Xerox WorkCentre 5021, WorkCentre 5019 Service Manual

WorkCentre 5021/5019

Service Documentation

WC 5021/5019 Service Documentation

702P00886

Initial Issue

08/2012

***Xerox Private Data***

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

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

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

CAUTION

This equipment generates, uses and can radiate radio frequency energy, and if not installed
and used in accordance with the instructions documentation, may cause interference to radio
communications. It has been tested and f ound to comply with t he limits for a Clas s A comput ­ing device pursuant to subpart B of part 15 of FCC rules, which are designed to provide rea­sonable protection against such interference when operated in a commercial environment.
Operation of this equipment in a residential area is likely to cause interference in which case
the user, at his own expense, will be required to correct the interference.

Prepared by Creative and Technical Communications – North America

800 Phillips Road, Building 218-01A

Webster, New York 14580

ISO9001 and ISO27001 Certified

©2012 by Xerox Corporation. All rights reserved.

XEROX® and XEROX and design® are trademarks of Xerox Corporation in the US and/or
other countries.

Changes are periodically made to this document. Changes, technical inacc uracies, and typo­graphic errors will be corrected in subsequent editions.

Initial Issue

08/2012

WorkCentre 5021/5019

Front Matter

0-1

0.1 Getting to know this Service Manual........................................................................ 0-3

0.2 How to use the Service Manual ................................................. .... ..... .... .. .... .. .. ....... 0-3

0.3 Description for Terminol og y And Symbols............................................ ................... 0- 4

0 Introduction

Initial Issue
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08/2012

0-1

Introduction

0.1 Getting to know this Service Manual

This manual is used as the standard service manual for WorkCentre 5021/ 5019.

0.2 How to use the Service Manual

This manual describes the standard procedures for the servicing this product. Refer to Chapter
1 Service Call Procedure for efficient and effective servicing during maintenance calls.

For more information on the options, refer to the options manual.

2.1 Contents of Manual

This manual is divided into 10 chapters as described below.

• Chapter 1 Service Call Procedure
This chapter describes the general work and servicing procedures for the maintenance of

this product.

• Chapter 2 Troubleshooting
This chapter describes the troubleshooting procedures other than image quality trouble-

shooting for this product.

• Chapter 3 Image Quality Troubleshooting
This chapter describes the image quality troubleshooting procedures for this product.

• Chapter 4 Disassembly/Assembly and Adjustment
This chapter describes the disass embly, assembly, adjustment and replacement proce-

dures for components of this product.

• Chapter 5 Parts List
This chapter contains the spare parts information for this product.

• Chapter 6 General
This chapter contains the following information.

6.1 Specifications

6.2 Tools/Service Consumables/Consumables

6.3 Service Data

6.4 Service Mode

6.6 KO PROGRAM# LIST

• Chapter 7 Wiring Data
This chapter contains the information about the Wiring Connector List/Locations, the Wir-

ing Data, and the BSD for this machine.

• Chapter 8 Accessories (not yet issued)

• Chapter 9 Installation/Removal
This chapter contains the installation and removal procedures for this product and the

options that are specific to it.

• Chapter 10 Mechanism & Functions Overview (not yet issued)

2.2 Information on Updating

This manual will be sent to each Service Center as specified below. Revisions must be incor­porated correctly to keep the manual up-to-date.

Initial Issue
WorkCentre 5021/5019

Updating Procedure:

• When the manual is updated, the issue number 'Ver. 1' will be changed to Ver. 1.1, Ver.

1.2, and so on.

08/2012

0-3

Introduction

0.1, 0.2

0.3 Description for Terminology And Symbols

The terms and symbols used throughout this manual are explained
here.

• The terms and symbols used at the beginning of a text are defined as follows:

DANGER

Indicates an imminently hazardous situation, such as death or serious injury if op era­tors do not handle the machine correctly by disregarding the statement.

WARNING

Indicates a potentially hazardous situation, such as death or serious injury if operators
do not handle the machine correctly by disregarding the statement.

CAUTION

Indicates a potentially hazardous situation, such as injury or property damage if operators do
not handle the machine correctly by disregarding the statement.

Instruction: Used to alert you to a procedure which, if not strictly observed, could result in dam­age to the machine or equipment.

Table 1 Terminology

Terminology Description

Assy Means Assembly.
TEC Value Abbreviation of Typical Electricity Consumption, which means the standard

power consumption. Read as 'tec'.

Purpose

Used to describe the purposes of Adjustment and Troubleshooting.

REP: Indicates the disassembly/assembly procedure for reference.

ADJ: Indicates the adjustment procedure for reference.

PL: Indicates the parts list for reference.

Terminology

Introduction

0.2, 0.3

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0-4

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1.1 Before Starting th e Servicing ... ................................................................................ 1-3

1.2 Service Call Procedure............................... ............................................................. 1-5

1.3 Detailed Contents of the Service Call...................................................................... 1-6

1.4 TRIM Check List....................................................................................................... 1-7

1.5 Periodic Replacement Parts/Consumables List....................................................... 1-7

1 Service Call Proced ur es

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1-1

Service Call Procedures

1.1 Before Starting the Servicing

1.1.1 Safety

To prevent any accident that may occur during a maintenance service, any warning or any cau­tion regarding the servicing must be strictly observed. Do not perform any haz ardous opera­tion.

1. Power Supply
To prevent electrical shocks, burns, or injury, etc., be sure to switch OFF the machine and

disconnect the plug before starting the maintenance service. If the machine has to be
switched ON, such as when measuring the voltage, take extra care not to get an electrical
shock.

2. Drive Area
Never inspect, clear or lubricate the drive area such as chain belts, chain wheel or gears

during the machine operation.

3. Heavy Parts
Position your hip lower when removing or installing heavy parts.

4. Safety Device
See that safety devices for preventing mechanical accidents, such as fuses, circuit break-

ers, interlock switches, etc., and those for pr otecting customers from injury, such as pan­els and covers, function properly. Modifications that hinder the function of any safety
devices are strictly prohibited.

5. Installing and Removing Parts
The edge of parts and covers may be sharp, take care not to touch them. Be careful not to

touch those parts, and wipe off any oil that may have adhered to your fingers or hands
before servicing. When removing parts, cables, and etc. do not pull them out by force but
remove them slowly.

6. Specified Tools
Follow the instruction when a tool is specified.

7. Cleaning the Toner and Developer
As the toner can be explosive, sweep or brush the spilled toner into a container for collect-

ing the sweepings.
Clean away the remaining toner with a damp cloth or use a standard vacuum cleaner that

is toner-tolerant. Never use the customer's vacuum cleaner.'
Do the same when cleaning the Developer because it also contains some toner.

8. Organic Solvents
When using an organic solvent such as the Drum Cleaner or Machine Cleaner, pay atten-

tion to the following:

• Ensure good ventilation in the room to prevent too much inhalation of solvent fumes.

• Do not use heated solvent.

• Keep it away from fire.

• Wash your hands thoroughly after use.

9. Harmful Laser

The customer or service personnel would not be exposed to any harmful laser during the
usual copying or scanning of documents. However, if a customer finds that the lamp that
is used for exposing documents is too bright when performing platen copy or scan, it is
possible to block the light from the platen glass by covering the portion of the platen doc­ument area that is usually not used for copying or scanning documents.

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1-3

Service Call Procedure

1.1

1.1.2 Things to Take Note When Handling Customer Information

1. Handling of customer's electronic information - samples of copy/print (paper data), log
files (Activity Report), and etc.

Before you bring back any samples for the purpose of investigation/analysis, always
obtain permission from the customer. Make sure to assure them that the data will not be
used for any other purpose.

2. Handling of a PWB, etc. that contains customer information.
Data such as Fax Address Numbers and URLs that are registered in the customer's

machine are all important customer information. These types of information are stored in
the PWB, etc. within the machine. Take extra care when handling them.

(1) In case of replacements, transfer the data to the new PWB and make sure that all

data in the old parts is thoroughly erased before disposing it. Make sure that no
important customer information gets leaked. (For details, refer to the preface in
Chapters 4 and 5)

(2) If a component was replaced and it was not found to be the cause of the malfunction,

return it to the machine it came from. (For components that were temporarily
installed/removed for troubleshooting, etc. clear the data using the CE Mode, etc.)

1.1.3 Other Precautions

Pay attention to the following when performing maintenance service to avoid wrong or redun­dant servicing:

1. Reference Materials
Before performing maintenance servicing, read all relevant technical mat erials to make a

systematic approach.

2. Disassembling
Make sure to check the assembled condition before removing parts or disassembling the

machine.

3. Installation/Adjustment
After the installation or adjustment is complete, check that no parts or tools are left inside

or on the assemblies before using the machine.

4. Handling of replaced parts/consumables
Make sure that the replaced parts or consumables as well as their packaging materials

are collected back to the Service Center.
For the separation and processing methods for the collected items, refer to the Common

Technical Information No. 2-027 for all machines.

• Drum Cleaner

WARNING

Never discard the Drum Cleaner into a fire. Always keep it away from open
flames to prevent it from catching and causing a fire. Always dispose of the
Drum Cleaner after it is completely used up. For recyclable parts, fill the nec­essary items in the [U-TAG] and perform collection.

5. General Precautions

• Take care not to disturb the customer's daily work.

• Place a drop cloth or paper on the floor of the service area to keep the site clean.

• Throw any trash generated during the maintenance service into a trash bag and

bring them back to the Service Center.

• Record clearly the service details and the consumables and parts replaced at visit in

the Machine Service Log.

Service Call Procedure

1.1, 1.2

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1.2 Service Call Procedure

1.2.1 Initial Actions

1. Ask the operator(s) about the machine condition.

2. Record the billing meter readings.

3. Inspect any error copies, then check the machine.

4. Check the Service Log.

1.2.2 When UM is requested, perform the following:

1. Check the problem status by performing the Level 1 Troubleshooting in [Chapter 2 Trou­bleshooting].

2. Perform the applicable Level 2 Troubleshooting FIP in [Chapter 2 Troubleshooting].

3. If there are no applicable items, troubleshoot by referring to [Chapter 7 BSD].

4. Check the copy quality.
Make several sheets of copies using the Test Chart (499T 00247), then check the quality

of the copies for problems.

5. Output the following [Error History Report] and check the [System Fail History] and [Paper
Jam History] in order to understand the machine status.

(1) Enter the System Administrator Mode.

i. Press the [Log In / Out] button and hold it down for 4 s or longer until the follow-

ing screen is displayed.

Figure 2 j0lj41897

(2) Load any one of A4 SEF, A4 LEF, Letter SEF, or Letter LEF into the Tray.
(3) Enter '202' at the Program Number and press the [Start] button.
(4) Enter '4' for [Error History Report] and press the [Start] button.
(5) Once printing has completed, press the [Log In / Out] button to exit from the Sy stem

Administrator Mode.

NOTE: When replacing parts that will incur cost to the customer, obtain the customer's
agreement before performing the replacement.

6. Repair all the secondary problems.

7. Perform TRIM Service.

ii. Use the keypad to enter the Passcode [11111 ]* 1 (5 '1 ' d ig it s) and pr ess the

[Start] button.

NOTE: *1: Default Value

iii. The Program Number input screen is displayed.

Initial Issue
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Figure 1 j0lj41896

1.2.3 When SM is requested, perform the following:

1. Check the copy quality.
Make several sheets of copies using the Test Chart (499T 00247), then check the quality

of the copies for problems.

2. Output the [Error History Report] and check the [System Fail History] and [Paper Jam His­tory] in order to understand the machine status.

• For how to output the [Error History Report], refer to [1.2.2 When UM is reque sted,

perform the following:].

NOTE: When replacing parts that will incur cost to the customer, obtain the customer's
agreement before performing the replacement.

3. Perform TRIM Service.

1.2.4 Final Actions

1. Check overall operation/features.

2. Check the machine exterior and consumables.

3. Train the operator as required.

4. Complete the Service Log and Service Report.

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Service Call Procedure

1.2

5. Keep the copy samples with the Service Log.

1.3 Detailed Contents of the Service Call

1.3.1 Initial Actions

1. Ask the operator(s) about the machine condition.

• How often and where do paper jams have been occurring recently

• How is the copy quality

2. Record the copy meter readings.

3. Inspect any error copies, then check the machine.

4. Check the print samples from previous service calls and the Service Log.

1.3.2 Checking Reproducibility of Problem

1. Check the problem status by performing the Level 1 Troubleshooting in [Chapter 2 Trou­bleshooting].

2. Perform the applicable Level 2 Troubleshooting FIP in [Chapter 2 Troubleshooting].

3. If there are no applicable items, troubleshoot by referring to [Chapter 7 BSD].

1.3.3 Checking Copy Quality

1. Make several sheets of copies using the Test Chart (499T 00247), then check the quality
of the copies.

1.3.4 TRIM Servicing

Perform TRIM servicing during a service call to maintain the machine performance.

1. Follow the TRIM Check List to perform the required TRIM items.

2. Check for parts that require periodical cleaning/replacement (consumables, parts) by
referring to the TRIM Chec List, the Periodic Replacement Parts/Consumables List, and
the Maintenance Report, and clean them if necessary. After a replacement, make sure
that you enter the CE Mode and use [HFSI Read / Clear] to clear the applicable
counter(s).

Service Call Procedure

1.3, 1.4

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Initial Issue

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1.4 TRIM Check List

C: Perform checking. Clean, replace, or feed if necessary.
O: Always perform cleaning and checking.
*: Always perform replacement service at the specified interval.

Table 1

No. Servicing Items

1.1 Pre-servicing Check
(Check the machine
operation sound)

1.2 Pre-servicing Check
(Copy and print the
Test Chart)

2 Clean the interior of the

machine
(Clean the paper trans­port system)

3 Cleaning the IIT C • Clean the Platen Glass surface and the Platen

4 Clean the DADF C • Clean the Feed Roll, Nudger Roll, and Retard

5 S af ety Check O • M ake sure that the power plug is plugged in

6.1 Post-servicing check
(Copy Quality Check)

6.2 Post-servicing check
(Check the machine
operation)

6.3 Post-servicing check
(Check the meter)

Every
time Service Details

C • Activate the machine and check that abnormal

noise is not heard.

C • Make several sheets of copies using the Test

Chart (499T 00247), then check the quality of
the copies.

C • Clean any paper dust and toner residue in the

paper path and on the jam sensor.

• Especially, clean the operation section of the
operator carefully.

Cushion with the optical cleaning cloth.

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

Roll with a cloth that has been wrung dry.

• Clean the DADF Platen Glass with the optical
cleaning cloth.

properly.

• Make sure that the power cords are not
cracked and no wires are exposed.

• Make sure that no extension cord with insuffi­cient length or power cord outside the specifi­cation, such as an off-the-shelf power strip, is
being used.

• Make sure that a single socket does not have
multiple power plugs plugged into it.

C • Make several sheets of copies using the Test

Chart (499T 00247), then check if the quality
satisfies the specification.

C • Check the paper feed and abnormal noise.

C • Create the Service Log and Service Report.

1.5 Periodic Replacement Parts/Consumables List

When servicing, check the number of copies and number of fed sheets for the consumables
and parts that require periodical cleaning/replacement. Clean or replace them if necessary.
The history can be checked by printing the Maintenance Report or by checking the approriate
counter in [HFSI Read / Clear] in CE Mode (6.4.2.9 HFSI Read / Clear).

For the items that cannot be checked in CE Mode, clean or replace them according to the
replacement intervals (standard PV).

CAUTION

Do not place the imaging materials, such as the Toner and the Drum, in the car for a long time.

NOTE: Clean the Platen Glass with a Platen Wax Cleane r 499D 00194 (194D) every 10K
Feeds.

Table 1

Parts/Consumables

No

Name/PL No.

1 Tray 1 Feed No.

Tray 1 Feed Roll / Retard
Pad
(PL 9.2)

2 Tray 2 Feed No.

Tray 2 Feed Roll/Nudger
Roll/Retard Roll
(PL 10.3)

3 MSI Feed Count

MSI Feed Roll/MSI Nudger
Roll/MSI Retard Pad
(PL 13.3)

4 Fusing Unit

(PL 7.1)

5 BTR Unit

(PL 6.1)

6 Document Feed No.

DADF Feed Roll/Nudger
Roll
(PL 56.5)
DADF Retard Pad
(PL 56.13)

7 Toner Cartridge

(PL 8.1)

8 Drum Cartridge *1

(PL 8.1)

HFSI
[Chain­Link]

950-803 50,000PV 1 Feed = 1 Count Up.

950-804 300,000PV 1 Feed = 1 Count Up.

950-802 50,000PV 1 Feed = 1 Count Up.

950-801 175,000PV 1 pass through the Fusing Unit

950-800 100,000PV 1 pass through the Fusing Unit

955-806 200,000PV Replace the Feed Roll,

- 9,000PV

950-807 343k cycle <Refer-

Replacement
Interval Check the counter

Replace both at the same
time.

Replace all 3 at the same
time.

Replace all 3 at the same
time.

Exit Sensor = 1 Count Up.

Exit Sensor = 1 Count Up.

Nudger Roll, and Retard Pad
at the same time.

NOTE: Clean the Platen Glass
with a Platen Wax Cleaner
499D 00914 (194D) every 10K
Feeds.

ence>75KPV*1@18PPM /
80KPV*1@20PPM

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1-7

Service Call Procedure

1.5

*1: The maximum number of prints is a reference value under the condition of A4 LEF and sim­plex printing. Some specific conditions such as paper size, number of copies for a print job, etc.
might cause a serious deterioration of image quality before the time to replace the drum car­tridge comes.

