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5216/5220 Service Information
Section 3
Disassembly
3-1
Table of Contents
5216/5220 Service Information Section 3: Disassembly
Introduction .............................................................................. 3-4 Covers/Doors .......................................................................... 3-4 Front Door ........................................................................ 3-4 Right Side Access Door .................................................... 3-5 Rear Cover ....................................................................... 3-6 Drawer 2 Rear Cover (5220 only) ..................................... 3-7 Left Side Cover ................................................................. 3-7 Right Side Cover .............................................................. 3-8 Ozone Filters .................................................................... 3-8 Control Panel .................................................................... 3-9 Front Cover ..................................................................... 3-10 PWAs..................................................................................... 3-11 AC/DC Power Supply High Voltage Power Supply PWAs ................................. 3-11 CCD Sensor PWA .......................................................... 3-11 Exposure Lamp Regulator PWA ..................................... 3-12 E-Sort Option PWA ......................................................... 3-13 Main Logic PWA ............................................................. 3-14 Network Interface Card PWA. ........................................ 3-15 Printer Interface PWA ..................................................... 3-16 Optional Memory PWA ................................................... 3-17 PostScript PWA .............................................................. 3-17 Fax NCU PWA ................................................................ 3-18 Fax Option PWA ............................................................. 3-19 Document Handling ............................................................... 3-20 Platen Cover ................................................................... 3-20 Platen Cover Open/Closed Sensor (S5) ......................... 3-20 Exposure Glass .............................................................. 3-21 Auto Paper Size Sensors (5220 only; S2A&B) ............... 3-21
3-2
Document Scanning ...............................................................3-22 Lens Assembly ................................................................3-22 Exposure Lamp Assembly ..............................................3-23 Exposure Lamp ...............................................................3-24 Scanner Home Position Sensor (S1) ..............................3-25 Scan Drive Motor (M5) ....................................................3-25 Photoconductor Process ........................................................3-26 TD Cartridge ....................................................................3-26 Photoconductor Unit ........................................................3-27 Charge Corona ................................................................3-28 Cleaning Blade ................................................................3-28 Transfer Corona ..............................................................3-29 Photoconductor Exposure ......................................................3-31 Laser Cautions ................................................................3-31 Laser Unit ........................................................................3-31 Paper Feed.............................................................................3-34 Main Drive Motor (M1) ....................................................3-34 Paper Feed Assembly .....................................................3-35 Paper Feed Drive Assembly ...........................................3-37 Registration Roller Solenoid (SOL2) ...............................3-38 Drawer 1 Paper Feed Solenoid (SOL6) ..........................3-38 Registration Roller Clutch ...............................................3-39 Registration Roller ...........................................................3-39 Drawer 1 Paper Feed Clutch ...........................................3-40 Paper Feed Roller ...........................................................3-40 Right Side Access Door Interlock Switch (SW2) .............3-41 Paper Registration Roller Sensor (S11) ..........................3-41 Drawer 2 Transport Sensor (5220 only; S14) .................3-41 Drawer 2 Door Open/Closed Sensor (5220 only; S13) ...3-41 Drawer 1 Present Switch (SW3) .....................................3-42 Drawer 2 Present Switch (5220 only; SW4) ....................3-42 Drawer 1 Paper Empty Sensor (S15) ..............................3-42 Drawer 2 Paper Empty Sensor (5220 only; S16) ............3-42 Bypass Feed Assembly ...................................................3-43
Table of Contents
Bypass Paper Transport Clutch ...................................... 3-44 Bypass Paper Feed Roller Assembly ............................. 3-45 Bypass Paper Feed Clutch ............................................. 3-47 Bypass Paper Feed Roller/Pickup Roller ....................... 3-48 Bypass Paper Feed Solenoid (SOL3) ............................ 3-49 Fuser...................................................................................... 3-50 Fuser Assembly .............................................................. 3-50 Fuser Paper Exit Sensor (S9) ......................................... 3-51 Fuser Thermofuse (TF) .................................................. 3-52 Fuser Thermistor (TH) .................................................... 3-52 Fuser Lamp .................................................................... 3-53 Fuser Roller .................................................................... 3-56 Separation Fingers ......................................................... 3-57 Pressure Roller ............................................................... 3-58 Copy Exit ............................................................................... 3-59 Paper Exit Assembly ...................................................... 3-59 Transport Roller .............................................................. 3-61 Copy Exit Roller .............................................................. 3-63 ADF-516 ................................................................................ 3-66 ADF Unit ......................................................................... 3-66 ADF Covers .................................................................... 3-67 ADF PWAs ..................................................................... 3-70 Original Feed Unit ........................................................... 3-72 ADF APS Length Sensors (S207, S208) ........................ 3-73 ADF Pickup Roller Solenoid (SOL201) ........................... 3-73 Original Pickup Clutch .................................................... 3-74 ADF Pickup Roller Assembly .......................................... 3-75 ADF Pickup Roller ADF Paper Feed Roller .................................................. 3-75 ADF Drive Frame ............................................................ 3-76 ADF Feed Motor Assembly ADF Drive Belt ................................................................ 3-76 ADF Feed Motor (M201) ................................................. 3-77 ADF Original Feed Clutch (CL201) ................................. 3-77
3-3
Transport Roller ..............................................................3-78 Registration Roller ...........................................................3-79 Paper Feed Guides (Upper/Lower) .................................3-80 Original Exit Roller ..........................................................3-81 SS-516 System Stand ............................................................3-82 Rear Covers ....................................................................3-82 Paper Feed Assembly .....................................................3-83 Paper Transport Solenoid (SOL701) Paper Feed Solenoid (SOL702; SOL703,2nd drawer) ....3-85 Transfer Roller Gear Assembly .......................................3-85 Transport Roller ..............................................................3-86 Paper Feed Roller Clutch ................................................3-86 Paper Feed Roller ...........................................................3-87 ET-516 One Bin Tray .............................................................3-88 1 Bin Tray ........................................................................3-88 1 Bin Tray Drive Motor (M51) ..........................................3-88
5216/5220 Service Information Disassembly
3-4 Introduction
Introduction
All disassembly instruction refer to both the 5216 and the 5220 except where noted. Reassemble the units in reverse order of the disassembly. If certain options are installed, part or all of the option may have to be removed to remove a basic machine component. This section will have links to the option if needs to be removed. If the option is not installed, skip the linked step and continue.
