Page 1 Xerox service documentation is intended for use by certified, product-trained service per- sonnel 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 mod- ules, 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.
Page 2: Initial Issue
0 Introduction 0.1 Getting to know this Service Manual................ 0.2 How to use the Service Manual ................0.3 Description for Terminology And Symbols ............... Initial Issue Introduction 08/2012 WorkCentre 5021/5019...
Page 3: Getting To Know This Service Manual
0.1 Getting to know this Service Manual 0.2 How to use the Service Manual This manual is used as the standard service manual for WorkCentre 5021/ 5019. 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.
Page 4: Description For Terminology And Symbols
Instruction: Used to alert you to a procedure which, if not strictly observed, could result in dam- age 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'. Introduction Initial Issue 08/2012 0.2, 0.3 WorkCentre 5021/5019...
Page 5: Initial Issue
1 Service Call Procedures 1.1 Before Starting the Servicing ................... 1.2 Service Call Procedure .................... 1.3 Detailed Contents of the Service Call ..............1.4 TRIM Check List....................... 1.5 Periodic Replacement Parts/Consumables List ............Initial Issue Service Call Procedures 08/2012 WorkCentre 5021/5019...
Page 6: Before Starting The Servicing
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. Harmful Laser Initial Issue Service Call Procedure 08/2012 WorkCentre 5021/5019...
Page 7: Service Call Procedure
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 Initial Issue 08/2012 1.1, 1.2 WorkCentre 5021/5019...
Page 8: Initial Issue
1.2.4 Final Actions iii. The Program Number input screen is displayed. Check overall operation/features. Check the machine exterior and consumables. Train the operator as required. Complete the Service Log and Service Report. Initial Issue Service Call Procedure 08/2012 WorkCentre 5021/5019...
Page 9: Detailed Contents Of The Service Call
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 Initial Issue 08/2012 1.3, 1.4 WorkCentre 5021/5019...
Page 10: Trim Check List
499D 00914 (194D) every 10K operation) Feeds. Post-servicing check • Create the Service Log and Service Report. Toner Cartridge 9,000PV (Check the meter) 8.1) Drum Cartridge *1 950-807 343k cycle <Refer- 8.1) ence>75KPV*1@18PPM / 80KPV*1@20PPM Initial Issue Service Call Procedure 08/2012 WorkCentre 5021/5019...
Page 11: Initial Issue
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 car- tridge comes. Service Call Procedure Initial Issue 08/2012 WorkCentre 5021/5019...
Page 12: Table Of Contents
010-311 Fusing Unit Center Thermistor Defect ............. 2-17 010-312 Fusing Unit Rear Thermistor Defect ..............2-17 CHAIN 71 010-320 Over Heat Temperature Fail ................2-17 071-105 Regi Sensor On Jam (Tray 1) ................2-35 Initial Issue Status Indicator RAPs 08/2012 WorkCentre 5021/5019...
Page 13 116-321 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 Status Indicator RAPs Initial Issue 08/2012 WorkCentre 5021/5019...
Page 14: Initial Issue
In such cases, proceed • As long as the button is being pressed, the Chain-Link number will be displayed and to troubleshoot by referring to 'Generic FIP'. flashing. Figure 2 j0lj21202 Initial Issue Status Indicator RAPs 08/2012 2.1.1, 2.1.2 WorkCentre 5021/5019...
Page 15: Glossary
+4.8 to +5.4VDC 0.0 to +1.0VDC +24VDC +23.3 to +25.7VDC 0.0 to +3.0VDC • PL 4.2 Refer to PL 4.2 in Chapter 5 Parts List. • CH 6.2 Zone J4 Status Indicator RAPs Initial Issue 08/2012 2.1.2, 2.1.3 WorkCentre 5021/5019...
Page 16 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 Status Indicator RAPs 08/2012 2.1.3 WorkCentre 5021/5019...
Page 17 Status Indicator RAPs Initial Issue 08/2012 2.1.3 WorkCentre 5021/5019...
Page 18: Level 1 Fip
Problems With Printer • 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 Status Indicator RAPs 08/2012 2.2.1.1 WorkCentre 5021/5019...
Page 19 Status Indicator RAPs Initial Issue 08/2012 2.2.1.1 WorkCentre 5021/5019...
Page 20: N-Up Ng Out Of Range/ Ams Ng Out Of Range
FIP to check the DADF. • 005-196 (Size Mismatch Jam on No Mix-size) Cause/Action • 005-948 (SS-Size Mismatch Jam on No Mix-size) Press [Stop] on the UI Panel and change the reduce/enlarge ratio. Initial Issue Status Indicator RAPs 08/2012 003-500/795, 003-951 WorkCentre 5021/5019...
Page 21 Status Indicator RAPs Initial Issue 08/2012 003-500/795, 003-951 2-10 WorkCentre 5021/5019...
Page 22: Hvps Communication Error
ESS/ MCU PWB J402 for open circuit, short circuit, and poor contact. If no problem is found, replace the following parts in sequence: • HVPS 18.1) • ESS/MCU PWB 18.1) Initial Issue Status Indicator RAPs 08/2012 004-345 WorkCentre 5021/5019 2-11...
Page 23 Status Indicator RAPs Initial Issue 08/2012 004-345 2-12 WorkCentre 5021/5019...
Page 24: Dadf Simplex/Side 1 Pre Regi Sensor On Jam
ON within the specified time. Cause/Action If no problem is found, replace the DADF PWB. 56.2) Check the following: • Transportation failure due to foreign substance on the document path. Initial Issue Status Indicator RAPs 08/2012 005-122, 005-125/145 WorkCentre 5021/5019 2-13...
Page 25: Dadf Invert Sensor Off Jam On Inverting/ Dadf Invert Sensor Off Jam
The Exit Pinch Roll for operation failure (including for the operation failure of the Exit Nip Release Solenoid (Output Check [005-072])). 56.7) • The Drive Gear for wear and damage. If no problem is found, replace the DADF PWB. 56.2) Status Indicator RAPs Initial Issue 08/2012 005-131/132, 005-135 2-14 WorkCentre 5021/5019...
Page 26: Dadf Pre Regi Sensor Off Jam On Inverting
005-197 Prohibit Combine Size Jam [DADF RAM Fail] BSD-ON:CH5.4 The DADF PWB RAM failed during the Read/Write operation. (At Power ON) A Mixed Size document was detected. [DADF EEPROM Fail] Initial Issue Status Indicator RAPs 08/2012 005-147, 005-198/199 WorkCentre 5021/5019 2-15...
Page 27: Dadf Feeder Cover Interlock Open
Check the applicable sensor for remaining paper, the Actuator for return failure, contami- nation on sensor, and etc. Check the applicable sensor for operation failure. • DADF Pre Regi Sensor (Input Check[005-206]) 56.14) • DADF Regi Sensor (Input Check[005-110]) 56.14) Status Indicator RAPs Initial Issue 08/2012 005-275/280, 005-940 2-16 WorkCentre 5021/5019...
Page 28: Fusing Unit Center Thermistor Defect
• The Center Thermistor for dropped parts, sensor contamination, and foreign substances blocking the sensor. • The Heat Roll for wound up, stuck paper. Initial Issue Status Indicator RAPs 08/2012 010-311, 010-320 WorkCentre 5021/5019 2-17...
Page 29 Cause/Action Check the NOHAD Fan (Output Check [042-002]) for operation failure. 4.1) Check the NOHAD Fan for foreign substances. If no problem is found, replace the ESS/MCU PWB. 18.1) Status Indicator RAPs Initial Issue 08/2012 010-327, 010-602 2-18 WorkCentre 5021/5019...
Page 30 The sending of commands to the PC remained unsuccessful 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 Status Indicator RAPs 08/2012 016-500, 016-570 WorkCentre 5021/5019 2-19...
Page 31 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 Press [Stop] on the UI Panel. Clear the count for the user. Status Indicator RAPs Initial Issue 08/2012 016-749/799, 016-776 2-20 WorkCentre 5021/5019...
Page 32 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 Status Indicator RAPs 08/2012 023-600 WorkCentre 5021/5019 2-21...
Page 33 Status Indicator RAPs Initial Issue 08/2012 023-600 2-22 WorkCentre 5021/5019...
