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XEROX 5018 style

1. p 37 Parts for the 5018 style are available at The Parts Drop 201 387 7776 TIPS amp TROUBLESHOOTING TIPS amp TIDBITS LOWER THE FUSER TEMPERATURE THESE BABIES TEND TO RUN HOT High heat shortens the life of the roller and can also contribute to the web unwrapping and spitting out of the machine this almost always destroys the roller We recommend that you turn the fuser temperature down as low as you possibly can and still get good fusing The range is from 0 to 99 The default setting from the factory is 50 Be sure to test for fusing from a cool start For the 5016 18 21 28 5126 5328 5818 20 XC 1875 2675 10 61 Hold 0 while turning on the machine Then press 10 followed by Start then 61 followed by Start The current setting will be displayed Enter 00 followed by Start to lock in the new value If it doesn t fuse at 00 turn it up in increments of 3 until fusing is acceptable For the 5034 20 0 Hold the 0 while turning on the power Then enter 20 followed by Start then 0 followed by Start Then use the P key to scroll to 10 61 the current setting will be shown to the right on the display Select a new setting in increments of 3 then press Start For the 5334 5830 NVM Access 10 61 Hold the 0 while turning on the power Press the NVM Access tab NVM Non Volatile Memory on the touch screen
2. U9 3 Exposure lamp problem or light not sensed U9 4 Logic doesn t see the Toner Motor turning usually the motor is turning but the signal isn t seen by the main board must be reset using diagnostic code 20 3 U9 5 Problem during warm up Try diagnostic code 20 3 to reset U9 6 Xerographic process problem refer to U9 5 www partsdrop com p 22 Parts for the 5018 style are available at The Parts Drop 201 387 7776 DIAGNOSTICS INPUT amp OUTPUT CODES DIAGNOSTICS Entering Diagnostic Mode To enter diagnostic mode hold down the 0 key while turning on the power It ll take about 3 seconds for the copier to power up at which time you can then release the 0 key The software revision level will be displayed at this time If you press the Start button the entire display will light up Entering Diagnostic Test Codes Once you enter Diagnostic Mode by holding down the 0 while turning on the power you ll want to find the procedure below for the specific model you re working on since there are several slightly different ways of entering a diagnostic code e 5016 5018 5021 5028 5034 5126 5321 5328 5818 5820 XC1875 XC2675 For these models from Diagnostic Mode you ll enter the first part of the code followed by Start then the second part of the code followed by Start example if the code is 50 15 you d enter 50 using the numeric keyboar
3. 8 58 Time from the Duplex Module output switch to the 8 59 Time from the Exit switch to the Duplex Module input Switch 5334 5624 5626 5824 5826 5828 5830 only 8 60 Time from the Duplex Module input switch to the Duplex Module output switch 5334 5624 5626 5824 5826 5828 5830 only 8 62 8 63 Bypass feeder test 5334 5624 5626 5824 5826 5828 5830 only 8 99 Scan speed registration adjustment NVM enable 5034 only 9 1 9 2 9 3 9 4 9 5 9 14 9 15 9 16 Inserts threshold 5034 only 9 20 Electrostatic Setup 5334 5624 5626 5824 5826 5828 5830 only 9 24 Toggle grid voltage 5334 5624 5626 5824 5826 5828 5830 only 9 25 Toggle bias voltage 5334 5624 5626 5824 5826 5828 5830 only 9 26 Contrast voltage 5334 5624 5626 5824 5826 5828 5830 only 9 27 Calculate the inserts detection value 5334 5624 5626 5824 5826 5828 5830 only 9 30 Dry ink reorder disable message 5334 5624 5626 5824 5826 5828 5830 only 9 50 ESU Electrostatic Set Up and drum count reset at next power up press 1 Start then turn power off and on to force an ESU 5624 5626 5824 5826 5828 5830 only 9 60 9 67 10 1 10 3 www partsdrop com p 31 Parts for the 5018 style are available at The Parts Drop 201 387 7776 10 4 DIAGNOSTICS ROUTINES amp NVM ADJUSTMENTS 10 10 Fuser extended web life enable 5034 only 10
4. which the Copy Cartridge slides into Slide the Cartridge in slowly amp check that it s fully seated on the front amp rear latches and is raised into position If the cartridge isn t seated right it sags down too low so that when the Solenoid pushes the Actuator Button the magnet on the Counter Mechanism doesn t raise up high enough to actuate the Switch You can check the latches for binding especially the front one and lubricating them with a little oil doesn t hurt Also check the integrity of the Receiver Frame above the fuser It commonly cracks and breaks loose allowing it to sag down a bit If you find it is cracked over the fuser you may be able to repair it with the Receiver Frame Repair Kit or you could replace the Receiver Frame with a new one ELIMINATING J2 ALL TOGETHER J2 KILL Want to set up one of these models so that it never displays the messages Order Copy Cartridge Replace Copy Cartridge or J2 again You ll need a 20 Jumper Wire 2 wire caps amp a few cable ties 1 On the Main Board behind the lower front cover of the machine clip the wires which go to the following pins for splicing P102 pin 20 black wire and P101 pin 7 violet wire 2 Cap the loose ends of the wires which go back into the machine so that you need not worry about shorting out the end of the wire later 3 Connect the 20 Jumper Wire between P102 pin 20 amp P101 pin 7 4 Use afew Cable Ties to se
5. D3 2 Paper detected on Duplex Module transport input switch when power is turned on or clamshell is closed D3 3 Paper detected on Two Tray Module exit switch when power is turned on or clamshell is closed EO The machine has reset during standby E1 5 Clamshell interlock E1 6 Right side interlock E1 7 Drawer interlock TTM or Duplex Module depending on model E1 8 Sorter interlock E1 9 Copy Cartridge interlock E2 Main board received a reset signal during a copy cycle This is a false paper jam open the clamshell and close it and observe what other code comes up and troubleshoot that other code because it is what triggered the E2 E3 Jam inside the machine paper passed registration switch but didn t reach the exit switch E4 Exit Jam E4 0 Paper on exit switch at power up F4 1 Exit Jam E4 2 Exit Jam paper late reaching transport input switch during duplexing or paper sensed on that switch at power up E4 3 Paper detected on Exit switch when power is turned on or clamshell is closed E4 10 Paper Tray 1 removed and paper stalled in Exit Area E5 Clamshell interlock www partsdrop com p 20 Parts for the 5018 style are available at The Parts Drop 201 387 7776 STATUS CODES E6 Right side door interlock E7 Duplex Door Interlock ES Tray 4 amp 5 interlock switch open E9 Copy Cartridge interlock F3 1 Sorter bin home switch not actuated in time F3 2 Sorter cam switch didn t see
6. 201 387 7776 DIAGNOSTICS INPUT amp OUTPUT CODES 8 20 Duplexing machines only Home cam sensor Q83 8 21 Duplexing machines only Tray 2 empty switch S89 8 22 Duplexing machines only Drawer interlock switch S810 9 6 Dry ink cartridge empty sensor Q91 9 7 9 11 10 5 ADF Interlock Switch see code 5 20 for some models 11 2 10 Bin Sorter bin home switch S111 11 3 10 Bin Sorter cam switch S113 11 5 10 Bin Sorter interlock switch S112 11 20 20 Bin Sorter interlock switch S116 11 21 20 Bin Sorter front door interlock switch S117 11 22 20 Bin Sorter top cover interlock switch S118 11 23 20 Bin Sorter output tray sensor Q115 11 24 20 Bin Sorter upper limit switch S119 11 25 20 Bin Sorter lower limit switch S120 11 26 20 Bin Sorter bin entry sensor Q114 12 1 20 Bin Sorter Finisher manual staple button S128 12 2 20 Bin Sorter Finisher Low on staples CR1202 12 7 20 Bin Sorter Finisher Path block sensor Q1203 12 17 20 Bin Sorter Finisher bin entry sensor Q121 12 18 20 Bin Sorter Finisher interlock switch S121 12 19 20 Bin Sorter Finisher cover interlock switch S122 12 20 20 Bin Sorter Finisher bin home switch S123 12 21 20 Bin Sorter Finisher bin paper sensor Q122 12 22 20 Bin Sorter Finisher tamper home sensor Q12
7. 201 387 7776 TIPS amp TROUBLESHOOTING seating all the way into the dv unit s connector The one on the machine side is known to get pushed out of place and result in poor connections on the toner sensor circuit as well as other developer circuits J2 Status Codes The J 2 Code normally clears automatically when you install a new Copy Cartridge photoreceptor unit If the J 2 refuses to go away having an understanding of how the cartridge s counter mechanism works can help tremendously J2 doesn t show up on the machines which use the 13R67 cartridges 5334 version of the cartridge The 13R67 s don t have the counter mechanism described below How the Cartridge Counter Mechanism works Inside the Copy Cartridge there s a gear box type of Counter Mechanism When the Cartridge Counter Solenoid in the machine energizes it pushes a square Plastic Actuator Button on the cartridge which does 2 things First of all it advances the Counter Mechanism one click Second it raises a magnet on the Mechanism up into range of the Cartridge Counter Sensor a reed switch in the machine Once the Cartridge Counter Mechanism reaches the end of its count designed for 25 000 copies the magnet comes up and a cam latches it into the up position If the machine sees the magnet cycle up amp back down it continues to operate If it sees the magnet come up amp stay up it calls a J2 1 code which means the Cartridge s count is up
8. then scroll down to 10 61 Press New Value and enter a new setting followed by Print Then press Print again to confirm for some reason you must make the change in increments of 3 5624 26 5824 26 28 30 NVM Access 10 61 Hold the 0 while turning on the power Press the P key to scroll to NVM Access on the message display Press the number 5 to select NVM Then use the Reduction Enlargement up amp down buttons to scroll down to 10 61 Fuser Temperature Enter a new value again you must make the change in increments of 3 Press Print to lock in your selection each time www partsdrop com p 38 Parts for the 5018 style are available at The Parts Drop 201 387 7776 TIPS amp TROUBLESHOOTING GROUND WIRES Ground wires are very important in these machines a loose or disconnected ground wire can cause all kinds of strange copy quality problems and in some cases intermittent false Status Codes as well PAY CLOSE ATTENTION TO PLUG JACK LOCATIONS Take care in these machines there are several places where connectors could be swapped if you re not paying close attention One place like this is on the Main PWB where connectors 102 amp 110 could be switched also 104 amp 111 Pay attention to the Plug and Jack numbering and color of the connectors mark wires if it helps you remember which goes where Another potential pitfall is with the Tray 1 Feed Solenoid a
