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Important:.. the information presented here is for the use of a qualified, experienced technician. Without the background knowledge which comes with training, you risk doing more damage than good to the copier & also risk your own safety.
If you are not willing to take 100% responsibility for your actions, do not use the information posted here. Thank you. Read our Conditions of Use for more information

1012 style
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1012 style TECH INFO
1012, 5011, 5012, 5014
1012 style Copier illustration

These model #’s are trademarks of Xerox Corporation.
All of this information plus far more detailed procedures and parts lists
can be found in their Service Manual. This is available for sale on their website at www.xdss.com

These models as well as many other makes and models are covered in Intravia’s Guides: 3rd Edition.

Status Codes:
C-8/C-9/C-0 : Manual Feed Mode Misfeed (or no paper detected in Manual Feed Mode) Check out the Manual Feed Sensor (actuated by the slide piece for the bypass).
E-1 Paper Jam (between the upper feed & fuser)
E-3 Paper Jam (Exit jam)
E-5 Clamshell is open
E-6 Lower tray jam clearance door is open
J-1 Toner Code : Read below about how to disable the toner light if you'd like to.
J-3 "Cartridge not Installed"... Or not seated properly. Check that the drum shaft on the cartridge is fully seated into the front end cap.
J-7 "End of Cartridge Life"... Time for a new Copy Cartridge, or you can recondition the cartridge. On a 1012, this code is triggered by an actuator on a float rising up into view in the 'window' on top of the cartridge (as the reclaim fills up). Can also be caused by a dirty window or sensor. On a 5012/14 or 5011, J-7 means an electronic timer reached 18K. J-7 can also be caused by no continuity (blown fuse) across pins 3&4 on the cartridge connector upon install. Also see J-3 "drum shaft note".
J-8 "Wrong Copy Cartridge"... This will happen if you attempt to use a 5011 cartridge in a 5012/14 machine (or vise-versa). Can also happen if fuse #2 (pins 3&5) is prematurely blown. Also see J-3 "drum shaft note".
L-6 Key Counter Problem
L-8 Optics Overheat Problem : Check that the optics cooling fan is working & the filter isn't all clogged up.
U-1 Clock-Pulse Problem : Check the timing disk on the Scanner for damage or excessive dust & make sure timing sensor is in position. Look for broken gears on the main motor, or mechanical binding in the copy cartridge or fuser. Read below in "Troubleshooting Tips" about Main Motor Gears breaking.
U-2 Lamp Carriage / Half-Rate Carriage Drive Problems
U-3 Lens & Mirror Drive Problem
U-4 Fuser Problem... Check out the Heat Lamp, reset the Thermal Fuse if needed, & make sure the Thermistor is in position & ok
U-6 Main Board Battery Low: Check voltage between TP1 & TP2 on the Main Board... if the voltage is below 2 VDC, replace the batteries.
U-8 Exposure Lamp Control Circuit Problem : Could be the Exposure Lamp or exposure thermal fuse... or the exposure sensor isn't seeing the lamp come on. The sensor looks through the mirrors at a reference strip on the flip side of the lead edge guide to the left of the platen glass. Make sure the mirrors, sensor, & reference strip are clean & in place.

Diagnostics:
To enter diagnostics: Turn on the copier while holding the '0' button... all display panel indicators will light.
To enter a code: Enter the code followed by the Start button.
To exit diagnostics: Turn power off.

Testing Switches & Sensors: (Input Component Codes)
In diagnostic mode, enter the code for the component followed by 'Print', then manually actuate the switch or sensor and watch for the quantity shown in the numeric display to increase by 2.
Code Components
2 The following Switches & Sensors:
  • Console Switches (except 'Stop/C')
  • Paper Path Switch
  • Exit Switch
  • Interlock Switches
  • Optical Registration Sensor
  • Low Toner Switch
  • 122%, 100% & Reduction Sensors
  • SW1 & SW2 on the Main Board
  • Key Coder Signal
  • Manual Feed Mode Sensor
  • Paper Size Sensor
3 Auto Exposure Sensor
4 Exposure Input Voltage
5 Hz Read Signal (1012F)
& Non-AE Light Quality Target (5012/14)
6 Platen Temperature Sensor
11 Preset Fuser Temperature
12 Fuser Temperature
13 Present Power for Heater Rod (Fuser Lamp)

Checking Clutches, Motors, Lamps, Solenoids & Corotrons: (Output Component Codes)
Use these codes to test a component such as a clutch or motor. Enter the code followed by 'Start' to activate a component. Most components will activate for 1 second (the Exposure lamp will light for 30 seconds).
Code Components
10 Optical Fan
31 Copy Motor
41 Main Motor & Erase Lamp
60 Exposure (upper limit control); includes Main Motor
61 Exposure (Auto Exposure Mode) and Main Motor
62 Exposure (Manual Exposure Mode) and Main Motor
64 Return Clutch
65 Scan Clutch & 77/82% Solenoid
66 Scan Clutch & 100% Solenoid
67 Scan Clutch & 130% Solenoid (5011/12/14 only)
68 Lens Motor (77/82%) (1012 only)
69 Lens Motor (122%) (1012 only)
70 Scan Clutch & 65/71% Solenoid (5011/12/14 only)
81 Upper Feed Solenoid
82 Lower Feed Solenoid
83 Registration Gate Solenoid
91 Interimage Lamp
92 High Voltage Power Supply
93 Developer Bias (LVPS)
Checking Total Copy Count: (5011, 5012/14) (Not available for 1012's)
Hold down the '0' for about 5 seconds, 'CC' will flash followed by the copy count 2 digits at a time (i.e.: CC, 01, 23, 67, CC would indicate 12,367 copies).