Page 34 10.3, 13.3) • The No Paper Sensor of the applicable Tray for contamination, improper installation, and Actuator operation failure. If no problem is found, replace the following parts: Initial Issue Status Indicator RAPs 08/2012 024-910/911/915 , 024-950/951/954 WorkCentre 5021/5019 2-23...
Page 35 Status Indicator RAPs Initial Issue 08/2012 024-910/911/915 , 024-950/951/954 2-24 WorkCentre 5021/5019...
Page 36 [STM NVM R/W Error] Unable to perform NVM Read / Write for the STM. Cause/Action Turn the power OFF and ON. If the problem persists, replace the STM PWB. 10.6) Initial Issue Status Indicator RAPs 08/2012 041-210/211 WorkCentre 5021/5019 2-25...
Page 37 Status Indicator RAPs Initial Issue 08/2012 041-210/211 2-26 WorkCentre 5021/5019...
Page 38 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 18.1) • Main Drive Motor 3.1) Initial Issue Status Indicator RAPs 08/2012 042-325/614 WorkCentre 5021/5019 2-27...
Page 39 Status Indicator RAPs Initial Issue 08/2012 042-325/614 2-28 WorkCentre 5021/5019...
Page 40 Install the correct version of the IOT firmware. If the problem persists, replace the ESS/MCU PWB. 18.1) Check the USB Cable (Local) for poor connection. If no problem is found, replace the ESS/MCU PWB. 18.1) Initial Issue Status Indicator RAPs 08/2012 045-310, 045-313 WorkCentre 5021/5019 2-29...
Page 41 Status Indicator RAPs Initial Issue 08/2012 045-310, 045-313 2-30 WorkCentre 5021/5019...
Page 42 If no problem is found, replace the following parts in sequence: If no problem is found, replace the following parts in sequence: • ROS Assembly 2.1) • ROS Assembly 2.1) • ESS/MCU PWB 18.1) • ESS/MCU PWB 18.1) Initial Issue Status Indicator RAPs 08/2012 061-321, 061-325 WorkCentre 5021/5019 2-31...
Page 43 Status Indicator RAPs Initial Issue 08/2012 061-321, 061-325 2-32 WorkCentre 5021/5019...
Page 44 The Carriage operation for mechanical loading. CCD Flexible Flat Cable PL 1.3 This value is not displayed If no problems are found, replace the ESS/MCU PWB. 18.1) This value is not displayed Initial Issue Status Indicator RAPs 08/2012 062-277, 062-371/380 WorkCentre 5021/5019 2-33...
Page 45 (especially, check whether the Flat Cable was inserted in a skewed manner). If no problem is found, replace the ESS/MCU PWB. 18.1) Status Indicator RAPs Initial Issue 08/2012 062-371/380, 062-389 2-34 WorkCentre 5021/5019...
Page 46 • 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. 18.1) Initial Issue Status Indicator RAPs 08/2012 071-105 WorkCentre 5021/5019 2-35...
Page 47 Status Indicator RAPs Initial Issue 08/2012 071-105 2-36 WorkCentre 5021/5019...
Page 48: Feed Out Sensor 2 On Jam
If no problem is found, replace the STM PWB. 10.6) If no problem is found, replace the following parts in sequence: 072-215 MCU-STM Communication Fail • ESS/MCU PWB 18.1) Initial Issue Status Indicator RAPs 08/2012 072-102, 072-105 WorkCentre 5021/5019 2-37...
Page 49 STM PWB J541C for open circuit, short circuit, and poor contact. If no problem is found, replace the following parts in sequence: • STM PWB 10.6) • ESS/MCU PWB 18.1) Status Indicator RAPs Initial Issue 08/2012 072-215 2-38 WorkCentre 5021/5019...
Page 50: Regi Sensor On Jam (Msi)
• 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. 18.1) Initial Issue Status Indicator RAPs 08/2012 075-135 WorkCentre 5021/5019 2-39...
Page 51 Status Indicator RAPs Initial Issue 08/2012 075-135 2-40 WorkCentre 5021/5019...
Page 52: Regi Sensor Off Jam
The Drive Gear for wear and damage. If no problems are found, replace the ESS/MCU PWB. 18.1) • Usage of out of spec paper. If no problems are found, replace the ESS/MCU PWB. 18.1) Initial Issue Status Indicator RAPs 08/2012 077-101, 077-104 WorkCentre 5021/5019 2-41...
Page 53: Regi Sensor On Jam (Duplex Wait)
• STM PWB (Feed Out Sensor 2) 10.6) If no problem is found, replace the following parts in sequence: • STM PWB 10.6) • ESS/MCU PWB 18.1) Status Indicator RAPs Initial Issue 08/2012 077-129, 077-300/301/305 2-42 WorkCentre 5021/5019...
Page 54: Crum Asic Communication Fail
Replace the Drum Cartridge as required. 8.1) When in Life Extension Mode, the Drum Cartridge was detected to be near the end of its lifespan. Cause/Action Replace the Drum Cartridge. 8.1) Initial Issue Status Indicator RAPs 08/2012 091-313, 091-406/424 WorkCentre 5021/5019 2-43...
Page 55: Drum Cartridge Near End
Drum Cartridge P615 for open circuit, short circuit, and poor contact. If no problem is found, replace the following parts in sequence: • Drum Cartridge 8.1) • ESS/MCU PWB 18.1) Status Indicator RAPs Initial Issue 08/2012 091-441, 091-915/916 2-44 WorkCentre 5021/5019...
Page 56: Atc Amplitude Fail/ Atc Average Fail
Check the connection between the HVPS J500-1 and the ESS/MCU PWB J402-14 for open circuit, short circuit, and poor contact. If no problem is found, replace the following parts in sequence: • HVPS 18.1) • ESS/MCU PWB 18.1) Initial Issue Status Indicator RAPs 08/2012 092-660/668, 092-910 WorkCentre 5021/5019 2-45...
Page 57 Status Indicator RAPs Initial Issue 08/2012 092-660/668, 092-910 2-46 WorkCentre 5021/5019...
Page 58: Toner Dispense Motor Rotation Fail
Preparation for replacing the Toner Cartridge is required. Cause/Action The Toner Cartridge needs to be replaced soon. Prepare a new Toner Cartridge. Replace the Toner Cartridge as required. 8.1) Initial Issue Status Indicator RAPs 08/2012 093-312, 093-912 WorkCentre 5021/5019 2-47...
Page 59 Status Indicator RAPs Initial Issue 08/2012 093-312, 093-912 2-48 WorkCentre 5021/5019...
Page 60: No Drum Cartridge
Drum Cartridge P615 for open circuit, short circuit, and poor contact. If no problem is found, replace the following parts in sequence: • Drum Cartridge 8.1) • ESS/MCU PWB 18.1) Initial Issue Status Indicator RAPs 08/2012 095-910 WorkCentre 5021/5019 2-49...
Page 61 Status Indicator RAPs Initial Issue 08/2012 095-910 2-50 WorkCentre 5021/5019...
Page 62: Controller Logic Fail
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 Turn the power OFF and ON. Perform NVM Matching (NVM[621-400]) in the CE Mode. Initial Issue Status Indicator RAPs 08/2012 116-321, 116-377 WorkCentre 5021/5019 2-51...
Page 63 Status Indicator RAPs Initial Issue 08/2012 116-321, 116-377 2-52 WorkCentre 5021/5019...
Page 64: Controller Backup Nvm Data Defect
Check the EEPROM (Master) on the ESS/MCU PWB for poor contact with the socket. Perform NVM Initialize in the CE Mode. (Refer to [6.4.2.5 NVM Initialize].) If the problem persists, replace the ESS/MCU PWB. 18.1) Initial Issue Status Indicator RAPs 08/2012 117-326 WorkCentre 5021/5019 2-53...
Page 65 Status Indicator RAPs Initial Issue 08/2012 117-326 2-54 WorkCentre 5021/5019...
Page 66: Ui Panel Communication Fail
MCU PWB J422 for open circuits, short circuits, and poor contacts. If no problem is found, replace the following parts in sequence: • UI PWB 1.6) • ESS/MCU PWB 18.1) Initial Issue Status Indicator RAPs 08/2012 123-314 WorkCentre 5021/5019 2-55...
Page 67 Status Indicator RAPs Initial Issue 08/2012 123-314 2-56 WorkCentre 5021/5019...