Covers/Doors
Front Door
1. 2. 3. 4. 5. Remove the first paper drawer from the machine. Open the Bypass Feed tray. Slide the right side access door open. Open the front door. Press each side of the front door in to release the pins from the hinge arm then pull the door out to remove.
Front door Pin Right side access door
Caution
The right side access door and the front door are mechanically interlocked. You must always open the right side access door before you can open the front door. The front door must be closed before the right side access door can be closed.
1st paper drawer Pin
Bypass Feed tray
5216/5220 Service Information Disassembly
Right Side Access Door
1. Open the Bypass Feed tray. 2. Slide the right side access door open. 3. Lift the door up and pull out to remove.
3-5 Introduction
Right side access door
Bypass Feed tray
5216/5220 Service Information Disassembly
Rear Cover
1. Remove the platen cover (or ADF). 2. Remove the screws. 3. Remove the rear cover.
Platen cover
3-6 Introduction
Platen cover open/ closed actuator arm
Rear cover
Caution
When removing the rear cover, take care not to damage the actuator arm for the platen cover open/close sensor.
5216/5220 Service Information Disassembly
Drawer 2 Rear Cover (5220 only)
1. Remove the screws. 2. Remove the lower rear cover.
3-7 Introduction
Lower rear cover
Left Side Cover
1. Remove the screws. 2. Remove the left side cover.
Left side cover
5216/5220 Service Information Disassembly
Right Side Cover
1. 2. 3. 4. Open the platen cover (or ADF). Remove the screws. Lift the cover to clear the tabs. Remove the cover.
Tabs
3-8 Introduction
Right side cover
Ozone Filters
1. Remove the right side cover. 2. Remove the ozone filters.
Ozone filter
5216/5220 Service Information Disassembly
Control Panel
1. Remove the front door. 2. Remove the left side cover. 3. Remove the ground wire attached to the cooling fan behind the left cover. 4. Remove the screws from the control panel. 5. Pull the control panel out and remove the ribbon cables and connector. 6. Remove the control panel.
Ribbon cables Connector
3-9 Introduction
Front door Control panel
5216/5220 Service Information Disassembly
Front Cover
1. Remove the control panel. 2. Remove the screws. 3. Remove the front cover.
3 - 10 Introduction
Front cover Control panel
Front door
5216/5220 Service Information Disassembly
3 - 11 PWAs
PWAs
AC/DC Power Supply High Voltage Power Supply PWAs
1. 2. 3. 4. Remove the left side cover. Remove the screws from the power supply. Remove the connectors form both power supplies. Remove the power supplies.
Connectors
Connectors
Power supplies
CCD Sensor PWA
1. Remove the exposure glass. 2. Remove the lens assembly cover. 3. Remove the CCD PWA.
CCD Sensor PWA
5216/5220 Service Information Disassembly
Exposure Lamp Regulator PWA
1. Remove the exposure lamp assembly. 2. Disconnect the 2 connectors (CN1, CN2) to the PWA. 3. Remove the PWA.
3 - 12 PWAs
5216/5220 Service Information Disassembly
E-Sort Option PWA
1. Remove the rear cover. 2. Remove the large RFI shield. 3. Remove the RFI shield over the main logic and E-Sort PWAs.
3 - 13 PWAs
RFI shield
Large RFI shield
4. Remove screws from the E-Sort option PWA. 5. Unplug the E-Sort PWA from the main logic PWA and remove the PWA.
E-Sort PWA
5216/5220 Service Information Disassembly
Main Logic PWA
1. 2. 3. 4. Remove the E-Sort PWA (if installed). Remove the connectors from the main logic PWA. Remove the screws from the main logic PWA. Remove the PWA.