9. 28 30 They are quickly recognizable because of the light colored plastic instead of the black plastic of the 5018 cartridges www partsdrop com p 41 Parts for the 5018 style are available at The Parts Drop 201 387 7776 TIPS amp TROUBLESHOOTING NOTE You can choose to set a machine up so that it never calls a J2 code Read the J2 KILL info below involves a jumper wire on the Main Board If the Cartridge Checks out test the machine end of things The Cartridge Counter Sensor is a reed switch located on the front end of the Side Edge Erase Board above where the Copy Cartridge sits Clean the Switch off developer on the switch can cause it to lose sensitivity To test the switch run diagnostic code 9 7 and manually actuate the Cartridge Counter Sensor with a magnet the display should change from Ready to Copy to Please Wait The Cartridge Counter Solenoid is on the front of the machine where the Cartridge s Counter Actuator Button lines up The Solenoid s pawl should be at a 90 degree angle from the solenoid bracket You can test the Solenoid by running diagnostic code 9 12 The solenoid should energize note that it s normal for the pawl to not return to it s relaxed postion because the return spring is in the Copy Cartridge Watch that the Solenoid s Actuator Arm is not binding against or hitting the optics frame The Cartridge Receiver Frame is the large plastic framework in the machine
10. 5018 version 5018FW is found in 5016 5018 5021 5028 50345818 5820 5328 version 5328FW is found in 5321 5328 5624 5626 5824 5826 5828 5830 XC1875 XC2675 Web Count Reset resets the U4 6 Codes amp Flashing L4 web end of life near For the 5016 5018 5021 5028 5126 5321 5328 5818 XC1875 XC2675 1 Hold 0 while turning the power on 2 Then enter 10 amp press Start 3 Enter 63 followed by Start www partsdrop com p 43 Parts for the 5018 style are available at The Parts Drop 201 387 7776 TIPS amp TROUBLESHOOTING 4 Enter 0 display will show CC 5 Press Print dn done should show 6 Turn power off amp after 10 seconds back on again For the 5034 5820 1 Hold 0 while turning the power on 2 Then enter 10 amp press Start 3 Enter 65 followed by Start 4 Enter 0 some later software required that you enter a different number for some reason for machines with Tag 8 enter an 18 for Tag 31 or 37 enter a 6 5 Press Print to lock it in For the 5334 5830 1 Enter the diagnostic mode hold the 0 while turning on the power 2 Press the HFST tab High Frequency Service Items on the touch screen 3 Then scroll down to 10 65 Web Count Press Reset Item 4 Press Confirm For the 5624 5626 5824 5826 5828 1 Enter diagnostic mode hold down 0 while t
11. 5826 5828 5830 only 6 55 Scan speed adjustment 5034 5624 5626 5824 5826 5828 5830 only 6 60 Lens Magnification 5034 5624 5626 5824 5826 5828 5830 only 6 62 Intake fan speed during standby 5334 5624 5626 5824 5826 5828 5830 only 6 63 Intake fan during standby timeout 5334 5624 5626 5824 5826 5828 5830 only 8 61 8 64 Tray feeds threshold is 150K 5334 5624 5626 5824 5826 5828 5830 only 8 65 Duplex Module right side tray 2 feeds threshold is 100K 5334 5624 5626 5824 5826 5828 5830 only 8 66 Duplex Module left side tray 3 feeds threshold is 100K 5334 5624 5626 5824 5826 5828 5830 only 8 67 Two Tray Module right side tray 4 feeds threshold is 150K 5334 5624 5626 5824 5826 5828 5830 only 8 68 Two Tray Module left side tray 5 feeds threshold is 150K www partsdrop com p 34 Parts for the 5018 style are available at The Parts Drop 201 387 7776 DIAGNOSTICS ROUTINES amp NVM ADJUSTMENTS 5334 5624 5626 5824 5826 5828 5830 only 8 70 Bypass Tray feeds threshold is 255K 5334 5624 5626 5824 5826 5828 5830 only 8 99 Auto scan speed registration correction factor 5334 5624 5626 5824 5826 5828 5830 only 9 16 Inserts threshold 5334 5624 5626 5824 5826 5828 5830 only 9 17 Dry Ink guage 5334 5624 5626 5824 5826 5828 5830 only 9 18 Charge voltage read only 5334 5624 5626 5824 5826 5828 5830 only 9
12. 8 Scan servo compensation line test read caution above 6 9 6 10 6 11 Scan encoder output test 5034 5334 only 6 60 Lens magnification value read only 5034 only 6 64 Exposure lamp Vrms 5334 5624 5626 5824 5826 5828 5830 only 6 61 7 1 7 2 Bypass tray size sensing test 5034 only 7 3 Two Tray Module trays 4 amp 5 5334 5624 5626 5824 5826 5828 5830 only 8 2 8 10 Duplex Module Transport clutch main drive motor stack routine 5334 5624 5626 5824 5826 5828 5830 only 8 13 Machine drives test Transport clutch amp Paper Path Drive Motor 5034 only 8 15 Exit roller drive motor speed direction routine 5034 5334 5624 5626 5824 5826 5828 5830 only 8 24 Duplex tray diagnostic routine 5034 only 8 25 Cam positioning and timing motor test 5034 5624 5626 5824 5826 5828 5830 only 8 50 8 51 8 52 8 53 8 54 8 55 Time to the transport output switch 5034 5624 5626 5824 5826 5828 5830 only 8 56 Time to the Two Tray Module output switch 5334 5624 5626 5824 5826 5828 5830 only 8 57 Time from the Two Tray Module output switch to the Duplex Module output switch 5334 5624 5626 5824 5826 5828 5830 www partsdrop com p 30 Parts for the 5018 style are available at The Parts Drop 201 387 7776 DIAGNOSTICS ROUTINES amp NVM ADJUSTMENTS Registration switch 5334 5624 5626 5824 5826 5828 5830 only
13. 99 Office light flicker prevention 5034 only 10 63 Web Reset enter 0 followed by Start the display will show dn when you re done Use 10 65 in NVM setting below for resetting web count on 5034 5820 5334 5624 26 5824 26 28 30 10 65 11 1 11 31 20 bin sorter bin index up to bin 1 5334 only 11 32 20 bin sorter bin index down to bin 20 5334 only 11 33 20 bin sorter bin index up one bin 5334 only 11 34 20 bin sorter bin index down one bin 5334 only 11 35 20 bin sorter bin index assembly cycle 5334 only 12 1 Sorter Finisher Manual Staple button 5624 5626 5824 5826 5828 5830 only 12 2 Sorter Finisher Low Staple LED 5624 5626 5824 5826 5828 5830 only 12 3 Sorter Finisher Tamper Set 8 5 x 11 5624 5626 5824 5826 5828 5830 only 12 4 Sorter Finisher Tamper Set A4 5624 5626 5824 5826 5828 5830 only 12 5 Sorter Finisher Front Tamper Cycle 5624 5626 5824 5826 5828 5830 only 12 8 Sorter Finisher Bin Up 1 5624 5626 5824 5826 5828 5830 only 12 9 Sorter Finisher Bin Down 1 5624 5626 5824 5826 5828 5830 only 12 10 Sorter Finisher Bins Down 5624 5626 5824 5826 5828 5830 only 12 11 Sorter Finisher Bins Up 5624 5626 5824 5826 5828 5830 only 12 12 Sorter Finisher Bins Cycle Up Down 5624 5626 5824 5826 5828 5830 only 12 13 Sorter Finisher Rear Tamper Cycle 5624 5626 5824 5826 5828 5830 only 12 16 Sorter Finisher Stapler Motor Reverse 562
14. Drop 201 387 7776 DIAGNOSTICS INPUT amp OUTPUT CODES 12 14 20 Bin Sorter Finisher inverter gate solenoid SOL1201 12 15 20 Bin Sorter Finisher stapler actuate MOT 1205 www partsdrop com p 27 Parts for the 5018 style are available at The Parts Drop 201 387 7776 DIAGNOSTICS ROUTINES amp NVM ADJUSTMENTS Diagnostic Routines follow the procedure for your exact model number below In the following diagnostic Routines Start will start the program Stop will stop a program allowing you to either begin that program again or enter a different one C CM Clear All button will stop the program and clear the current program and clear also the chain to start fresh It is common sense to always record all changes you make in case you need to return the machine to the settings from before you began The OEM Manual refers to the 1 part of the code as the Chain and the 2 part of the code after the hyphen as the Program e 5016 5018 5021 5028 5126 5321 5328 5818 XC1875 XC2675 Enter diagnostics then enter the first part of the code known as the Chain followed by Start then the Pi part of the code known as the program followed by Start again to begin the routine e 5034 5820 earlier machines with message displays Enter diagnostics then enter the first part of the code followed by Start then the 2 part of
15. If for whatever reason the machine doesn t see the magnet come up at all the machine calls a J2 2 code to see the subcode you d need to press the 0 button when the J2 is displayed First Check the Copy Cartridge First of all check out the Copy Cartridge for possible problems with the counter mechanism Find the square plastic Actuator Button see illustration 1 Ifthe Actuator Button is down then the Counter s Mechanism is expired Time to recondition the cartridge or at least go in and reset the Counter Mechanism read the Cartridge Reconditioning Instructions for details on that 2 Ifthe button is up press it once amp see if it springs Agwat 7s back up ok don t do that too often each click represents a whole bunch of copies If it gets stuck then the Counter Mechanism has a problem probably a loose piece 3 If you see a square hole but there is no actuator button present then either the cartridge is a 113R93 or if it s reconditioned the button was lost during reconditioning The 113R93 cartridges were sold to customers under full Service Maintenance Agreements These machines were set up for run to life so that the J2 code would never appear This type of cartridge has no Counter Mechanism amp no Actuator Button Likewise if the cartridge in the machine turns out to be a 13R67 it also would be missing the Counter Mechanism The 13R67 s are for the 5334 machines and also the 5624 26 5824 26
16. There are also many parts which remain the same as the 5018 s including the AC Driver Board Main Board again the eproms are different the Low Voltage Power Supply The machines share the same Copy Cartridge as well as the same Fuser components with the exception of the exit roller being different Another change came with the release of the 5328 5321 1993 release and later the XC1875 XC2675 1997 release Basically a 5018 copier as far as logic goes these use a 5034 like ADF some changes were made including a different Takeaway Roll They use a Two Tray Module no duplexing here Many parts remain the same as the 5018 with a few changes including the use of a different Lower Fuser Roller looks very close but has a different diameter this is critical because if you install the wrong lower roller wrinkled copies will result This newer Lower Roller version is used on all of the higher model numbers which came later There is also a different Scan Drive Board a different Bypass Feed Assembly and a different Paper Cassette which uses the top cover of the tray as the Bypass tray These machines use the same basic Sorter but with a difference in the front cover On the 5018 s the Sorter s front cover fills in under where the release handle for the clamshell of the machine is On the 5328 and all higher models the Front Cover of the machine fills in that area and the Sorter has a smaller cover You can use a 5018 or 5034 s