Page 68: Ac Power Fip
1 and pin-3 for open circuits and poor contacts. If no problems are found, replace the Main Power Switch. 18.1) Check the AC circuit to each component by referring to Chapter 7 Wiring Data. Initial Issue Status Indicator RAPs 08/2012 2.2.3.1, 2.2.3.2 WorkCentre 5021/5019 2-57...
Page 69: Vdc Power Fip
Check the +24VDC 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. Status Indicator RAPs Initial Issue 08/2012 2.2.3.3 2-58 WorkCentre 5021/5019...
Page 70: Reflective Sensor Failure Fip
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 Status Indicator RAPs 08/2012 2.2.4.1, 2.2.4.2 WorkCentre 5021/5019 2-59...
Page 71: Switch (Normal/Open) Failure Fip
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. Status Indicator RAPs Initial Issue 08/2012 2.2.4.3, 2.2.4.4 2-60 WorkCentre 5021/5019...
Page 72: Solenoid/Clutch Left Energized Failure Fip
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 Status Indicator RAPs 08/2012 2.2.4.5, 2.2.4.6 WorkCentre 5021/5019 2-61...
Page 73: Motor Left Running Failure Fip
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 (-)? Status Indicator RAPs Initial Issue 08/2012 2.2.4.7, 2.2.4.8 2-62 WorkCentre 5021/5019...
Page 74 NIP/RELEASE SOLENOID pin-2 (+) and the GND (-)? Replace the NIP/RELEASE SOLENOID. Check the connection between the PWB pin-6 and the NIP/RELEASE SOLENOID pin-2 for an open circuit and poor contact. Replace the PWB. Initial Issue Status Indicator RAPs 08/2012 2.2.4.8 WorkCentre 5021/5019 2-63...
Page 75 Status Indicator RAPs Initial Issue 08/2012 2.2.4.8 2-64 WorkCentre 5021/5019...
Page 76: No Output Is Available, No Data Is Printed
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 Status Indicator RAPs 08/2012 2.3.1, 2.3.2 WorkCentre 5021/5019 2-65...
Page 77 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 Initial Issue Image Quality 08/2012 WorkCentre 5021/5019...
Page 78: Composition Of Chapter 3 Image Quality Troubleshooting
For the Test Patterns, refer to the following. The Image Quality Troubleshooting section describes the causes of image quality failures • 6.4.2.14 Test Pattern Print and the troubleshooting procedure for them. Initial Issue Image Quality 08/2012 3.1.1, 3.1.2 WorkCentre 5021/5019...
Page 79: Image Quality Troubleshooting
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 Initial Issue 08/2012 3.1.3 WorkCentre 5021/5019...
Page 80: Image Quality Raps
IQ12 Spots Toner spots and blank areas are spread irregularly over IQ13 the whole page. Black Prints Paper is printed completely black. IQ14 Blank Image Paper is printed completely white. IQ15 Initial Issue Image Quality 08/2012 IQ1, IQ2 WorkCentre 5021/5019...
Page 81: Iq3 Low Image Density Rap
Drum. There is a considerable amount of toner left on the surface of the drum. Replace the ESS/MCU PWB 18.1) (REP 18.1.1). Replace the BTR Roll 6.1) (REP 4.1.1), followed by the HVPS 18.1) (REP 18.1.2) and the ESS/MCU PWB 18.1) (REP 18.1.1). Image Quality Initial Issue 08/2012 IQ3, IQ4 WorkCentre 5021/5019...
Page 82: Iq5 Residual Image (Ghosting) Rap
Clean the BTR. If there is distortion, replace the BTR Roll 6.1) (REP 4.1.1). Remove the HVPS and reinstall it. Turn the power OFF then ON and print. The problem reoccurs. Replace the ESS/MCU PWB 18.1) (REP 18.1.1). Initial Issue Image Quality 08/2012 IQ5, IQ6 WorkCentre 5021/5019...
Page 83: Iq7 Deletion Rap
Check the surface of the BTR for distortion. There is no distortion on the surface of the BTR. Replace the ESS/MCU PWB 18.1) (REP 18.1.1). Replace the BTR Roll 6.1) (REP 4.1.1). Replace the ESS/MCU PWB 18.1) (REP 18.1.1). Image Quality Initial Issue 08/2012 IQ7, IQ8 WorkCentre 5021/5019...
Page 84: Iq9 Process Direction Bands,Streaks,And Smears Rap
Check the mirror at the IIT Carriage. The mirror is clean and there is no distortion. 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 Image Quality 08/2012 WorkCentre 5021/5019...
Page 85: Iq10 Unfused Copy/Toner Offset Rap
Clean the Heat Roll. If there is difficulty in removing the contamination, replace the Fusing Unit 7.1) (REP 7.1.1). Replace the ROS Assembly 2.1) (REP 2.1.1), followed by the ESS/MCU PWB 18.1) (REP 18.1.1). Image Quality Initial Issue 08/2012 IQ10, IQ11 3-10 WorkCentre 5021/5019...
Page 86: Iq12 Mottle Rap
Check the paper type. Paper used is within specifications. Use paper within specifications. Use paper from a freshly opened packet. The problem reoccurs. Replace the ESS/MCU PWB 18.1) (REP 18.1.1). Initial Issue Image Quality 08/2012 IQ12, IQ13 WorkCentre 5021/5019 3-11...
Page 87: Iq14 Black Prints Rap
18.1.2) and the ESS/MCU PWB 18.1) (REP 18.1.1). and no short circuit. Repair the open circuit or short circuit. Replace the ROS Assembly 2.1) (REP 2.1.1), followed by the ESS/MCU PWB 18.1) (REP 18.1.1). Image Quality Initial Issue 08/2012 IQ14, IQ15 3-12 WorkCentre 5021/5019...
Page 88 Replace the BTR Roll 6.1) (REP 4.1.1), followed by the HVPS 18.1) (REP 18.1.2) and the ESS/MCU PWB 18.1) (REP 18.1.1). Initial Issue Image Quality 08/2012 IQ15 WorkCentre 5021/5019 3-13...
Page 89 Image Quality Initial Issue 08/2012 IQ15 3-14 WorkCentre 5021/5019...
Page 90: Iot Image Defect Sample
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) Initial Issue Image Quality 08/2012 3.3.1, 3.3.2 WorkCentre 5021/5019 3-15...
Page 91: Ids1 Auger Mark
(REP 8.1.1) Replace the Drum Cartridge 8.1) (REP 8.1.1) NOTE: This may occur immediately after a new CRU is installed.-> Correct this by feed- ing a few sheets of paper. Image Quality Initial Issue 08/2012 IDS1, IDS2 3-16 WorkCentre 5021/5019...
Page 92: Ids3 White Streaks (Process Direction)
Mix the developing powder by processing blank paper. Clean the light path and the seal glass between the ROS Assembly 2.1) (REP 2.1.1) and the Drum Cartridge 8.1) (REP 8.1.1). Replace the Drum Cartridge 8.1) (REP 8.1.1) Initial Issue Image Quality 08/2012 IDS3, IDS4 WorkCentre 5021/5019 3-17...
Page 93: Ids5 Toner Contamination
The resistance of the paper increased under dry conditions. Action Mix the developing powder by feeding blank paper. Replace the Drum Cartridge 8.1) (REP 8.1.1) Check the tray settings. Use paper from a freshly opened packet. Image Quality Initial Issue 08/2012 IDS5, IDS6 3-18 WorkCentre 5021/5019...
Page 94: Ids7 White Spots (Irregular)
44 mm pitch -> BCR: Scratches or foreign substances 80 mm pitch -> Heat Roll: Scratches or foreign substances Action 1,4: Clean or replace the Drum Cartridge 8.1) (REP 8.1.1)/Fusing Unit 7.1) (REP 7.1.1) Initial Issue Image Quality 08/2012 IDS7, IDS8 WorkCentre 5021/5019 3-19...
Page 95: Ids9 Regular Toner Contamination In Process Direction (Spots, Streaks, Bands Etc.)
47 mm pitch -> Heat Roll (Fusing Unit): Contamination 63 mm pitch -> Registration Roll: Contamination 47 mm pitch -> If this occurs during Duplex feed - Duplex Roll 1, Duplex Roll 2: Contami- nation Image Quality Initial Issue 08/2012 IDS8, IDS9 3-20 WorkCentre 5021/5019...
