B8
IIT PWB
J409 J721 CN3 INV CN1 INVERTER PWB 6.2
20 2 3 3
GRY
21 1
FLAT
CABLE
J416
2
J414
A11
A12

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.

7.1.2 P/J List Table 1
Figure
Table 1 P/J No. No. Item No. Description
Figure P/J158 Figure 4 6 Tray 1 Feed Sensor
P/J No. No. Item No. Description P/J160 Figure 2 6 ROS, Video
F25 Figure 5 1 Fuser Thermostat P/J161 Figure 4 5 Tray 1 Interlock Sensor
F26 Figure 5 4 Fuser Lamp P/J171 Figure 6 2 STM No Paper Sensor
F27 Figure 5 3 Fuser Lamp P/J172 Figure 6 1 STM Feed Sensor
F28 Figure 5 2 Fuser Thermostat P/J173 Figure 6 3 STM Interlock Switch
FS11 Figure 9 4 Inlet P/J201 Figure 8 6 IOT Motor
FS12 Figure 9 6 Inlet P/J201 Figure 2 4 ROS, SOS PWB
FS151 Figure 4 8 LH Cover Interlock Switch P/J2011 Figure 2 1 ROS, SOS PWB
FS152 Figure 4 7 LH Cover Interlock Switch P/J202 Figure 8 7 Tray 1 Feed Clutch
FS153 Figure 3 4 Front Cover Interlock Switch P/J203 Figure 8 8 Tray 1 No Paper Sensor
FS154 Figure 3 5 Front Cover Interlock Switch P/J210 Figure 3 1 Erase Lamp
FS31 Figure 9 7 Power Switch P/J212 Figure 6 4 STM Feed Clutch
FS32 Figure 9 1 Power Switch P/J401 Figure 7 6 UI
FS33 Figure 9 3 Power Switch P/J402 Figure 7 11 CRU ID
FS34 Figure 9 2 Power Switch P/J403 Figure 7 12 ROS
FS60 Figure 9 5 Inlet GND P/J404 Figure 7 5 ROS, Video
IIT4 Figure 1 5 Carriage Sensor P/J405 Figure 7 9 Nohad Fan
IIT5 Figure 1 6 Carriage Motor P/J406 Figure 7 8 HVPS
INV CN1 Figure 1 2 Inverter PWB P/J407 Figure 9 16 LVPS-AIOC PWB
INV CN2 Figure 1 1 Inverter PWB P/J408 Figure 7 13 AIOC PWB
J411 Figure 7 1 AIOC PWB P/J409 Figure 7 4 AIOC PWB
J508 Figure 6 8 STM P/J410 Figure 7 3 AIOC PWB
J610 Figure 8 2 CRU P/J414A/B Figure 7 7 AIOC PWB
NBCR CN6 Figure 1 7 NBCR PWB P/J416 Figure 7 10 AIOC PWB
NSC CN1 Figure 1 8 NSC PWB P/J501 Figure 9 13 LVPS
P412 Figure 7 14 AIOC PWB P/J502 Figure 9 10 LVPS
P508 Figure 9 15 LVPS P/J506 Figure 9 11 LVPS
P610 Figure 8 9 CRU P/J509 Figure 9 8 LVPS
P/J3 Figure 9 18 Fuser Lamp P/J520 Figure 3 3 HVPS
P/J5 Figure 9 17 Choke Coil P/J521 Figure 3 2 HVPS
P/J110 Figure 3 6 Toner Empty Sensor P/J540 Figure 6 7 STM
P/J130 Figure 2 2 ROS MPA P/J541 Figure 6 5 STM Feed Motor
P/J140 Figure 2 5 ROS P/J542 Figure 6 6 STM (TOTAL CL, SNR, SW)
P/J153 Figure 4 1 Fuser Exit Sensor P/J600 Figure 4 2 Fuser Lamp
P/J156 Figure 4 4 IOT Regi. Sensor P/J601 Figure 4 3 Fuser Thermistor
P/J157 Figure 3 7 Tray 1 No Paper Sensor P/J620 Figure 2 3 ROS MPA