17. are marked as to what DC voltages you should read there If those voltages are off then the LVPS is probably dead The Test points are located on the upper left on the 5018 version of the Main PWB or across the top right on the 5334 version of the Main PWB OPERATION PANEL Operation panels have been known to burn out Xerox doesn t spare the bulbs but fortunately you can get aftermarket replacement bulbs these days if you don t mind doing lots of soldering The problem is lamps not LED s wired in series One fails a whole bank fails These lamps provide the backlight needed to read the display Be aware that some of what looks like foam or gasket is actually conductive padding It is wise to replace all 10 bulbs or 12 on the 5034 5820 if even one is bad because they are known to follow each other in buring out OPTICS SECTION Up top you ll find the Exposure Carriage which has the Exposure Lamp Exposure Thermal Fuse and Mirror 1 then the Half Rate Carriage has Mirror 2 amp 3 Mirrors 4 5 amp 6 are down under the Lens Cover behind the lens The mirrors sometimes fall out of place because the clips which hold the 4 5 amp 6 mirrors in place tend to disintegrate eventually Also the clips on the half rate carriage sometimes allow the 2 amp 3 mirrors to get loose Next to the lens you ll find the Auto Exposure Sensor Anything which keeps the light of the exposure lamp from reaching that sensor will result i
18. for example if U4 shows up press 0 and if a 1 appears then your dealing with a U4 1 code One code particularly worth mentioning is the E2 code the E2 looks like a paper jam but don t let it fake you out it really means that the machine had a reset signal during the copy run When you get an E2 open the clamshell and close it back down and read the other code which comes up that will be the code to troubleshoot For some of the machines the 5034 for example the machine will display a message which says only Call for Service and you ll need to press the 0 button to get the code For the machines which are equipped with a touchscreen you need to press the telephone icon on the touchscreen to get a current status code Note that false codes can be caused by poor grounding connections The machine is about 95 plastic Be sure to reconnect any ground cable that you might have disconnected Some codes are not used in some of the models and some faults have different codes from machine to machine but if you see it displayed on whichever model you re working on you can look it up in the following list with confidence Some of the Status Codes are covered in more detail in the Troubleshooting section of this book the codes which are expanded on are marked with an asterisk Al Document still in ADF A1 8 Main board received a reset signal during ADF cycle A2 Jam in ADF A2 0 AD
19. ll cover 90 of those differences both in diagnostic entry and parts changes The important thing to remember to assure that you get the right parts is to always specify exactly which model you re working on www partsdrop com p 2 Parts for the 5018 style are available at The Parts Drop 201 387 7776 INTRO DIFFERENCES BETWEEN MODELS The machines which cross most closely to the 5018 include later releases some of which were Retail Outlet Store equivalents 5016 1992 release 5021 amp 5126 1994 release 5818 1998 release all have exactly the same diagnostics the initial version of the original Intravia s Mini Manual would be sufficient for any of these models and aside from the eproms on the main board and control console board and a few outer covers the parts are interchangeable If you wanted to use the Main Board from any one in any of the others you d need to also swap the Control Console because the eproms on the Main Board would need to be compatible with the one on the Control Console Then there s the 5034 1990 release and the newer 5820 1997 release these also share most of the Status Codes with the addition of the Duplex related codes including the C5 s D codes amp U3 codes Diagnostic entry is similar as well The 5018 books cover most of the input amp output component codes to test switches sensors and other components The primary difference is in a new way to approach Non Volatil
20. more extensive book Exposure Lamp 122E80 Exposure Thermal Fuse 130E200 Heater Lamp 126K760 Upper Fuser Roller 22k10080 or 22K10070 Upper Bearings 13E3580 Thermal Fuse Assy 108K90 Upper Picker Finger 19F12610 Pressure Picker Fingers 19E4850 Thermistor 130K46130 Pressure Roller 5016 18 21 28 34 5126 5818 20 only 22K10991 5321 28 34 5624 26 5824 26 28 30 XC 1875 2675 only 22K20672 www partsdrop com p 47 Parts for the 5018 style are available at The Parts Drop 201 387 7776
21. procedure varies slightly from model to model Once the code is cleared the display will show dn for done For 5016 5018 502 1 5028 5 126 532 1 5328 5818 5820 XC 1875 2675 Enter diagnostics then enter 20 Print 3 Print then 0 and Print again The display will show dn for Done Machines with newer software Tag 6 or 14 do not require pressing the 0 on those enter 20 Print 3 Print and then Print again For 5034 Enter diagnostics then enter 20 Print 3 Print 0 Print For 5624 5626 5824 5826 5828 enter diagnostics then use the P button to scroll to Routines then press 4 to choose Routines Mode Enter 20 Print 3 Print then 0 Print The display will show dn for Done For 5334 5830 Enter diagnostics then press the Routines tab on the Touchscreen Enter 20 Print 3 Print 0 Print The display will show dn for Done U4 6 Status Code You will need to replace the web and then reset the Web Count from Diagnostics The machine uses an electrical counter to keep track there is no other sensor or such involved in detecting a low web A red line will become visible near the end of the web when it is close to the end of it s life Note there are 2 versions of these webs
22. side door flopping down the handle which says J1 and pulling straight out use 2 hands and it comes out pretty easily As was mentioned in the information about the toner cartridge above you shouldn t need to replace developer material unless it becomes contaminated or because there s not enough in the system to coat the mag roll completely If however you do need to replace the developer you need only brush off the old stuff from the mag roll If you are using a vacuum keep in mind that static discharge can damage the toner low sensor so you need to use a Static controlled vacuum or detach the sensor and let it hang from it s wires while you are vacuuming Then pour the new shot of developer on the magnetic roller and keep turning in until the whole bottle is in there keep the unit tilted towards the front slightly to help avoid losing developer into the rear over flow port There is no diagnostic program needed when replacing developer the machine will set itself up TRAY 1 FEED MODULE This module includes the 4 feed tires feed clutch amp feed solenoid and feed clutch for Tray 1 the right side cassette as well as the Registration Roller clutch and solenoid To remove this module you ll need to first remove the DV Unit and the Copy Cartridge then open up the clamshell There is a strap which hangs from the top which must be disconnected Also there is a plastic cover which covers the gears and wires at www p
23. the cam turning F3 3 Sorter Failure logic didn t see indexing cam switch deactuate in time F4 codes 20 bin sorter problems F5 Sorter interlock J1 1 Add toner J1 2 Machine had a momentary low toner signal toner probably low J2 1 Copy Cartridge life expired replace Copy Cartridge J2 2 Replace Copy Cartridge problem with counter mechanism detected J4 0 Electrostatic Setup Failure J5 Auto set up problem J6 Auto set up problem L2 2000 copy warning before end of copy cartridge life after which U4 6 will come up and the machine will lock up until the code is reset L3 Communication failure between copier and ADF L4 flashing 1000 copy warning before end of fuser web life L5 Duplex Module failure and duplex module has been disabled requires 20 3 code to clear code once problem is addressed L6 Auditron or other accessory which counts copy usage is not installed LL Main board memory failure Try reinitializing the NVM non volatile memory using diagnostic code 1 1 RR Bad eprom on main board Try turning off and on again you may need to reinitialize the Main board or replace the eprom or in some cases the Main PWB RC means 5028 control panel was installed on a machine with Main PWB eproms intended for use in a 5018 machine or vice versa U0 Main board problem try 1 1 to reset U1 0 Ground fault U2 Scanner pro
24. the code followed by Start again to begin the routine e 5334 5830 machines equipped with touchscreens Enter diagnostic mode hold 0 while powering up Press the Routines tab on the touchscreen Enter the first part of the code followed by Start then the 2 part of the code followed by Start again to begin the routine e 5624 5626 5824 5826 5828 machines equipped with message displays Enter diagnostic mode hold 0 while powering up Press the P button to scroll through to Routines mode Press the 4 button Enter the first part of the code followed by Start then the gra part of the code followed by Start again to begin the routine www partsdrop com p 28 Parts for the 5018 style are available at The Parts Drop 201 387 7776 DIAGNOSTICS ROUTINES amp NVM ADJUSTMENTS The list which follows is complete for many of the models but needs more work to finish up on the more recent models 2 4 Touch screen button test 5334 only 2 7 Magnification ratio display test for 5034 only 2 7 Coin Op paper size signal for 5334 5624 5626 5824 5826 5828 5830 only 2 8 Coin Op Reduction Enlargement signal 2 10 LED instructional diagrams test 5034 only 2 11 Electronic copy count read reset 5034 5334 5624 5626 5824 5826 5828 5830 only 2 70 Photoreceptor end of life option setting of 0 run to life 1 limit
25. 1 5028 5034 5126 5818 5820 Separate bypass feed tray uses a bypass feeder with 4 tires and an o ring Note that the 5034 5818 5820 have a white colored tray as opposed to the brown color of the others Bypass B 5321 5328 5334 5624 5626 5824 5826 5828 5830 Uses the top cover of the Tray one Cassette as the bypass tray Bypass feeder has a single feed tire www partsdrop com p 6 Parts for the 5018 style are available at The Parts Drop 201 387 7776 INTRO DIFFERENCES BETWEEN MODELS DUPLEX DRAWERS Duplex Drawer A Tray 3 uses a Feed Roller exit roll driver on Duplex Board 5034 5820 Duplex Drawer B Tray 3 uses a Feed Belt exit roll driver on AC Driver Board 5334 5626 5826 5828 5830 DOCUMENT FEEDERS ADF A 3 Rollers in a Prefeed Module 5016 5018 5021 5028 5126 5818 ADF BP Prefeed Belt amp 1 Takeaway Roll 5034 5820 ADF C Prefeed Belt amp a different Takeaway Roll 5321 5328 5334 5624 5626 5824 5826 5828 5830 XC1875 XC2675 LOWER FUSER ROLLERS Lower Fuser Roll A larger diameter roller larger diameter bearings 5016 5018 5021 5028 5034 5126 5818 5820 Lower Fuser Roll B smaller diameter roller smaller diameter bearings 5321 5328 5334 5624 5626 5824 5826 5828 5830 XC1875 XC2675 PRINTED WIRE BOARDS PWB s LVPS AC Driver Main PWB Scanner Drive PWB