3 - 14 PWAs
Main logic PWA
5216/5220 Service Information Disassembly
Network Interface Card PWA.
1. Remove the rear cover. 2. Remove the large RFI shield.
3 - 15 PWAs
Large RFI shield
3. Remove the NIC PWA.
NIC PWA
5216/5220 Service Information Disassembly
Printer Interface PWA
1. Remove the rear cover. 2. Remove the NIC PWA. 3. Remove the RFI shield over the main logic and ESort PWAs.
3 - 16 PWAs
RFI shield
4. Remove the mother board PWA. 5. Remove the printer interface PWA.
Mother board PWA
Printer interface PWA
5216/5220 Service Information Disassembly
Optional Memory PWA
1. Remove the rear cover. 2. Remove the large RFI shield. 3. Remove the optional memory PWA.
3 - 17 PWAs
Optional memory PWA
PostScript PWA
1. Remove the rear cover. 2. Remove the large RFI shield. 3. Remove the PostScript PWA.
PostScript PWA
5216/5220 Service Information Disassembly
Fax NCU PWA
1. 2. 3. 4. Remove the rear cover. Remove the large RFI shield. Remove the ribbon cable connector Remove the NCU PWA.
Ribbon cable (Blue line to the inside)
3 - 18 PWAs
NCU PWA
5216/5220 Service Information Disassembly
Fax Option PWA
1. Remove the fax NCU PWA. 2. Remove the mother board PWA. 3. Remove the fax option PWA.
3 - 19 PWAs
Mother board PWA
Fax option PWA
5216/5220 Service Information Disassembly
3 - 20 Document Handling
Document Handling
Platen Cover
1. Open the platen cover. 2. Lift the platen cover straight up to remove.
Platen cover
Platen Cover Open/Closed Sensor (S5)
1. 2. 3. 4. Remove the rear cover. Remove the RFI shield over the main logic PWA. Remove the E-Sort option PWA (if installed). Disconnect the platen cover open/closed sensor connector. 5. Remove the screw then remove the sensor.
Platen cover open/closed sensor
Rear cover
5216/5220 Service Information Disassembly
Exposure Glass
1. 2. 3. 4. Remove the platen cover. Remove the left side exposure glass retainer. Remove the right side exposure glass retainer. Remove the exposure glass.
Left side exposure glass retainer
3 - 21 Document Handling
Right side exposure glass retainer
Auto Paper Size Sensors (5220 only; S2A&B)
1. Remove the exposure glass. 2. Remove the length sensor 3. Remove the width sensor.
Length sensor
Width sensor
5216/5220 Service Information Disassembly
3 - 22 Document Scanning
Document Scanning
Lens Assembly
1. Remove the exposure glass. 2. Remove the lens assembly cover. 3. Remove the lens assembly.
Lens assembly cover
Lens assembly
Note: When installing the lens assembly, note the lens unit number on the lens assembly, then align the lens assembly with the scribe marks (1.4mm each) in the lens chassis. For example, the lens unit number is +2.8. Divide 2.8 by 1.4mm (distance between each mark). Since the answer is 2, align the lens assembly with the second scribe mark in the positive direction.
One scribe mark equals 1.4mm
Lens unit number
Negative direction Zero reference Positive direction
5216/5220 Service Information Disassembly
Exposure Lamp Assembly
1. Remove the exposure glass. 2. Slide the exposure lamp assembly all the way to the right (carriage 2 is touching the positioning plates). 3. Remove the scan cable retaining screws.
Carriage 2 Positioning plates
3 - 23 Document Scanning
Scan cable retaining screws
4. Move the exposure lamp assembly to the front and slide the scan cable off the retaining bracket. 5. Move the exposure lamp assembly to the rear and slide the scan cable off the retaining bracket.
Scan cables
Retaining brackets
5216/5220 Service Information Disassembly
6. Move the rear of the assembly to the left and remove the assembly from the copier. 7. Turn the assembly over, remove the bracket holding the exposure lamp assembly ribbon cable then remove the assembly from the copier.
3 - 24 Document Scanning
Ribbon cable
Exposure lamp assembly
Bracket
Exposure Lamp
1. Remove the exposure lamp assembly. 2. Disconnect the lamp connector from the exposure lamp regulator PWA. 3. Remove the screw, then remove the lamp from the assembly.
Exposure lamp Screw
Connector
5216/5220 Service Information Disassembly
Scanner Home Position Sensor (S1)
1. Remove the rear cover. 2. Remove the sensor.
3 - 25 Document Scanning
Scanner home position sensor
Scan Drive Motor (M5)
1. Remove the rear cover. 2. Remove the E-Sort PWA (if installed). 3. Remove the scan drive motor connector from the main logic PWA. 4. Remove the screws from the scan drive motor then remove the motor.