Service Call Procedure

1.5

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Initial Issue

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2 Status Indicator RAPs

2.1 Introduction

2.1.1 How to Troubleshoot............................................................................................. 2-3

2.1.2 How to Switch the Error Code Display.................................................................. 2-3

2.1.3 Glossary..................................................... ........................................................... 2-4

2.2 Product FIP

2.2.1 Leve l 1 FIP

2.2.1.1 Level 1 FIP..................................................................... .................................... 2-7

2.2.2 Leve l 2 FIP
CHAIN 3

003-500/795 N-Up NG Out Of Range/ AMS NG Out Of Range..................................... 2-9

003-754 IPS Overrun ..................................................................................................... 2-9

003-942 Not-Supported Doc Size .................................................................................. 2-9

003-951 1Job Max Page Over....................................................................................... 2-9

003-963 APS NG Out Of Range.................................................................................... 2-9

003-972 EPC Memory Full . ............................................................................................ 2-9

003-973 Auto Rotation NG Out Of Range...................................................................... 2-9

CHAIN 4

004-345 HVPS Communication Error ......................... .... ......... .... .... .... ........... .... .... ....... 2-11

CHAIN 5

005-122 DADF Simplex/Side 1 Pre Regi Sensor On Jam ............................................. 2-13

005-123 DADF Simplex/Side 1 Regi Sensor On Jam.................................................... 2-13

005-125/145 DADF Regi Sensor Off Jam/ DADF Regi Sensor Off Jam on Inverting.... 2-13

005-131/132 DADF Invert Sensor On Jam on Inverting/ DADF Invert Sensor On Jam. 2-13
005-134/139 DADF Invert Sensor Off Jam on Inverting/ DADF Invert Sensor Off Jam. 2-14

005-135 DADF Side 2 Pre Regi Sensor On Jam........................................................... 2-14

005-136 DADF Side 2 Regi Sensor On Jam.................................................................. 2-14

005-147 DADF Pre Regi Sensor Off Jam on Inverting .................................................. 2-15

005-196 Size Mismatch Jam on No Mix-Size ................................................................ 2-15

005-197 Prohibit Combine Size Jam.............................................................................. 2-15

005-198/199 Too Short Size Jam/ Too Long Size Jam ...................................... .... ....... 2-15

005-210 DADF Download Fail ............................ .. .. .. .... .. ..... .. .... .. .. .. .. ....... .. .. .... .. .. .. .. ..... 2-15

005-275/280 DADF RAM Fail/ DADF EEPROM Fail ..................................................... 2-15

005-305 DADF Feeder Cover Interlock Open................................................................ 2-16

005-500 DADF Download Flash Write Error .................................................................. 2-16

005-907/908/913 DADF Pre Regi Sensor/DADF Regi Sensor/DADF Invert Sensor Static Jam
2-16

005-940 DADF No Original Fail ..................................................................................... 2-16

005-948 SS-Size Mismatch Jam on No Mix-size........................................................... 2-16

CHAIN 10

010-311 Fusing Unit Center Thermistor Defect ............................................................. 2-17

010-312 Fusing Unit Rear Thermistor Defect ................................................................ 2-17

010-320 Over Heat Temperature Fail ...... ....... .... .. .... .. .... ....... .. .... .. .... .. ....... .... .. .... .. ....... 2-17

010-327 Fusing Unit On Time Fail ................................................................................. 2-17

010-379 Fusing Unit Hot Not Ready Return Time Fail................................................... 2-18

010-392 NOHAD Fan Defect.......................................................................................... 2-18

010-602 Over Temp Cooling Mode..................................................................... .... .... .. . 2-18

CHAIN 16

016-500 Controller Download Flash Write Error ............................................................ 2-19

016-501 Controller Boot Flash Write Error..................................................................... 2-19

016-502 UI Panel Download Flash Write Error.............................................................. 2-19

016-570 No Response from USB-Host for Scan Job..................................................... 2-19

016-571 No Response from USB-Host for Print Job...................................................... 2-19

016-742/744 Download File Error/ Download File Check Sum Error............................. 2-19

016-749/799 HBPL or XPJL Syntax Error/ Print Instruction Fail .................................... 2-20

016-759 Copy Counter Full ............................................................................................ 2-20

016-776 Marker Code Detection Fail ............................................................................. 2-20

CHAIN 23

023-600 Held Down key Error (UI Panel)....................................................................... 2-21

CHAIN 24

024-910/911/915 Tray 1/Tray 2/MSI Paper Length Mismatch ....................................... 2-23

024-950/951/954 Tray 1/Tray 2/MSI No Paper.............................................................. 2-23

024-958/959/960 MSI/Tray 1/Tray 2 Paper Size Mismatch ........................................... 2-23

024-965 APS NG Unselected......................................................................................... 2-23

CHAIN 41

041-210/211 STM NVM Out-Of-Order/ STM NVM R/W Error........................................ 2-25

CHAIN 42

042-325/614 Main Motor Rotation Error/ Main Motor Rotation Warning........................ 2-27

CHAIN 45

045-310 Image Ready Error........................................................................................ ... 2-29

045-313 IOT Logic Fail................................................................................................... 2-29

CHAIN 61

061-321 ROS Motor Fail ............... .. ......... .. .... .. .... ....... .... .. .... .. ......... .. .... .. .... .. ......... .. .... . 2-31

061-325 No SOS Fail ............................................................................................ .... .. ... 2-31

CHAIN 62

062-277 DADF Communication Fail............................................................................... 2-33

062-311 IIT Software Logic Fail..................................................................................... 2-33

062-360 Carriage Position Fail....................................................................................... 2-33

062-371/380 Lamp Illumination Fail/ AGC Fail............................................................... 2-33

062-386 AOC Fail....................................................................................... .. ......... .. .... .. . 2-34

062-389 Carriage Over Run Fail (Scan End Side)......................................................... 2-34

062-396 CCD Cable Connection Fail................................................. .. .. .... .. .. ....... .. .... .. . 2-34

CHAIN 71

071-105 Regi Sensor On Jam (Tray 1). ......................................................................... 2-35

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2-1

Status Indic a tor RAPs

CHAIN 72

072-102 Feed Out Sensor 2 On Jam............................................................................. 2-37

072-105 Regi Sensor On Jam (Tray 2).......................................................................... 2-37

072-210 Tray 2 Lift Up Fail..................................................... .... .. .... .. .. ....... .... .. .. .... .. ..... 2-37

072-212 Tray 2 Size Sensor Broken.............................................................................. 2-37

072-215 MCU-STM Communication Fail .................. .... .. ......... .... .. .... ....... .... .... .. .... ....... 2-37

CHAIN 75

075-135 Regi Sensor On Jam (MSI) . ............................................................................. 2-39

CHAIN 77

077-101 Regi Sensor Off Jam........................................................................................ 2-41

077-103 Fusing Unit Exit Sensor Off Jam (Long) .......................................................... 2-41

077-104 Fusing Unit Exit Sensor Off Jam (Short).......................................................... 2-41

077-106 Fusing Unit Exit Sensor On Jam . ..................................................................... 2-41

077-129 Regi Sensor On Jam (Duplex Wait)................................................................. 2-42

077-212 Tray Module Reset Fail............................................................................. .. ..... 2-42

077-300/301/305 Front Cover/Left Hand Cover/STM Cover Open................................ 2-42

077-900/901/904 Regi Sensor/Fusing Unit Exit Sensor/Feed Out Sensor 2 Static Jam 2-42

CHAIN 91

091-313 CRUM ASIC Communication Fail.................................................................... 2-43

091-401/402 Drum Cartridge Quality Life Over/ Drum Cartridge Life Over ................... 2-43

091-406/424 Drum Cartridge Normal Life Over/ Drum Cartridge Abnormal Life Over... 2-43

091-430 Drum Cartridge Life End ........ .... ......... .... .... .. .... ......... .... .. .... ......... .... .... .. .... ..... 2-43

091-440 Drum Cartridge Pre Near End.......................................................................... 2-43

091-441 Drum Cartridge Near End ............ ....... .... .. .... .... ....... .... .... .. .... ....... .... .... .. .... ..... 2-44

091-914 Drum CRUM Communication Fail.................................................................... 2-44

091-915/916 Drum CRUM ID Error/ Drum CRUM Market Identity Mismatch ................ 2-44

CHAIN 92

092-660/668 ATC Amplitude Fail/ ATC Average Fail..................................................... 2-45

092-661 Temperature Sensor Fail ....... .... ......... .... .. .... .... ......... .. .... .... ......... .. .... .... .... ..... 2-45

092-910 ATC Sensor Fail............................................................................ .... .. .... .... ..... 2-45

CHAIN 93

093-312 Toner Dispense Motor Rotation Fail................................................................ 2-47

093-400 Toner Near Empty............................................................................................ 2-47

093-406 Toner Pre Near Empty..................................................................................... 2-47

093-912 Toner Empty .................................................................................................... 2-47

093-956 Drum New CRU Installation Fail ..................... .. ....... .. .... .. .... .. ....... .. .... .. .... .. ..... 2-47

093-959 Drum New CRU Installation Fail Exceeds Thresholding Times....................... 2-47

CHAIN 95

095-910 No Drum Cartridge........................................................................................... 2-49

CHAIN 116

116-321 Controller Logic Fail......................................................................................... 2-51

116-323 Controller NVM Data Defect ............................................................................ 2-51

116-334 NVM Data Mismatch........................................................................................ 2-51

116-377 IIT Interrupt Time out ....................................................................................... 2-51

116-747 Invalid Page Margin ........................................................... .... ....... .... .. .... .. ....... 2-51

CHAIN 117

117-326 Controller Backup NVM Data Defect................................................................ 2-53

CHAIN 123

123-314 UI Panel Communication Fail........................................................................... 2-55

2.2.3 Other Failure FIP

2.2.3.1 AC Power FIP..................................................................................................... 2-57

2.2.3.2 +5VDC Power FIP.............................................................................................. 2-57

2.2.3.3 +24VDC Power FIP............................................................................................ 2-58

2.2.4 Generic FIP

2.2.4.1 Reflective Sensor Failure FIP............................................................................. 2-59

2.2.4.2 Permeable Sensor Failure FIP........................................................................... 2-59

2.2.4.3 Switch (Normal/Open) Failure FIP ..................................................................... 2-60

2.2.4.4 Solenoid/Clutch Not Energized Failure FIP........................................................ 2-60

2.2.4.5 Solenoid/Clutch Left Energized Failure FIP....................................................... 2-61

2.2.4.6 Motor Does Not Rotate Failure FIP.................................................................... 2-61

2.2.4.7 Motor Left Running Failure FIP.......................................................................... 2-62

2.2.4.8 NIP/RELEASE SOLENOID Not Energized Failure FIP...................................... 2-62

2.3 NET System Fault Check

2.3.1 No output is available, no data is printed .............................................................. 2-65

2.3.2 Printing can be performed but abnormally ........................................................... . 2-65

Status Indicator RAPs

08/2012

2-2

Initial Issue

WorkCentre 5021/5019

2.1.1 How to Troubleshoot

Level 1 Troubleshooting:

• Level 1 Troubleshooting (Level 1 FIP) is the first step to diagnose a problem. Level 1 FIP
asks you whether any Fault Code and other problematic symptoms exist, guiding you to
Level 2 Troubleshooting or BSD to resolve the problem.

Level 2 Troubleshooting:

• Level 2 Troubleshooting is a diagnostic procedure of separating a problem by Fault Code,
document/paper jam and other problematic symptoms. Performing a FIP or an appropri­ate procedure in the Check Procedure enables you to discover causes of a problem in a
short period of time.

How to proceed with troubleshooting and Cautions:

• First, perform Level 1 FIP to categorize a problem. Second, proceed to an appropriate
Level 2 FIP or BSD to resolve the problem. To fi nd t he causes of the problem using FIP or
Check Procedure etc., thoroughly read the instructions and follow the procedure properly.
Sometimes, when two or more causes exist, they cannot be identified at once, so the
same FIP should be repeated. In this case, pay attention to a different judgment made in
the process of the same FIP.

• For source voltage related problems, such as being unable to power up the machine,
refer to 'Other Failure FIP' to proceed with the troubleshooting.

2.1.2 How to Switch the Error Code Display

When a problem has occurred in the machine, an Error Code or a Fault Code (Chain-Link) will
be displayed on the UI screen. When an Error Code is being displayed, you can perform the
following operation to switch the display to the Chain-Link number that correspond to that Error
Code. To repair, check the Chain-Link number and proceed with the appropriate FIP.

How to switch to the Chain-Link number

1. When a problem has occurred, the displayed Error Code will be flashing.

Figure 1 j0lj21201

• The Check Procedure for general electrical parts (Motor, Solenoid/Clutch, Switch, Sensor
etc.) may not be shown in each troubleshooting for some cases. In such cases, proceed
to troubleshoot by referring to 'Generic FIP'.

Initial Issue
WorkCentre 5021/5019

2. With the Error Code being displayed, press and hold down the [ID Card Copy] button on
the Control Panel.

• As long as the button is being pressed, the Chain-Link number will be displayed and

flashing.

Figure 2 j0lj21202

08/2012

2-3

Status Indic a tor RAPs

2.1.1, 2.1.2

3. Releasing the [ID Card Copy] button returns the display to the Error Code.

2.1.3 Glossary

The following terminology are used throughout the t roubleshooting section. The meaning of
these terminology must be fully understood when performing problem analysis.

Common terms:

• Fault Code
This 6-digit code appears when the machine has found problems.

• Actuate (Deactuate)
To mechanically push (release) t he Actuator of the switch or the connected mechanical

linkage.

•Block
To place a sheet of document or paper on the photo sensor surface for detection.

• Check
To visually check for operation failure of parts such as relay or mechanical linkage, and

the failure status of the parts.

• Enter the CE Mode
To enter the CE Mode by following the procedure described in 'How to Enter/Exit the CE

Mode' of Chapter 6.

• Check the connection for short circuit
Turn the power OFF. Measure the resistance between the wire and the frame using the

ohm range of a tester.

• Check the connection for open circuit
Turn the power OFF. Measure the resistance between both ends of the wire using the

ohm range of a tester.

• Input Check [xxx-xxx]/Output Check [xxx-xxx]
To enter the Component Check by following the procedure described in 'How to Us e the

CE Mode' of Chapter 6.

• Analog Monitor [xxx-xxx]
To enter the Analog Monitor by following the procedure described in 'How to Use the CE

Mode' of Chapter 6.

• Check the voltage level

Status Indicator RAPs

2.1.2, 2.1.3

Voltage Level Range

+3.3VDC (H)

(L)

+5VDC (H)

(L)

+24VDC (H)

(L)

• PL 4.2
Refer to PL 4.2 in Chapter 5 Parts List.

• CH 6.2 Zone J4

08/2012

2-4

Table 1

+3.2 to +3.6VDC

0.0 to +1.0VDC
+4.8 to +5.4VDC

0.0 to +1.0VDC
+23.3 to +25.7VDC

0.0 to +3.0VDC

Initial Issue

WorkCentre 5021/5019

Refer to Chain 6.2 Zone J4 in Chapter 7 BSD.

• REP 4.1.3
Refer to REP 4.1.3 in Chapter 4.

• ADJ 4.1.3
Refer to ADJ 4.1.3 in Chapter 4.

• Replace the parts in sequence
When it is impossible to analyze causes of a problem further, replace the parts in

sequence. The part with a higher replacement frequency or higher possibility of causing a
problem is listed first for replacement.

Initial Issue
WorkCentre 5021/5019

08/2012

2-5

Status Indic a tor RAPs

2.1.3

Status Indicator RAPs

2.1.3

08/2012

2-6

Initial Issue

WorkCentre 5021/5019

2.2.1.1 Level 1 FIP

Procedure

Ask the operator about the problem. Did the operator operate the machine correctly?
YN

Explain the correct way to operate the machine to the operator.

Output all jobs that are stored in the memory. Turn the power OFF and ON. Is the UI display

normal?
YN

Refer to [BS D (CH2.1)] and [2.2.3 Other Failure FIP] to repair the malfunction in UI dis­play.

Check the Shutdown History. Refer to [6.4.2.1 Shutdown History] to display the Fault Code on
the UI. Is the Fault Code displayed on the UI?

YN

Refer to [Troubleshooting] in the User guide and repair the following errors.

• Problems With Hardware

• Problems With Image Quality

• Problems With Copy

• Problems W it h P ri n ter

• Problems With Scanner

• Problems With Network

• In Case of Paper Jam

• In Case of Document Jam

Proceed to Level 2 Troubleshooting and perform the applicable FIP.

Initial Issue
WorkCentre 5021/5019

08/2012

2-7

Status Indic a tor RAPs

2.2.1.1

Status Indicator RAPs

2.2.1.1

08/2012

2-8

Initial Issue

WorkCentre 5021/5019

003-500/795 N-Up NG Out Of Range/ AMS NG Out Of
Range

BSD-ON:-

[N-Up NG Out Of Range]

During 2-Up or 4-Up, the reduce/enlarge ration was not within the range of 25 to 400%.

[AMS NG Out Of Range]

003-951 1Job Max Page Over

BSD-ON:-

During Copy Job, the number of pages that can be scanned has been exceeded.

Cause/Action

Press [Stop] on the UI Panel and reduce the number of document pages.

During AMS (Auto Magnification Selection), the reduce/enlarge ration was not within the range
of 25 to 400%

Cause/Action

Press [Stop] on the UI Panel and change the settings.

003-754 IPS Overrun

BSD-ON:-

The IPS processing has overtook the Scan processing.

Cause/Action

This might be avoided by setting the R/E ratio to 99% or 101%. If this occurs frequently, obtain
the document from the User and contact the Support Department for assistance.

003-942 Not-Supported Doc Size

BSD-ON:-

During DADF Scan of a Copy Job, an unsupported document size was detected.

Cause/Action

1. Press [Stop] on the UI Panel.

2. Check the setting of the document size group.

3. Check whether the document size is a supported size.

4. If the document size is a supported size, the DADF might have malfunctioned. Refer to
following FIP to check the DADF.

• 005-196 (Size Mismatch Jam on No Mix-size)

• 005-948 (SS-Size Mismatch Jam on No Mix-size)

003-963 APS NG Out Of Range

BSD-ON:-

During Copy Job, when APS is selected, the image size obtained from document size x
reduce/enlarge ratio was detected to be larger than the largest Standard Paper Size.

Cause/Action

Press [Stop] on the UI Panel and change the settings.

003-972 EPC Memory Full

BSD-ON:-

During Copy Job, the EPC memory is filled up.

Cause/Action

Print out all the images that had been successfully scanned by the DADF so far and then per­form the copy again for the documents (images) that were unable to be scanned.

003-973 Auto Rotation NG Out Of Range

BSD-ON:-

During Copy Job, the following conditions were met.

• Rotation is required.

• The length of the image obtained by document x reduce/enlarge ratio is longer than 297
mm.

Cause/Action

Press [Stop] on the UI Panel and change the reduce/enlarge ratio.

Initial Issue
WorkCentre 5021/5019

08/2012

2-9

Status Indic a tor RAPs

003-500/795, 003-951

Status Indicator RAPs

003-500/795, 003-951

08/2012

2-10

Initial Issue

WorkCentre 5021/5019

004-345 HVPS Communication Error

BSD-ON:CH9.2

Communication failure between the ESS/MCU PWB and the HVPS was detected.

Cause/Action

1. Turn the power OFF and ON.

2. Turn OFF the power and check the connection between the HVPS J500 and the ESS/
MCU PWB J402 for open circuit, short circuit, and poor contact.

3. If no problem is found, replace the following parts in sequence:

• HVPS (PL 18.1)

• ESS/MCU PWB (PL 18.1)

Initial Issue
WorkCentre 5021/5019

08/2012

2-11

Status Indic a tor RAPs

004-345

Status Indicator RAPs

004-345

08/2012

2-12

Initial Issue

WorkCentre 5021/5019

005-122 DADF Simpl ex/Side 1 Pre Regi Sensor On Jam

BSD-ON:CH5.4

• After Pre-Feed started for the first sheet (DADF Feed M otor On (CW)) in Simplex and
Duplex, the DADF Pre Regi Sensor did not turn ON within the specified time.

• After Pre-Feed started for the second sheet onwards (DADF Feed Motor On (CW)) in
Duplex, the DADF Pre Regi Sensor did not turn ON within the specified time.