26. 19 Bias voltage read only 5334 5624 5626 5824 5826 5828 5830 only 9 21 Maintain Vddp enable 5334 5624 5626 5824 5826 5828 5830 only 9 22 Belt revolutions since last Electrostatic Set Up 5334 5624 5626 5824 5826 5828 5830 only 9 23 Belt revolutions on the copy cartridge 5334 5624 5626 5824 5826 5828 5830 only 9 28 Wast Sump guage 5334 5624 5626 5824 5826 5828 5830 only 9 29 Auto Contrast Shift 0 1 or 2 5334 5624 5626 5824 5826 5828 5830 only 9 40 Perform Set Vbg every 1250 belt revolutions 1 disabled 5334 5624 5626 5824 5826 5828 5830 only 9 42 Lead edge bias timing 5334 5624 5626 5824 5826 5828 5830 only 9 56 Open platen increases lead edge erase 1 disabled 5334 5624 5626 5824 5826 5828 5830 only 9 61 Tag 5 Magnification Exposure Adjustment 5624 5626 2824 5826 5828 5830 only 9 62 9 63 9 64 9 65 9 66 9 68 9 69 9 73 Dry ink dispense rate increase 5034 5334 only 10 8 Exhaust fan speed in power saver 5334 only 10 9 10 61 Fuser temperature adjustment lower is better 10 65 Web count reset for 5034 5334 5624 5626 5820 5824 5826 www partsdrop com p 35 Parts for the 5018 style are available at The Parts Drop 201 387 7776 DIAGNOSTICS ROUTINES amp NVM ADJUSTMENTS 5828 5830 only use 10 63 in the Diagnostic Routines section above for 5016 5021 5028 5126 5321 532
27. 3 12 23 20 Bin Sorter Finisher stapler home position sensor Q124 12 24 20 Bin Sorter Finisher low staple sensor Q125 12 25 20 Bin Sorter Finisher stapler paper sensor Q126 12 26 20 Bin Sorter Finisher cam position switch S124 12 27 20 Bin Sorter Finisher non staple position sensor Q127 12 28 20 Bin Sorter Finisher staple position sensor Q128 12 29 20 Bin Sorter Finisher paper clemp switch S125 Output Codes Testing motors clutches solenoids etc These codes test components such as motors clutches solenoids fans and voltages PAY ATTENTION to the CAUTIONS they are critical If you run some of these codes recklessly damage can result to various components and parts in the machine www partsdrop com p 25 Parts for the 5018 style are available at The Parts Drop 201 387 7776 DIAGNOSTICS INPUT amp OUTPUT CODES 2 1 2 6 2 9 Message display test 5034 only 2 10 Console LED test 5334 5624 5628 5824 5826 5828 5830 only 3 2 Wraparound LED test 5034 only 4 1 Main Drive Motor 5624 5626 5824 5826 5828 5830 only 5 1 5 2 5 3 Document Belt Drive Motor 5624 5626 5824 5826 5828 5830 only 5 7 5 8 ADF Feed Motor 5 9 ADF motor and clutch CAUTION unlatch the feed head before doing a 5 9 code 5 11 ADF feed motor only or prefeed motor only in 5034 s CAUTION unl
28. 4 5626 5826 5828 5830 only The Duplex Module or DM as it s often referred to as in the Service Manual uses tray 3 as the duplex tray for stacking multiple sheets in a duplex run Tray 2 is then available as an additional feed tray The DM is easily the most complicated part of any of these machines It is a mechanical nightmare for the unfamiliar You really need to have a full Service Manual or a healthy dose of prior experience to get anywhere in this section of the machine The 5034 machine will not function at all if the machine is removed from it s Duplex Module so transforming the machine into a desktop would not be possible Some of the duplex related fault codes need to be reset from the diagnostics once the problem has been repaired 20 3 code The feed head sags down a bit under normal circumstances which looks rather odd there is a green handle which sticks out a bit which looks like it should be held up to a bracket above it But that bracket is misleading it was used for shipping purposes only and should not be holding the feed assembly up there s nothing missing there if you are wondering TRANSFER COROTRON ASSEMBLY This unit provides the high voltage for the Transfer and also the Detack It is known for developing arcing across the end blocks which results in blank areas on the copies which can eventually develop into blank copies There is also a metallic baffle which helps guide the paper into the fuser a
29. 4 5626 5824 5826 5828 5830 only 20 0 NVM Adjustments 5034 amp 5820 only read NVM section www partsdrop com p 32 Parts for the 5018 style are available at The Parts Drop 201 387 7776 DIAGNOSTICS ROUTINES amp NVM ADJUSTMENTS which follows 20 1 20 2 20 3 Clears U4 s except U4 6 web code U9 4 amp L3 codes Enter 0 then Start the display will show dn for done Then turn the power off and back on and the machine will attempt to warm up again NVM Non Volatile Memory Adjustments follow the procedure for your exact model e 5016 5018 5021 5028 5126 5321 5328 5818 XC1875 XC2675 Enter diagnostics then enter the first part of the code followed by Start then the 2 part of the code followed by Start again in most cases the current setting will be displayed Change the current setting using the numeric keys and press Start to lock in your new setting e 5034 5820 earlier machines with message displays Enter diagnostics then enter code 20 0 Then press the P button to scroll through the list of NVM settings Enter a new value and press Start to lock it in Press Interrupt to exit diagnostics after you ve made the change e 5334 5830 machines equipped with touchscreens Enter diagnostic mode hold 0 while power
30. 8 XC1875 2675 10 73 Ozone filter count reset 11 61 Output configuration 0 exit tray only 1 10 bin sorter 2 20 bin sorter 6 20 bin sorter finisher 5334 5624 5626 5824 5826 5828 5830 only TAGS Mods Tags are modifications to the equipment Some will be done in the field Occasionally when ordering parts you may need to check whether your machine has a specific tag installed or not to make sure you get the correct version of a part Tags will also determine which software revision level is loaded in a machine R1 R2 etc The Tag Matrix can be found on the left side of the machine on the upper clamshell you need to open the clamshell to see the matrix The Tag Matrix will look like a sticker with a grid of numbers on it if a particular number is blacked out crossed off or punched out it means that Tag has been installed on the machine There is little point in naming all of the tags in this publication because it would become quite extensive and wouldn t serve you well anyway there are different sets of tags for different models www partsdrop com p 36 Parts for the 5018 style are available at The Parts Drop 201 387 7776 CUSTOMER PROGRAMMING MODE CUSTOMER PROGRAMMING MODE The information below is for the 5016 5018 5021 5028 5321 5328 XC1875 XC2675 other models may have some differences in how to enter Programming Mode or they may have different sets o
31. CUSTOMER PROGRAMMING MODE 4 Turn the machine off wait 5 seconds and turn the power back on 5 Press the 4 four times followed by Stop a P should show up on the display 6 Select the Code you want to change from the chart below and press Start When you re finished press Stop to leave the Programming Mode Code Description Instructions 20 Paper Supply Enter 20 Start then use the Paper Supply button to select the paper size you want the machine to default to auto paper size is one choice which will only work if the machine is equipped with size sensors in the Platen Cover Then Press Start to lock in your choice 22 Auto Tray Switching Enter 22 Start then enter a 1 to enable the copier to switch paper trays automatically or 2 to disable this option 24 Power Saver Time Out Enter 24 Start then enter your choice from the list below followed by Start to lock in your choice 0 no timeout 5 120 minutes 1 15 minutes 6 180 minutes 2 30 minutes 7 240 minutes 3 60 minutes 8 480 minutes 4 90 minutes www partsdrop com p 46 Parts for the 5018 style are available at The Parts Drop 201 387 7776 FINDING PARTS PARTS This listing of parts is valid for the 5018 5028 only unless item is marked with an asterisk in which case it fits all machines in this series to include the part numbers for all of the model s would require a far
32. F Registration or Feed Sensor on when power is turned on A2 1 Copier reset during ADF feed www partsdrop com p 18 Parts for the 5018 style are available at The Parts Drop 201 387 7776 STATUS CODES A2 2 Document Feed Jam feed sensor never saw lead edge of sheet enter A2 3 Single Sheet Document Feed Jam A2 6 Document Registration Jam A2 7 Document feed sensor didn t see the trail edge of the sheet leave A2 8 ADF Inverter Jam A9 0 ADF interlock open during ADF use Cl Tray 1 feed problem C1 1 Tray 1 feed problem C1 2 Bypass feed problem 5624 5626 5824 5826 5830 only C1 3 Tray 1 cassette removed and paper stalled in tray C2 Tray 2 feed problem C2 1 Duplex Module transport exit switch didn t see paper from Tray 2 C2 2 Registration switch didn t detect paper from Tray 2 of the TTM C3 Tray 3 Feed problem C3 1 Duplex Module transport exit switch didn t see paper from Tray 3 C3 2 Registration switch didn t detect paper from Tray 3 of the TTM C4 Bypass feed problem C4 1 Two Tray Module output switch didn t see paper from Tray 4 C5 1 Two Tray Module output switch didn t see paper from Tray 5 5624 5626 5824 5826 5828 5830 only C5 1 Duplex jam sheet late arriving at the registration switch 5034 5820 5334 only C5 2 Misfeed from Tray 2 C5 3 Misfeed from Tray 3 C5 4 Duplex Module misfeed trans
33. Hi Voltage Power Supply There are also some differences from model to model but generally they fit into these two categories Boards 5018 version 5016 5018 5021 5028 5034 5126 5321 5328 5818 5820 XC1875 XC2675 Boards 5334 version 5334 5624 5626 5824 5826 5828 5830 COMMON TO ALL IN SERIES Toner Cartridge in spite of the varying reorder s DV Unit and Developer Transfer Corotron Upper Fuser Roll Thermistor Thermal Fuse Picker Fingers Upper Bearings Tray 1 Feed Head Assy ADF Transport Belt www partsdrop com p 7 Parts for the 5018 style are available at The Parts Drop 201 387 7776 MODULES REMOVAL PROCEDURES MACHINE MODULES REMOVAL PROCEDURES COPY CARTRIDGE The Copy Cartridge includes the charge corona OPC Belt Photoreceptor or PR Belt and cleaner unit The 13R9 13R74 113R161 and the 113R93 see notes below cartridges are used in the 5016 5018 5021 5028 5034 5126 5321 5328 5818 5820 XC1875 XC2675 The 13R67 is designed to be used in the 5334 5624 5626 5824 5826 5828 5830 The difference being that the 13R67 is lighter in color and it uses a row of teeth for the charge corona instead of a pair of wires In addition the 13R67 has no counter mechanism and is missing a piece of the rear rail the 5018 version of the cartridge has that piece of the rear rail intact which prevents it from sliding into the 5334 etc m