Table 1
Figure
P/J No. No. Item No. Description
P/J630 Figure 8 1 Billing ID
P/J640 Figure 8 5 IOT Regi Clutch
P/J710 Figure 1 9 UI
P/J711 Figure 1 10 Platen Switch
P/J720 Figure 1 4 IIT Data
P/J721 Figure 1 3 IIT Power

Figure 1 IIT

Figure 2 ROS

Figure 3 HVPS

Figure 4 LH

Figure 5 Fuser

Figure 6 STM

Figure 7 AIOC PWB

Figure 8 Rear

P/
J503
P/
J505
Figure 9 Inlet & LVPS


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WorkCentre 5020 CAUTION

***Xerox Private Data***

©Copyright 2007 Xerox Corporation. All rights reserved.

Global Knowledge & Language Services

800 Phillips Road - Bldg. 845-17S

Webster, New York 14580-9791

Printed in the United States of America.

Initial Issue July, 2007 Introduction

Section 1 Service Call Procedures

Chain 1 Standby Power

Initial Issue July, 2007 Introduction

Initial Issue July, 2007 Service Call Procedures

Initial Issue July, 2007 Service Call Procedures

Service Call Procedures July, 2007 Initial Issue

Initial Issue July, 2007 Service Call Procedures

Initial Issue July, 2007 Status Indicator RAPS

Fault Repair Overview

Check the status of Installation

Check the problem status

Figure 1 Troubleshooting Procedure

Initial Issue July, 2007 Status Indicator RAPS

Status Indicator RAPS July, 2007 Initial Issue

Does the error recur when operating the

Yes Refer to the Error Code List and perform the

Figure 2 RAP Flow

Initial Issue July, 2007 Status Indicator RAPS

Status Indicator RAPS July, 2007 Initial Issue

Initial Issue July, 2007 Status Indicator RAPS

Status Indicator RAPS July, 2007 Initial Issue

Initial Issue July, 2007 Status Indicator RAPS

• Tray1 No Paper Sensor dirty and Sensor Actuator deformed or damaged

Status Indicator RAPS July, 2007 Initial Issue

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

Initial Issue July, 2007 Status Indicator RAPS

Status Indicator RAPS July, 2007 Initial Issue

Initial Issue July, 2007 Status Indicator RAPS

Status Indicator RAPS July, 2007 Initial Issue

Initial Issue July, 2007 Status Indicator RAPS

Status Indicator RAPS July, 2007 Initial Issue

• Drive gear worn or damaged

Initial Issue July, 2007 Status Indicator RAPS

Status Indicator RAPS July, 2007 Initial Issue

Initial Issue July, 2007 Status Indicator RAPS

Status Indicator RAPS July, 2007 Initial Issue

Initial Issue July, 2007 Status Indicator RAPS

Status Indicator RAPS July, 2007 Initial Issue

Initial Issue July, 2007 Status Indicator RAPS

Status Indicator RAPS July, 2007 Initial Issue

Remove any foreign substances and fix any installation errors.

Initial Issue July, 2007 Status Indicator RAPS

Status Indicator RAPS July, 2007 Initial Issue

Initial Issue July, 2007 Status Indicator RAPS

Status Indicator RAPS July, 2007 Initial Issue

Initial Issue July, 2007 Status Indicator RAPS

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

Status Indicator RAPS July, 2007 Initial Issue

Initial Issue July, 2007 Status Indicator RAPS

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

Status Indicator RAPS July, 2007 Initial Issue

Initial Issue July, 2007 Image Quality

Initial Issue July, 2007 Image Quality

Image Quality July, 2007 Initial Issue

Initial Issue July, 2007 Image Quality

Xerox Private Data