Scan drive motor Connector
Main logic PWA
E-Sort PWA
5216/5220 Service Information Disassembly
3 - 26 Photoconductor Process
Photoconductor Process
TD Cartridge
1. Open the right side access door. 2. Open the front door.
Front door Right side access door
3. Remove the screw.
Screw
5216/5220 Service Information Disassembly
4. Remove the TD cartridge. Note: The T/D cartridge is normally replaced as an assembly. Refer to the Preventive Maintenance section of the Service Information for instruction on re-conditioning of the T/D cartridge.
TD cartridge
3 - 27 Photoconductor Process
Photoconductor Unit
1. Remove the TD cartridge. 2. Slide the photoconductor unit out of the copier. Note: The photoconductor unit is normally replaced as an assembly. Refer to the Preventive Maintenance section of the Service Information for instruction on re-conditioning of the photoconductor unit.
Photoconductor unit
5216/5220 Service Information Disassembly
Charge Corona
1. Remove the photoconductor unit. 2. Remove 2 screws from the charge corona. 3. Slide the corona towards the front of the machine, pulling the locking tabs out from the left side of the PCU. 4. Lift the charge corona from the front and remove.
Screws
3 - 28 Photoconductor Process
Charge corona
Left
Front
Cleaning Blade
1. 2. 3. 4. Remove the photoconductor unit. Remove the charge corona. Remove 3 screws. Remove the cleaning blade.
Screws
Cleaning blade
5216/5220 Service Information Disassembly
Transfer Corona
1. Remove the right side access door from the copier. 2. Remove the springs from the transfer corona. 3. Release the tabs on the bottom of the transfer corona 4. Remove the corona from the right side access door.
3 - 29 Photoconductor Process
Springs
Transfer corona
Tabs
5216/5220 Service Information Disassembly
Replacing the Corona Wire Installing the Corona When installing new corona wire: · Make sure the wire is not twisted or bent · Make sure the wire is in the groove as shown When installing the springs, make sure the end of the spring is between the ribs as shown.
Set end of spring here
3 - 30 Photoconductor Process
Do not twist or bend corona wire
Groove
Corona wire
5216/5220 Service Information Disassembly
3 - 31 Photoconductor Exposure
Photoconductor Exposure
Laser Cautions
WARNING
Turn off the main power switch and unplug the machine before attempting any of the procedures in this section. Laser beams can seriously damage your eyes.
Laser Unit
Note: The laser unit in this copier is replaced only as a unit. No component parts are available. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Remove the rear cover. Remove the left side cover Remove the right side cover. Remove the front cover. Remove the exposure lamp assembly. Remove the lens assembly Remove the CCD sensor PWA. Remove the scan drive motor. Remove the scanner home sensor. Remove the platen over/closed sensor. Remove the optical frame.
Optical frame
5216/5220 Service Information Disassembly
Note: Install the optical frame as shown.
Step1 Step 3 Step 2
3 - 32 Photoconductor Exposure
12. Remove the copy exit tray. 13. Remove the left and rear frames.
Left frame Rear frame
Copy exit tray
5216/5220 Service Information Disassembly
14. Remove the laser unit.
3 - 33 Photoconductor Exposure
Laser unit
Note: After replacing the laser unit, the following adjustments must be done: · · · · · · · · Lead edge registration adjustment Lead edge void Drawer 1 Lead edge void Drawer 2 Lead edge void Bypass Image trailing edge void adjustment Rear edge void area Image centering Drawer 1 Image centering Bypass
5216/5220 Service Information Disassembly
3 - 34 Paper Feed
Paper Feed
Main Drive Motor (M1)
1. Remove the rear cover. 2. Disconnect the connector from the main logic PWA. 3. Remove 2 screws then remove the main drive motor.
Connector
Main drive motor
5216/5220 Service Information Disassembly
Paper Feed Assembly
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Remove the rear cover. Remove the left side cover. Remove the right side cover. Remove the front cover. Remove the exposure lamp assembly. Remove the lens assembly. Remove the CCD sensor PWA. Remove the scan drive motor. Remove the scanner home sensor. Remove the platen over/closed sensor. Remove the optical frame. Remove the right side frame (front and rear).
3 - 35 Paper Feed
Right frame (rear)
Right frame (front)
5216/5220 Service Information Disassembly
13. Remove the paper feed assembly.
3 - 36 Paper Feed
Paper feed assembly
5216/5220 Service Information Disassembly
Paper Feed Drive Assembly
1. Remove the paper feed assembly. 2. Remove the paper feed drive assembly.
3 - 37 Paper Feed
Paper feed drive assembly
Clutch pawl
Note: When installing the paper feed drive assembly, push the clutch pawl down as shown.
5216/5220 Service Information Disassembly
Registration Roller Solenoid (SOL2)
1. 2. 3. 4. Remove the paper feed drive assembly. Remove the gear. Remove the screw from the registration roller solenoid. Remove the solenoid.
3 - 38 Paper Feed
Drawer 1 Paper Feed Solenoid (SOL6)
1. 2. 3. 4. Remove the paper feed drive assembly. Remove the gear. Remove the screw from the tray 1 paper feed solenoid. Remove the solenoid.