34. Toner Cartridges include 6R244 amp 6R708 they are interchangeable regardless of which reorder number they are sold under The toner cartridge is accessed from the right side door of the machine It rotates up and pulls up and out There is a small box attached to the cartridge hanging from a mylar strip which is the reclaim for the old developer This machine is designed such that it shouldn t need developer changes if it s working properly Each new toner cartridge has a small amount of fresh developer mixed in with the toner As the new developer is added to the system some of the older stuff is walked out the back of the developer unit and is deposited in the waste box attached to the toner cartridge The only time you d need to replace developer is if the developer gets contaminated or depleted It is extremely important with this toner cartridge that the customer know to always shake a new cartridge before installation shake it good the instructions say to shake it 20 times and they mean it If these aren t shaken good enough the clumped up toner inside will bind up the stirring auger inside the toner cartridge and it ll break and fail to dispense toner When the toner cartridge is out of toner or fails to drop toner down into the augering system the toner empty sensor will see the lack of toner and the machine will call a J1 code These toner cartidges are rated for 8 000 copies assuming 5 coverage DEVELOPER
35. UNIT The DV Unit includes the cradle where the toner cartridge goes It is spared in the Parts List as two halves the Toner Hopper is the upper half and then the lower half is sold seperately This module also has the toner dispense motor amp toner empty sensor The toner motor turns a large gear on the toner cartridge to stir the toner and dispense it into the augering system which brings the toner forward and then across to mix into the developer The toner motor also has a second gear on it which drives the augers themselves The Toner Low Sensor is located on the rear end right next to where the toner cartridge drops toner into www partsdrop com p 9 Parts for the 5018 style are available at The Parts Drop 201 387 7776 MODULES REMOVAL PROCEDURES the augering system It is an ultrasonic sensor which sees if there is no toner in the beginning of the auger There s a spring at the end of the main auger which cleans the surface of the sensor to keep it from getting all caked up with toner The electrical connections for the DV unit components all go through a large blue plug The blue plug in the machine is known to sometimes get pushed out of place such that the connection is not made when the DV Unit is latched in This can cause problems such as U9 4 codes toner motor not seen turning also DV bias problems which can cause very light copies The Developer Unit is easily removed by removing the bypass opening the right
36. XEROX 5018 style TECHNICAL INFORMATION 5016 5018 5021 5028 5126 5818 5034 5820 5321 5328 XC1875 XC2675 5334 5624 5626 5824 5826 5828 5830 CREDITS e Xerox and the model s covered in this guide are Registered Trademarks of the Xerox Corporation Much of the information provided in this book was drawn from or confirmed by the OEM Service Manual available for sale on www xdss com which is the OEM site for Documentation and Software Sales e This book was originally begun with the intention of providing information to expand the now out of print INTRAVIA S SERVICE GUIDE 5018 5028 MINI MANUAL published by Knight Business Systems Thanks to Jim Intravia for having published the original Mini Manual and allowing me to use some of the original text particularly the Modules descriptions Knight s Business Systems www intravia com publishes many extremely helpful books which cover a very wide range of makes and models e Credit to ENX Magazine www enxmag com for first publishing articles called What s the Difference from which the Introduction of this book is drawn p 1 INTRO DIFFERENCES BETWEEN MODELS INTRODUCTION DIFFERENCES BETWEEN MODELS The 5018 style is put together differently than most other copiers which came before it Working on the machine can be a bit unsettling to a technician who is unfamiliar with its idiosyncrasies The various modules can be removed from
37. achines unless you first remove a limiting block from the rear rail of the 5334 cartridge receiver frame held on by one screw from the rear The 113R93 comes without the counter mechanism and is designed for machines under contract which are set up for a run to life instead of only running 25 000 copies between cartridges like most of the machines do Any of these machines can be set up so that they run to life and never call J2 again It involves an OEM retrofit which is a jumper wire between two of the pins on the Main PWB A more detailed look at how the counter mechanism in the cartridge works how to use a 5018 cartridge in a 5334 machine and how to disassemble these cartridges for refurbishing is included later in the Reconditioning Section of this book To remove the Copy Cartridge it is considered a customer replaceable unit requires that you open the right side door remove the DV Unit and then pull the copy cartridge out by it s green handle being careful not to allow the Photoreceptor Belt to touch anything on the way out Installing a new cartridge is best done with two hands can be a little tricky with some jiggling needed to find the track again If the cartridge is the correct one for the machine it should reset the J2 status code automatically www partsdrop com p 8 Parts for the 5018 style are available at The Parts Drop 201 387 7776 MODULES REMOVAL PROCEDURES TONER CARTRIDGE Reorder numbers for the
38. ard detected a fault during self initialization At the point of E 2 being displayed open and close the clamshell The original status code that caused the E 2 will be displayed Then press the 0 key to observe the subcode This will surely help you to further diagnose the situation J1 Status Codes The machine sees that there is a low toner condition Right behind the hole where the toner drops from the Toner Cartridge into the Developer Unit s augering system is an ultrasonic sensor which detects if the toner is out If the customer just replaced the toner cartridge check to see if the stirring spring inside the toner cartridge may have snapped off Remove the toner cartridge and look to see if the well hole under the cartridge is full it should be If it is full the toner sensor is suspect There is a spring which is designed to clean off the face of the toner sensor make sure there isn t any impacted toner against the face of the sensor that can make the sensor insenstive Sometimes one of the gears on the Toner Dispense Motor s D shaft strips on the inside so that it can spin on the D shaft instead of driving properly Also you ll want to make sure the DV Unit is latching properly Check the big blue connector in the machine where the DV Unit plugs in to make sure it is seated good and that the male pins on the machine side are www partsdrop com p 40 Parts for the 5018 style are available at The Parts Drop
39. artsdrop com p 10 Parts for the 5018 style are available at The Parts Drop 201 387 7776 MODULES REMOVAL PROCEDURES the rear which is clipped in and must be removed Unplug the connectors for the Feed and Registration Solenoids take note of which solenoid plugs in where because they are identical and can be switched later if you aren t careful You ll also need to remove the Transfer Corotron read below about that Finally you ll find 4 screws one near each corner of the module you ll need a stubby phillips head screwdriver to get to two of the screws There is also a ground wire which is attached to the transfer corona assembly tension spring near the front of the machine which needs to be released If the fuser is still in the machine then yov ll need to release the drive belt tension There is a white plastic tension pulley between the feed section and fuser Insert an 8mm nutdriver from the rear and slightly loosen the shoulder screw which acts as the shaft for this idler Then using the nutdriver like a lever or handle raise the pulley and wiggle the belt out from under it There is a strong spring pulling this pulley down If you remove the screw completely it is rather difficult to get back on If the screw is completely removed bge sure to get the spring in the correct groove when reassembling Remember to connect this belt and tighten this screw again at re assembly If you don t have a nutdriver you can
40. atch the feed head before doing a 5 11 code 6 14 Intake fan 8 0 Single Sheet Bypass Feed Motor 5321 5328 5334 5624 5626 5824 5826 5828 5830 XC1875 XC2675 only 8 1 Paper Path Drive Motor 8 2 Tray 1 paper feed solenoid 8 4 Registration solenoid 8 5 Two Tray Module TTM takeaway clutch 8 8 Two Tray Module TTM right feed clutch 8 9 Two Tray Module TTM left feed clutch 8 13 Duplex Module DM Transport clutch amp Main Drive Motor 8 14 Duplexing machines only Exit Roll Drive motor forward test 8 18 Duplexing machines only Deflector Gate Solenoid 8 23 Duplexing machines only Duplex Module Feed Head Clutch 8 26 Duplexing machines only Duplex Module Transport Clutch 9 8 _ Interimage Side Edge Erase Lamps 9 12 Cartridge counter solenoid CAUTION Remove the Copy Cartridge before entering code 9 12 or you ll reduce the life of the cartridge rather quickly 10 1 Exhaust Fan 10 2 Web Motor Turns extremely slow 10 minutes for one revolution 10 6 Fuser Relay K101 5624 5626 5824 5826 5828 5830 only 11 27 20 Bin Sorter diverter gate solenoid 11 28 20 Bin Sorter index up clutch 11 29 20 Bin Sorter index solenoid 11 30 20 Bin Sorter drive motor 11 97 20 Bin Sorter duplex solenoid 12 6 20 Bin Sorter Finisher tranport drive motor MOT 1202 www partsdrop com p 26 Parts for the 5018 style are available at The Parts
41. blem U2 1 Scan home sensor problem U2 2 Scan home sensor or scanner motor encoder motor not turning dirty disk or photosensor U2 4 Scan home sensor or scan dual page mode sensor www partsdrop com p 21 Parts for the 5018 style are available at The Parts Drop 201 387 7776 STATUS CODES U2 5 Excessive scan speed U2 6 Excessive return scan speed U2 7 Scan home sensor U2 8 Electrical Noise problem or other Scanner problems U3 codes All U3 codes are duplex module related problems with the cam and the tamper If you need to work on the duplex unit you ll want to have either plenty of experience or you d best have the full Service Manual at hand U4 1 Fuser problem Too long to warm up usually a bad fuser lamp or blown thermal fuse diagnostic code 20 3 to reset see Diagnostic Routines for model specific reset procedures U4 2 Fuser problem temperature dropped but recovered within 30 seconds U4 3 Fuser problem Temperature too high U4 4 Thermistor problem open thermistor U4 6 Fuser web count expired You ll need to replace the web and then reset the web count from diagnostics diagnostic code 10 63 details follow in the Diagnostic Routines later in this book U4 7 4 5 volt signal to thermistor dropped below 4 2 U7 1 Copy cartridge belt hole not sensed at the right time sensor didn t see the hole come around