Page 96: Ids10 Regular Toner Contamination In Process Direction (Side 2)
94 mm pitch -> Pressure Roll (Fusing Unit): Scratches or foreign substances 50 mm pitch -> BTR: Contamination, scratches or paper size mismatch 38 mm pitch -> BCR: Contamination Action 1,2,3: Clean or replace the relevant parts. 2: Paper Tray Settings Initial Issue Image Quality 08/2012 IDS9, IDS10 WorkCentre 5021/5019 3-21...
Page 97: Ids11 Moire Due To Interference With Copy Documents
Lead Registration Edge. As there were dark frames along the Lead Registration Edge, it could not detect the original background density, which resulted in the Background Suppression being performed based on the density of the frames. Image Quality Initial Issue 08/2012 IDS11, IDS12 3-22 WorkCentre 5021/5019...
Page 98: Ids13 Background Smear When Using Platen Copy With Non-Standard Documents
Action • This can be improved by performing density adjustment. Initial Issue Image Quality 08/2012 IDS12, IDS13 WorkCentre 5021/5019 3-23...
Page 99: Ids14 Fluctuation In Background Suppression Values For Copies Of Documents With Medium Density
Turn OFF the Background Suppression. Use KO to change the default value of P4001 • If the Scan resolution is 600 dpi, change it to a lower resolution (200 dpi or 300 dpi). from '1' to '0'. Image Quality Initial Issue 08/2012 IDS14, IDS15 3-24 WorkCentre 5021/5019...
Page 100: Fusing Unit Paper Wrinkle Alignment Adjustment
(2) Depending on the case, assemble the Fusing Unit 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 Image Quality 08/2012 WorkCentre 5021/5019 3-25...
Page 101 Fusing Unit. (2) *2: Sampling • Paper: A3 SEF • Pattern: Half Tone K50% • No. of sheets: Simp 5 sheets Figure 6 j0lj31014 Image Quality Initial Issue 08/2012 3-26 WorkCentre 5021/5019...
Page 102: Cycle Table
Regi Roll DEVE Mag Roll 27*1 13.5 (half-pitch) XERO DRUM(OPC) Fusing Unit Heat Roll Pressure Roll Exit Roll *1: This is 50.24/1.86=27 mm because the rotation is at 1.86 times the peripheral speed. Initial Issue Image Quality 08/2012 WorkCentre 5021/5019 3-27...
Page 103 REP 13.3.2 MSI Retard Pad ..................4-41 18. Electrical 14. L/H Cover ADJ 18.1.1 IOT Lead Edge/Side Edge Registration ............4-91 REP 14.1.1 L/H Cover....................4-43 ADJ 18.1.2 Edge Erase Value Adjustment..............4-92 Initial Issue Repairs and Adjustments 08/2012 WorkCentre 5021/5019...
Page 104 (ISC)..........................4-92 ADJ 18.2.2 Firmware Version Upgrade ................. 4-93 56. DADF ADJ 56.1.1 DADF Lead-Skew Adjustment..............4-97 ADJ 56.1.2 DADF Side Registration ................4-98 ADJ 56.1.3 DADF Lead Edge Registration ..............4-100 Repairs and Adjustments Initial Issue 08/2012 WorkCentre 5021/5019...
Page 105: Introduction
(2) Right: Right-hand side when facing the front of the machine. (3) Left: Left-hand side when facing the front of the machine. (4) Rear: Rear when facing the front of the machine. Initial Issue Disassembly/Assembly and Adjustment 08/2012 WorkCentre 5021/5019...
Page 106 Disassembly/Assembly and Adjustment Initial Issue 08/2012 WorkCentre 5021/5019...
Page 107: Rep 1.2.1 Iit Top Cover
Remove the IIT Carriage Belt from the IIT Carriage. (Figure 2) To install, carry out the removal steps in reverse order. (1) Remove the IIT Carriage Belt in the direction of the arrow. Initial Issue Repairs and Adjustments 08/2012 REP 1.2.1, REP 1.3.1 WorkCentre 5021/5019...
Page 108 (1) Remove the IIT Carriage and Shaft. After a replacement, enter the Diag Mode and use [Initialize HFSI Counter] to clear the HFSI counter. 'Chain Link : 956-804' Refer to [6.4.2.9 HFSI Counter Read/Clear]. Repairs and Adjustments Initial Issue 08/2012 REP 1.3.1 WorkCentre 5021/5019...
Page 109: Rep 1.3.2 Iit Carriage Belt
Relax the tension of the IIT Carriage Belt. (Figure 2) (1) Remove the spring. Figure 3 j0lj40115 (2) Loosen the screw (x2). Remove the IIT Carriage Belt. (Figure 4) (1) Remove the IIT Carriage Belt from the pulley (x2). Initial Issue Repairs and Adjustments 08/2012 REP 1.3.2 WorkCentre 5021/5019...
Page 110: Rep 1.4.1 Carriage Motor
To install, carry out the removal steps in reverse order. Figure 1 j0lj40107 Relax the tension of the IIT Carriage Belt. (Figure 2) (1) Remove the spring. (2) Loosen the screw (x2). Repairs and Adjustments Initial Issue 08/2012 REP 1.3.2, REP 1.4.1 WorkCentre 5021/5019...
Page 111 After a replacement, enter the Diag Mode and use [Initialize HFSI Counter] to clear the (4) Remove the Carriage Drive and Motor. HFSI counter. (5) Disconnect the connector. 'Chain Link : 956-802' (6) Remove the cable band. Initial Issue Repairs and Adjustments 08/2012 REP 1.4.1 WorkCentre 5021/5019...
Page 112: Rep 1.5.1 Led Lamp Pwb
(2) Pull out and remove the LED Cable in the direction of the arrow. Figure 3 j0lj40125 Remove the LED Lamp PWB. (Figure 4) (1) Remove the screw (short: x2). (2) Remove the LED Lamp PWB. Repairs and Adjustments Initial Issue 08/2012 REP 1.5.1 4-10 WorkCentre 5021/5019...
Page 113 'Chain Link : 956-804' When installing the LEB Bracket, tighten the screw of the LED Bracket in the order of 1 to Refer to [6.4.2.9 HFSI Counter Read/Clear]. (Figure 6) Initial Issue Repairs and Adjustments 08/2012 REP 1.5.1 WorkCentre 5021/5019 4-11...
Page 114: Rep 1.6.1 Lcd Display
(1) Release the hooks (x4). (Figure 2) (2) Move the LCD Display in the direction of the arrow. (1) Pull out and remove the UI Cable from the Connector Housing. Repairs and Adjustments Initial Issue 08/2012 REP 1.6.1 4-12 WorkCentre 5021/5019...
Page 115 To install, carry out the removal steps in reverse order. When installing the Control Panel, press the hook (x3) of the Control Panel in the direction of the arrow to affix the Control Panel securely. (Figure 6) Initial Issue Repairs and Adjustments 08/2012 REP 1.6.1 WorkCentre 5021/5019 4-13...
Page 116 Repairs and Adjustments Initial Issue 08/2012 REP 1.6.1 4-14 WorkCentre 5021/5019...
Page 117: Rep 2.1.1 Ros Assembly
To install, carry out the removal steps in reverse order. Figure 1 j0lj40201 Remove the ROS Assembly. (Figure 2) (1) Remove the screw (x5). (2) Remove the ROS Assembly. Initial Issue Repairs and Adjustments 08/2012 REP 2.1.1 WorkCentre 5021/5019 4-15...
Page 118 Repairs and Adjustments Initial Issue 08/2012 REP 2.1.1 4-16 WorkCentre 5021/5019...
Page 119: Rep 3.1.1 Main Drive Motor
To install, carry out the removal steps in reverse order. Figure 1 j0lj40302 14. Remove the Fusing Unit Rear Bracket. (Figure 2) (1) Remove the screw (x2). Initial Issue Repairs and Adjustments 08/2012 REP 3.1.1, REP 3.1.2 WorkCentre 5021/5019 4-17...
Page 120 Figure 5 j0lj40306 16. Remove the Stud Bracket. (Figure 4) Replacement (1) Remove the screw (x2). To install, carry out the removal steps in reverse order. (2) Remove the Stud Bracket. Repairs and Adjustments Initial Issue 08/2012 REP 3.1.2 4-18 WorkCentre 5021/5019...