Cause/Action

Check the following:

• Transportation failure due to foreign substance on the document path.

• The surface of the Feed Roll and Nudger Roll for foreign substances.

• The surface of the Feed Roll and Nudger Roll for wear.

• The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

• The DADF Feed Clutch (Output Check [005-062]) for operation failure. (PL 56.7)

• The DADF Feed Motor (Output Check [005-008]) for operation failure. (PL 56.6)

• The Drive Gear for wear and damage.

If no problem is found, replace the DADF PWB. (PL 56.2)

005-123 DADF Simpl ex/Side 1 Regi Sensor On Jam

BSD-ON:CH5.5, CH5.4

005-125/145 DADF Regi Sensor Off Jam/ DADF Regi
Sensor Off Jam on Inverting

BSD-ON:CH5.5, CH5.4

[DADF Regi Sensor Off Jam]

After the DADF Pre Regi Sensor turned OFF at Scan operation, the DADF Regi Sensor did not
turn OFF within the specified time.

[DADF Regi Sensor Off Jam on Inverting]

After the DADF Pre Regi Sensor turned OFF at Invert operation, the DADF Regi Sensor did
not turn OFF within the specified time.

Cause/Action

Check the following:

• Transportation failure due to foreign substance on the document path.

• The surface of the Regi Roll, Out Roll, and Exit Roll for foreign substances.

• The surface of the Regi Roll, Out Roll, and Exit Roll for wear.

• The DADF Regi Sensor (Input Check [005-110]) for operation failure. (PL 56.14)

• The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

• The DADF Feed Motor (Output Check [005-008]) for operation failure. (PL 56.6)

• The Drive Gear for wear and damage.

If no problem is found, replace the DADF PWB. (PL 56.2)

The DADF Regi Sensor does not turn ON within the specified time after the DADF Pre Regi
Sensor On.

Cause/Action

Check the following:

• Transportation failure due to foreign substance on the document path.

• The surface of the Takeaway Roll and Regi Roll for foreign substances.

• The surface of the Takeaway Roll and Regi Roll for wear.

• The DADF Regi Sensor (Input Check [005-110]) for operation failure. (PL 56.14)

• The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

• The DADF T/A Clutch (Output Check [005-098]) for operation failure. (PL 56.7)

• The DADF Feed Motor (Output Check [005-008]) for operation failure. (PL 56.6)

• The Drive Gear for wear and damage.

If no problem is found, replace the DADF PWB. (PL 56.2)

Initial Issue
WorkCentre 5021/5019

08/2012

005-131/132 DADF Invert Sensor On Jam on Inverting/
DADF Invert Sensor On Jam

BSD-ON:CH5.5, CH5.4

[DADF Invert Sensor On Jam on Inverting]

After the DADF Regi Sensor turned ON at Invert operation, the DADF Invert Sensor did not
turn ON within the specified time.

[DADF Invert Sensor On Jam]

After the DADF Regi Sensor turned ON in the Scan operation, the DADF Invert Sensor did not
turn ON within the specified time.

Cause/Action

Check the following:

• Transportation failure due to foreign substance on the document path.

Status Indic a tor RAPs

2-13

005-122, 005-125/145

• The surface of the Out Roll for foreign substances.

• The surface of the Out Roll for wear.

• The DADF Invert Sensor (Input Check [005-211]) for operation failure. (PL 56.10)

• The DADF Regi Sensor (Input Check [005-110]) for operation failure. (PL 56.14)

• The DADF Feed Motor (Output Check [005-008]) for operation failure. (PL 56.6)

• The Drive Gear for wear and damage.

If no problem is found, replace the DADF PWB. (PL 56.2)

005-134/139 DADF Invert Sensor Off Jam on Inverting/
DADF Invert Sensor Off Jam

BSD-ON:CH5.5, CH5.4

[DADF Invert Sensor Off Jam on Inverting]

During the Invert operation where there is a next document, after the DADF Regi Sensor
turned OFF, the DADF Invert Sensor did not turn OFF within the specified time.

[DADF Invert Sensor Off Jam]

005-135 DADF Side 2 Pre Regi Sensor On Jam

BSD-ON:CH5.4, CH5.5

After the DADF Feed Motor started the reverse rotation at Invert operation, the DADF Pre Regi
Sensor did not turn ON within the specified time.

Cause/Action

Check the following:

• Transportation failure due to foreign substance on the document path.

• The surface of the Exit Roll for foreign substances.

• The surface of the Exit Roll for wear

• The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

• The DADF Feed Motor (Output Check [005-048]) for operation failure. (PL 56.6)

• The Exit Pinch Roll for operation failure (including for the operation failure of the Exit Nip
Release Solenoid (Output Check [005-072])). (PL 56.7)

• The Drive Gear for wear and damage.

If no problem is found, replace the DADF PWB. (PL 56.2)

During the Simplex and Duplex Scan operation, after the DADF Regi Sensor turned OFF, the
DADF Invert Sensor did not turn OFF within the specified time.

Cause/Action

Check the following:

• Transportation failure due to foreign substance on the document path.

• The surface of the Out Roll and Exit Roll for foreign substances.

• The surface of the Out Roll and Exit Roll for wear.

• The DADF Invert Sensor (Input Check [005-211]) for operation failure. (PL 56.10)

• The DADF Regi Sensor (Input Check [005-110]) for operation failure. (PL 56.14)

• The DADF Feed Motor (Output Check [005-008]) for operation failure. (PL 56.6)

• The Exit Pinch Roll for operation failure (including for the opera tion failure of the Exit Nip
Release Solenoid (Output Check [005-072])). (PL 56.7)

• The Drive Gear for wear and damage.

If no problem is found, replace the DADF PWB. (PL 56.2)

Status Indicator RAPs

005-131/132, 005-135

005-136 DADF Side 2 Regi Sensor On Jam

BSD-ON:CH5.5, CH5.4

After the DADF Pre Regi Sensor turned ON at Invert operation, the DADF Regi Sensor did not
turn ON within the specified time.

Cause/Action

Check the following:

• Transportation failure due to foreign substance on the document path.

• The surface of the Exit Roll, Takeaway Roll, and Regi Roll for foreign substances.

• The surface of the Exit Roll, Takeaway Roll, and Regi Roll for wear.

• The DADF Regi Sensor (Input Check [005-110]) for operation failure. (PL 56.14)

• The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

• The DADF Feed Motor (Output Check [005-008]) for operation failure. (PL 56.6)

• The DADF T/A Clutch (Output Check [005-098]) for operation failure. (PL 56.7)

• The Exit Pinch Roll for operation failure (including for the operation failure of the Exit Nip
Release Solenoid (Output Check [005-072])). (PL 56.7)

• The Drive Gear for wear and damage.

If no problem is found, replace the DADF PWB. (PL 56.2)

08/2012

2-14

WorkCentre 5021/5019

Initial Issue

005-147 DADF Pre Regi Sensor Off Jam on Inverting

BSD-ON:CH5.4, CH5.5

Cause/Action

Explain to the User that Mixed Size is not supported.

After the DADF Feed Motor started the reverse rotation at Invert operation, the DADF Pre Regi
Sensor did not turn OFF within the specified time.

Cause/Action

Check the following:

• Transportation failure due to foreign substance on the document path.

• The surface of the Exit Roll, Takeaway Roll, Regi Roll, and Out Roll for foreign sub­stances.

• The surface of the Exit Roll, Takeaway Roll, Regi Roll, and Out Roll for wear.

• The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

• The DADF Feed Motor (Output Check [005-048/ 008] (CCW/CW)) for operation failure.
(PL 56.6)

• The Exit Pinch Roll for operation failure (including for the opera tion failure of the Exit Nip
Release Solenoid (Output Check [005-072])). (PL 56.7)

• The Drive Gear for wear and damage.

If no problem is found, replace the DADF PWB. (PL 56.2)

005-196 Size Mismatch Jam on No Mix-Size

BSD-ON:CH5.4, CH5.2

The 2nd sheet or later of the document was detected to be of a different size conpared to the
1st sheet (the length of the document's 2nd sheet or later in SS direction is longer).

005-198/199 Too Short Size Jam/ Too Long Size Jam

BSD-ON:CH5.4, CH5.2

[Too Short Size Jam]

It was detected that the document length in Slow Scan direction is shorter than the specifica­tions (Simpex: 85 mm, Duplex: 110 mm).

[Too Long Size Jam]

It was detected that the document length in Slow Scan direction is at the specifications (Sim­pex: 1275 mm, Duplex: 480.1 mm) or longer.

Cause/Action

Check the size of the document that was fed by the user. If it is within the permitted length for
DADF transport, check the following:

• The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

• The Document Tray Size Sensor 1/2 (Input Check [005-221/222]) for operation failure.
(PL 56.11)

If no problem is found, replace the DADF PWB. (PL 56.2)

005-210 DADF Download Fail

BSD-ON:CH3.1

Cause/Action

1. Check the size of the document that was fed by the User.

2. If the error is not cleared, check the following:

• The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

• The Document Tray Size Sensor 1/2 (Input Check [005-221/222]) for operation fail­ure.

(PL 56.11)

3. If no problem is found, replace the DADF PWB. (PL 56.2)

005-197 Prohibit Combine Size Jam

BSD-ON:CH5.4

A Mixed Size document was detected.

Initial Issue
WorkCentre 5021/5019

When the IISS starts up (including at Power ON/Sleep recovery), it was detected that the
DADF is in Download Mode.

Cause/Action

Perform the DADF software download.

005-275/280 DADF RAM Fail/ DADF EEPROM Fail

BSD-ON:CH3.1

[DADF RAM Fail]

The DADF PWB RAM failed during the Read/Write operation. (At Power ON)

[DADF EEPROM Fail]

08/2012

2-15

005-147, 005-198/199

Status Indic a tor RAPs

Write failure to DADF EEPROM or communication failure with EEPROM was detected.

Cause/Action

1. Turn the power OFF and ON.

2. If the problem persists, replace the DADF PWB. (PL 56.2)

• DADF Invert Sensor (Input Check[005-211]) (PL 56.10)

3. If no problem is found, replace the DADF PWB. (PL 56.2)

005-940 DADF No Original Fail

BSD-ON:CH5.1

It was detected that the document was pulled out during document feed.

005-305 DADF Feeder Cover Interlock Open

BSD-ON:CH5.1

The DADF Feeder Cover Interlock Switch was opened during DADF operation.

Cause/Action

1. Check the DADF Feeder Cover for mismatch.

2. Check the DADF Feeder Cover Interlock Switch (Input Check [005-212]) for operation
failure.

(PL 56.6)

3. If no problem is found, replace the DADF PWB. (PL 56.2)

005-500 DADF Download Flash Write Error

BSD-ON:CH3.1

Failed to write into the Flash ROM during DAFD Download.

Cause/Action

1. Turn the power OFF and ON.

2. If the problem persists, replace the following parts in sequence:

• DADF PWB (PL 56.2)

• ESS/MCU PWB (PL 18.1)

005-907/908/91 3 DADF Pre Regi Sensor/DADF Regi
Sensor/DADF Invert Sensor Static Jam

BSD-ON:CH5.4, CH5.5

Cause/Action

Reload the document.

005-948 SS-Size Mismatch Jam on No Mix-size

BSD-ON:CH5.4, CH5.2

In No Mix mode, it was detected that a document with a shorter size in Slow Scan (SS) direc­tion was transported from the DADF.

Cause/Action

1. Check the size of the document that was fed by the User.

2. If the error is not cleared, check the following:

• The DADF Pre Regi Sensor (Input Check [005-206]) for operation failure. (PL 56.14)

• The Document Tray Size Sensor 1/2 (Input Check [005-221/222]) for operation fail­ure.

(PL 56.11)

3. If no problem is found, replace the DADF PWB. (PL 56.2)

Paper was detected by the applicable sensor at Power ON, Feeder Cover Interlock Close, or
DADF Open Sensor Close.

Cause/Action

1. Check the applicable sensor for remaining paper, the Actuator for return failure, contami­nation on sensor, and etc.

2. Check the applicable sensor for operation failure.

• DADF Pre Regi Sensor (Input Check[005-206]) (PL 56.14)

• DADF Regi Sensor (Input Check[005-110]) (PL 56.14)

Status Indicator RAPs

005-275/280, 005-940

08/2012

2-16

Initial Issue

WorkCentre 5021/5019

010-311 Fusing Unit Center Thermistor Defect

BSD-ON:CH10.2

010-320 Over Heat Temperature Fail

BSD-ON:CH10.2, CH10.1

An open circuit abnormality (the AD value of the STS is equivalent to the open circuit value) of
the Heat Roll Center Thermistor was detected.

Procedure

Turn OFF the power and disconnect the Heat Roll Center Thermistor connector P/J600. Mea­sure the resistance between the Heat Roll Center Thermistor J600 pin-1 and J600 pin-2. Is

the resistance infinite?
YN

Reconnect the connector P/J600 and measure the resistance between the ESS/MCU
PWB J403 pin-1 and J403 pin-2. Is the resistance infinite?

YN

Replace the ESS/MCU PWB. (PL 18.1)

Check the following connections for open circuits and poor contacts.

• Between ESS/MCU PWB J403-1 and Heat Roll Center Thermistor P600-4

• Between ESS/MCU PWB J403-2 and Heat Roll Center Thermistor P600-3

Replace the Fusing Unit. (PL 7.1)

010-312 Fusing Unit Rear Thermistor Defect

BSD-ON:CH10.2

An open circuit abnormality (the AD value of the STS is equivalent to the open circuit value) of
the Heat Roll Rear Thermistor was detected.

Procedure

Turn OFF the power and disconnect the Heat Roll Rear Thermistor connector P/J600. Mea­sure the resistance between the Heat Roll Rear Thermistor J600 pin-3 and J600 pin-4. Is the

resistance infinite?
YN

Reconnect the connector P/J600 and measure the resistance between the ESS/MCU
PWB J403 pin-3 and J403 pin-4. Is the resistance infinite?

YN

Replace the ESS/MCU PWB. (PL 18.1)

Check the following connections for open circuits and poor contacts.

• Between ESS/MCU PWB J403-3 and Heat Roll Rear Thermistor P600-2

• Between ESS/MCU PWB J403-4 and Heat Roll Rear Thermistor P600-1

A high temperature error was detected at the Center Thermistor (245 degrees C or higher) or
the Rear Thermistor (270 degrees C or higher).

NOTE: To clear this Fail, first remove the cause, next clear the value of NVM [744-040] (Over
Heat T emp Fail) to '0', and then turn the power OFF then ON. The relationship between the dis­played value and the Thermistor that detected the high temperature error is as follows:

•0: Normal

• 1: High Temperature Error of Heat Roll Center Thermistor

• 2: High Temperature Error of Heat Roll Rear Thermistor

Cause/Action

Check the following:

• The Center Thermistor or the Rear Thermistor for dropped parts, sensor contamination,
and foreign substances blocking the sensor.

• The Heat Roll for wound up, stuck paper.

• The Heat Roll Center Thermistor (Analog Monitor [010-050]) for operation failure.

• The Heat Roll Rear Thermistor (Analog Monitor [010-051]) for operation failure.

• The Heater Rod for operation failure.

If no problem is found, replace the following parts in sequence:

• Fusing Unit (PL 7.1)

• LVPS (PL 18.1)

• ESS/MCU PWB (PL 18.1)

010-327 Fusing Unit On Time Fail

BSD-ON:CH10.2, CH10.1

Any of the following was detected:

• The Heater Rod did not turn OFF within the specified time after the Heater Rod On.

• After power ON, the temperature of the Fusing Unit does not reach the specified value
within the specified time.

Cause/Action

Check the following:

Replace the Fusing Unit. (PL 7.1)

Initial Issue
WorkCentre 5021/5019

• The Heater Rod for operation failure.

• The connection between the LVPS J511 and the Fusing Unit P10 for open circuit and
poor contact

• The Center Thermistor for dropped parts, sensor contamination, and foreign substances
blocking the sensor.

• The Heat Roll for wound up, stuck paper.

08/2012

2-17

Status Indic a tor RAPs

010-311, 010-320

If no problem is found, replace the following parts in sequence:

• Fusing Unit (PL 7.1)

• LVPS (PL 18.1)

• ESS/MCU PWB (PL 18.1)

010-379 Fusing Unit Hot Not Ready Return Time Fail

BSD-ON:CH10.2, CH10.1

The time taken to recover from High Temperature Not Ready state has exceeded the specified
time.

Cause/Action

1. Turn the power OFF and ON.

2. Turn OFF the power and check the following:

• The Fusing Unit for improper installation.

• The connection between the Fusing Unit P10 and the LVPS J511 for open circuit,
short circuit, and poor contact.

• The connection between the Fusing Unit P600 and the ESS/ MCU PWB J403 for
open circuit, short circuit, and poor contact.

• The connection between the ESS/MCU PWB J401 and the LVPS J513 for open cir-
cuit, short circuit, and poor contact.

• The Heat Roll for wound up, stuck paper.

3. If the problem persists, replace the following parts in sequence:

• Fusing Unit (PL 7.1)

• LVPS (PL 18.1)

• ESS/MCU PWB (PL 18.1)

010-602 Over Temp Cooling Mode

BSD-ON:CH10.2

Unable to print because the temperature in the machine has risen above the specification
value.

Cause/Action

Wait until the temperature in the machine has dropped.

010-392 NOHAD Fan Defect

BSD-ON:CH10.3

NOHAD Fan failure was detected. When the NOHAD Fan Fail signal indicating an abnormality
of the Fan was monitored at the specified time interval, it was found to have failed the specified
number of times or higher in a row.

Cause/Action

1. Check the NOHAD Fan (Output Check [042-002]) for operation failure. (PL 4.1)

2. Check the NOHAD Fan for foreign substances.

3. If no problem is found, replace the ESS/MCU PWB. (PL 18.1)

Status Indicator RAPs

010-327, 010-602

08/2012

2-18

Initial Issue

WorkCentre 5021/5019

016-500 Controller Download Flash Write Er ror

BSD-ON:-

Unable to write the Download File of Controller Main into the Flash ROM.

Cause/Action

1. Turn the power OFF and ON.
(If the contents of the Flash ROM is corrupted, the machine will boot up in Emergency

Boot Download mode after Power ON.)

2. If the problem persists, replace the ESS/MCU PWB. (PL 18.1)

Cause/Action

1. Press [Stop] on the UI Panel.

2. Check the connection of the USB Cable between this machine and the PC.

3. Check the status (is it powered OFF, frozen, etc.) of the PC.

016-571 No Response from USB-Host for Print Job

BSD-ON:CH3.2

When any of the following has occurred as USB Print or Download data interpretation is in
progress.

016-501 Controller Boot Flash Write Error

BSD-ON:-

Unable to write the Download File of Controller Boot into the Flash ROM.