42. cure the Jumper Wire to the Main Board s Wiring Harness Don t forget to inform the customer since the machine will not call a J2 code the only way to know that it is time to replace the cartridge is to notice when the copy quality begins to degrade cleaning blade streaks or washed out copies from the PR Belt wearing down www partsdrop com p 42 Parts for the 5018 style are available at The Parts Drop 201 387 7776 TIPS amp TROUBLESHOOTING Machines which have this retrofit installed can use the 113R93 variety of copy cartridge which comes without a counter mechanism Also the 13R67 designed for use in the 5334 s would now work This procedure was offered as a Retrofit Kit under the part 606K 4280 It is a Tag Modification called Tag 70 L4 Status Code Flashing This code will be displayed for the final 2000 copies of the web life Replace the web and read U4 6 below for details on how to reset the code and also some tips on what to watch out for U4 1 Status Code A U4 1 code indicates that the fuser took too long to warm up Usually this means a bad heat lamp or blown thermal fuse NOTE After you clear the code you ll want to watch the heat lamp to make sure it comes on amp cycles out ok If it doesn t shut off once the machine comes to ready turn off the power before you get a melt down a shorted Triac would be the first suspect if the lamp stays on continuously To reset the code
43. d then Start then 15 followed by Start In this way you can enter a code which allows you to test an Input component such as a switch or sensor Use the same system for testing an Output component such as a motor lamp or solenoid e 5334 5830 machines equipped with touchscreens On machines with touchscreens once you re in Diagnostic Mode you ll press the Routines tab on the touchscreen then yov ll enter the code the same way as above the touchscreen will prompt you for the Chain which is the first part of the code and then the Function which is the second part of the code e 5624 5626 5824 5826 5828 machines equipped with message displays On these machines from Diagnostic Mode use the P button to scroll to Routines and press the 4 to select Routine mode Then you ll enter the code the same as above enter the first part www partsdrop com p 23 Parts for the 5018 style are available at The Parts Drop 201 387 7776 DIAGNOSTICS INPUT amp OUTPUT CODES of the code the chain then press Start then the second part of the code the Routine followed by Start again Changing Modes If you are using one Diagnostic Code and wish to change to another you don t have to power down Just press the key marked C CM Then enter the digits for the next code you wish to use INPUT CODES Testing sens
44. e Memory NVM adjustments for example the Registration Exposure and Fuser Temperature adjustments Read about how to approach these in the NVM Adjustments section of this book There were a few significant changes in parts for the 5034 amp 5820 First the color of the covers became almost white next the newer machine uses a single motor to drive both the Paper Path and the Xerographic components where there were two separate motors in the 5018 The 5034 also has a different ADF with different feed components The 5034 had a Duplex tray in the left side of the tray 2 amp 3 drawer They call it a DM duplex module instead of the TTM Two Tray Module Here is where the most difficult problems to solve come from if you must work on the Duplex Module you will need the full Service Manual or a really good dose of prior experience The DM has unique feed components 2 single round Feed Rollers instead of the 2 or 3 Half Moon tires found in each tray of a Two Tray Module www partsdrop com p 3 Parts for the 5018 style are available at The Parts Drop 201 387 7776 INTRO DIFFERENCES BETWEEN MODELS Another change which came with the fuser included an exit roll motor which could reverse to pull sheets back down into the machine for the 2 side this was the only change in the fuser assembly A 5034 Sorter would fit perfectly on a 5018 and vice versa but the color of the covers would look odd next to each other
45. e interchangeable although there are some exceptions especially with the 5334 version Main PWB s some of which have non removable eproms The Main PWB main logic board is located on the front of the machine Most models have removable eproms 2 of them which need to stay true to the correct model and must match the ones on the Control Console for the machine to communicate and operate Be particularly careful Damage to the optics can result if the machine is powered up with certain connectors disconnected The AC Driver PWB is located on the rear of the machine mounted on the NOHAD Module It is responsible for driving many functions of the machine including the Exposure Lamp Fuser Triac Blanking Lamps except in the 5334 model and a host of other functions The Scanner Drive PWB is on the upper half of the rear of the machine open the clamshell and you ll see it there The LVPS Low Voltage Power Supply and the Hi Voltage Power Supply are both located down below the fuser in www partsdrop com p 15 Parts for the 5018 style are available at The Parts Drop 201 387 7776 MODULES REMOVAL PROCEDURES the base of the machine To get to these you must first remove the DV Unit Copy Cartridge Tray 1 Feed Module Transfer Corotron and Fuser Module Fortunately when you have a no power symptom you can test the LVPS s outputs without having to dig it out of the machine There are Test Points on the Main PWB which
46. ed part of the web amp turn the web gear counter clockwise to take up any slack 4 The metal Clicker piece which touches the Web Gear should be positioned so as to not allow the Web Gear to turn backwards Helping to Avoid Web wrapping problems It s no fun when the web wraps around the rollers Here are the things we know of which you can do to help avoid this www partsdrop com p 44 Parts for the 5018 style are available at The Parts Drop 201 387 7776 TIPS amp TROUBLESHOOTING Turn down the Fuser Temperature to be as cool as possible ask for the write up if you don t have it Avoid fuser jams whenever possible you can reduce the chance of a fuser jam if you increase the lead edge deletion simulation 9 65 This is particularly important if your customer runs a lot of graphic heavy copies Educate your customer to clear jams properly Inform the customer to always clear jams by first opening the clamshell and then pull paper out of the fuser towards the exit turning the Fuser Rolls backwards will run a high risk of a web wrap Make certain the web is advancing properly You can test the web drive motor using simulation 10 2 Mark the gear run the simulation and walk away for a while since the motor turns extremely slowly 10 minutes to make one revolution www partsdrop com p 45 Parts for the 5018 style are available at The Parts Drop 201 387 7776 TIPS amp TROUBLESHOOTING
47. eplaced after around 40 000 copies an L6 code will flash for the final 2000 copies before the web runs out then a U4 6 code comes up locking up the machine until the web count is reset in the diagnostics read in the Diagnostic Routines how to go about resetting the web count There is also a red line which shows up on the web material when the web is actually close to the end of it s life The web is definitely something which a technician should be replacing not the customer as miss assembly can be disastrous If the web wraps around the upper roller it can push the thermistor away from the roller causing a major over heat lots of stuff can get damaged that way Read in the final section of this book about particulars of the web replacement including how to reset the web count and how to help avoid web wraps www partsdrop com p 13 Parts for the 5018 style are available at The Parts Drop 201 387 7776 MODULES REMOVAL PROCEDURES It s important to know that there are 2 versions of the lower Pressure Roller The original version fits the 5016 5018 5021 5028 5034 5 126 5818 5820 The newer version to come out has a slightly smaller diameter almost indiscernable with the naked eye The more obvious difference is that the new version has a lower fuser bearing with a smaller outer diameter The two versions are not interchangeable and if you install the wrong one which is definitely possible to do wrinkling copies will resul
48. f variables which can be altered 1 Turn the machine off wait 5 seconds and turn the power back on 2 Press the 4 four times followed by Stop a P should show up on the display 3 Select the Code you want to change from the chart below and press Start When you re finished press Stop to leave the Programming Mode Code Description Instructions 20 Paper Supply Enter 20 Start then use the Paper Supply button to select the paper size you want the machine to default to auto paper size is one choice which will only work if the machine is equipped with size sensors in the Platen Cover Then Press Start to lock in your choice 22 Auto Tray Switching Enter 22 Start then enter a 1 to enable the copier to switch paper trays automatically or 2 to disable this option 24 Power Saver Time Out Enter 24 Start then enter your choice from the list below followed by Start to lock in your choice 0 no timeout 5 120 minutes 1 15 minutes 6 180 minutes 2 30 minutes 7 240 minutes 3 60 minutes 8 480 minutes 4 90 minutes 29 Single Sheet Feeder Enter 29 Start then enter a 1 to make Auto Start only for machines with Document Feeders the original feed automatically when you insert it or enter a 2 if you want the machine to wait till you press Start Then press Start to lock in your new choice www partsdrop com
49. ing up Press the NVM tab on the touchscreen Scroll through the settings till you have the setting you want to change highlighted Press the button on the touchscreen which says new val and enter your new value Press the Start button to confirm When you re done press the Call Close tab and select Quick Exit to assure that your new setting is saved in memory www partsdrop com p 33 Parts for the 5018 style are available at The Parts Drop 201 387 7776 DIAGNOSTICS ROUTINES amp NVM ADJUSTMENTS e 5624 5626 5824 5826 5828 machines equipped with message displays Enter diagnostic mode hold 0 while powering up Press the P button to scroll through to NVM mode Press the 5 button and use the Reduction Enlargement up and down arrows to scroll through the list to the setting you d like to change Then enter the new value and press Start to lock in the new value Follow the instructions on the message display 1 3 Line frequency check 0 USCO 1 RX European 5334 only 2 60 2 61 2 62 Drawer configuration for 5624 5626 5824 5826 5828 5830 only 0 TTM only 3 trays 1 Duplex Module only 3 trays 2 Duplex and Two Tray Modules 5 trays 4 No TTM No Duplex Module 1 tray for 5334 only 1 Duplex Module only 3 trays 2 Duplex and Two Tray Modules 5 trays 5 16 5 55 Document Prefeed Belt Feeds 5334 5624 5626 5824
