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
WorkCentre 5021/5019
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
08/2012
0-4
Initial Issue
WorkCentre 5021/5019
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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08/2012
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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Initial Issue
WorkCentre 5021/5019
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
WorkCentre 5021/5019
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.
08/2012
1-5
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
08/2012
1-6
Initial Issue
WorkCentre 5021/5019
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
Initial Issue
WorkCentre 5021/5019
08/2012
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
08/2012
1-8
Initial Issue
WorkCentre 5021/5019
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
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