Cause/Action

1. Turn the power OFF and ON.

2. If the problem persists, replace the ESS/MCU PWB. (PL 18.1)

016-502 UI Panel Download Flash Write Error

BSD-ON:CH2.1

Unable to write the Download File of UI Panel into the Flash ROM.

Cause/Action

1. Turn the power OFF and ON.

2. If the problem persists, replace the following parts in sequence:

• ESS/MCU PWB (PL 18.1)

•UI PWB (PL 1.6)

016-570 No Response from USB-Host for Scan Job

BSD-ON:CH3.2

When any of the following has occurred as Scan to PC (USB) is in progress.

• The command from the PC was disrupted for 2 minutes.

• The machine has detected a communication error with the USB Device.

• The sending of commands to the PC remained uns uccessful even when 500 ms has
passed.

NOTE: This Fault will clear automatically. (It will not be displayed on the UI Panel)

Cause/Action

1. Check the connection of the USB Cable between this machine and the PC.

2. Check the status (is it powered OFF, frozen, etc.) of the PC.

016-742/744 Download File Error/ Download File Check
Sum Error

BSD-ON:-

[Download File Error]

It was detected that there is an error with either the file format of the Download File, the Device
Identifier, the Device Serial Number, or the Target Device Character String.

[Download File Check Sum Error]

The Download File checksum error was detected.

Cause/Action

1. Turn the power OFF and ON.

2. Install a firmware with the correct version.

• The command from the PC was disrupted for 5 seconds.

• The machine has detected a communication error with the USB Device.

• The sending of commands to the PC remained uns uccessful even when 500 ms has
passed.

(The timeout time is the time calculated from the size of the data being sent only when
sending image data.)

Initial Issue
WorkCentre 5021/5019

08/2012

2-19

Status Indic a tor RAPs

016-500, 016-570

016-749/799 HBP L or X PJL Syntax Error/ Print Instruction
Fail

BSD-ON:-

[HBPL or XPJL Syntax Error]

When the Print Job data interpretation is in progress, an illegal command that cannot be
ignored was received from the Client driver.

[Print Instruction Fail]

During the Print Job, the Job cannot be executed with the specified combination of print param­eters (Stored File Size, Paper Size, Paper Tray, Duplex Settings, Output Tray, and etc.).

NOTE: During Continuous Print, this error will not occur until the paper that immediately pre­cedes the paper where the applicable image is supposed to be printed on has been output suc­cessfully.

Cause/Action

1. Press [Stop] on the UI Panel.

2. Check whether the Printer Driver that is being used is the correct one.

3. Check whether the specified print parameters are correct.

016-759 Copy Counter Full

BSD-ON:-

During Multi Account Mode, any of the following has occurred:

016-776 Marker Code Detection Fail

BSD-ON:-

During Copy Job or Print Job, when expanding only up to the size that was specified at the
expansion, the End Code cannot be found in the compressed data.

NOTE: Before the occurrence of this fail, there are cases where [045-310 Image Ready Error]
would occur first.

NOTE: During Continuous Print, this error will not occur until the paper that immediately pre­cedes the paper where the applicable image is supposed to be printed on has been output suc­cessfully.

Cause/Action

1. Turn the power OFF and ON.

2. If the problem reoccurs, determine whether it is caused by the Copy document or the Print
data and contact the Support Department for assistance.

• The general user that is logged in has reached the alotted maximum print count.

• A general user that has reached the alotted maximum print count has logged in.

Cause/Action

1. Press [Stop] on the UI Panel.

2. Clear the count for the user.

Status Indicator RAPs

016-749/799, 016-776

08/2012

2-20

Initial Issue

WorkCentre 5021/5019

023-600 Held Down key Error (UI Panel)

BSD-ON:CH2.1

Any key on the UI Panel has been pressed and held down for 1 minute or longer.

Cause/Action

Check whether any key on the UI Panel is pressed and held down.

Initial Issue
WorkCentre 5021/5019

08/2012

2-21

Status Indic a tor RAPs

023-600

Status Indicator RAPs

023-600

08/2012

2-22

Initial Issue

WorkCentre 5021/5019

024-910/911/915 Tray 1/Tray 2/MSI Paper Length Mismatch

BSD-ON:CH8.3, CH8.1

The Paper Size for the applicable Tray is longer by 10.1 mm or more, or shorter by 13.1 mm or
more than the setting.

Cause/Action

Check the following:

• Transportation failure due to foreign substance on the document path.

• The surface of the Feed Roll, T/A Roll 2 (Tray 2), Regi. Roll, and Idler Roll of the applica­ble Tray for foreign substances.

• The surface of the Feed Roll, T/A Roll 2 (Tray 2), Regi. Roll, and Idler Roll of the applica­ble Tray for wear.

• The Regi Sensor (Input Check [071-105]) for operation failure. (PL 15.1)

• The Regi Clutch (Output Check [071-001]) for operation failure. (PL 15.1)

• The MSI Feed Clutch (Output Check [072-006]) for operation failure. (MSI) (PL 13.3)

• The BTR for contamination, wear, and transportation failure due to deterioration.

• The Drive Gear for wear and damage.

• Usage of out of spec paper.

• ESS/MCU PWB (Tray 1/MSI) (PL 18.1)

• STM PWB (Tray 2) (PL 10.6)

024-958/959/960 MSI/Tray 1/Tray 2 Paper Size Mismatch

BSD-ON:-

During Print Job, the paper size settings of the selected Tray is different from the paper size
specified for the Job.

Cause/Action

Change the paper settings of the selected Tray to the appropriate one.

024-965 APS NG Unselec ted

BSD-ON:-

During Copy Job, Print Job, and Report Job with APS settings, the Pa per Size and paper ori­entation (SEF/LEF) settings specified by the Job are different from the s ettings at Tray 1 and
Tray 2.

If no problems are found, replace the ESS/MCU PWB. (PL 18.1)

024-950/951/954 Tray 1/Tray 2/MSI No Paper

BSD-ON:CH7.2, CH7.3, CH7.4

Any of the following was detected:

• The paper in the applicable Tray has ran out.
(When the APS function of Tray 1 and Tray 2 is disabled)

• Although the paper in the applicable Tray was detected to have ran out, paper is not sup­plied from another Tray. (When the APS function of Tray 1 and Tray 2 is enabled)

Cause/Action

1. Load paper into the applicable Tray. (If this had occurred during AP S of Tray 1 or Tray 2,
load paper with the same settings as for the aplicable Tray into other than MSI.)

2. If the problem persists, check the following:

• The paper supply mechanism of the applicable Tray for damage and foreign s ub-

stances.

• The No Paper Sensor of the applicable Tray (Input Check [072-100/101/102]) for

operation failure. (PL 9.1, PL 10.3, PL 13.3)

• The No Paper Sensor of the applicable Tray for contamination, improper installation,

and Actuator operation failure.

3. If no problem is found, replace the following parts:

Cause/Action

Change the paper settings of the Tray to the appropriate one.

Initial Issue
WorkCentre 5021/5019

08/2012

2-23

Status Indic a tor RAPs

024-910/911/915 , 024-950/951/954

Status Indicator RAPs

024-910/911/915 , 024-950/951/954

08/2012

2-24

Initial Issue

WorkCentre 5021/5019

041-210/211 STM NVM Out-Of-Order/ STM NV M R/W Error

BSD-ON:CH3.2

[STM NVM Out-Of-Order]

The NVM of the STM is malfunctioning.

[STM NVM R/W Error]

Unable to perform NVM Read / Write for the STM.

Cause/Action

1. Turn the power OFF and ON.

2. If the problem persists, replace the STM PWB. (PL 10.6)

Initial Issue
WorkCentre 5021/5019

08/2012

2-25

Status Indic a tor RAPs

041-210/211

Status Indicator RAPs

041-210/211

08/2012

2-26

Initial Issue

WorkCentre 5021/5019

042-325/614 Main Motor Rotation Error/ Main Motor
Rotation Warning

BSD-ON:CH4.1

[Main Motor Rotation Error]

The Main Drive Motor revolution failure was detected. When the Lock Up (Main Drive Motor
Fail) signal of the Motor Drive output was monitored at the specified time interval after a certain
time has passed since the Main Drive Motor operation had started, it was found to have failed
5 times in a row.

[Main Motor Rotation Warning]

The Main Drive Motor revolution failure was detected. When the Lock Up (Main Drive Motor
Fail) signal of the Motor Drive output was monitored at the specified time interval after a certain
time has passed since the Main Drive Motor operation had started, it was found to have failed
2 times in a row.

Procedure

Enter the CE Mode and turn ON the Output Check [042-001] (Main Drive Motor). Does the
Main Drive Motor rotate?
YN

Check the power supply line (+24VDC, +5VDC) of the Main Drive Motor. Is the power
supply of the Main Drive Motor normal?
YN

Check the power supply circuit to the Main Drive Motor.

Turn OFF the power and check the following:

• The connection between the Main Drive Motor J202 and the ESS/MCU PWB J403

for open circuit, short circuit, and poor contact.

• The Drive Gear for wear, damage, and bearing blockage.

• The Main Drive Motor for loading.
If no problem is found, replace the following parts in sequence:

• Main Drive Motor (PL 3.1)

• ESS/MCU PWB (PL 18.1)

Press [Stop] and turn OFF the power. Check the connection between the Main Drive Motor

J202-8 and the ESS/MCU PWB J403-5 for open circuit, short circuit, and poor contact.

If no problem is found, replace the following parts in sequence:

• ESS/MCU PWB (PL 18.1)

• Main Drive Motor (PL 3.1)

Initial Issue
WorkCentre 5021/5019

08/2012

2-27

Status Indic a tor RAPs

042-325/614

Status Indicator RAPs

042-325/614

08/2012

2-28

Initial Issue

WorkCentre 5021/5019

045-310 Image Ready Error

BSD-ON:CH3.2

045-313 IOT Logic Fail

BSD-ON:-

Unable to send the Image-valid signal cannot within the specified time.

NOTE: When the attempt to expand the image has failed, [016-776 Marker Code Detection
Fail] occurs after the recover operation.

Cause/Action

1. Check the USB Cable (Local) for poor connection.

2. If no problem is found, replace the ESS/MCU PWB. (PL 18.1)

The IOT Software error was detected.

Cause/Action

1. Turn the power OFF and ON.

2. Install the correct version of the IOT firmware.

3. If the problem persists, replace the ESS/MCU PWB. (PL 18.1)

Initial Issue
WorkCentre 5021/5019

08/2012

2-29

Status Indic a tor RAPs

045-310, 045-313

Status Indicator RAPs

045-310, 045-313

08/2012

2-30

Initial Issue

WorkCentre 5021/5019

061-321 ROS Motor Fail

BSD-ON:CH6.4

061-325 No SOS Fail

BSD-ON:CH6.4

The number of rotation of the ROS Motor did not come within the standard range within the
specified time (5 s) after the ROS Motor On.

Cause/Action

1. Turn the power OFF and ON.

2. Check whether the Drum Cartridge is installed.

3. Check the ROS Motor (Output Check [061-001]) for operation failure.

4. Check the LD +5VDC power supply of the LD PWB J140 pin-8.

5. If no problem is found, replace the following parts in sequence:

• ROS Assembly (PL 2. 1)

• ESS/MCU PWB (PL 18.1)

After the detection of ROS Motor Ready (steady rotation), the SOS interval was detected to be
longer than the reference value 5 times in a row.

Cause/Action

1. Turn the power OFF and ON.

2. Check whether the Drum Cartridge is installed.

3. Turn OFF the power and check the connections between the ESS/MCU PWB J410,

J411 and the LD PWB J140, J160 for open circuits, short circuits, and poor contacts.

4. If no problem is found, replace the following parts in sequence:

• ROS Assembly (PL 2.1)

• ESS/MCU PWB (PL 18.1)

Initial Issue
WorkCentre 5021/5019

08/2012

2-31

Status Indic a tor RAPs

061-321, 061-325

Status Indicator RAPs

061-321, 061-325

08/2012

2-32

Initial Issue

WorkCentre 5021/5019

062-277 DADF Communi cation Fail

BSD-ON:CH3.1

062-371/380 Lamp Illumination Fail/ AGC Fail

BSD-ON:CH6.3, CH6.1

Transmission cannot be established between the ESS/MCU PWB and the DADF PWB.

Cause/Action

1. Turn the power OFF and ON.

2. Turn OFF the power and check the connections between the ESS/MCU PWB J421 and
the DADF PWB J751, J752 for open circuits, short circuits, and poor contacts.

3. If no problem is found, replace the following parts in sequence:

• DADF PWB (PL 56.2)

• ESS/MCU PWB (PL 18.1)

062-311 IIT Software Logic Fail

BSD-ON:-

A software error was detected at the ESS/MCU PWB.

Cause/Action

1. Turn the power OFF and ON.

2. Update the software version to the latest one.

3. If no problem is found, replace the ESS/MCU PWB. (PL 18.1)

062-360 Carriage Position Fail

BSD-ON:CH6.2

Any of the following was detected:

• An error with the count value of the Carriage Position Control.

• There is no Regi Sensor input during Carriage initialization.

• An error with the Regi Sensor detection position.

Cause/Action

Check the following:

• The Pre Regi Sensor (Input Check [062-212]) for operation failure. (PL 1.3)

• The Carriage Motor (Output Check [062-005/006] (Scan/Return)) for opera tion failure.
(PL 1.4)

• The Drive Belt and Drive Wire for slack and wear.

• The Carriage operation for mechanical loading.

If no problems are found, replace the ESS/MCU PWB. (PL 18.1)

[Lamp Illumination Fail]

Insufficient light from Lamp detected in CCD. (During white gradation correction/AGC before
Scan starts)

[AGC Fail]

Insufficient lamp brightness was detected when performing AGC.

Initial Actions

Check whether there is something blocking the light and check the Lamp, Lens, Mirror, and
White Color Correction Plate for deterioration or contamination.

Procedure

1. Turn ON the power and enter the Diag mode. Change the value for NVM [715-030] to '1'
and then perform [NVM Write].

2. A 3 or 4-digit number is displayed in the current value column.

3. Check the upper 1 or 2 digits, or the lower 2 digits using the following table and replace
the appropriate parts.

Sample Display

• 110 (3-digit display):

LED Lamp failure and LED Lamp Flexible Flat Cable is damaged or has poor con­tact.

(The first digit '1' in '1 10' is t he upper digit, which indicates the LED Lamp ('0' in '01' is
not displayed). The lower 2 digits '10' indicates the LED Lamp Flexible Flat Cable.)

• 1000 (4-digit display):

The LED Lamp Flexible Flat Cable is damaged or has poor contact.
(The first 2 digits '10' in '1000' are the upper digits, which indicates the LED Lamp

Flexible Flat Cable. The lower 2 digits '00' indicates that nothing is applicable (no
failures).)

NOTE: Perform IIT diagnostic and then call NVM [715-030] again (press the Change Set­tings button) to check the value (diagnostic result).

Table 1

Current value Component Name PL No.

00 Not applicable (No errors) ­01 LED Lamp (LED Lamp PWB) PL 1.5
02 IIT Carriage PL 1.3
03 CCD Flexible Flat Cable PL 1.3
04 This value is not displayed ­05 This value is not displayed -

Initial Issue
WorkCentre 5021/5019

08/2012

2-33

Status Indic a tor RAPs

062-277, 062-371/380

Table 1

Current value Component Name PL No.

06 This value is not displayed ­07 This value is not displayed ­08 This value is not displayed ­09 This value is not displayed ­10 LED Lamp Flexible Flat Cable PL 1.5

4. After replacing the appropriate parts, again change the value for NVM [715-030] to '1' and
then perform 'NVM Write'.

5. Check that the current value column becomes '0'.

6. If the problem persists after performing the above procedure, check the following:

• Check for burnt out LED Lamp (DC330 [062-002]). (PL 1.5)

• Check the Flat Cable between the LED Lamp PWB J7002 and the IIT Carriage

J7001 for open circuits, short circuits, and poor contacts (especially, check whether

the Flat Cable was inserted in a skewed manner).

• Check the Flat Cable between the IIT Carriage J700 and the ESS/MCU PWB J420

for open circuits, short circuits, and poor contacts (especially, check whether the Flat
Cable was inserted in a skewed manner).

7. If no problem is found, replace the ESS/MCU PWB. (PL 18.1)

062-386 AOC Fail

BSD-ON:CH6.3

A CCD output error was detected when performing AOC.

Cause/Action

1. Turn ON the power and enter the Diag mode. Change the value for NVM [715-030] t o '1'
and then perform [NVM Write].

2. A 3 or 4-digit number is displayed in the current value column.

3. Check the upper 1 or 2 digits, or the lower 2 digits and replace the appropriate parts.
(For more information on display example and part selection, refer to Procedure 3 in 062-

371 FIP.)

NOTE: Perform IIT diagnostic and then call NVM [715-030] again (press the Change Set­tings button) to check the value (diagnostic result).

4. After replacing the appropriate parts, again change the value for NVM [715-030] to '1' and
then perform 'NVM Write'.

5. Check that the current value column becomes '0'.

6. If the problem persists after performing the above procedure, check the Flat Cable
between the IIT Carriage J700 and the ESS/MCU PWB J420 f or open circuits, short cir­cuits, and poor contacts (especially, check whether the Flat Cable was inserted in a
skewed manner).

7. If no problem is found, replace the ESS/MCU PWB. (PL 18.1)

062-389 Carriage Over Run Fail (Scan End Side)

BSD-ON:CH6.2

The Carriage has overrun at the Scan End.

Cause/Action

Check the following:

• The Drive Belt and Drive Wire for slack and wear.

• The Carriage operation for mechanical loading.

• The Carriage Motor (Output Check [062-005/006] (Scan/Return)) for operation failure.
(PL 1.4)

• The IIT Regi. Sensor (Input Check [062-212]) for operation failure. (PL 1.3)

If no problems are found, replace the ESS/MCU PWB. (PL 18.1)

062-396 CCD Cable Connection Fail

BSD-ON:CH3.1

A CCD Flat Cable connection error was detected.

Cause/Action

1. Turn the power OFF and ON.

2. Turn OFF the power and check the Flat Cable between the IIT Carriage J700 and the
ESS/MCU PWB J420 for open circuits, short circuits, and poor contacts (especially,
check whether the Flat Cable was inserted in a skewed manner).

3. If no problem is found, replace the following parts in sequence:

• CCD Flexible Flat Cable (PL 1. 3)

• ESS/MCU PWB (PL 18.1)

Status Indicator RAPs

062-371/380, 062-389

08/2012

2-34

Initial Issue

WorkCentre 5021/5019

071-105 Regi Sensor On Jam (Tray 1)

BSD-ON:CH8.3, CH4.1, CH8.1

During paper feed from Tray 1, the Regi Sensor did not turn ON within the specified time after
the Tray 1 Feed Clutch On.

Cause/Action

Check the following:

• The Regi Sensor (Input Check [071-105]) for operation failure. (PL 15.1)

• The Main Drive Motor (Output Check [042-001]) for operation failure. (PL 3.1)

• The Tray 1 Feed Clutch (Output Check [072-001]) for operation failure. (PL 9.1)

• The Feed Roll for contamination, wear, and transportation failure due to deterioration.