Drawer 1 paper feed solenoid
Registration roller solenoid
Gear
5216/5220 Service Information Disassembly
Registration Roller Clutch
1. Remove the paper feed assembly. 2. Remove the E-ring from the registration roller clutch. 3. Remove the clutch from the paper feed assembly.
3 - 39 Paper Feed
Registration Roller
1. 2. 3. 4. Remove the paper feed assembly. Remove the green jam clearing knob. Remove the E-ring from the font and rear of the registration roller. Remove the roller.
E-ring Registration roller clutch
E-ring Jam clearing knob
Registration roller E-ring
5216/5220 Service Information Disassembly
Drawer 1 Paper Feed Clutch
1. Remove the paper feed assembly. 2. Remove the E-ring from the paper feed clutch. 3. Remove the paper feed clutch.
3 - 40 Paper Feed
Paper Feed Roller
1. Remove the paper feed assembly. 2. Remove the E-ring from the rear of the paper feed roller. 3. Remove the roller.
Drawer 1 paper feed clutch
E-ring
E-ring
Drawer 1 paper feed roller
5216/5220 Service Information Disassembly
Right Side Access Door Interlock Switch (SW2)
1. Remove the paper feed assembly. 2. Remove the right side access door interlock switch.
3 - 41 Paper Feed
Paper Registration Roller Sensor (S11)
1. Remove the paper feed assembly. 2. Remove the paper registration roller sensor.
Drawer 2 Transport Sensor (5220 only; S14)
1. Remove the paper feed assembly. 2. Remove the drawer 2 transport sensor.
Drawer 2 Door Open/Closed Sensor (5220 only; S13)
1. Remove the paper feed assembly. 2. Remove the drawer 2 door open/closed sensor.
Right side access door interlock switch
Paper registration roller sensor Drawer 2 open/closed sensor Drawer 2 transport sensor
5216/5220 Service Information Disassembly
Drawer 1 Present Switch (SW3)
1. Remove the paper feed assembly. 2. Remove the drawer 1 present switch.
3 - 42 Paper Feed
Drawer 2 Present Switch (5220 only; SW4)
1. Remove the paper feed assembly. 2. Remove the drawer 2 present switch.
Drawer 1 Paper Empty Sensor (S15)
1. Remove the paper feed assembly. 2. Remove the drawer 1 paper empty sensor.
Drawer 2 Paper Empty Sensor (5220 only; S16)
1. Remove the paper feed assembly. 2. Remove the drawer 2 paper empty sensor.
Drawer 1 paper empty sensor Drawer 1 present sensor
Drawer 2 paper empty sensor
Drawer 2 present sensor
5216/5220 Service Information Disassembly
Bypass Feed Assembly
1. Remove the rear cover. 2. Disconnect the bypass feed connector.
3 - 43 Paper Feed
Bypass feed connector
Lower left rear of copier
3. Remove the screws and slide the bypass feed assembly out of the copier.
Bypass feed assembly
5216/5220 Service Information Disassembly
Bypass Paper Transport Clutch
1. 2. 3. 4. Remove the bypass feed assembly from the copier. Remove the paper guide. Remove the clutch bracket. Remove the bypass paper transport clutch.
3 - 44 Paper Feed
Paper guide
Clutch bracket
Bypass paper transport clutch
5216/5220 Service Information Disassembly
Bypass Paper Feed Roller Assembly
1. Remove the bypass feed assembly from the copier. 2. Remove the paper guide. 3. Remove the clutch bracket.
Paper guide
3 - 45 Paper Feed
Clutch bracket
4. Remove the shutter arm. Note: When installing the shutter arm, make sure the lever fits as shown.
Shutter arm
Lever
5216/5220 Service Information Disassembly
5. Remove the spring. 6. Remove the cam arm.
Cam arm
3 - 46 Paper Feed
Spring
Roller assembly
Cam arm
Note: When installing the cam arm, make sure it is under the roller assembly.
5216/5220 Service Information Disassembly
7. Remove the E-ring. 8. Remove the bypass paper feed roller assembly.
Bypass paper feed clutch
3 - 47 Paper Feed
E-ring
Bypass Paper Feed Clutch
1. Remove the bypass paper feed roller assembly. 2. Remove the E-ring from the bypass paper feed clutch. 3. Remove the clutch.
E-ring Bypass paper feed roller assembly
5216/5220 Service Information Disassembly
Bypass Paper Feed Roller/Pickup Roller
1. Remove the bypass paper feed roller assembly. 2. Remove the E-ring and pin then slide the shaft out of the rollers. 3. Remove the rollers. Note: When installing the paper feed roller, make sure it is installed in the direction shown.
Shaft
3 - 48 Paper Feed
E-ring Pin
Pickup roller Paper feed roller
5216/5220 Service Information Disassembly
Bypass Paper Feed Solenoid (SOL3)
1. Remove the bypass feed assembly. 2. Remove the screw. 3. Remove the solenoid.
3 - 49 Paper Feed
Screw
Bypass feed solenoid
Latches
Note: When installing the solenoid, make sure the latches move freely.