50. located close to the Main Power Switch all of the other models which came before and after the 5334 use a lamp driven by the AC Driver Board It uses a Lower Fuser Roller like the newer 5328 version The 10 Bin Sorter is the 5328 version There is also available a 20 Bin Sorter in addition to the 10 Bin Sorters The machine does duplexing so it has a Duplex Module similar to but also substantially different from the 5034 s Unlike the 5034 the newer duplex drawer uses a Feed Belt instead of a Feed Roller for Tray 3 The fuser exit drive motor which was driven by the Duplex PWB in the 5034 is now driven by the AC Driver Board Some configurations of the 5334 and higher models include the Two Tray Module in addition to the Duplex Module which are named Tray 4 amp 5 The ADF is the same as the one from the 5328 Finally the newest releases include the 5624 5626 5824 5826 5828 5830 which are like the 5334 as far as the new style boards the Copy Cartridge the ADF the Sorters again both 10 Bin and 20 Bin versions available and the Duplex Module where it appears the 5624 5824 has a Two Tray Module for Tray 2 amp 3 and they don t duplex The 5830 also has the Touchscreen although the others have a Message Display instead Using Diagnostics on a machine with the Message Display is a bit different from the other machines and once again will be explained in the diagnostic test and adjustment sections of this manual www part
51. n a U9 3 code The light from the exposure lamp bounces off a white reflecting plate located on the flip side of the Lead Edge Guide the guide on the left side of the platen glass with the markings of where to line the original up against Then the light passes through mirrors 1 2 amp 3 and is www partsdrop com p 16 Parts for the 5018 style are available at The Parts Drop 201 387 7776 MODULES REMOVAL PROCEDURES bounced down to the Auto Exposure Sensor so the machine knows that the lamp is firing o k COPY CARTRIDGE RECEIVER FRAME This is the plastic housing that the copy cartridge slides into Removing it can be a real pain in the neck but is sometimes necessary when the frame cracks usually over the fuser area and causes problems with the cartridge sagging down Pressure problems in the fuser can also result because the pads which come down and push down on the fuser pressure towers are attached to the receiver frame right where it often cracks and falls apart First remove the DV Unit and Copy Cartridge then remove the Nohad module from the rear of the machine You don t need to totally disconnect it but be careful that if it dangles you do not damage any wires You may want to remove the Fuser Unit to help you get better access but it is not essential Now remove the one screw in the rear right corner first above the xerographic motor This should be removed first because it is difficult to get to and also yo
52. nd Registration Solenoid connectors DON T POWER UP TILL ALL CONNECTORS ARE IN PROPER PLACES The AC Driver PWB can be damaged if power is switched on when there is an open circuit to the Triac There are other connectors which must not be disconnected when power is switched on STATIC CONTROL IS IMPORTANT en Static discharges can be a great danger to boards J especially to the Main PWB Always ground yourself by touching metal ground when you plan on handling any board Never vacuum or use forced air on boards CAUTION The toner sensor is also rather sensitive to static vo Nor sip o SORE NEAR ONG TELL THE CUSTOMER 1 When the machine calls for toner J1 Status Code replace the toner cartridge right away don t open and close the right door to tone up and force a few more copies through This is because a poor toner condition can cause the developer to get drawn out onto the Photoreceptor belt This could result in developer loss and also can damage the Photoreceptor by getting trapped against the Cleaning Blade 2 When installing a new Toner Cartridge always shake the new toner cartridge really really really good These things are infamous for clumped up toner in the cartridge causing the stirring spring inside the toner cartridge to break then the cartridge becomes useless and the J1 code returns very soon after 3 Never overload the paper trays or the Tray 1 Cassette too much paper can cau
53. nd then pull them apart Be careful to note which end is which when installing the new lamp The two ends are not identical one is male and the other female it is possible to install the lamp backwards which results in no continuity through the circuit www partsdrop com p 14 Parts for the 5018 style are available at The Parts Drop 201 387 7776 MODULES REMOVAL PROCEDURES NOHAD MODULE NOHAD Noise Ozone Heat and Dust This module is the rear framework which is home to the fans the AC Driver Board the fuser Triac and a bunch of other wiring amp stuff It can be removed if necessary 5 or 6 screws The Fuser Triac is tucked back into this module just above the fuser cooling fan to the right of the AC Driver Board If you need to test the Triac remove it and check for continuity between the two legs which are the same size as one another T1 and T2 If you get continuity the Triac is shorted and must be replaced When the triac shorts it keeps the Fuser Lamp on continuously usually resulting in a major over heat in the fuser PRINTED WIRE BOARDS PWB s Most of the boards follow one of two morphologies which are interchangeable within their group of models The 5018 version is used on models 5018 5021 5028 5034 5 126 532 1 5328 58 18 5820 XC1875 XC26 75 and then there is the 5334 version of the boards which are found in models 5334 5624 5626 5824 5826 5828 5830 Within each group most boards ar
54. ors and switches These codes test things like sensors switches amp Interlocks 1 1 Clam shell interlock switch 1 2 Line voltage 1 3 Line frequency 50 50hz 60 60 hz 5 14 ADF upper cover interlock switch S56 5 15 Document cover size sensors for flat tops with document size sensing option 5 20 ADF interlock switch S55 see code 10 5 for some models 6 2 6 3 7 2 Two Tray Module TTM interlock switch 7 4 Two Tray Module TTM right tray empty switch S77 7 5 Two Tray Module TTM left tray empty switch S78 7 6 Duplex Module DM right tray empty switch S74 7 7 Duplex Module DM long paper switch S73 7 8 Duplex Module DM interlock switch S75 7 9 Single Sheet Bypass prefeed switch S72 5321 5328 5334 5624 5626 5824 5826 5828 5830 XC1875 XC2675 only 8 0 Bypass prefeed switch S84 5016 5018 5021 5028 5034 5126 only 8 3 8 6 Two Tray Module TTM output switch S85 8 7 Exit switch S101 8 11 Duplexing machines only Transport input switch S86 8 12 Duplexing machines only Transport output switch S87 8 16 Duplexing machines only Tamper sensor test Q81 8 17 Duplexing machines only Tray 3 long paper switch S88 8 19 Duplexing machines only Control cam sensor Q82 www partsdrop com p 24 Parts for the 5018 style are available at The Parts Drop
55. orter on the 5328 after a minor modification to the machine s front cover which allows the larger Sorter cover to slide in behind the machine s Cover The 5034 sorter matches the 5328 s light color The newest morphology of this series began with the 5334 1994 release This is the first one with a Touchscreen on the console Entering diagnostics is the same as are the codes for the most part the difference is that you use the touchscreen to get around Read details in the Diagnostic sections of this book www partsdrop com p 4 Parts for the 5018 style are available at The Parts Drop 201 387 7776 INTRO DIFFERENCES BETWEEN MODELS One very important change which starts with the 5334 is the new version of the Copy Cartridge basically a 5018 cartridge with a different color to it but missing the Counter Mechanism the machine has a block aptly named the Lock out block in the OEM Parts List which is held in by one screw from the rear which prevents the 5018 cartridge from sliding all the way in remove the block and the 5018 cartridge will function in this machine install a counter and the counter s actuator button in a 5334 cartridge and it will function in a 5018 copier Many parts have changed with the 5334 The Main Board AC Driver Board Low Voltage amp Hi Voltage Power Supplies are different Also they used a cold cathode lamp for the discharge lamp driven by a separate little power supply board
56. port exit switch in the drawer didn t see the sheet leave when feeding from Tray 2 or 3 C6 2 Registration switch didn t detect paper from Tray 2 of the Duplex Module C6 3 Registration switch didn t detect paper from Tray 3 of the Duplex Module C6 4 Registration switch didn t detect paper from Tray 4 C6 5 Registration switch didn t detect paper from Tray 5 C6 1 Registration switch didn t detect paper from Trayless path of duplex C7 0 Duplex Module output switch didn t deactuate between copies from the duplex C7 1 Two Tray Module output switch didn t deactuate between copies from Tray 4 or 5 www partsdrop com p 19 Parts for the 5018 style are available at The Parts Drop 201 387 7776 STATUS CODES C7 4 Duplex Module transport exit switch didn t see paper from Tray 4 C7 5 Duplex Module transport exit switch didn t see paper from Tray 5 D1 Tray 3 Stack Jam Duplex input switch never saw sheet leave D2 0 Paper sensed on transport ouput switch in drawer at power up or at closing of the clamshell D2 1 Sheet never reached transport output switch when duplexing D2 2 Sheet never reached transport output switch from Tray 2 D2 3 Sheet never reached transport output switch from Tray 3 D3 1 Paper detected on Duplex Module Transport output switch when power is turned on or clamshell is closed
57. s to 35K 5334 only 2 71 Order Photoreceptor message 5334 only 3 0 Exit diagnostics without shutting down 5034 only 3 2 Wraparound LED test 5034 only 3 5 Serial communications lines program ADF 5034 5624 5626 5824 5826 5828 5830 only 3 6 Serial communications lines program ADF 5034 5624 5626 5824 5826 5828 5830 only 3 9 Serial communicatoins lines program Interimage edge erase 5034 5624 5626 5824 5826 5828 5830 only 3 10 Duplex PWB serial lines test 5034 only 3 11 Duplex PWB reset line test 5034 only 3 12 Control Console PWB serial line test 5034 only 3 13 Control console PWB reset line test 5034 only 3 60 3 61 Watchdog timer test 5034 only 3 99 Read administrator ID number 5334 5624 5626 5824 5826 5828 5830 only 4 2 Main drive motor stack routine 5334 only 5 12 Document Feed Motor stack routine 5334 only 5 21 ADF inversion routine 5034 5624 5626 5824 5826 5828 5830 only 5 51 5 52 5 53 6 0 6 1 6 2 6 3 CAUTION otherwise www partsdrop com p 29 Parts for the 5018 style are available at The Parts Drop 201 387 7776 DIAGNOSTICS ROUTINES amp NVM ADJUSTMENTS 6 4 Scan reference read caution above 6 5 Scan reference read caution above 6 6 Scan direction line test read caution above 6 7 Scan enable line test read caution above 6