• The Drive Gear for wear and damage.

• A paper transportation failure due to foreign substances on the paper path.

• Usage of out of spec paper.

If no problems are found, replace the ESS/MCU PWB. (PL 18.1)

Initial Issue
WorkCentre 5021/5019

08/2012

2-35

Status Indic a tor RAPs

071-105

Status Indicator RAPs

071-105

08/2012

2-36

Initial Issue

WorkCentre 5021/5019

072-102 Feed Out Sensor 2 On Jam

BSD-ON:CH8.2, CH7.3

• STM PWB (PL 10.6)

During paper feed from Tray 2, the Feed Out Sensor 2 did not turn ON within the specified time
after the Tray 2 Feed Motor On.

Cause/Action

Check the following:

• The Feed Out Sensor 2 (Input Check [072-104]) for operation failure. (PL 10.5)

• The STM Take Away Motor (Output Check [072-004]) for operation failure. (PL 10.6)

• The STM T ake A way Roll Clutch (Output Check [072-003]) for operation failure. (PL 10.6)

• The Tray 2 Feed/Lift Up Motor (Output Check [072-002] (Feed)) for operation failure. (PL

10.3)

• The T/A Roll 2, Feed Roll, Nudger Roll, and Pinch Roll for transportation failure due to
contamination, wear, and deterioration.

• The LH Cover for improper latching.

• The Drive Gear for wear and damage.

• A paper transportation failure due to foreign substances on the paper path.

• Usage of out of spec paper.

If no problem is found, replace the STM PWB. (PL 10.6)

072-105 Regi Sensor On Jam (Tray 2)

BSD-ON:CH8.3, CH8.2

During paper feed from Tray 2, the Regi Sensor did not turn ON within the specified time after
the Feed Out Sensor 2 On.

072-210 Tray 2 Lift Up Fail

BSD-ON:CH7.3

Any of the following was detected:

• A Tray 2 Lifter error.

• A Tray 2 Paper Size detector component malfunction.

Cause/Action

Check the following:

• The Tray 2 Nudger Level Sensor (Input Check [072-103]) for operation failure. (PL 10.3)

• The Tray 2 Feed/Lift Motor (Output Check [072-005] (Lift Up)) for operation failure. (PL

10.3)

• The drive system between the Bottom Plate and the Tray 2 Feed/Lift Motor for operation
failure.

• The Tray for Paper misload

• The Tray for existence of objects other than Paper.

If no problem is found, replace the STM PWB. (PL 10.6)

072-212 Tray 2 Size Sensor Broken

BSD-ON:CH7.1

Abnormal output AD value from Tray 2 Paper Size Switch was detected.

Cause/Action

Check the following:

• The Regi Sensor (Input Check [071-105]) for operation failure. (PL 15.1)

• The STM Take Away Motor (Output Check [072-004]) for operation failure. (PL 10.6)

• The STM T ake A way Roll Clutch (Output Check [072-003]) for operation failure. (PL 10.6)

• The T/A Roll 2, Feed Roll, and Pinch Roll for transportation failure due to contamination,
wear, and deterioration.

• The Drive Gear for wear and damage.

• A paper transportation failure due to foreign substances on the paper path.

• Usage of out of spec paper.

If no problem is found, replace the following parts in sequence:

• ESS/MCU PWB (PL 18.1)

Initial Issue
WorkCentre 5021/5019

Cause/Action

Check the following:

• Broken link and damage at the bottom of the Tray

• The Actuator at the rear of the Tray for operation failure

• The Tray 2 Paper Size Switch (Analog Monitor [072-050], Output Check [072-105]) for
operation failure. (PL 10.1)

• The Tray for Paper misload

• The Tray for existence of objects other than Paper.

If no problem is found, replace the STM PWB. (PL 10.6)

072-215 MCU-STM Communication Fail

08/2012

2-37

Status Indic a tor RAPs

072-102, 072-105

BSD-ON:CH3.2

Communication failure between the ESS/MCU PWB and the STM PWB was detected.

Cause/Action

1. Turn the power OFF and ON.

2. Turn OFF the power and check the connection between the ESS /MCU PWB J413 and
the STM PWB J541C for open circuit, short circuit, and poor contact.

3. If no problem is found, replace the following parts in sequence:

•STM PWB (PL 10.6)

• ESS/MCU PWB (PL 18.1)

Status Indicator RAPs

072-215

08/2012

2-38

Initial Issue

WorkCentre 5021/5019

075-135 Regi Sensor On Jam (MSI)

BSD-ON:CH8.3, CH4.1, CH8.1

During paper feed from the MSI, the Regi Sensor did not turn ON within the specified time after
the MSI Feed Clutch On.

Cause/Action

Check the following:

• The Regi Sensor (Input Check [071-105]) for operation failure. (PL 15.1)

• The Main Drive Motor (Output Check [042-001]) for operation failure. (PL 3.1)

• The MSI Feed Clutch (Output Check [072-006]) for operation failure. (PL 13.3)

• The MSI Feed Roll and the MSI Nudger Roll for contamination, wear, and transportation
failure due to deterioration.

• The Drive Gear for wear and damage.

• A paper transportation failure due to foreign substances on the paper path.

• Usage of out of spec paper.

If no problems are found, replace the ESS/MCU PWB. (PL 18.1)

Initial Issue
WorkCentre 5021/5019

08/2012

2-39

Status Indic a tor RAPs

075-135

Status Indicator RAPs

075-135

08/2012

2-40

Initial Issue

WorkCentre 5021/5019

077-101 Regi Sensor O ff Jam

BSD-ON:CH8.3, CH4.1

077-104 Fusing Unit Exit Sensor Off Jam (Short)

BSD-ON:CH10.3, CH8.3, CH4.1, CH10.4

The Regi Sensor did not turn OFF within the specified time after the Regi Clutch On.

Cause/Action

Check the following:

• The Regi Sensor (Input Check [071-105]) for operation failure. (PL 15.1)

• The Main Drive Motor (Output Check [042-001]) for operation failure. (PL 3.1)

• The Regi Clutch (Output Check [071-001]) for operation failure. (PL 15.1)

• The Regi Roll and Pinch Roll for transportation failure due to contamination, wear, and
deterioration.

• The Transfer Unit for a decrease in the transportation force.

• The Drive Gear for wear and damage.

• A paper transportation failure due to foreign substances on the paper path.

• Usage of out of spec paper.

If no problems are found, replace the ESS/MCU PWB. (PL 18.1)

077-103 Fusing Unit Exit Sensor Off Jam (Long)

BSD-ON:CH10.3, CH4.1, CH10.4

After the Regi Sensor Off, the Fusing Unit Exit Sensor did not turn OFF within the specified
time.

Cause/Action

Check the following:

• The Fusing Unit Exit Sensor (Input Check [071-106]) for operation failure. (PL 7.1)

• The Main Drive Motor (Output Check [042-001]) for operation failure. (PL 3.1)

• The Invert Motor (Output Check [071-003] (Exit)) for operation failure.
(When Duplex is installed) (PL 17.1)

• The Exit Roll and Pinch Roll for transportation failure due to contamination, wear, and
deterioration.

• The Transfer Unit for a decrease in the transportation force.

• The Heat Roll for wound up, stuck paper.

• The Drive Gear for wear and damage.

• Usage of out of spec paper.

The time taken for the Fusing Unit Exit Sensor to turn from ON to OFF is shorter than the spec­ified time.

Cause/Action

Check the following:

• The Fusing Unit Exit Sensor (Input Check [071-106]) for operation failure. (PL 7.1)

• The Regi Sensor (Input Check [071-105]) for operation failure. (PL 15.1)

• The Main Drive Motor (Output Check [042-001]) for operation failure. (PL 3.1)

• The Invert Motor (Output Check [071-003] (Exit)) for operation failure.
(When Duplex is installed) (PL 17.1)

• The Heat Roll for wound up, stuck paper.

• Usage of out of spec paper.

If no problems are found, replace the ESS/MCU PWB. (PL 18.1)

077-106 Fusing Unit Exit Sensor On Jam

BSD-ON:CH10.3, CH8.3, CH4.1

The Fusing Unit Exit Sensor did not turn ON within the specified time after the Regi Clutch On.

Cause/Action

Check the following:

• The Fusing Unit Exit Sensor (Input Check [071-106]) for operation failure. (PL 7.1)

• The Main Drive Motor (Output Check [042-001]) for operation failure. (PL 3.1)

• The Regi Clutch (Output Check [071-001]) for operation failure. (PL 15.1)

• The Fusing Unit Exit Chute for improper installation and deformation.

• The Transfer Unit for a decrease in the transportation force.

• The Drive Gear for wear and damage.

• The Heat Roll for wound up, stuck paper.

• A paper transportation failure due to foreign substances on the paper path.

• Usage of out of spec paper.

If no problems are found, replace the ESS/MCU PWB. (PL 18.1)

If no problems are found, replace the ESS/MCU PWB. (PL 18.1)

Initial Issue
WorkCentre 5021/5019

08/2012

2-41

Status Indic a tor RAPs

077-101, 077-104

077-129 Regi Sensor On Jam (Duplex Wait)

BSD-ON:CH8.3, CH4.1, CH10.4

During the paper stop at the invert wait position at D uplex print, the Regi Sensor did not turn
ON within the specified time after the Duplex Clutch On.

077-300/301/305 Front Cover/Left Hand Cover/STM Cover
Open

BSD-ON:CH1.5, CH1.6

The applicable Cover Switch was detected to be open.

Cause/Action

Check the following:

• The Regi Sensor (Input Check [071-105]) for operation failure. (PL 15.1)

• The Main Drive Motor (Output Check [042-001]) for operation failure. (PL 3.1)

• The Invert Motor (Output Check [071-005] (Dup)) for operation failure. (PL 17.1)

• The Dupex Clutch (Output Check [071-002]) for operation failure. (PL 14.4)

• The Exit Roll, Duplex Roll 1, 2, and Pinch Roll for transportation failure due to contamina­tion, wear, and deterioration.

• The Drive Gear and Belt for wear and damage.

• A paper transportation failure due to foreign substances on the paper path.

• Usage of out of spec paper.

If no problems are found, replace the ESS/MCU PWB. (PL 18.1)

077-212 Tray Module Reset Fail

BSD-ON:CH3.2

The Tray Module was detected to be reset.

Cause/Action

1. Turn the power OFF and ON.

2. Check voltages of the following pins:

•STM PWB J541C-5 (+5VDC)

•STM PWB J541C-8 (+24VDC)

3. Turn OFF the power and check the connection between the ESS /MCU PWB J413 and
the STM PWB J541C for open circuit, short circuit, and poor contact.

4. If no problem is found, replace the following parts in sequence:

•STM PWB (PL 10.6)

• ESS/MCU PWB (PL 18.1)

Cause/Action

1. Check the applicable Cover Switch for operation failure.

• Front Cover Switch (Input Check[071-301]) (PL 19.1)

• Front Cover Interlock Switch and L/H Cover Interlock Switch (Input Check[071-300])
(PL 19.1, PL 14.1)

• STM Left Cover Switch (Input Check[072-300]) (PL 10.4)

2. Check the applicable Cover Switch for damage and mismatch.

3. If no problem is found, replace the following parts:

• ESS/MCU PWB (Front Cover Open, L/H Cover Open) (PL 18.1)

• STM PWB (STM Left Cover Open) (PL 10.6)

077-900/901/904 Regi Sensor/Fusing Unit Exit Sensor/
Feed Out Sensor 2 Static Jam

BSD-ON:CH8.3, CH10.3, CH8.2

Paper was detected by the applicable sensor at Power ON, M/C Stop, or Interlock Close.

Cause/Action

1. Check the applicable sensor for remaining paper, the Actuator for return failure, contami­nation on sensor, and etc.

2. Check the applicable sensor for operation failure.

• Regi Sensor (Input Check[071-105]) (PL 15.1)

• Fusing Unit Exit Sensor (Input Check[071-106]) (PL 7.1)

• Feed Out Sensor 2 (Input Check[072-104]) (PL 10.5)

3. If no problem is found, replace the following parts:

• ESS/MCU PWB (Regi Sensor, Fusing Unit Exit Sensor) (PL 18.1)

• STM PWB (Feed Out Sensor 2) (PL 10.6)

Status Indicator RAPs

077-129, 077-300/301/305

08/2012

2-42

Initial Issue

WorkCentre 5021/5019

091-313 CRUM ASIC Communi cation Fail

BSD-ON:CH9.1

Communication failure between the CRUM ASIC and the CPU was detected.

The CRUM ASIC has malfunctioned.

Cause/Action

1. Turn the power OFF and ON.

NOTE: If this resolves the problem, it is highly probable that the ESS/MCU PWB had mis­detected due to external noise abnormal or noise caused by elect rical discharge in the
machine. Check for any noise source around the machine and check for any abnormal
electrical discharge, etc.

2. Turn OFF the power and check the following:

• The Drum CRUM PWB and Drum Cartridge CRUM connection terminals in the
Drum Cartridge for poor contact.

• The connection between the Drum Cartridge J615 and the Drum CRUM PWB JA
for open circuit, short circuit, and poor contact.

• The connection between the ESS/MCU PWB J426 and the Drum Cartridge P615
for open circuit, short circuit, and poor contact.

3. If no problem is found, replace the following parts in sequence:

• Drum Cartridge (PL 8.1)

• ESS/MCU PWB (PL 18.1)

091-401/402 Drum Cartridge Quality Life Over/ Drum
Cartridge Life Over

BSD-ON:CH9.1

[Drum Cartridge Quality Life Over]

091-406/424 Drum Cartridge Normal Life Over/ Drum
Cartridge Abnormal Life Over

BSD-ON:CH9.1

[Drum Cartridge Normal Life Over]

The operation guarantee period for the Drum Cartridge has ended.

(When Drum Hard Stop-less is enabled)

[Drum Cartridge Abnormal Life Over]

The Drum Cartridge is out of warranty and this could result in a malfunction of the machine.

(When Drum Hard Stop-less is enabled)

Cause/Action

Replace the Drum Cartridge. (PL 8.1)

091-430 Drum Cartridge Life End

BSD-ON:CH9.1

The Drum Cartridge must be replaced.

Cause/Action

Replace the Drum Cartridge. (PL 8.1)

091-440 Drum Cartridge Pre Near End

BSD-ON:CH9.1

The image quality guarantee period for the Drum Cartridge has ended.

(When Drum Hard Stop-less is enabled)

[Drum Cartridge Life Over]

When in Life Extension Mode, the Drum Cartridge was detected to be near the end of its
lifespan.

Cause/Action

Replace the Drum Cartridge. (PL 8.1)

Initial Issue
WorkCentre 5021/5019

08/2012

Preparation for replacing the Drum Cartridge is required.

Cause/Action

The Drum Cartridge needs to be replaced soon. Prepare a new Drum Cartridge.

Replace the Drum Cartridge as required. (PL 8.1)

2-43

091-313, 091-406/424

Status Indic a tor RAPs

091-441 Drum Cartridge Near End

BSD-ON:CH9.1

The Drum Cartridge needs to be replaced soon.

Cause/Action

The Drum Cartridge needs to be replaced soon. Replace the Drum Car tridge as required. (PL

8.1)

091-914 Drum CRUM Communication Fail

BSD-ON:CH9.1

Communication failure with Drum CRUM was detected.

The CRUM ASIC has malfunctioned.

Cause/Action

1. Turn the power OFF and ON.

2. Turn OFF the power. Disconnect and reconnect the Drum Cartridge.

NOTE: If turning the power OFF and ON or removing and reinstalling the Drum Cartridge
resolves the problem, it is highly probable that the ESS/MCU PWB had misdetected due
to external noise abnormal or noise caused by electrical discharge in the machine. Check
for any noise source around the machine and check for any abnormal electrical dis­charge, etc.

3. Turn OFF the power and check the following:

• The Drum CRUM PWB and Drum Cartridge CRUM connection terminals in the
Drum Cartridge for poor contact.

• The connection between the Drum Cartridge J615 and the Drum CRUM PWB JA
for open circuit, short circuit, and poor contact.

• The connection between the ESS/MCU PWB J426 and the Drum Cartridge P615
for open circuit, short circuit, and poor contact.

4. If no problem is found, replace the following parts in sequence:

• Drum Cartridge (PL 8.1)

• ESS/MCU PWB (PL 18.1)

091-915/916 Drum CRUM ID Error/ Drum CRUM Market
Identity Mismatch

BSD-ON:CH9.1

[Drum CRUM ID Error]

The Drum CRUM ID error was detected.

[Drum CRUM Market Identity Mismatch]

The Drum CRUM region mismatch was detected.

Cause/Action

Replace it with the correct Drum Cartridge. (PL 8.1)

Status Indicator RAPs

091-441, 09 1-915/916

08/2012

2-44

Initial Issue

WorkCentre 5021/5019

092-660/668 ATC Amplitude Fail/ ATC Average Fail

BSD-ON:CH9.3

092-910 ATC Sensor Fail

BSD-ON:CH9.3

[ATC Amplitude Fail]

The output amplitude of the ATC Sensor in the ATC (Automatic Toner Control) measurement is
small.

[ATC A verage Fail]

The average output value is not within the specified range in the ATC (Automatic Toner Con­trol) measurement.

Cause/Action

1. Install a Toner Cartridge that contains Toner. Copy a Test Chart (499T 00247), etc. and
check whether the density has recovered.

2. Check the Toner Dispense Motor (Output Check [092-001]) for operation failure. (PL 8.2)

3. Check the Toner transport path for Toner blockage.

4. Check the connection between the ATC Sensor (Drum Cartridge) P6 15 and the ESS/
MCU PWB J409 for open circuit, short circuit, and poor contact.

5. If no problem is found, replace the following parts in sequence:

• Drum Cartridge (PL 8.1)

• ESS/MCU PWB (PL 18.1)

092-661 Temperature Sensor Fail

BSD-ON:CH9.4

The output value of the Temperature Sensor is not within the specification range.

The frequency at which the ATC Average Fail or the ATC Amplitude Fail has been occurring is
at the threshold value or higher.

NOTE: To clear this Fail, clear the value of NVM [752-059] (ATC Fail) or NVM [752-060] (ATC
Fail Continuous Count) to '0'. If the machine is not repaired back to norm al status, this Fa il will
occur again during the operation.

NOTE: Setting the NVM [752-005] (Dispense Mode) to '0' (Timer Disp) or '2' (ICDC Disp) will
prevent ATC related fail from occurring and enable you to use the M/C. However, this means
that the Toner density will not be controlled.

Cause/Action

1. Install a Toner Cartridge that contains Toner. Copy a Test Chart (499T 00247), etc. and
check whether the density has recovered.