Page 121: Rep 4.1.1 Nohad Fan
(3) Remove the wire harness from the guide (x2). (4) Release the hook (x2) and remove the NOHAD Fan. Figure 1 j0lj40401 Replacement To install, carry out the removal steps in reverse order. Initial Issue Repairs and Adjustments 08/2012 REP 4.1.1 WorkCentre 5021/5019 4-19...
Page 122 Repairs and Adjustments Initial Issue 08/2012 REP 4.1.1 4-20 WorkCentre 5021/5019...
Page 123: Rep 6.1.1 Btr Roll
After a replacement, enter the Diag Mode and use [Initialize HFSI Counter] to clear the HFSI counter. 'Chain Link : 950-800' Figure 1 j0lj40601 Reference: This shows the removed BTR Roll. (Figure 2) Initial Issue Repairs and Adjustments 08/2012 REP 6.1.1 WorkCentre 5021/5019 4-21...
Page 124 Repairs and Adjustments Initial Issue 08/2012 REP 6.1.1 4-22 WorkCentre 5021/5019...
Page 125: Fusing Unit
To install, carry out the removal steps in reverse order. After a replacement, enter the Diag Mode and use [Initialize HFSI Counter] to clear the HFSI counter. 'Chain Link : 950-801' Initial Issue Repairs and Adjustments 08/2012 REP 7.1.1 WorkCentre 5021/5019 4-23...
Page 126 Repairs and Adjustments Initial Issue 08/2012 REP 7.1.1 4-24 WorkCentre 5021/5019...
Page 127: Rep 8.1.1 Drum Cartridge
When replacing the Drum Cartridge with a new one, install the Drum Cartridge, and then bag. pull the Heat Seal horizontally out of the Drum Cartridge.(Figure 4) (Figure 2) Initial Issue Repairs and Adjustments 08/2012 REP 8.1.1 WorkCentre 5021/5019 4-25...
Page 128: Rep 8.2.1 Cartridge Guide
To install, carry out the removal steps in reverse order. When installing the Cartridge Guide, insert the boss of the Cartridge Guide into the hole for the boss. (Figure 2) Repairs and Adjustments Initial Issue 08/2012 REP 8.1.1, REP 8.2.1 4-26 WorkCentre 5021/5019...
Page 129: Rep 8.2.2 Dispense Drive
(1) Remove the gear. (2) Remove the screw (x3). (3) Remove the Dispense Drive. Figure 1 j0lj40807 Replacement To install, carry out the removal steps in reverse order. Initial Issue Repairs and Adjustments 08/2012 REP 8.2.1, REP 8.2.2 WorkCentre 5021/5019 4-27...
Page 130 Repairs and Adjustments Initial Issue 08/2012 REP 8.2.1, REP 8.2.2 4-28 WorkCentre 5021/5019...
Page 131: Rep 9.1.1 Tray 1 Feed Clutch
To install, carry out the removal steps in reverse order. When installing the Drive Bracket, align the Tab of the Drive Bracket to the Cutout of the Tray 1 Feed Clutch. (Figure 4) Initial Issue Repairs and Adjustments 08/2012 REP 9.1.1 WorkCentre 5021/5019 4-29...
Page 132: Rep 9.1.2 Tray 1
(2) Free the rear left side of Tray 1 in the direction of the arrow. Figure 4 j0lj40904 Figure 1 j0lj40905 Replacement To install, carry out the removal steps in reverse order. Repairs and Adjustments Initial Issue 08/2012 REP 9.1.1, REP 9.1.2 4-30 WorkCentre 5021/5019...
Page 133: Rep 9.2.1 Tray 1 Feed Roll And Tray 1 Retard Pad
Remove the Tray 1 Retard Pad. (Figure 4) (1) Release the hook and open the Tray 1 Retard Pad. (2) Remove the Tray 1 Retard Pad. (3) Pull out and remove the shaft. Initial Issue Repairs and Adjustments 08/2012 REP 9.2.1 WorkCentre 5021/5019 4-31...
Page 134 When installing the Tray 1 Retard Pad, attach the spring (x2) to the hole (x2) of the Tray 1 Retard Pad. (Figure 5) Figure 5 j0lj40908 After a replacement, enter the Diag Mode and use [Initialize HFSI Counter] to clear the HFSI counter. 'Chain Link : 950-803' Repairs and Adjustments Initial Issue 08/2012 REP 9.2.1 4-32 WorkCentre 5021/5019...
Page 135: Rep 10.1.1 Tray 2 Feeder
(1) Remove the screw. Figure 3 j0xh41003 (2) Remove the Stud Assembly. Remove the Tray 2 Feeder. (Figure 4) (1) Remove the screw (x2). (2) Remove the Tray 2 Feeder. Initial Issue Repairs and Adjustments 08/2012 REP 10.1.1 WorkCentre 5021/5019 4-33...
Page 136: Rep 10.3.1 Tray 2 Feed/Retard/Nudger Roll
To install, carry out the removal steps in reverse order. After a replacement, enter the CE Mode and use [Initialize HFSI Counter] to clear the HFSI counter. 'Chain Link : 950-804' Repairs and Adjustments Initial Issue 08/2012 REP 10.1.1, REP 10.3.1 4-34 WorkCentre 5021/5019...
Page 137: Rep 10.6.1 Stm Pwb
Remove the Rear Cover of the One Tray Module. (Figure 2) (1) Remove the screw (x2). Replacement (2) Remove the Rear Cover. To install, carry out the removal steps in reverse order. Initial Issue Repairs and Adjustments 08/2012 REP 10.6.1 WorkCentre 5021/5019 4-35...
Page 138: Rep 10.6.2 Stm Takeaway Motor
Remove the Rear Cover of the One Tray Module. (Figure 2) (1) Remove the screw (x2). Replacement (2) Remove the Rear Cover. To install, carry out the removal steps in reverse order. Repairs and Adjustments Initial Issue 08/2012 REP 10.6.2 4-36 WorkCentre 5021/5019...
Page 139: Rep 13.1.1 Msi
Replacement To install, carry out the removal steps in reverse order. When installing the MSI, insert the boss (x2) of the MSI into the holes for the boss. (Figure Initial Issue Repairs and Adjustments 08/2012 REP 13.1.1 WorkCentre 5021/5019 4-37...
Page 140: Rep 13.3.1 Msi Nudger/Feed Roll
'Chain Link : 950-802' Refer to [6.4.2.9 HFSI Counter Read/Clear]. Figure 1 j0lj41305 Remove the MSI Tray. (Figure 2) (1) Remove the MSI Tray in the direction of the arrow. Repairs and Adjustments Initial Issue 08/2012 REP 13.1.1, REP 13.3.1 4-38 WorkCentre 5021/5019...
Page 141 Remove the MSI Nudger Roll. (Figure 4) Figure 5 j0lj41309 Remove the MSI Feed Roll Assembly. (Figure 6) (1) Remove the KL-Clip (x2). (2) Remove the MSI Feed Roll Assembly. Initial Issue Repairs and Adjustments 08/2012 REP 13.3.1 WorkCentre 5021/5019 4-39...
Page 142 After installing the MSI Top Cover, check and make sure that the Link is at the posi- (2) Remove the MSI Feed Roll. tion shown in the figure from the hole of the MSI Top Cover. Repairs and Adjustments Initial Issue 08/2012 REP 13.3.1 4-40 WorkCentre 5021/5019...
Page 143: Rep 13.3.2 Msi Retard Pad
HFSI Counter Read/Clear]. Figure 1 j0lj41315 Release the hook (x3) and release the boss (x3) from the installation holes to remove the MSI Lower Cover. (Figure 2) Initial Issue Repairs and Adjustments 08/2012 REP 13.3.1, REP 13.3.2 WorkCentre 5021/5019 4-41...
Page 144 To install, carry out the removal steps in reverse order. After a replacement, enter the Diag Mode and use [Initialize HFSI Counter] to clear the HFSI counter. 'Chain Link : 950-802' Repairs and Adjustments Initial Issue 08/2012 REP 13.3.2 4-42 WorkCentre 5021/5019...