58. sdrop com p 5 Parts for the 5018 style are available at The Parts Drop 201 387 7776 INTRO DIFFERENCES BETWEEN MODELS Well that covers all the releases up to 99 the 5830 was still being sold on the Xerox website as late as 2002 On the following two pages is a synopsis of the different morphologies and which models follow which version MORPHOLOGIES Different Versions of some of the parts COPY CARTRIDGES Copy Cartridge A 13R9 13R74 113R161 13R93 without counter mechanism 5016 5018 5021 5028 5034 5126 5321 5328 5818 5820 XC1875 XC2675 Copy Cartridge B 13R67 5334 5624 5626 5824 5826 5828 5830 10 BIN SORTERS 5018 version brown in color larger front cover on sorter 5016 5018 5021 5028 5126 5818 5034 version white in color larger front cover on sorter 5034 5820 5328 version white color smaller front cover 5321 5328 5334 5624 5626 5824 5826 5828 5830 XC1875 XC2675 PAPER CASSETTE Tray 1 5018 versions 5016 5018 5021 5028 5034 5126 Uses different cassettes for the different paper sizes 5328 version 5321 5328 5334 5624 5626 5818 5820 5824 5826 5828 5830 Universal cassette with the bypass tray being part of the top cover except for the 5818 5820 which use this cassette but has a separate bypass tray like the 5018 predecessors BYPASS FEED TRAY Bypass A 5016 5018 502
59. se the Feed Tire Shaft to get all bent out of shape www partsdrop com p 39 Parts for the 5018 style are available at The Parts Drop 201 387 7776 TIPS amp TROUBLESHOOTING HOW TO GET PARTS Getting parts for any Xerox machine has become easier There are an increasing number of parts vendors who can support your needs As it stands right now Xerox does not offer any discounts to independents so often the aftermarket vendors are the way to go It is possible to order parts from Xerox directly you will need the part number and also you ll need either an account number or the serial number of the machine In any case always order by the exact model number you are working on this will help improve the likelihood that you ll get the correct part HOW TO GET MORE INFORMATION You can pick up a full Service Manual on Xerox s Documentation website www xdss com They get a pretty penny over 300 bucks but the manuals are actually extremely well done There are actually 4 manuals to cover this whole group of machines The 5624 26 5824 26 28 30 are in one book the 5334 is covered alone the 5034 5820 are covered in a 3 book and all the rest are covered in a 4 book Another way to get info is to participate in one of the online Tech Forums such as Smarka www smarka com TROUBLESHOOTING STATUS CODES E 2 Status Code We get lots of calls about E 2 fake paper jams The fact of the matter is that E 2 means the main bo
60. ssembly after it www partsdrop com p 12 Parts for the 5018 style are available at The Parts Drop 201 387 7776 MODULES REMOVAL PROCEDURES crosses the transfer and detack wires That baffle can be removed but is supposed to be snapped onto the corotron assembly sometimes they break and no longer sit properly resulting in paper jams just before the fuser To remove the Transfer Corotron raise the small arms at either end and pull up on the front end where it is pressed down onto a contact then pull out of the rear FUSER UNIT The Fuser Unit is also removable as a module It is held in by 4 screws one at each corner You ll need to unplug some of the connectors including one near the front end which has 4 small orange wires coming out of it Look closely before you start tugging at something that won t come apart There s also a large brown connector which comes from the rear of the fuse through the rear frame Then you ll want to release the tension on the drive belt read about a good way to do that above in the description of how to remove the Tray 1 Feed Module Now you can get to the 4 screws The top cover of the fuser houses the web material and the web pinch roll That Web cover is removable by 2 screws on top The Web Cleaning Assembly on the Top Cover is actually quite important as it provides lubrication and also keeps the roller clean This fuser would not function without it The web material needs to be r
61. t The new version fits 532 1 5328 5624 5626 5824 5826 5828 5830 XC1875 XC2675 Pressure problems are another dilemma which is not much fun to face There are quite a few parts which figure into creating the correct pressure on either end of the pressure roller Read about wrinkling problems in the Troubleshooting section Anything which causes the fuser temperature to not come up in time will result in a U4 1 code needs to reset from the diagnostics using 20 3 once the cause of the problem is repaired Read more about the U4 1 s in the Troubleshooting section Removing the Upper Fuser Roller is simple enough once the web cover is off Just lift the two little retaining arms which flop down over the upper fuser bearings be careful that you don t loose the little metal spacers on these little retaining arms they fall off rather easily and will cause problems with pressure in the fuse if one or both is lost Make sure to take note of how the bearings and heat sleeves sit so that when you go to reassemble you can place them correctly folks have been known to put these together backwards resulting in the heat sleeves and bearings walking out destroying the roller The collars of the heat sleeves amp bearings should be facing away from the center of the roller Replacing the Fuser Lamp is easy enough with the web cover off To release the fuser lamp terminals squeeze and press the two connectors together twist lightly a
62. the machine for servicing The annoying thing is that it seems that some relatively common parts can only be replaced by removing a great number of these modules For example to replace the Low Voltage Power Supply requires first removing the DV Unit the Copy Cartridge the Feed Transport Module the Transfer Corotron Assy and the Fuser Assembly Resign yourself to this fact and accept it and just remember that if it was easy they wouldn t need someone like you There are many many models in this series A background understanding of what has changed over the years may give you a bit more comfort working on the newer versions of this machine Following is a quick history and comparison much of the text of this section is drawn from a pair of articles by Britt Horvat which were first published by ENX Magazine under the title What s the Difference In 1998 1999 Xerox first released it s new 5018 5028 copiers the only true difference being the speed 18 cpm vs 28 cpm Since then they have created model after model using the same basic machine Keeping up with what the differences are has been challenging to say the least there are subtle changes in diagnostic entry procedures as well as changes in some of the parts Following is a brief but rather thorough exploration into the different morphs these machines have gone through as each new model was released There are many minor changes from model to model but here we
63. u don t want weight on it while you re trying to remove it which would happen if it you leave it for last You will be tempted to remove the Xerographic motor to get a better shot as the screw Don t do it it s too much work But be prepared to use a variety of phillips screwdrivers including an offset The screw points up into the upper frame and you will find it between the uppermost gear on the Xerographic motor and the scan motor Next remove the two screws in the upper frame that hold two metal tabs Note that these tabs are odd shaped and are not interchangeable Note which is which and how they are mounted On the front one after you remove it also remove the screw under it not a phillips Remove the two screws going into the upper frame on the right side near where the developer unit came out One screw is near the large blue female connector for the developer unit The other is toward the rear Remove the two flat head screws which mount the blue connector Disconnect the wires from the copy cartridge receiver Now you ll need to wiggle twist etc to sneak the receiver frame out of there towards the exit end www partsdrop com p 17 Parts for the 5018 style are available at The Parts Drop 201 387 7776 STATUS CODES STATUS CODES FAULT CODES In many of the machines the main code will appear in the display when there is a problem When a code is displayed press the 0 button to display the sub code
64. urning on the power 2 Press the P key to scroll to HFST on the message display Then press the number 3 to select HFSP 3 Then use the Reduction Enlargement up amp down buttons to scroll down to 10 65 Web Count Enter a 0 4 Press Print to confirm Once you ve followed the appropriate instructions above turn the power off wait 5 seconds and turn the machine back on the web count should be reset and the Status Code should go away How does this thing go together anyway note there was an older version which was completely different if you run across one of them use your noggen if you get stuck or have questions give us a call 1 Remove the old web on either end pull back a little spring loaded collar to release the feed part of the web The web gear is on the take up it is just clipped in place on the gear end pull straight up on the gear end to release 2 The orange or Blue pinch Roller which pushes the Web against the Upper Fuser Roller should have a pretty good tension on it If the springs feel kind of wimpy snap the orange roller out of place and remove the springs from either end Stretch out the springs a bit put it all back together and check the orange roller s springiness again 3 Slide the Web Gear Shaft into the takeup end of the new Web so that the pins engage the drive slots Install the web feed roll in place Hold back the fe
65. use a long phillips screwdriver to loosen the screw but holding up the pulley would be more difficult Now you can lift the assembly out When reassembling pay attention to the way the Feed tires sit flat area of the half moon tires should be down parallel with the ground TWO TRAY MODULE Tray 2 amp 3 on non duplexing machines Abbreviated as the TTM The Two Tray Module is the drawer below the machine To remove the TTM Feed Head requires first removing the Drawer The drawer is removed by releasing a catch on the right side rail push in a little tab towards the rear of the rail to allow the rail to slide back releasing the drawer Then the Feed Head has a little plastic catch on the left side of the front of the module which you can pull back to release www partsdrop com p 11 Parts for the 5018 style are available at The Parts Drop 201 387 7776 MODULES REMOVAL PROCEDURES the assembly allowing it to slide out on the rails it is attached to It 1l come all the way out so that you can service it These TTM Feed Heads are extremely similar from the 5018 s to the 5328 s but the 5328 uses a different Takeaway Roll the round rolls common to both trays 2 and 3 and a different Takeaway Clutch Some of the duplexing machines also have a TTM down below the Duplex Module which serves as Tray 4 amp 5 That type of TTM is closer to the 5328 TTM DUPLEX MODULE Tray 2 amp 3 on duplex capable machines 533

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