Checking the Copy Cartridge Count: (5011, 5012/14) (Not available for 1012's)
Hold down the 'Stop/C' button for 5 seconds. A number from 0 to 18 will show up. Than number is the rounded number in thousands of copies which the current cartridge has run to date.

Adjustments, VR's (Variable Resistors):
VR1: Manual Exposure Adjustment Clockwise increases exposure & lightens the copy.
VR2: Fuser Temperature Adjustment Run 3 copies of a Test Pattern first, then immediately open the copier & lower the front cover, enter Diagnostic Code 11 to view the current fuser temperature setting… Adjust VR2 until the display says '8d' which is Hexidecimal for 177 c (nominal temperature)
VR3: Auto Exposure Adjustment Clockwise increases exposure & lightens the copy.
VR4: Lead Edge Registration Clockwise increases registration
(NOTE: VR5,6,&7 are not found on the 1012's)
VR5: 65/71% Manual Exposure Adjustment Clockwise increases exposure (lighter copy)
VR6: Lead Edge Void (Erase Lamp Timing) Clockwise increases Lead Edge Void.
VR7: 130/122% Manual Exposure Adjustment Clockwise increases exposure (lightens copy).
1012: 1012 Variable Resistors 5011/5012/14: 5011, 5012 & 5014 Variable Resistors

CONFIGURATIONS, SW's (Switches on Main Board):
SW1: Power Saver On / Off
SW2 #1:
For 5012/14: On=5012, Off=5011 or 5014
For 1012: Off = Normal Position
SW2 #2: On = Priority for Lower Tray,
Off = Priority for Upper (Side) Cassette
SW2 #3: For 5012/14: On = U.S. R/E Settings (130%, 65%),
Off = European (Rank) R/E (122%,71%)
For 1012: On = Priority for Auto Exposure
Off = Priority for Manual Exposure
SW2 #4: For 5012/14 (Not Used)
For 1012: On = 1012 1:1, Off = 1012 R/E
Xerox 1012 style Configuration Dip Switches

TROUBLESHOOTING TIPS:

  • Inform the Customer: When XeroxÒ says to shake the toner well, they are not kidding. Unshaken toner cartridges may contain clumped toner which can cause the dispensing auger in the cartridge or the main motor gears to break.
  • Light copies, Toner not dispensing (sometimes clicking)... If a new toner ctg. was just installed, read the "Inform the Customer" above.
  • Blank Copies (sometimes intermittent)... This is usually caused by shorting end blocks on the transfer/detack corotron.
  • Strobing Copies... Even strobes is most often the DV Unit... Try scrubbing down the mag roller with some Scotch-Brite (or similar stuff)
  • Copier runs only one copy at a time... Weird symptom but rather simple answer... this is what the machine does when it thinks the bypass tray is engaged.
  • Copy Cartridge toner reclaim fills up very rapidly... Make a copy & when the lamp carriage is returning after the scan is complete, turn off the power. Look at the drum, if it is coated with toner, the Inter-Image Lamp isn't doing its job. Take notice of the # of wires going to the lamp (2,3 or 4) so you can order the correct lamp.
  • Checking the Connector on the Copy Cartridge: Looking at the connector as it sits on the back of the cartridge, we refer to the pins as numbers one through six from left to right (the ribbon cable is attached to pins 1 & 2). A new copy cartridge's connector will measure continuity across pins 3 & 4 (Fuse 1). Pins 3 & 5 should show continuity (Fuse 2). Pins 3 & 6 should measure 1,500 W on a 5012/14 or 15,000 W on a 5011 cartridge.
  • Main Motor Gears Breaking... This problem is usually caused by binding in the Scanner Transmission (not usually obvious during a physical inspection). Also can be commonly caused by a seized toner cartridge. Clean the Scan Rail and lube it with a light oil. The Scan Transmission should have no grease or oil. Degreasing the Transmission with 'Parts Cleaner' can do wonders. If the problem repeats itself, you may want to replace the Scanner Transmission. It is possible for just about any part of the gear train to cause this problem.
  • Unusual Feeding (Tires turn 1/2 way, often intermittent)... May be caused by the tooth on the feed clutch making contact with the frame of the machine (caused by cracks in the frame). Try filing down the rear (opposite the gear) 1/3 of the two 'clutch teeth' where the clutch goes through the frame.
  • Toner Light Disable... You can disable the sensor which watches for a magnet in the toner cartridge's meter by simply unplugging it (follow the wires from the sensor back to the board it plugs into). The sensor is located on the front of the machine close to the toner cartridge). The toner cartridge's meter counts copies & calls for a new toner cartridge regardless of how much toner remains in the current cartridge. Of course you'll need to inform your customer that when the toner actually runs low, they'll see the copies getting lighter (usually starting in the center).

1012 style
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