2. Check the Toner Dispense Motor (Output Check [092-001]) for operation failure. (PL 8.2)

3. Check the Toner transport path for Toner blockage.

4. Check the connection between the ATC Sensor (Drum Cartridge) P615 and the ESS/
MCU PWB J409 for open circuit, short circuit, and poor contact.

5. Check for toner blockage within the Developer Unit.

6. If no problem is found, replace the following parts in sequence:

• Drum Cartridge (PL 8.1)

• ESS/MCU PWB (PL 18.1)

Cause/Action

1. Turn the power OFF and ON.

2. Check the connection between the HVPS J 500-1 and the ESS/MCU PW B J402-14 for
open circuit, short circuit, and poor contact.

3. If no problem is found, replace the following parts in sequence:

• HVPS (PL 18.1)

• ESS/MCU PWB (PL 18.1)

Initial Issue
WorkCentre 5021/5019

08/2012

2-45

Status Indic a tor RAPs

092-660/668, 092-910

Status Indicator RAPs

092-660/668, 092-910

08/2012

2-46

Initial Issue

WorkCentre 5021/5019

093-312 Toner Dispense Motor Rotation Fail

BSD-ON:CH9.3

093-912 Toner Empty

BSD-ON:CH9.3

Regardless of low usage of toner from Toner Cartridge, it was detected to be empty.

Cause/Action

Check the following:

• The Toner Cartridge for improper installation

• The Toner Dispense Motor (Output Check [092-001]) for operation failure. (PL 8.2)

• The Toner transport path for Toner blockage.

• The Drive Gear for wear and damage.

If no problem is found, replace the following parts in sequence:

• Toner Cartridge (PL 8.1)

• ESS/MCU PWB (PL 18.1)

093-400 Toner Near Empty

BSD-ON:CH9.3

The Toner Cartridge needs to be replaced soon.

Cause/Action

The Toner Cartridge needs to be replaced soon. Replace the Toner Cartridge as required. (PL

8.1)

The toner must to be replaced as it has ran out.

Cause/Action

Replace the Toner Cartridge. (PL 8.1)

093-956 Drum New CRU Installation Fail

BSD-ON:CH9.3

During the developing powder installation mode after installing the Drum Cartridge, the ATC
Measured Value is found to be abnormal. (Seal not removed)

Cause/Action

1. Remove the developing powder seal from the Drum Cartridge.

2. If the problem persists after removing the seal, replace the Drum Cartridge. (PL 8.1)

093-959 Drum New CRU Installation Fail Exceeds
Thresholding Times

BSD-ON:-

The number of developing powder installation mode executions has exceeded the upper limit.

Cause/Action

Replace it with the correct Drum Cartridge. (PL 8.1)

093-406 Toner Pre Near Empty

BSD-ON:CH9.3

Preparation for replacing the T oner Cartridge is required.

Cause/Action

The Toner Cartridge needs to be replaced soon. Prepare a new Toner Cartridge.

Replace the Toner Cartridge as required. (PL 8.1)

Initial Issue
WorkCentre 5021/5019

08/2012

2-47

Status Indic a tor RAPs

093-312, 093-912

Status Indicator RAPs

093-312, 093-912

08/2012

2-48

Initial Issue

WorkCentre 5021/5019

095-910 No Drum Cart ridge

BSD-ON:CH9.1

The Drum Cartridge cannot be detected.

Cause/Action

1. Turn the power OFF and ON.

2. Turn OFF the power and check the following:

• The Drum CRUM PWB and Drum Cartridge CRUM connection terminals in the

Drum Cartridge for poor contact.

• The connection between the Drum Cartridge J615 and the Drum CRUM PWB JA

for open circuit, short circuit, and poor contact.

• The connection between the ESS/MCU PWB J426 and the Drum Cartridge P615

for open circuit, short circuit, and poor contact.

3. If no problem is found, replace the following parts in sequence:

• Drum Cartridge (PL 8.1)

• ESS/MCU PWB (PL 18.1)

Initial Issue
WorkCentre 5021/5019

08/2012

2-49

Status Indic a tor RAPs

095-910

Status Indicator RAPs

095-910

08/2012

2-50

Initial Issue

WorkCentre 5021/5019

116-321 Controller Logic Fail

BSD-ON:-

116-377 IIT Interrupt Time out

BSD-ON:CH6.3

• A software defect that cannot be ignored was found in the Controller software.

• The CPU has rebooted due to the occurrence of an exception.

Cause/Action

1. Turn the power OFF and ON.

2. Install a Controller Firmware with the correct version.

116-323 Controller NVM Data Defect

BSD-ON:-

Any of the following was detected:

• The On Board NVM data of the Controller is corrupted.

• The On Board NVM of the Controller is not installed.

• Any one of the Print Counter has reached its maximum value.

• The number of times the NVM can be changed has reached its limit.

NOTE: If this Fault reoccurrs after performing Data Backup/Restore, perform Data Restore
again.

(Perform NVM Matching (NVM[621-400]) in the CE Mode.)

Cause/Action

1. Turn the power OFF and ON.

2. Perform NVM Initialize in the CE Mode. (Refer to [6.4.2.5 NVM Initialize].)

The DMA start trigger when scanning documents cannot be detected for a specified time.

Cause/Action

1. Turn the power OFF and ON.

2. Turn OFF the power and check the Flat Cable between the IIT Carriage J700 and the
ESS/MCU PWB J420 for open circuits, short circuits, and poor contacts (especially,
check whether the Flat Cable was inserted in a skewed manner).

3. Check the ESS/MCU PWB for improper installation (loose screw).

4. If no problem is found, replace the ESS/MCU PWB. (PL 18.1)

116-747 Invalid Page Margin

BSD-ON:-

During Copy Job, subtracting the amount of edge erase from the section that should have
been scanned resulted in a negative value.

Cause/Action

Change the value for NVM [790-301] (Document Edge Erase Amount) or NVM [790-302] (Doc­ument Edge Erase Amount (for ID Card Copy)).

116-334 NVM Data Mismatch

BSD-ON:-

The verification result between the On Board NVM and the Backup NVM of the Controller is
mismatched.

(This includes cases where one of the NVM is Blank)

Cause/Action

1. Turn the power OFF and ON.

2. Perform NVM Matching (NVM[621-400]) in the CE Mode.

Initial Issue
WorkCentre 5021/5019

08/2012

2-51

Status Indic a tor RAPs

116-321, 116-377

Status Indicator RAPs

116-321, 116-377

08/2012

2-52

Initial Issue

WorkCentre 5021/5019

117-326 Controller Back up NVM Data Defect

BSD-ON:-

Any of the following was detected:

• The Backup NVM data of the Controller is corrupted.

• The Backup NVM of the Controller is not installed.

• Any one of the Print Counter has reached its maximum value.

• The number of times the NVM can be changed has reached its limit.

Cause/Action

1. Turn the power OFF and ON.

2. Check the EEPROM (Master) on the ESS/MCU PWB for poor contact with the socket.

3. Perform NVM Initialize in the CE Mode. (Refer to [6.4.2.5 NVM Initialize].)

4. If the problem persists, replace the ESS/MCU PWB. (PL 18.1)

Initial Issue
WorkCentre 5021/5019

08/2012

2-53

Status Indic a tor RAPs

117-326

Status Indicator RAPs

117-326

08/2012

2-54

Initial Issue

WorkCentre 5021/5019

123-314 UI Panel Communication Fail

BSD-ON:CH2.1

Communication failure between the ESS/MCU PWB and the UI Panel was detected.

Cause/Action

1. Turn the power OFF and ON.

2. Turn OFF the power and check the Flat Cable between the UI PWB J740 and the ESS/
MCU PWB J422 for open circuits, short circuits, and poor contacts.

3. If no problem is found, replace the following parts in sequence:

•UI PWB (PL 1.6)

• ESS/MCU PWB (PL 18.1)

Initial Issue
WorkCentre 5021/5019

08/2012

2-55

Status Indic a tor RAPs

123-314

Status Indicator RAPs

123-314

08/2012

2-56

Initial Issue

WorkCentre 5021/5019

2.2.3.1 AC Power FIP

BSD-ON:CH1.1

2.2.3.2 +5VDC Power FIP

BSD-ON:CH1.2, CH1.1

Procedure

Turn OFF the Main Power Switch. Is the voltage between the Main Power Switch J3 and

J4 120VAC/220 to 240VAC?

YN

Is the voltage between the AC Inlet J1 and J2 120VAC/220 to 240VAC?
YN

Unplug the Power Cord from the outlet. Is 120VAC/220 to 240VAC measured at
the outlet?
YN

Check the customer's Breaker, etc.

Check the Power Cord for open circuit and poor contact. If no problems are found,
replace the AC Inlet. (PL 18.1)

Check the connections between the AC Inlet J1, J2 and the Main Power Swit ch J3, J4
for open circuits and poor contacts.

Turn ON the Main Power Switch. Is the voltage between the LVPS J510-1 and J510-3

120VAC/220 to 240VAC?
YN

Turn OFF the power and unplug the Power Cord from the outlet.

- LVPS [120VAC] ­Check the connections between the Main Power Switch J5 , J6 and the LVPS J510 pin­1 and pin-2 for open circuits and poor contacts.

- LVPS [220VAC] ­Check the connections between the Main Power Switch J5 , J6 and the LVPS J510 pin­1 and pin-3 for open circuits and poor contacts.
If no problems are found, replace the Main Power Switch. (PL 18.1)

Procedure

Turn ON the power. Is the voltage between the LVPS J512-1 (+) and the GND (-) +5VDC?
YN

- LVPS [120VAC] ­Is the voltage between the LVPS J510-1 and J510-2 120VAC?

- LVPS [220VAC] - Is the voltage between the LVPS J510-1 and J510-3 220 to

240VAC?
YN

Go to '2.2.3.1 AC Power FIP'.

Turn OFF the power and disconnect the L VPS J512. After 15 s or longer has passed, turn
ON the machine. Is the voltage between the LVPS P512-1 (+) and the GND (-)

+5VDC?
YN

Replace the LVPS. (PL 18.1)

Check the +5VDC circuit for a short circuit in the frame by referring to Chapter 7 Wiring
Data.

Check the wire to the applicable component for an open circuit or poor contact by referring to
Chapter 7 Wiring Data.

Check the AC circuit to each component by referring to Chapter 7 Wiring Data.

Initial Issue
WorkCentre 5021/5019

08/2012

2-57

Status Indic a tor RAPs

2.2.3.1, 2.2.3.2

2.2.3.3 +24VDC Power FIP

BSD-ON:CH1.3, CH1.2, CH1.1

Procedure

Turn ON the power. Is the voltage between the LVPS J512-1 (+) and the GND (-) +5VDC?
YN

Go to 2.2.3.2 +5VDC Power FIP.

Are the voltages between the LVPS J512-3/6 (+) and the GND (-) +24VDC?
YN

Is the voltage between the LVPS J513-4 (+) and the GND (-) +3.3VDC?
YN

Check the circuit to the LVPS J513 pin-4.

Turn OFF the power and disconnect the LVPS J512.After 15 s or longer has passed, turn
ON the machine. Are the voltages between the LVPS P512-3/6 (+) and the GND (-)

+24VDC?
YN

Replace the LVPS. (PL 18.1)

Check the +24VDC circuit for a short circuit in the fr ame by referring to Chapter 7 Wiring
Data.

Check the wire to the applicable component for an open circuit or poor contact by referring to
Chapter 7 Wiring Data.

Status Indicator RAPs

2.2.3.3

08/2012

2-58

Initial Issue

WorkCentre 5021/5019

2.2.4.1 Reflective Sensor Failure FIP

Procedure

2.2.4.2 Permeable Sensor Failure FIP

Procedure

Figure 1 2001

Enter DC330[XXXX-XXX]. Block the sensor w ith a sheet of blank paper. Is [LOW] dis­played?
YN

Is +5VDC measured between the sensor pin-2 (+) and the GND (-)?
YN

Check the connection between the sensor pin-2 and the PWB pin-8 for an open cir­cuit and poor contact.
If no problem is found, replace the PWB.

Is +5VDC measured between the sensor pin-1 (+) and pin-3 (-)?
YN

Is +5VDC measured between the PWB pin-4 (+) and pin-5 (-)?
YN

Replace the PWB.

Check the connection between the PWB pin-4 and the sensor pin-1, as well as
between the PWB pin-5 and the sensor pin-3 for open circuits and poor contacts.

Check the sensor for contamination and improper installation.
If no problems are found, replace the sensor.

Remove the sheet of paper blocking the sensor. Is [HIGH] displayed?
YN

Disconnect the sensor connector. Does the display change to [HIGH]?
YN

Check the connection between the sensor pin-2 and the PWB pin-8 for a short cir­cuit.
If no problem is found, replace the PWB.

Figure 1 2002

Enter DC330[XXX-XXX]. Block the sensor. Is [HIGH] displayed?
YN

Disconnect the sensor connector. Does the display change to [HIGH]?
YN

Check the connection between the sensor pin-2 and the PWB pin-8 for a short cir­cuit. If no problem is found, replace the PWB.

Replace the sensor.

Remove any obstruction on the sensor light path. Does the display change to [LOW]?

YN

Is +5VDC measured between the sensor pin-2 (+) and the GND (-)?
YN

Check the connection between the sensor pin-2 and the PWB pin-8 for an open cir­cuit and poor contact.
If no problem is found, replace the PWB.

Is +5VDC measured between the sensor pin-1 (+) and pin-3 (-)?
YN

Check the connection between the PWB pin-4 and the sensor pin-1, as well as
between the PWB pin-5 and the sensor pin-3 for open circuits and poor contacts.
If no problem is found, replace the PWB.

Check the sensor for contamination.
If no problems are found, replace the sensor.

Check the sensor for improper installation and the Actuator for bending or failure.
If no problems are found, replace the sensor.

Check the sensor for improper installation and incident light diffraction. If no problems are
found, replace the sensor.

Check the installation of the sensor. If no problems are found, replace the sensor.

Initial Issue
WorkCentre 5021/5019

08/2012

2-59

Status Indic a tor RAPs

2.2.4.1, 2.2.4.2

2.2.4.3 Switch (Normal/Open) Failure FIP

Procedure

2.2.4.4 Solenoid/Clutch Not Energized Failure FIP

Procedure

Figure 1 2003

Enter DC330[XXX-XXX]. Turn the switch ON. Is [LOW] displayed?
YN

Is +5VDC measured between the switch pin-2 (+) and the GND (-) ?
YN

Check the connection between the switch pin-2 and the PWB pin-3 for an open cir­cuit and poor contact.
If no problem is found, replace the PWB.

Is +5VDC measured between the switch pin-1 (+) and the GND (-) ?

YN

Replace the switch.

Check the connection between the switch pin-1 and the PWB pin-4 for an open circuit
and poor contact.
If no problem is found, replace the PWB.

Turn the switch OFF. Is [HIGH] displayed?
YN

Disconnect the switch connector. Is [HIGH] displayed?
YN

Check the connection between the switch pin-2 and the PWB pin-3 for a short circuit.
If no problem is found, replace the PWB.

Replace the switch.

Check the installation of the switch.
If no problems are found, replace the switch.

Figure 1 2004

NOTE: Before performing this FIP, ensure that there is no (mechanical) operation failure with
the solenoid and the clutch.

Enter DC330[XXX-XXX] and turn it ON. Is +24VDC measured between th e PWB pin-3 (+)
and the GND (-)?
YN

Is +24VDC measured between the solenoid/clutch pin-2 (+) and the GND (-) ?
YN

Is +24VDC measured between the solenoid/clutch pin-1 (+) and the GND (-) ?
YN

Check the connection between the PWB pin-4 and the solenoid/clutch pin-1 for
an open circuit and poor contact.
If no problem is found, replace the PWB.

Replace the solenoid/clutch.

Check the connection between the PWB pin-3 and the solenoid/clutch pin-2 for an open
circuit and poor contact.

Replace the PWB.

Status Indicator RAPs

2.2.4.3, 2.2.4.4

08/2012

2-60

Initial Issue

WorkCentre 5021/5019

2.2.4.5 Solenoid/Clutch Left Energized Failure FIP

Procedure

2.2.4.6 Motor Does Not Rotate Failur e FIP

Procedure

Figure 1 2004

Turn OFF the power.
Disconnect the PWB connector. Is the resistance between the connector pin-3 and the

frame 10Ohm or less?
YN

Replace the PWB.

Check the connection between the connector pin-3 and the solenoid/clutch pin-2 for a short cir­cuit.
If no problems are found, replace the solenoid/clutch.

Figure 1 2005

NOTE: Before performing this FIP, ensure that the motor is not locked or loaded.

Enter DC330[XXX-XXX] and turn it ON.
Is +24VDC measured between the PWB pin-3 (+) and the GND (-) ?

YN

Is +24VDC measured between the motor pin-2 (+) and the GND (-) ?
YN

Is +24VDC measured between the motor pin-1 (+) and the GND (-) ?
YN

Is +24VDC measured between the PWB pin-4 (+) and the GND (-) ?
YN

Replace the PWB.

Check the connection between the PWB pin-4 and the motor pin-1 for an open
circuit and poor contact.

Replace the motor.

Check the connection between the PWB pin-3 and the motor pin-2 for an open circuit and
poor contact.

Replace the PWB.

Initial Issue
WorkCentre 5021/5019

08/2012

2-61

Status Indic a tor RAPs

2.2.4.5, 2.2.4.6

2.2.4.7 Motor Left Running Failure FIP

Procedure

Figure 1 2005

Turn OFF the power. Disconnect the PWB connector. Is the resistance between the con­nector pin-3 and the frame 10Ohm or less?
YN

Replace the PWB.

Check the connection between the connector pin-3 and the motor pin-2 for a short circuit.
If no problems are found, replace the motor.

2.2.4.8 NIP/RELEASE SOLENOID Not Energized Failure
FIP

Procedure

Figure 1 2017

NOTE: Before performing this FIP, ensure that there is no (mechanical) operation failure with
the solenoid.

Is +24VDC measured between the NIP/RELEASE SOLENOID pin-1 (+) and the GND (-)?
YN

Is +24VDC measured between the PWB pin-5 (+) and the GND (-)?
YN

Check the +24VDC inputs of the PWB. If no problem is found, replace the PWB.

Status Indicator RAPs

2.2.4.7, 2.2.4.8

Check the connection between the PWB pin-5 and the NIP/RELEAS E SOLENOID pin-1
for an open circuit and poor contact.

Use the following FIP when there is a problem with the NIP.
Enter DC330[XXX-XXX] and turn the SOL NIP ON. Is +24VDC measured be tween the PW B

pin-4 (+) and the GND (-)?
YN

Enter DC330[XXX-XXX] and turn the SOL NIP ON. Is +24VDC measured between the
NIP/RELEASE SOLENOID pin-3 (+) and the GND (-)?
YN

Replace the NIP/RELEASE SOLENOID.

Check the connection between the PWB pin-4 and the NIP/RELEAS E SOLENOID pin-3
for an open circuit and poor contact.