Page 145: Rep 14.1.1 L/H Cover
(2) With the L/H Cover in 90 degrees opened state, align the Tab of the L/H Cover to the Cutout of the Right Hinge and release the boss (x2) of the L/H Cover in the direction of the arrow. Initial Issue Repairs and Adjustments 08/2012 REP 14.1.1 WorkCentre 5021/5019 4-43...
Page 146 Figure 4 j0lj41404 Replacement To install, carry out the removal steps in reverse order. Repairs and Adjustments Initial Issue 08/2012 REP 14.1.1 4-44 WorkCentre 5021/5019...
Page 147: Rep 15.1.1 Registration Chute
Rotate the Registration Chute. (Figure 4) (1) Remove the Tapping Screw. (2) Move the Registration Chute slightly to the rear and rotate it in the direction of the arrow. Initial Issue Repairs and Adjustments 08/2012 REP 15.1.1 WorkCentre 5021/5019 4-45...
Page 148 (1) Disconnect the connector and remove the Registration Chute. Figure 7 j0lj41506 When installing the Drum Cartridge Guide, insert the boss (x2) of the Drum Cartridge Guide into the holes for the boss. (Figure 8) Repairs and Adjustments Initial Issue 08/2012 REP 15.1.1 4-46 WorkCentre 5021/5019...
Page 149: Rep 15.1.2 Registration Roll
(2) Disconnect the connector. (3) Remove the wire harness from the Harness Guide. (4) Remove the E-Clip. (5) Remove the Registration Clutch and the gear. Figure 1 j0lj41508 Initial Issue Repairs and Adjustments 08/2012 REP 15.1.1, REP 15.1.2 WorkCentre 5021/5019 4-47...
Page 150 Clutch to the Cutout (x2, top and bottom) of the gear. (Figure 3) Figure 3 j0lj41512 When installing the Registration Clutch, align the Cutout of the Registration Clutch to the Tab. (Figure 4) Repairs and Adjustments Initial Issue 08/2012 REP 15.1.2 4-48 WorkCentre 5021/5019...
Page 151: Rep 17.1.1 Exit Cover
When installing the Exit Cover, insert the boss of the Exit Cover into the hole of the Frame. (Figure 3) Figure 3 j0lj41705 Figure 1 j0lj41701 Reference: This shows the removed Exit Cover. (Figure 2) Initial Issue Repairs and Adjustments 08/2012 REP 17.1.1 WorkCentre 5021/5019 4-49...
Page 152: Rep 17.1.2 Exit Roll
To install, carry out the removal steps in reverse order. Remove the Exit Roll. (Figure 2) (1) Remove the E-Clip or the KL-Clip. (2) Move the bearing in the direction of the arrow. (3) Remove the Exit Roll. Repairs and Adjustments Initial Issue 08/2012 REP 17.1.2 4-50 WorkCentre 5021/5019...
Page 153: Rep 18.1.1 Ess/Mcu Pwb
When replacing the ESS/MCU PWB, remove the EEP ROM from the old ESS/MCU PWB, and install it to the new one. (Figure 4) Disconnect the connector. (Figure 2) (1) Disconnect the connector (x19). Initial Issue Repairs and Adjustments 08/2012 REP 18.1.1 WorkCentre 5021/5019 4-51...
Page 154: Rep 18.1.2 Hvps
(1) Disconnect the connector. Counter (621-400)]. (2) Remove the screw (x4). (3) Remove the HVPS. Figure 1 j0lj41805 Replacement To install, carry out the removal steps in reverse order. Repairs and Adjustments Initial Issue 08/2012 REP 18.1.1, REP 18.1.2 4-52 WorkCentre 5021/5019...
Page 155: Rep 18.1.3 Lvps
(1) Remove the screw (x5). (2) Remove LVPS. Figure 1 j0lj41806 Remove the Rear Lower Cover. (Figure 2) (1) Remove the screw (x2). (2) Remove the Rear Lower Cover. Initial Issue Repairs and Adjustments 08/2012 REP 18.1.3 WorkCentre 5021/5019 4-53...
Page 156: Rep 19.1.1
Figure 4 j0lj41809 Replacement To install, carry out the removal steps in reverse order. Repairs and Adjustments Initial Issue 08/2012 REP 18.1.3 4-54 WorkCentre 5021/5019...
Page 157 Remove the Connector Blank Cover. (Figure 2) (1) Remove the screw. Figure 3 j0lj41902 (2) Remove the Connector Blank Cover. Remove the Front Cover. (Figure 4) (1) Remove the screw. (2) Remove the Front Cover. Initial Issue Repairs and Adjustments 08/2012 REP 19.1.1 WorkCentre 5021/5019 4-55...
Page 158: Rep 19.1.2 Top Cover
There are also hooks at the left of the Front Cover. Figure 1 j0lj41905 Remove the Top Cover. (Figure 2) (1) Remove the Top Cover. Figure 5 j0lj41904 Repairs and Adjustments Initial Issue 08/2012 REP 19.1.1, REP 19.1.2 4-56 WorkCentre 5021/5019...
Page 159 Figure 3 j0lj41907 When installing the Top Cover, insert the portion of the Top Cover that is shown in the fig- ure into the Slot of the Exit Cover. (Figure 4) Initial Issue Repairs and Adjustments 08/2012 REP 19.1.2 WorkCentre 5021/5019 4-57...
Page 160: Rep 19.2.1 Rear Cover
[Machines with One Tray Module]: Disconnect the connector. (Figure 2) (1) Release the Wire Harness from the clamp. (2) Remove the cable band. Figure 7 j0lj41910 (3) Disconnect the connector. Repairs and Adjustments Initial Issue 08/2012 REP 19.1.2, REP 19.2.1 4-58 WorkCentre 5021/5019...
Page 161 Remove the Rear Cover. (Figure 3) (1) Remove the screw (x5). (2) Remove the Rear Cover. Figure 3 j0yg41905 Replacement To install, carry out the removal steps in reverse order. Initial Issue Repairs and Adjustments 08/2012 REP 19.2.1 WorkCentre 5021/5019 4-59...
Page 162 Repairs and Adjustments Initial Issue 08/2012 REP 19.2.1 4-60 WorkCentre 5021/5019...
Page 163: Rep 56.1.1 Dadf
After a replacement, enter the Diag Mode and use [Initialize HFSI Counter] to clear the HFSI counter. 'Chain Link : 955-806' 'Chain Link : 955-807' 'Chain Link : 955-808' 'Chain Link : 955-810' 'Chain Link : 955-812' 'Chain Link : 955-826' Initial Issue Repairs and Adjustments 08/2012 REP 56.1.1 WorkCentre 5021/5019 4-61...
Page 164: Rep 56.1.2 Dadf Platen Cushion
(1) Place the DADF Platen Cushion on the Platen Glass. (2) Set up the gap between the Regi Guide and Platen Guide. (3) Slowly lower the DADF to paste the DADF Platen Cushion to it. Repairs and Adjustments Initial Issue 08/2012 REP 56.1.1, REP 56.1.2 4-62 WorkCentre 5021/5019...
Page 165: Rep 56.2.1 Dadf Front Cover
(2) Remove the DADF Front Cover in the direction of the arrow. Figure 2 j0lj45604 Figure 1 j0lj45605 Replacement To install, carry out the removal steps in reverse order. Initial Issue Repairs and Adjustments 08/2012 REP 56.1.2, REP 56.2.1 WorkCentre 5021/5019 4-63...
Page 166: Rep 56.2.2 Dadf Rear Cover
(1) Open the Document Tray. (2) Remove the Tapping Screw. Figure 3 j0lj45608 Remove the DADF Rear Cover. (Figure 4) (1) Remove the DADF Rear Cover in the direction of the arrow. Repairs and Adjustments Initial Issue 08/2012 REP 56.2.2 4-64 WorkCentre 5021/5019...
Page 167: Rep 56.2.3 Dadf Pwb
To install, carry out the removal steps in reverse order. Remove the DADF Rear Cover. (REP 56.2.2) Disconnect the connector. (Figure 1) (1) Disconnect the connector (x9). Figure 1 j0lj45610 Initial Issue Repairs and Adjustments 08/2012 REP 56.2.2, REP 56.2.3 WorkCentre 5021/5019 4-65...