5216/5220 Service Information Disassembly
3 - 50 Fuser
Fuser
Fuser Assembly
1. 2. 3. 4. Remove the rear cover. Disconnect the fuser connectors. Remove the right side access door. Remove the right side cover.
Connectors Left lower corner
5. Remove the screws from the fuser assembly. 6. Remove the fuser from the copier.
Fuser assembly
5216/5220 Service Information Disassembly
Fuser Paper Exit Sensor (S9)
1. Remove the fuser assembly. 2. Remove the sensor.
3 - 51 Fuser
Fuser paper exit sensor
5216/5220 Service Information Disassembly
Fuser Thermofuse (TF)
1. Remove the fuser assembly from the copier. 2. Remove the screws from the thermofuse. 3. Remove the fuse.
Thermofuse
3 - 52 Fuser
Fuser Thermistor (TH)
1. Remove the fuser assembly from the copier. 2. Remove the screw from the thermistor. 3. Remove the thermistor. Note: When installing the thermistor make sure it is in contact with the fuser roller.
Thermistor
5216/5220 Service Information Disassembly
Fuser Lamp
1. Remove the fuser assembly from the copier. 2. Remove the screw from the front (left) side. 3. Remove the jam access door from the fuser assembly.
3 - 53 Fuser
Hole
Screw Spring end
Jam access door
Note: When installing the jam access door make sure the spring end fits in the hole on the fuser frame as shown.
5216/5220 Service Information Disassembly
4. Remove the 2 screws, then remove the pressure roller assembly.
Grounding plate Paper guide Grounding spring
3 - 54 Fuser
Screw
Screw
Pressure roller assembly
Note: When assembling the pressure roller unit make sure the grounding spring is under the grounding plate as shown.
5216/5220 Service Information Disassembly
5. 6. 7. 8. 9. 10. Remove the screw from the fuser cover. Slide the fuser cover to the rear (right) to release the pawls holding the cover. Removes the screw attaching the fuser lamp to the fuser cover. Remove the fuser lamp lead from the thermofuse. Remove the fuser lamp bracket. Slide the fuser lamp out of the fuser roller to remove.
Fuser cover pawl
3 - 55 Fuser
Fuser lamp Fuser cover screw
Fuser lamp bracket
Fuser lamp screw
Note: When installing the fuser lamp make sure to route the cable inside the ribs on the fuser cover.
5216/5220 Service Information Disassembly
Fuser Roller
1. 2. 3. 4. Remove the fuser assembly from the copier. Remove the fuser lamp. Remove the separation finger bracket. Remove the fuser roller.
3 - 56 Fuser
Ground strap
Separation finger bracket
Fuser roller
Note: When installing the fuser roller, make sure the grounding strap is touching the roller.
5216/5220 Service Information Disassembly
Separation Fingers
1. 2. 3. 4. Remove the fuser assembly from the copier. Remove the fuser cover. Remove the separation fingers bracket. Remove the separation fingers
3 - 57 Fuser
Separation finger
5216/5220 Service Information Disassembly
Pressure Roller
1. 2. 3. 4. Remove the fuser assembly from the copier. Remove the lower pressure roller assembly. Remove the mylar paper guide. Remove the pressure roller.
Mylar paper guide
3 - 58 Fuser
Pressure roller
Pressure roller assembly case
Mylar paper guide
Note: When installing the paper guide, make sure it touches the case of the pressure roller assembly.
5216/5220 Service Information Disassembly
3 - 59 Copy Exit
Copy Exit
Paper Exit Assembly
1. 2. 3. 4. 5. 6. Remove the rear cover. Remove the right side cover. Remove the front cover. Remove the fuser assembly. Remove the connectors from the main logic PWA Remove the E-ring from the lower drive gear then remove the main drive belt.
E-ring
Drive belt
5216/5220 Service Information Disassembly
7. 8. 9. 10. Remove the right side frame bracket. Remove 2 screws from the paper exit assembly. Slide the paper exit unit to the front to release the pawls. Remove the paper exit assembly from the copier.
Pawl
3 - 60 Copy Exit
Paper exit assembly screw
Paper exit assembly
Right side frame bracket Pawl Paper exit assembly screw
5216/5220 Service Information Disassembly
Transport Roller
1. Remove the paper exit assembly from the copier. 2. Remove the top cover from the paper exit assembly.
3 - 61 Copy Exit
Top cover
5216/5220 Service Information Disassembly
3. 4. 5. 6. Remove the 2 screws from the paper guide. Remove the gear from the transport roller. Press the pawls in and remove the paper guide as shown. Remove the transport roller.
3 - 62 Copy Exit
Transport roller
Gear Paper guide
Pawls
5216/5220 Service Information Disassembly
Copy Exit Roller
1. Remove the optical frame. 2. Remove the wire harnesses from the copy exit roller unit cover.
3 - 63 Copy Exit
Top view
Wire harnesses
3. Remove the top cover from the copy exit roller unit.
Top cover
5216/5220 Service Information Disassembly
4. Remove the gear from the rear of the copy exit roller. Note: When installing the gear make sure the pin is installed as shown. 5. Remove the E-ring and bearing from the from of the copy exit roller unit. 6. Remove the bracket from the front of the copy exit roller unit. 7. Remove the paper copy roller unit as shown. Note: When installing the copy exit roller unit make sure the ribs fit into the slots on the assembly as shown.