Use the following FIP when there is a problem with the RELEASE.
Enter DC330[XXX-XXX] and turn the SOL RELEASE ON. Is +24VDC measured between

the PWB pin-6 (+) and the GND (-)?

08/2012

2-62

WorkCentre 5021/5019

Initial Issue

YN

Enter DC330[XXX-XXX] and turn the SOL RELEASE ON. Is +24VDC measured
between the NIP/RELEASE SOLENOID pin-2 (+) and the GND (-)?
YN

Replace the NIP/RELEASE SOLENOID.

Check the connection between the PWB pin-6 and the NIP/RELEAS E SOLENOID pin-2
for an open circuit and poor contact.

Replace the PWB.

Initial Issue
WorkCentre 5021/5019

08/2012

2-63

Status Indic a tor RAPs

2.2.4.8

Status Indicator RAPs

2.2.4.8

08/2012

2-64

Initial Issue

WorkCentre 5021/5019

2.3.1 No output is available, no data is printed

1. Check whether or not the Controller Firmware and Printer Driver are the latest version.
If it is not the latest, always upgrade the software. (See ADJ 18.2.2 Firmware Version

Upgrade.)

2.3.2 Printing can be performed but abnormally

1. Check whether the Controller Firmware and Printer Driver are the latest version.
If it is not the latest, always upgrade the software. (See ADJ 18.2.2 F irmware Version

Upgrade.)

After checking the above items, check whether the Indicator is blinking and take the cor­rective actions accordingly.

2. When the Indicator (Panel Send/Receive Lamp) is blinking
It is highly possible that print data cannot be decomposed in the Printer main processor.
Collect the following information:

• System Settings Report

• Check the panel message (error message, etc).

• Error History Report

• Service Settings Report

• Job History Report

• Maintenance Report (CE)

• Check the Printer Driver name and version.

• Check the Printer Driver settings in details.

• Create Print files on the PC and collect them on CD-R.

[How to Create Print file]
Method 1)
(1) Select [Print] from File menu in the target document.
(2) In [Print] screen, select the [Output to File] check box and click [OK].

If there is no [Output to File] check box displayed in the [Print] screen, create the file
in Method 2.

(3) Enter a descriptive file name in 'File Name' using a customer name and dat e, and

click [OK] to create a Print file in the specified destination.

2. Ask a customer about the status of unavailable printing and collect information based on
it.

• System Settings List

• Service Settings Report

• Job History Report

• Maintenance Report (CE)

• Check the Printer Driver name and version.

• Check the Printer Driver settings in details.

• Print sample that has been printed improperly.

• Print sample that has been printed properly (including the samples from other

machines).

• Create Print files on the PC and collect them on CD-R.

Method 2)
(1) Open the Printer Driver Properties and select the [Ports] tab.
(2) In [Ports], select [FILE:] in the list and click [OK] to close the Properties screen.

Take note of the port setting before it was changed in [FILE:] in or der to restore the

port to original setting after creating a Print file.
(3) Select [Print] from File menu in the target document.
(4) The [Output to File] screen appears. Specify a storage destination and file name,

and click [OK] to create a Print file in the specified destination.
(5) Restore the port to the original setting in the procedures a and b shown above.

3. When the Indicator (Panel Send/Receive Lamp) is not blinking
It is highly possible that USB connection is not established and hence print data has not

reached the Printer main processor.

Initial Issue
WorkCentre 5021/5019

08/2012

2-65

Status Indic a tor RAPs

2.3.1, 2.3.2

3.1 Introduction

3.1.1 Composition of Chapter 3 Image Quality Troubleshooting ................................... 3-3

3.1.2 Test Pattern...... ..................................................................................................... 3-3

3.1.3 Image Quality Troubleshooting............................................................................. 3-4

3.2 Image Quality RAPs

IQ1 IOT Image Quality Entry RAP ................................................................................. 3-5

IQ2 IIT Image Quality Entry RAP ................................................................................... 3-5

IQ3 Low Image Density RAP ......................................................................................... 3-6

IQ4 Wrinkled Image RAP............................................................................................... 3-6

IQ5 Residual Image (Ghosting) RAP............................................................................. 3-7

IQ6 Background RAP..................................................................................................... 3-7

IQ7 Deletion RAP....................................... ........................................................... ......... 3-8

IQ8 Skew/Misregistr a tio n RAP...................................................................... ................. 3-8

IQ9 Process Direction Bands,Streaks,and Smears RAP............................................... 3-9

IQ10 Unfused Copy/Toner Offset RAP.......................................................................... 3-10

IQ11 Repeating Bands,Streaks,Spots,and Smears RAP............................................... 3-10

IQ12 Mottle RAP.................................................................... ........................................ 3-11

IQ13 Spots RAP..................................... ........................................................................ 3-11

IQ14 Black Prints RAP................................................................................................... 3-12

IQ15 Blank Image RAP...................................................................... ............................ 3-12

3.3 Image Defect Sample

3.3.1 IOT Image Defect Sample.......................................................................... .. .... ..... 3-15

3.3.2 IIT Image Defect Sample .................................................. .. .... .... ....... .... .... .. .... ..... 3-15

IDS1 Auger Mark............................................................................................................ 3-16

IDS2 Strobing (27mm or 13.5mm Pitch Density)........................................................... 3-16

IDS3 White Streaks (Process Direction)........................................................................ 3-17

IDS4 Black Bands .......................................................................................................... 3-17

IDS5 Toner Contamination............................................................................................. 3-18

IDS6 Toner Splattering................................................................................................... 3-18

IDS7 White Spots (Irregular).......................................................................................... 3-19

IDS8 Regular Blank Areas In Process Direction (Spots, Streaks, Bands etc.) .............. 3-19

IDS9 Regular Toner Contamination In Process Direct io n (Spots, Streaks , Bands etc.) 3-20

IDS10 Regular Toner Contamination In Process Direction (Side 2) .............................. 3-21

IDS11 Moire Due to Interference With Copy Documents............................................... 3-22

IDS12 Light Background Due to Background Suppression in Copies of Documents With

Frames............................................................................................................................ 3-22

IDS13 Background Smear When Using Platen Copy With Non-Standard Documents . 3-23
IDS14 Fluctuation In Background Suppression Values for Copies of Documents With Medium

Density............................................................................................................................ 3-24

IDS15 Defects Related To Scan Print............................................................................ 3-24

3.4 Fusing Unit Paper Wrinkle Alignment Adjustment ................................................... 3-25

3.5 Cycle Table .............................................................................................................. 3-27

3 Image Quality

Initial Issue
WorkCentre 5021/5019

08/2012

3-1

Image Quality

3.1.1 Composition of Chapter 3 Image Quality

Troubleshooting

1. Chapter 3 Image Quality Troubleshooting is mainly composed of two sections:
Test Pattern and Image Quality Troubleshooting.

3.1.2 Test Pattern

The following are the test patterns that are used.

1. The copy quality check mainly uses the Test Pattern (Mono A3) (499T 00247).

2. The Test Pattern section contains the method to output the Built-in Test Patterns for the
copy quality check.

3. The Image Quality Specifications section also contains [6.1.24 Alignment Specifications].

4. The Image Quality Troubleshooting section describes the causes of image quality failures
and the troubleshooting procedure for them.

2. For copy quality check, Standard paper is used.

3. The Built-in Test Patterns are stored in the following locations.
(1) IOT ESS/MCU PWB

4. For the Test Patterns, refer to the following.

• 6.4.2.14 Test Pattern Print

Initial Issue
WorkCentre 5021/5019

08/2012

3-3

Image Quality

3.1.1, 3.1.2

3.1.3 Image Quality Troubleshooting

Check the Defect Sample that is obtained during visit or the one that is provided by the cus ­tomer and proceed with the appropriate IQ-FIP.

Image Quality

3.1.3

08/2012

3-4

Initial Issue

WorkCentre 5021/5019

IQ1 IOT Image Quality Entry RAP

Initial Actions

Determine whether the image quality problem occurs in Copy Mode or Printer Mode. If the
problem occurs in Copy Mode, go to [IQ2 IIT Image Quality Entry RAP].

Procedure

Determine the image quality problem and go to the relevant RAP.

Table 1

Image Quality
Problem

Low Image Density Overall low density of images. IQ3 RAP
Wrinkled Image The printed paper is creased, folded or torn. IQ4 RAP
Residual Image

(Ghosting)

Background The whole page or part of the page is contaminated by

Deletion Part of the image is missing. IQ7 RAP
Skew/Misregistra-

tion
Process Direction

Bands, Streaks, and
Smears

Unfused Copy/Toner
Offset

Repeating Bands,
Streaks, Spots, and
Smear

Mottle Uneven printed image density. IQ12 RAP
Spots T oner spots and blank areas are spread irregularly over

Black Prints Paper is printed completely black. IQ14 RAP
Blank Image Paper is printed completely white. IQ15 RAP

Ghost images appear on the paper. Parts of the previ­ous page or current page appear as ghost images on
the paper.

toner. The contamination appears as very light grayish
color.

Printed images are not parallel to the edges of the
paper.

Black lines or blank areas running along the paper in
vertical direction.

Printed images are not properly fused onto the paper.
When rubbed, the image comes off easily.

Black lines or blank areas running along the paper in
h.orizontal direction.

the whole page.

Symptoms RAP

IQ5 RAP

IQ6 RAP

IQ8 RAP

IQ9 RAP

IQ10 RAP

IQ11 RAP

IQ13 RAP

IQ2 IIT Image Quality Entry RAP

Initial Actions

Clean the Platen Glass.

Clean the mirrors and lens with lint-free cloth.

Procedure

Determine the image quality problem and go to the relevant RAP.

T able 1

Image Quality
Problem

Low Image Density Overall low density of images. IQ3 RAP
Background The whole page or part of the page is contaminated by

toner. The contamination appears as very light grayish
color.

Process Direction
Bands, Streaks, and
Smears

Repeating Bands,
Streaks, Spots, and
Smear

Spots T oner spots and blank areas are spread irregularly over

Black Prints Paper is printed completely black. IQ14 RAP

Black lines or blank areas running along the paper in
vertical direction.

Black lines or blank areas running along the paper in
h.orizontal direction.

the whole page.

Symptoms RAP

IQ6 RAP

IQ9 RAP

IQ11 RAP

IQ13 RAP

Initial Issue
WorkCentre 5021/5019

08/2012

3-5

Image Quality

IQ1, IQ2

IQ3 Low Image Density RAP

Overall low density of images.

IQ4 Wrinkled Image RAP

The printed paper is creased, folded or torn.

Procedure

Check for contamination on the Platen Glass. The Platen Glass is clean.
YN

Clean any contamination on the Platen. If it is very dirty, replace the Top Cover (PL 1.2)
(REP 1.2.1).

Check the drum ground contact point for contamination and distortion. The drum ground

contact point is clean and there is no distortion.
YN

Clean the drum ground contact point. Correct the distortion.

Remove the Drum Cartridge (PL 8.1) (REP 8.1.1) and reinstall it. Turn the power OFF then ON
and print. The problem reoccurs.

YN

End

Enter the Diag Mode and set '30' into Chain-Link 752-350. Then, set '10' into Chain-Link 752-

230. Exit from the Diag Mode and make a printout.
If the problem reoccurs, enter the Diag Mod e again, set '20' into Chain-Link 752-230, and
make another printout. (The maximum value that can be set for 752-230 is '30').
Install the new Drum Cartridge (PL 8.1) (REP 8.1.1) securely. Turn the power OFF then ON
and print. The problem reoccurs.

YN

End

Print a page that is entirely black. During the print cycle, turn OFF the power after the feeding
sound is heard. (i.e. forcing to stop the transfer in mid-progress). Check the surface of the
Drum. There is a considerable amount of toner left on the surface of the drum.

YN

Replace the ESS/MCU PWB (PL 18.1) (REP 18.1.1).

Procedure

Check the paper type. Paper used is within specifications.
YN

Use paper within specifications.

Use paper from a freshly opened packet. The problem reo c c ur s .

YN

End

Remove the Fusing Unit (PL 7.1) (REP 7.1.1) and reinstall it. Turn the power OFF then ON and
print. The problem reoccurs.

YN

End

Check for foreign substances and distortion in the paper transport path. No distortion or for-

eign substances are found in the paper transport path.
YN

Remove the foreign substances. Correct the distortion.

Replace the Fusing Unit (PL 7.1) (REP 7.1.1).

Replace the BTR Roll (PL 6.1) (REP 4.1.1), followed by the HVPS (PL 18.1) (REP 18.1.2) and
the ESS/MCU PWB (PL 18.1) (REP 18.1.1).

Image Quality

IQ3, IQ4

08/2012

3-6

Initial Issue

WorkCentre 5021/5019

IQ5 Residual Image (Ghosting) RAP

Ghost images appear on the paper. Part s of the previous page or current p age appear as ghost
images on the paper.

IQ6 Background RAP

The whole page or part of the page is contaminated by toner. The contamination appears as
very light grayish color.

Procedure

Remove the Drum Cartridge (PL 8.1) (REP 8.1.1) and reinstall it. Turn the power OFF then ON
and print. The problem reoccurs.

YN

End

Install the new Drum Cartridge (PL 8.1) (REP 8.1.1) securely. Turn the power OFF then ON
and print. The problem reoccurs.

YN

End

Remove the Fusing Unit (PL 7.1) (REP 7.1.1) and check the surface of the Heat Roll for con­tamination. The surface of the Heat Roll is clean.

YN

Clean away the contamination. If there is difficulty in removing the contamination, replace
the Fusing Unit (PL 7.1) (REP 7.1.1).

Replace the ESS/MCU PWB (PL 18.1) (REP 18.1.1).

Procedure

Check for contamination on the Platen Glass. The Platen Glass is clean.
YN

Clean any contamination on the Platen. If it is very dirty, replace the Top Cover (PL 1.2)
(REP 1.2.1).

Remove the Drum Cartridge (PL 8.1) (REP 8.1.1) and reinstall it. Turn the power OFF then ON
and print. The problem reoccurs .

YN

End

Install the new Drum Cartridge (PL 8.1) (REP 8.1.1) securely. Turn the power OFF then ON
and print. The problem reoccurs .

YN

End

Check the surface of the BTR for contamination and distortion. The surface of the BTR is

clean and there is no distortion.
YN

Clean the BTR. If there is distortion, replace the BTR Roll (PL 6.1) (REP 4.1.1).

Remove the HVPS and reinstall it. Turn the power OFF then ON and print. The problem

reoccurs.
YN

End

Replace the ESS/MCU PWB (PL 18.1) (REP 18.1.1).

Initial Issue
WorkCentre 5021/5019

08/2012

3-7

Image Quality

IQ5, IQ6

IQ7 Deletion RAP

Part of the image is missing.

IQ8 Skew/Misregistration RAP

Printed images are not parallel to the edges of the paper.

Procedure

Check the paper type. Paper used is within specifications.
YN

Use paper within specifications.

Use paper from a freshly opened packet. The problem reoc c ur s .

YN

End

Remove the Drum Cartridge (PL 8.1) (REP 8.1.1) and reinstall it. Turn the power OFF then ON
and print. The problem reoccurs.

YN

End

Install the new Drum Cartridge (PL 8.1) (REP 8.1.1) securely. Turn the power OFF then ON
and print. The problem reoccurs.

YN

End

Check the surface of the BTR for distortion. There is no distortion on the surface of the

BTR.
YN

Replace the BTR Roll (PL 6.1) (REP 4.1.1).

Replace the ESS/MCU PWB (PL 18.1) (REP 18.1.1).

Procedure

Check the location where the machine is installed. The machine is installed on a stable
level surface.
YN

Install the machine on a stable level surface.

Remove the Drum Cartridge (PL 8.1) (REP 8.1.1) and reinstall it. Turn the power OFF then ON
and print. The problem reoccurs .

YN

End

Check the installation of the Paper Cassette. The Paper Cassette is installed correctly.

YN

Install the mirror properly.

Check for distortion in the paper transport path. There is no distortion in the paper trans-

port path.
YN

Correct the distortion or replace the distorted part.

Replace the ESS/MCU PWB (PL 18.1) (REP 18.1.1).

Image Quality

IQ7, IQ8

08/2012

3-8

Initial Issue

WorkCentre 5021/5019

IQ9 Process Direction Ba nds,Streaks,and Smears RAP

Black lines or blank areas running along the paper in vertical direction.

Procedure

Check the IIT Carriage Mirrors for scratches and contamination. There are no scratches or
contamination on the mirrors.
YN

Clean the mirrors. If it is very dirty or sc ratched, replace the IIT Carriage (PL 1.3) (REP

1.3.2).

Remove the Drum Cartridge (PL 8.1) (REP 8.1.1) and reinstall it. Turn the power OFF then ON
and print. The problem reoccurs.

YN

End

Install the new Drum Cartridge (PL 8.1) (REP 8.1.1) securely. Turn the power OFF then ON
and print. The problem reoccurs.

YN

End

Check the surface of the BTR for contamination and distortion. The surface of the BTR is

clean and there is no distortion.
YN

Clean the BTR. If there is distortion, replace the BTR Roll (PL 6.1) (REP 4.1.1).

Check for contamination in the paper transport path. The paper transport path is clean.

YN

Clean away the contamination.

YN

Clean the ROS Window. If there are scratches, replace the ROS Window.

Replace the ROS Assembly (PL 2.1) (REP 2.1.1) and the ESS/MCU PW B (PL 18.1) (REP

18.1.1).

Check the mirror at the IIT Carriage. The mirror is clean and there is no distortion.

YN

Clean the mirror. If there is distortion, replace the mirror.

Remove the Fusing Unit (PL 7.1) (REP 7.1.1) and check the surface of the Heat Roll for con­tamination. The surface of the Heat Roll is clean.

YN

Clean away the contamination. If there is difficulty in removing the contamination, replace
the Fusing Unit (PL 7.1) (REP 7.1.1).

Check the surface of the BTR for contamination and distortion. The surface of the BTR is

clean and there is no distortion.
YN

Clean the BTR. If there is distortion, replace the BTR Roll (PL 6.1) (REP 4.1.1).

Check the mirror at the IIT Carriage. The mirror is clean and there is no distortion.

YN

Clean the mirror. If there is distortion, replace the mirror.

Check the ROS Window for scratches and contamination. The ROS Window is clean and

there are no scratches.

Initial Issue
WorkCentre 5021/5019

08/2012

3-9

Image Quality

IQ9

IQ10 Unfused Copy/Toner Offset RAP

Printed images are not properly fused onto the paper. When rubbed, the image comes off eas­ily.

Procedure

Check the paper type. Paper used is within specifications.
YN

Use paper within specifications.

Use paper stored under room conditions. The problem reoccurs.

YN

End

Check the power supply voltage. The voltage is within the specified range.

YN

Connect a power supply with voltage within the specified range.

Remove the Fusing Unit (PL 7.1) (REP 7.1.1) and reinstall it. Turn the power OFF then ON and
print. The problem reoccurs.

YN

End

Check the fusing temperature using the Diagnostics. A normal fusing temperature is set.