Page 168: Rep 56.2.4 Upper Feeder
Remove the Hinge Bracket at the rear and remove the Upper Feeder. (Figure 2) (1) Remove the Tapping Screw. (2) Remove the Hinge Bracket. (3) Remove the Upper Feeder. Figure 3 j0lj45612 Repairs and Adjustments Initial Issue 08/2012 REP 56.2.3, REP 56.2.4 4-66 WorkCentre 5021/5019...
Page 169: Rep 56.2.5 Dadf Feeder Assembly
To install, carry out the removal steps in reverse order. Figure 1 j0lj45643 Remove the screws that secure the DADF Feeder Assembly at the rear. (Figure 2) (1) Remove the Tapping Screw (x3). Initial Issue Repairs and Adjustments 08/2012 REP 56.2.4, REP 56.2.5 WorkCentre 5021/5019 4-67...
Page 170 To install, carry out the removal steps in reverse order. (2) Remove the DADF Feeder Assembly. Figure 3 j0lj45645 Reference: This shows the removed DADF Feeder Assembly. (Figure 4) Repairs and Adjustments Initial Issue 08/2012 REP 56.2.5 4-68 WorkCentre 5021/5019...
Page 171: Rep 56.3.1 Left Counter Balance
(1) Remove the Tapping Screws that secure the Ground Wire. Replacement (2) Remove the Tapping Screw (x4). (3) Remove the Right Counter Balance. To install, carry out the removal steps in reverse order. Initial Issue Repairs and Adjustments 08/2012 REP 56.3.1, REP 56.3.2 WorkCentre 5021/5019 4-69...
Page 172: Rep 56.5.1 Dadf Feed/Nudger Roll
Remove the Feed Roll Nudger Roll Assembly. (Figure 2) (1) Remove the KL-Clip. (2) Move the bearing in the direction of the arrow. (3) Remove the Feed Roll Nudger Roll Assembly. Repairs and Adjustments Initial Issue 08/2012 REP 56.3.2, REP 56.5.1 4-70 WorkCentre 5021/5019...
Page 173 When installing the Feed Roll Nudger Roll Assembly, install it such that the Tab (x2) of the Feed Roll Nudger Roll Assembly are at the inner side of the Set Link. (Figure 4) Initial Issue Repairs and Adjustments 08/2012 REP 56.5.1 WorkCentre 5021/5019 4-71...
Page 174: Rep 56.6.1 Harness Guide And Wire Harness
Harness Guide. (Figure 2) (1) Disconnect the connector. (2) Remove the wire harness from the Harness Guide. Figure 3 j0lj45620 Disconnect the DADF PWB connectors. (Figure 4) (1) Disconnect the connector (x2). Repairs and Adjustments Initial Issue 08/2012 REP 56.6.1 4-72 WorkCentre 5021/5019...
Page 175 Figure 7 j0lj45624 Disconnect the connector of the DADF Feed Motor. (Figure 6) Reference: This shows the removed Harness Guide and wire harness. (Figure 8) (1) Disconnect the connector. Initial Issue Repairs and Adjustments 08/2012 REP 56.6.1 WorkCentre 5021/5019 4-73...
Page 176: Rep 56.6.2 Dadf Feed Motor
When installing the DADF Feed Motor, align the Tab (x2) of the DADF Feed Motor Bracket to the Cutout (x2) of the DADF Feed Clutch and DADF Takeaway Clutch. (Figure Repairs and Adjustments Initial Issue 08/2012 REP 56.6.1, REP 56.6.2 4-74 WorkCentre 5021/5019...
Page 177: Rep 56.7.1 Dadf Drive Belt
Figure 1 j0lj45631 Remove the gear and bracket. (Figure 2) (1) Remove the washer (large: thin). (2) Remove the washer (small: thick). (3) Remove the gear and bracket. Initial Issue Repairs and Adjustments 08/2012 REP 56.6.2, REP 56.7.1 WorkCentre 5021/5019 4-75...
Page 178 Figure 3 j0lj45633 Replacement Remove the gear. (Figure 4) To install, carry out the removal steps in reverse order. (1) Loosen the screw. (2) Remove the spring. (3) Remove the gear. Repairs and Adjustments Initial Issue 08/2012 REP 56.7.1 4-76 WorkCentre 5021/5019...
Page 179: Rep 56.9.1 Document Tray
Reference: This shows the removed wire harness of the Document Tray. (Figure 2) Figure 3 j0lj45616 Remove the wire harness through the hole at the rear. (Figure 4) (1) Remove the wire harness through the hole. Initial Issue Repairs and Adjustments 08/2012 REP 56.9.1 WorkCentre 5021/5019 4-77...
Page 180: Rep 56.9.2 Retard Chute
Figure 4 j0lj45617 (1) Remove the Retard Chute in the direction of the arrow. Replacement To install, carry out the removal steps in reverse order. Figure 1 j0lj45647 Repairs and Adjustments Initial Issue 08/2012 REP 56.9.1, REP 56.9.2 4-78 WorkCentre 5021/5019...
Page 181: Rep 56.9.3 Invert Chute
Figure 2 j0lj45648 Replacement To install, carry out the removal steps in reverse order. Figure 1 j0lj45649 Replacement To install, carry out the removal steps in reverse order. Initial Issue Repairs and Adjustments 08/2012 REP 56.9.2, REP 56.9.3 WorkCentre 5021/5019 4-79...
Page 182: Rep 56.10.1 Dadf Takeaway Roll
(1) Remove the washer (large: thin). (1) Loosen the screw. (2) Remove the washer (small: thick). (2) Remove the spring. (3) Remove the gear and bracket. (3) Remove the gear. Repairs and Adjustments Initial Issue 08/2012 REP 56.10.1 4-80 WorkCentre 5021/5019...
Page 183 (3) Remove the Bracket and Ground Plate. (1) Remove the gear. (2) Remove the Knob Handle. Figure 5 j0lj45636 Figure 7 j0lj45637 14. Remove the bearing at the front. (Figure 8) Initial Issue Repairs and Adjustments 08/2012 REP 56.10.1 WorkCentre 5021/5019 4-81...
Page 184 Replacement To install, carry out the removal steps in reverse order. When installing the Bracket and Ground Plate, install the Ground Plate as shown in the figure. (Figure 10) Repairs and Adjustments Initial Issue 08/2012 REP 56.10.1 4-82 WorkCentre 5021/5019...
Page 185: Rep 56.10.2 Sensor Bracket
(2) Remove the Knob Handle. Figure 1 j0lj45636 Figure 3 j0lj45659 Remove the Bearing of the DADF Takeaway Roll. (Figure 4) (1) Remove the KL-Clip. (2) Remove the Bearing. Initial Issue Repairs and Adjustments 08/2012 REP 56.10.2 WorkCentre 5021/5019 4-83...
Page 186 (1) Lift up the Front side of the DADF Takeaway Roll. (1) Release the hook to remove the DADF Regi Sensor. (2) Remove the Sensor Bracket. (2) Disconnect the connector. Repairs and Adjustments Initial Issue 08/2012 REP 56.10.2 4-84 WorkCentre 5021/5019...
Page 187 Takeaway Clutch at the Rear side to the Tab of the Bracket of the DADF Feed Motor. (Fig- ure 9) Figure 9 j0lj45665 When installing the Bracket and Ground Plate, install the Ground Plate as shown in the figure. (Figure 10) Initial Issue Repairs and Adjustments 08/2012 REP 56.10.2 WorkCentre 5021/5019 4-85...
Page 188: Rep 56.13.1 Dadf Retard Pad
To install, carry out the removal steps in reverse order. When installing the DADF Retard Pad, attach the spring to the boss of the DADF Retard Pad. (Figure 2) Repairs and Adjustments Initial Issue 08/2012 REP 56.13.1 4-86 WorkCentre 5021/5019...
Page 189: Adj 1.3.1 Iit Lead Edge Registration
Increment of the value: The image moves towards the IN side. • Decrement of the value: The image moves towards the Lead Edge. • Decrement of the value: The image moves towards the OUT side. Initial Issue Repairs and Adjustments 08/2012 ADJ 1.3.1, ADJ 1.3.2 WorkCentre 5021/5019 4-87...
Page 190 Repairs and Adjustments Initial Issue 08/2012 ADJ 1.3.2 4-88 WorkCentre 5021/5019...