Gear
3 - 64 Copy Exit
Pin
Slots
Bracket
Ribs E-ring
5216/5220 Service Information Disassembly
8. Remove the E-ring from each end of the copy exit roller. 9. Slide the copy exit roller forward. 10. Remove the copy exit roller.
E-ring
3 - 65 Copy Exit
E-ring Copy exit roller
5216/5220 Service Information Disassembly
3 - 66 ADF-516
ADF-516
ADF Unit
1. Disconnect the ADF connector at the rear of the copier.
ADF connector
2. Open the ADF to a 100 degree angle and lift up to remove.
ADF
5216/5220 Service Information Disassembly
ADF Covers
Original Feed Cover 1. Open the original feed assembly. 2. Remove 2 screws from the cover. 3. Remove the cover.
Original feed cover
3 - 67 ADF-516
Screws
ADF Feed/Jam Access Cover 1. Open the ADF feed/jam access cover. 2. Remove the screws from the plastic hinges. 3. Open the hinges and remove the cover.
Hinge Hinge
ADF feed/jam access cover
5216/5220 Service Information Disassembly
Front Cover 1. Lift ADF unit. 2. Release the 3 pawls holding the front cover. 3. Remove the cover. Rear Cover 1. Lift the ADF unit. 2. Remove 2 screws. 3. Release the 2 pawls. 4. Remove the cover.
3 - 68 ADF-516
Rear cover
Pawls Front cover
Pawls
5216/5220 Service Information Disassembly
Original Tray 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the 2 screws holding the tray. 4. Slide the tray to the rear. 5. Disconnect the connector. 6. Remove the tray.
Connector
3 - 69 ADF-516
Original tray
Screw
Screw
Original Tray Lower Cover 1. Remove the original tray. 2. Turn the tray upside down and remove the screws. 3. Remove the lower cover.
Lower cover
5216/5220 Service Information Disassembly
ADF PWAs
ADF Sensor PWA 1. Remove the original feed cover. 2. Remove the screw from the PWA. 3. Remove the spring. 4. Disconnect the connector. 5. Remove the PWA.
3 - 70 ADF-516
Sensor PWA
Connector
Spring
5216/5220 Service Information Disassembly
ADF Logic PWA 1. Remove the rear cover. 2. Remove the connectors. 3. Remove the PWA.
Logic PWA
3 - 71 ADF-516
Connectors
5216/5220 Service Information Disassembly
Original Feed Unit
1. 2. 3. 4. 5. Remove the front cover. Remove the rear cover. Remove the drive belt. Disconnect the connectors. Remove the original feed unit.
Drive belt
3 - 72 ADF-516
Original feed unit
Connectors
5216/5220 Service Information Disassembly
ADF APS Length Sensors (S207, S208)
1. Remove the original tray. 2. Remove the original tray lower cover. 3. Remove the sensors.
Length sensor 2
3 - 73 ADF-516
Length sensor 1
ADF Pickup Roller Solenoid (SOL201)
1. Remove the original feed cover. 2. Remove the screws. 3. Remove the solenoid.
Pickup roller solenoid
5216/5220 Service Information Disassembly
Original Pickup Clutch
Remove the original feed cover. Remove the drive belt. Remove the E-ring. Remove the rear bearing, gear, hinge and hinge spring. 5. Slide the shaft forward to free the front bearing. 6. Lift the arm and remove the shaft. 1. 2. 3. 4.
Shaft E-ring
3 - 74 ADF-516
Hinge spring Arm Front bearing Hinge
Rear Bearing
7. Remove the E-ring. 8. Remove the clutch.
Clutch
E-ring
5216/5220 Service Information Disassembly
ADF Pickup Roller Assembly
1. Remove the original feed cover. 2. Lift the shutter arm. 3. Slide the assembly toward the rear, removing the front bearing from the cover. 4. Remove the pickup roller assembly. Note: When installing the pickup roller assembly, make sure the guide fits in the slot as shown.
Shutter arm Guide Slot
3 - 75 ADF-516
Front bearing Pickup roller assembly
ADF Pickup Roller ADF Paper Feed Roller
1. 2. 3. 4. 5. 6. Remove the ADF pickup roller assembly. Remove the E-ring and pin. Remove the gear. Remove the shaft. Remove the pin and gear. Remove the rollers.
Pin
Gear
Gear Pin Shaft E-ring
5216/5220 Service Information Disassembly
ADF Drive Frame
1. 2. 3. 4. Remove the front cover. Remove the rear cover. Remove the screws. Remove the drive frame.