YN

Set a normal fusing temperature.

Replace the Fusing Unit (PL 7.1) (REP 7.1.1).

IQ11 Repeating Bands,Streaks,Spots ,and Smea rs RA P

Black lines or blank areas running along the paper in h.orizontal direction.

Procedure

Check the operating parts of the IIT Carriage for foreign substances and distortion. No distor­tion or foreign substances are found in the operating parts of the carriage.
YN

Remove the foreign substances. If the Pulley, Shaft, IIT Carriage Belt (PL 1.3) (REP

1.3.2), etc. is deformed, replace it.

Remove the Drum Cartridge (PL 8.1) (REP 8.1.1) and reinstall it. Turn the power OFF then ON
and print. The problem reoccurs .

YN

End

Install the new Drum Cartridge (PL 8.1) (REP 8.1.1) securely. Turn the power OFF then ON
and print. The problem reoccurs .

YN

End

Check the surface of the BTR for contamination and distortion. The surface of the BTR is

clean and there is no distortion.
YN

Clean the BTR. If there is distortion, replace the BTR Roll (PL 6.1) (REP 4.1.1).

Check the pitch of the black lines or blank areas. The pitch of the black lines is approx. 78

mm (Heat Roll circumference).
YN

Clean the Heat Roll. If there is difficulty in removing the cont amination, replace t he Fusing
Unit (PL 7.1) (REP 7.1.1).

Image Quality

IQ10, IQ11

Replace the ROS Assembly (PL 2.1) (REP 2.1.1), followed by the ESS/MCU PWB (PL 18.1)
(REP 18.1.1).

08/2012

3-10

WorkCentre 5021/5019

Initial Issue

IQ12 Mottle RAP

A phenomenon where an uneven density is occurring in the high density patch image.

IQ13 Spots RAP

Toner spots and blank areas are spread irregularly over the whole page.

Procedure

Check the paper type. Paper used is within specifications.
YN

Use paper within specifications.

Use paper from a freshly opened packet. The problem reoc c ur s .

YN

End

Remove the Drum Cartridge (PL 8.1) (REP 8.1.1) and reinstall it. Turn the power OFF then ON
and print. The problem reoccurs.

YN

End

Install the new Drum Cartridge (PL 8.1) (REP 8.1.1) securely. Turn the power OFF then ON
and print. The problem reoccurs.

YN

End

Check the surface of the BTR for contamination and distortion. The surface of the BTR is

clean and there is no distortion.
YN

Clean the BTR. If there is distortion, replace the BTR Roll (PL 6.1) (REP 4.1.1).

Remove the HVPS and reinstall it. Turn the power OFF then ON and print. The problem

reoccurs.
YN

End

Replace the ESS/MCU PWB (PL 18.1) (REP 18.1.1).

Procedure

Check for contamination on the Platen Glass. The Platen Glass is clean.
YN

Clean any contamination on the Platen. If it is very dirty, replace the Top Cover (PL 1.2)
(REP 1.2.1).

Remove the Drum Cartridge (PL 8.1) (REP 8.1.1) and reinstall it. Turn the power OFF then ON
and print. The problem reoccurs .

YN

End

Install the new Drum Cartridge (PL 8.1) (REP 8.1.1) securely. Turn the power OFF then ON
and print. The problem reoccurs .

YN

End

Check the surface of the BTR for contamination and distortion. The surface of the BTR is

clean and there is no distortion.
YN

Clean the BTR. If there is distortion, replace the BTR Roll (PL 6.1) (REP 4.1.1).

Check for contamination in the paper transport path. The paper transport path is clean.

YN

Clean away the contamination.

Remove the Fusing Unit (PL 7.1) (REP 7.1.1) and check the s urface of the Heat Roll for c on-
tamination. The surface of the Heat Roll is clean.

YN

Clean away the contamination. If there is difficulty in removing the contamination, replace
the Fusing Unit (PL 7.1) (REP 7.1.1).

Initial Issue
WorkCentre 5021/5019

Check the paper type. Paper used is within specifications.
YN

Use paper within specifications.

Use paper from a freshly opened packet. The problem reo c c ur s .

YN

End

Replace the ESS/MCU PWB (PL 18.1) (REP 18.1.1).

08/2012

3-11

Image Quality

IQ12, IQ13

IQ14 Black Prints RAP

Paper is printed completely black.

IQ15 Blank Image RAP

Paper is printed completely white.

Procedure

Check the operating parts of the IIT Carriage for foreign substances and distortion. No distor­tion or foreign substances are found in the operating parts of the carriage.
YN

Remove the foreign substances. If the IIIT Carriage (PL 1.3) (REP 1.3.2), IIT Carriage
Belt (PL 1.3) (REP 1.3.2), etc. is deformed, replace it.

Remove the Drum Cartridge (PL 8.1) (REP 8.1.1) and reinstall it. Turn the power OFF then ON
and print. The problem reoccurs.

YN

End

Install the new Drum Cartridge (PL 8.1) (REP 8.1.1) securely. Turn the power OFF then ON
and print. The problem reoccurs.

YN

End

Remove the HVPS (PL 18.1) (REP 18.1.2) and reinstall it. Turn the power OFF then ON and
print. The problem reoccurs.

YN

End

Check the connection of the HVPS P/J500 and ESS/ MCU PWB P/J402 connectors. The con-

nectors are connected correctly.
YN

Connect the connector cable securely.

Check the connection between J500-7 and J402-8 for open circuit and short circuit. The

connection between J500-7 and J402-8 is conducting normally wit h no o pen c ir cui t a nd
no short circuit.
YN

Repair the open circuit or short circuit.

Check the connection between the ROS Assembly (PL 2.1) (REP 2. 1.1) and the ESS/MCU
PWB (PL 18.1) (REP 18.1.1) for open circuit and short circ uit. The connections between the
ROS J140 and the ESS/MCU PWB J410, as well as between the ROS J130 and the ESS/

MCU J410 are conducting normally with no open circuits and no short circuits.
YN

Repair the open circuit or short circuit.

Replace the ROS Assembly (PL 2.1) (REP 2.1.1), followed by the HVPS (PL 18.1) (REP

18.1.2) and the ESS/MCU PWB (PL 18.1) (REP 18.1.1).

Procedure

Check the installation of the ROS Assembly. The ROS U n it is in s tall e d c o r rectly.
YN

Install the ROS Assembly (PL 2. 1) (REP 2.1.1) correctly.

Check the drum ground contact point for contamination and distortion. The drum ground

contact point is clean and there is no distortion.
YN

Clean the drum ground contact point. Correct the distortion.

Remove the Drum Cartridge (PL 8.1) (REP 8.1.1) and reinstall it. Turn the power OFF then ON
and print. The problem reoccurs .

YN

End

Install the new Drum Cartridge (PL 8.1) (REP 8.1.1) securely. Turn the power OFF then ON
and print. The problem reoccurs .

YN

End

Print a page that is entirely black. During the print cycle, turn OFF the power after the feeding
sound is heard. (i.e. forcing to stop the transfer in mid-progress). Check the surface of the
Drum. There is a considerable amount of toner left on the surface of the drum.

YN

Check the connection of the P/J140, P/J410, P/J160, and P/J411 connectors. The
connectors are connected correctly.
YN

Connect the connector cable securely.

Check the installation of the ROS Assembly (PL 2.1) (REP 2.1.1). The ROS Assembly

is installed securely.
YN

Install the ROS Assembly (PL 2. 1) (REP 2.1.1) securely.

Measure the voltage between the ESS/MCU PWB (PL 18.1) (REP 18.1.1) P410 pin-1
and pin-2. The voltage is +5VDC.

YN

Replace the ESS/MCU PWB (PL 18.1) (REP 18.1.1).

Check the connection between J140 and J410 for open circuit and short circuit. The

connection between J140 and J410 is conducting normally with no open circuit
and no short circuit.
YN

Repair the open circuit or short circuit.

Image Quality

IQ14, IQ15

08/2012

3-12

Replace the ROS Assembly (PL 2.1) (REP 2.1.1), followed by the ESS/MCU PWB (PL

REP 18.1.1).

18.1) (

A

Initial Issue

WorkCentre 5021/5019

A

Replace the BTR Roll (PL 6.1) (REP 4.1.1), followed by the HVPS (PL 18.1) (REP 18.1.2) and
the ESS/MCU PWB (PL 18.1) (REP 18.1.1).

Initial Issue
WorkCentre 5021/5019

08/2012

3-13

Image Quality

IQ15

Image Quality

IQ15

08/2012

3-14

Initial Issue

WorkCentre 5021/5019

3.3.1 IOT Image Defect Sample

This section describes some Defect Samples and the actions to be taken in case of the follow­ing IOT problems:

• IDS1 Auger Mark

• IDS2 Strobing (27mm or 13.5mm Pitch Density)

• IDS3 White Streaks (Process Direction)

• IDS4 Black Bands

• IDS5 Toner Contamination

• IDS6 Toner Splattering

• IDS7 White Spots (Irregular)

• IDS8 Regular Blank Areas in Process Direction (Spots, Streaks, Bands etc.)

• IDS9 Regular Toner Contamination in Process Direction (Spots, Streaks, Bands etc.)

• IDS10 Regular Toner Contamination in Process Direction (Side 2)

3.3.2 IIT Image Defect Sample

This section describes some Defect Samples and the actions to be taken in case of the follow­ing IIT problems:

• IDS11 Moire Due to Interference With Copy Documents

• IDS12 Light Background Due to Background Suppression in Copies of Documents With
Frames

• IDS13 Background Smear When Using Platen Copy With Non-Standard Documents

• IDS14 Fluctuation In Backgr ound Suppression Values for Copies of Documents With
Medium Density

• IDS15 Defects Related To Scan Print

Initial Issue
WorkCentre 5021/5019

08/2012

3-15

Image Quality

3.3.1, 3.3.2

IDS1 Auger Mark

IDS2 Strobing (27mm or 13.5mm Pitch Density)

Figure 1 Auger Mark Defect Sample (j0ch3217)

Cause

1. The Developer Magnetic Roll magnetic field failed.

2. There was a drop in the level of developing powder.

Action

1. Replace the Drum Cartridge (PL 8.1) (REP 8.1.1)

NOTE: This may occur immediately after a new CRU is installed.-> Correct this by feed­ing a few sheets of paper.

Image Quality

IDS1, IDS2

Figure 1 Strobing (27 mm or 13.5 mm Pitch Density) Defect Sample (j0ch3218)

Cause

1. Developer Magnetic Roll bias.

Action

1. Replace the Drum Cartridge (PL 8.1) (REP 8.1.1)

08/2012

3-16

Initial Issue

WorkCentre 5021/5019

IDS3 White Streaks (Process Direction)

IDS4 Black Bands

Figure 1 White Streaks (Process Direction) Defect Sample (j0ch3219)

Cause

1. Foreign substances are blocking the ROS Laser.

2. Developing powder clogging on the Developer Magnetic Roll due to foreign substances.

Action

1. Clean the light path and the seal glass between the ROS Assembly (PL 2.1) (REP 2 .1.1)
and the Drum Cartridge (PL 8.1) (REP 8.1.1).

2. Replace the Drum Cartridge (PL 8.1) (REP 8.1.1)

Initial Issue
WorkCentre 5021/5019

Figure 1 Black Bands Defect Sample (j0ch3220)

Cause

1. The developing powder is not well mixed.

Action

1. Mix the developing powder by processing blank paper.

08/2012

3-17

Image Quality

IDS3, IDS4

IDS5 Toner Contamination

IDS6 Toner Splattering

Figure 1 Toner Contamination Defect Sample (j0ch3221)

Cause

1. Cloud toner dropped from the XERO/DEVE Cartridge.

Action

1. Mix the developing powder by feeding blank paper.

2. Replace the Drum Cartridge (PL 8.1) (REP 8.1.1)

Image Quality

IDS5, IDS6

Figure 1 Toner Splattering Defect Sample (j0ch3222)

Cause

1. Paper size mismatch occurred (tray settings and paper size are different).

2. The resistance of the paper increased under dry conditions.

Action

1. Check the tray settings.

2. Use paper from a freshly opened packet.

08/2012

3-18

Initial Issue

WorkCentre 5021/5019

IDS7 White Spots (Irregular)

IDS8 Regular Blank Areas In Process Direction (Spots,
Streaks, Bands etc.)

Figure 1 White Spots (Irregular) Defect Sample (j0ch3223)

Cause

1. The resistance of the paper increased under dry conditions.

Action

1. Use paper from a freshly opened packet.

Initial Issue
WorkCentre 5021/5019

Figure 1 Regular Blank Areas In Process Direction (Spots, Streaks, Bands etc.) Defect

Sample (j0ch3225)

Cause

1. 94 mm pitch -> Drum: Scratches or foreign substances

2. 27 mm pitch -> Magnetic Roll: Developing powder stuck on the Magnetic Roll

3. 44 mm pitch -> BCR: Scratches or foreign substances

4. 80 mm pitch -> Heat Roll: Scratches or foreign substances

Action

1. 1,4: Clean or replace the Drum Cartridge (PL 8.1) (REP 8.1.1)/Fusing Unit (PL 7.1) (REP

7.1.1)

08/2012

3-19

IDS7, IDS8

Image Quality

2. 2,3: Replace the Drum Cartridge (PL 8.1) (REP 8.1.1)

IDS9 Regular Toner Contamination In Process Direction
(Spots, Streaks, Bands etc.)

Image Quality

IDS8, IDS9

Figure 1 Regular Toner Contamination In Process Direction (Spots, Streaks, Bands etc.)

Defect Sample (j0ch3226)

Cause

1. 94 mm pitch -> Drum: Scratches or foreign substances

2. 27 mm pitch -> Magnetic Roll: Developing powder stuck on the Magnetic Roll

3. 38 mm pitch -> BCR: Scratches or foreign substances

4. 79 mm pitch -> Heat Roll: Scratches or foreign substances

5. 47 mm pitch -> Heat Roll (Fusing Unit): Contamination

6. 63 mm pitch -> Registration Roll: Contamination

7. 47 mm pitch -> If this occurs during Duplex f eed - Duplex Roll 1, Duplex Roll 2: Contami­nation

08/2012

3-20

WorkCentre 5021/5019

Initial Issue

Action

1. 1,4,5,6: Clean or replace the Drum Cartridge (PL 8.1) (REP 8.1.1)/Fusing Unit (PL 7.1)
(REP 7.1.1)

2. 2,3: Replace the Drum Cartridge (PL 8.1) (REP 8.1.1)

3. 7: Clean or replace the Duplex Roll1, Duplex Roll 2 (PL 14.4)

IDS10 Regular Toner Contamination In Process Direction
(Side 2)

Initial Issue
WorkCentre 5021/5019

Figure 1 Regular Toner Contamination In Process Direction (Side 2) Defect Sample

(j0ch3227)

Cause

1. 94 mm pitch -> Pressure Roll (Fusing Unit): Scratches or foreign substances

2. 50 mm pitch -> BTR: Contamination, scratches or paper size mismatch

3. 38 mm pitch -> BCR: Contamination

Action

1. 1,2,3: Clean or replace the relevant parts.

2. 2: Paper Tray Settings

08/2012

3-21

Image Quality

IDS9, IDS10

IDS11 Moire Due to Interference With Copy Documents

Cause

When copying, interference with the document may cause moire. Combinations of certain
angles of screen ruling near 150lpi and Reduce/Enlarge ratio may cause moire. Pr ecautions
should be taken during enlargement.

Action

• Reduce sharpness. Use KO to change the default value of P4000 from '2' to '1'.
– Secondary defect: Text is blurred.

• Make copies at a different Reduce/Enlarge ratio.

• Change the orientation of the document.

• If the moire occurs in Photo Mode, change to Photo & Text Mode.

IDS12 Light Background Due to Background Suppression
in Copies of Documents With Frames

For documents with dark frames along the Lead Registration Edge, the suppression value is
set so large such that areas of medium density appear extremely light.

Image Quality

IDS11, IDS12

Figure 1 Light Background Due to Background Suppression in Copies of Documents

With Frames Defect Sample (j0lj3229)

Cause

Background Suppression performs background detection of images at a distance of up to 10
mm from the Lead Registration Edge. As there were dark frames along the Lead Registr ation
Edge, it could not detect the original background density, which resulted in the Background
Suppression being performed based on the density of the frames.

08/2012

3-22

WorkCentre 5021/5019

Initial Issue

Action

• Turn OFF the Background Suppression. Use KO to change the default value of P4001
from '1' to '0 '.

IDS13 Background Smear When Using Platen Copy With
Non-Standard Documents

When the document size is non-standard and the specified scan size is larger than the docu­ment size, smear might be generated depending on the background density of the document.

Cause

For cases where the document size is smaller than the scan size, the density of the back of the
platen is detected as the background density of the document as the actual scan area includes
the back of the platen.

Action

• This can be improved by performing density adjustment.

Initial Issue
WorkCentre 5021/5019

08/2012

3-23

Image Quality

IDS12, IDS13

IDS14 Fluctuation In Background Suppression Values for
Copies of Documents With Medium Density

When Automatic Exposure is enabled for documents with medium density background (0.5G),
the effectiveness fluctuates for each job.

Cause

As medium density (0.5G) is near the upper limit value for background detection, the Back­ground Suppression value fluctuates according to the result of background detection that va r­ies according to the variations in the density of the document and how the document is placed.

Action

• Turn OFF the Background Suppression. Use KO to change the default value of P4001
from '1' to '0 '.

IDS15 Defects Related To Scan Print

Moire may occur when printing out the scanned images.

Cause

Interference with the printer screen and printer driver resolution conversion processing by the
document causes moire.

Action

• Reduce sharpness. Use KO to change the default value of P4000 from '2' to '1'.
Secondary defect: Text is blurred.

• If the Scan resolution is 600 dpi, change it to a lower resolution (200 dpi or 300 dpi).

Image Quality

IDS14, IDS15

08/2012

3-24

Initial Issue

WorkCentre 5021/5019

3.4 Fusing Unit Paper Wrinkle Alignment Adjustment

[Procedure]

1. Installation/removal of Adjustment Bracket
(1) Remove the Fusing Unit.
(2) Remove the front screw of the Adjustment Bracket at the front.

Figure 1 j0lj31009

2. Assembly of Adjustment Bracket
(1) Parts Configuration

• At shipment (+/- 0 mm): Triangle mark

Minus (-0.5 mm) state: '-' mark

Figure 3 j0lj31011

3. Adjustment Method
(1) If the wrinkle is at the front, use '-'.

Figure 2 j0lj31010

(2) Depending on the case, assemble the Fusing U nit Stud Plate and the Adjust Plate

such that the surface with the triangle marks ( +, -) is at the top.

• Plus (+0.5 mm) state: '+' mark

Initial Issue
WorkCentre 5021/5019

08/2012

3-25

Figure 4 j0rk31012

(2) If the wrinkle is at the rear, use '+'.

Image Quality

3.4