3 - 76 ADF-516
Drive frame
ADF Feed Motor Assembly ADF Drive Belt
1. Remove the ADF drive frame. 2. Remove the ADF feed motor assembly from the ADF drive frame. 3. Remove the drive belt.
ADF feed motor assembly
Drive belt
5216/5220 Service Information Disassembly
ADF Feed Motor (M201)
1. Remove the ADF feed motor assembly. 2. Disconnect the connector. 3. Remove the feed motor.
Connector
3 - 77 ADF-516
Drive frame
Feed motor
ADF Original Feed Clutch (CL201)
1. Remove the drive frame. 2. Cut the Tie-wrap and disconnect the connector from the frame. 3. Remove the E-ring. 4. Remove the clutch. Note: When installing the clutch make sure the arm on the clutch fits into the cover rib as shown.
Tie-wrap Rib Arm E-ring
Connector
5216/5220 Service Information Disassembly
Transport Roller
1. 2. 3. 4. 5. Remove the drive frame. Remove the original feed clutch. Remove the front E-rings. Remove the transport roller gear. Remove the transport roller bearings
Gear E-ring
3 - 78 ADF-516
Bearings
6. Remove the transport roller cover. 7. Remove the transport roller.
Transport roller
Transport roller cover
5216/5220 Service Information Disassembly
Registration Roller
1. 2. 3. 4. 5. Remove the transport roller. Remove the front and rear E-rings. Remove the gear. Remove the front and rear bearings. Remove the registration roller.
3 - 79 ADF-516
E-ring
Bearing Gear
E-ring Bearing
Registration roller
5216/5220 Service Information Disassembly
Paper Feed Guides (Upper/Lower)
1. Remove the drive frame. 2. Remove the screws. 3. Remove the upper paper feed guide. Note: When installing the upper paper feed guide, make sure the guide fits the frame as shown.
Fit as shown Upper paper feed guide
3 - 80 ADF-516
4. Remove the screws. 5. Remove the lower paper feed guide.
Lower paper feed guide
5216/5220 Service Information Disassembly
Original Exit Roller
1. 2. 3. 4. Remove the upper and lower paper feed guides. Remove the front and rear E-rings. Remove the gear and bearings. Remove the original exit roller.
Gear
3 - 81 ADF-516
Bearing E-ring
Bearing
E-ring
Original exit roller
5216/5220 Service Information Disassembly
3 - 82 SS-516 System Stand
SS-516 System Stand
Note: The SS-516-2 (2 drawer model) is shown. The disassembly for SS-516-1 (1 drawer model) is the same except that it only has one drawer.
Rear Covers
1. Remove the screws. 2. Remove the rear covers.
Covers
Screws
5216/5220 Service Information Disassembly
Paper Feed Assembly
1. Remove the system stand rear covers. 2. Remove the copier from the system stand. Note: Refer to the Installation section of the Service Information CD for additional details, if needed, about removing the copier from the system stand.
3 - 83 SS-516 System Stand
5216/5220 Service Information Disassembly
3. 4. 5. 6. 7. 8. Disconnect the connectors to the paper feed units. Open the system stand access doors. Remove the screws from the paper feed units. Remove the drive belt. Release the gear, Remove the paper feed assembly.
Gear
3 - 84 SS-516 System Stand
Connectors
Paper feed assy's System stand access door
Drive belt
5216/5220 Service Information Disassembly
Paper Transport Solenoid (SOL701) Paper Feed Solenoid (SOL702; SOL703,2nd drawer)
1. Remove the system stand rear cover. 2. Remove the solenoids
Paper transport solenoid
3 - 85 SS-516 System Stand
Paper feed solenoid
Transfer Roller Gear Assembly
1. 2. 3. 4. 5. Remove the paper feed assembly. Remove the first pin Remove the 2 E-rings. Remove the second pin Remove the gear assembly.
E-rings
Pin Pin
5216/5220 Service Information Disassembly
Transport Roller
1. Remove the transport roller gear assembly. 2. Remove the E-rings from the transport roller. 3. Remove the transport roller from the paper feed assembly. Note: Be sure to route the grounding spring over the bearing when installing the transport roller.
E-ring
3 - 86 SS-516 System Stand
Transport roller
Grounding spring
Bearing
E-ring
Paper Feed Roller Clutch
1. Remove the rear covers. 2. Remove the E-ring from the clutch. 3. Remove the clutch. Note: When installing the clutch, be sure to assemble it as shown.
E-ring
Clutch assembly
5216/5220 Service Information Disassembly
Paper Feed Roller
1. 2. 3. 4. Remove the paper feed assembly. Remove the paper feed gear assembly (including paper feed clutch). Remove the E-ring. Remove the paper feed roller.
3 - 87 SS-516 System Stand
Note: When installing make sure the spring is in the grooves as shown.
Groove Spring E-ring
Groove
Paper feed roller Paper feed gear assembly
5216/5220 Service Information Disassembly
3 - 88 ET-516 One Bin Tray
ET-516 One Bin Tray
1 Bin Tray
1. Press inwards to remove the tray from the levers.
Levers
1 Bin Tray Drive Motor (M51)
1. 2. 3. 4. Remove the right side cover. Remove the front cover. Disconnect the motor connector. Remove the motor.
Connector Motor