Page 191: Adj 8.1.1 Atc Sensor Read & Tone Up/Down
The maximum number of sheets for each Tone Up / Down is 20 sheets. Adjustment • For the adjustment procedure, refer to the following: 6.4.2.12 ATC Sensor Read 6.4.2.13 Tone Up/Down Initial Issue Repairs and Adjustments 08/2012 ADJ 8.1.1 WorkCentre 5021/5019 4-89...
Page 192 Repairs and Adjustments Initial Issue 08/2012 ADJ 8.1.1 4-90 WorkCentre 5021/5019...
Page 193: Adj 18.1.1 Iot Lead Edge/Side Edge Registration
Lead Edge (A) 30 +/- 2.4 mm 30 +/- 3.4 mm 30 +/- 3.1 mm Side Edge (B) 30 +/- 3.0 mm 30 +/- 3.4 mm 30 +/- 3.2 mm Adjustment Enter the CE Mode. Initial Issue Repairs and Adjustments 08/2012 ADJ 18.1.1 WorkCentre 5021/5019 4-91...
Page 194: Adj 18.1.2 Edge Erase Value Adjustment
Parameter PWB, remove the the old PWB, and install it to EEP ROM from the the new one. old PWB, and install it to the new one. Repairs and Adjustments Initial Issue 08/2012 ADJ 18.2.1, ADJ 18.2.2 4-92 WorkCentre 5021/5019...
Page 195: Adj 18.2.2 Firmware Version Upgrade
(4) Enter '1' for [System Settings] and press the [Start] button. (5) Once printing has completed, press the [Log In / Out] button to exit from the System Administrator Mode. Initial Issue Repairs and Adjustments 08/2012 ADJ 18.2.2 WorkCentre 5021/5019 4-93...
Page 196: Dadf
Figure 3 j0lj41891 Set the machine to Download Mode. (1) Press and hold down the [Energy Saver] button, then turn ON the power to start the machine in Download Mode. Repairs and Adjustments Initial Issue 08/2012 ADJ 18.2.2 4-94 WorkCentre 5021/5019...
Page 197 Figure 6 j0lj41898 (4) When the Download Mode has completed successfully, the machine will reboot automatically. Figure 7 j0lj41894 Initial Issue Repairs and Adjustments 08/2012 ADJ 18.2.2 WorkCentre 5021/5019 4-95...
Page 198 Repairs and Adjustments Initial Issue 08/2012 ADJ 18.2.2 4-96 WorkCentre 5021/5019...
Page 199: Adj 56.1.1 Dadf Lead-Skew Adjustment
(1) Loosen the screw (x3). (2) Move the DADF in direction A or B. Figure 3 j0ku42044 (3) Tighten the screw (x3). • The DADF moved in direction B. (Figure 4) Initial Issue Repairs and Adjustments 08/2012 ADJ 56.1.1 WorkCentre 5021/5019 4-97...
Page 200: Adj 56.1.2 Dadf Side Registration
Place the Test Chart (499T 00283) on the DADF facing down with the Test Chart fed from the lead edge. Make a copy using the following settings in Copy mode. • 2 to 1 Sided mode • Paper Tray: 'A3' Repairs and Adjustments Initial Issue 08/2012 ADJ 56.1.1, ADJ 56.1.2 4-98 WorkCentre 5021/5019...
Page 201 Enter the value to perform correction for each size in the NVM [715-056 to 072]. If it is not within the specified range in Check Step 5, change the NVM value. Initial Issue Repairs and Adjustments 08/2012 ADJ 56.1.2 WorkCentre 5021/5019 4-99...
Page 202: Adj 56.1.3 Dadf Lead Edge Registration
(Figure 1) copy is 10 +/-1.9 mm. If it is not within the specified range, adjust to the specified range using the following pro- cedure. (Figure 2) Figure 1 j0sr42053 Repairs and Adjustments Initial Issue 08/2012 ADJ 56.1.3 4-100 WorkCentre 5021/5019...
Page 203 As there will be differences in the Regi according to the ratio, adjust the following NVM. Table 2 Basic Scan Speed [mm/s] Reduce / Enlarge NVM [711-022] 165.0 100.0% NVM [711-024] 82.5 Other than 100.0% Initial Issue Repairs and Adjustments 08/2012 ADJ 56.1.3 WorkCentre 5021/5019 4-101...
Page 204 PL 10.4 Left Cover ......................5-27 PL 10.5 Takeaway Roll ....................5-28 99. Adjustment/Consumables Area Code List PL 10.6 Electrical ......................5-29 99.1 Paper........................5-60 PL 10.7 Cover ........................ 5-30 99.2 Environment ......................5-60 Initial Issue Parts List 08/2012 WorkCentre 5021/5019...
Page 205 99.8 DMP/Network Functions Related ................5-63 5.3 Parts Navi Navi 1.1 Processor + Option ..................5-65 Navi 2.1 IOT ........................5-65 Navi 2.2 One Tray Module ..................... 5-66 Navi 2.3 DADF ....................... 5-66 Parts List Initial Issue 08/2012 WorkCentre 5021/5019...
Page 206: How To Use The Parts List
(illustration) to perform servicing efficiently. For how to use the navigation, refer to '5.1.5 Using Parts Navigation'. Initial Issue Parts List 08/2012 5.1.1, 5.1.2 WorkCentre 5021/5019...
Page 207: Plate Composition
This symbol shows the whole area of the framed illustration is modified by the number in the circle. The area has the modified configuration. Figure 4 5005 Parts List Initial Issue 08/2012 5.1.3, 5.1.4 WorkCentre 5021/5019...
Page 208: Using Parts Navigation
ISC followed by part name in the DESCRIPTION column represents Important Information Stored Component that stores important cus- tomer information. To replace and discard an ISC, follow the procedure for it described in chapter 4. Initial Issue Parts List 08/2012 5.1.4, 5.1.5 WorkCentre 5021/5019...
Page 209 Parts List Initial Issue 08/2012 5.1.4, 5.1.5 WorkCentre 5021/5019...
Page 210: Pl 1.1 Platen Cover
ID Label 11B1 848E 87121 Platen Cover (REP 99.1.1)2001 036K 92150 Counter Balance (REP 99.1.1)2005 004K 03410 Platen Cushion 2003 – Code Label 11B2 848K 69520 Platen Cover (Item 3,4) (REP 99.1.1)2001 Initial Issue Parts List 08/2012 PL 1.1 WorkCentre 5021/5019...
Page 211: Pl 1.2 Top Cover (With Platen Glass)
(REP 1.2.1, REP 99.1.1)1021 – Data Plate 11C2 – IIT Front Cover 11C3 – CVT Plate 11C4 868E 80610 Conductor 11C5 – Lead Regi. Label 11C6 – Side Regi. Label 11C7 Parts List Initial Issue 08/2012 PL 1.2 WorkCentre 5021/5019...
Page 212: Pl 1.3 Iit Base Frame Component
848K 68874 IIT Carriage 1.5) (REP 1.3.1) 11D9 117K 47661 CCD Cable 11DB 952K 03781 Sensor Wire Harness (REP 99.1.1) 11DC 930W 00123 IIT Registration Sensor 11DD 117K 47680 UI Cable 11DE Initial Issue Parts List 08/2012 PL 1.3 WorkCentre 5021/5019...
Page 213: Pl 1.4 Carriage Motor
(REP 1.4.1, 99.1.1)1041 807E 40871 Helical Gear 11E2 807E 40880 Helical Gear 11E3 807E 40890 Gear Pulley 11E4 005E 33441 Flange 11E5 952K 03771 Motor Wire Harness (REP 99.1.1) 11E6 Parts List Initial Issue 08/2012 PL 1.4 5-10 WorkCentre 5021/5019...
Page 214: Pl 1.5 Iit Carriage
PL 1.5 IIT Carriage Item Parts No Description A.C. – Lens Housing 11F1 960K 64290 LED Lamp PWB (REP 1.5.1)11F2 – LED Bracket 11F3 117K 47740 LED Cable 11F4 Initial Issue Parts List 08/2012 PL 1.5 WorkCentre 5021/5019 5-11...
Page 215: Pl 1.6 Control Panel
Ten Key 75BB 123E 91650 LCD Display (REP 1.6.1) 75BC 803E 13280 ID Key 75BD 868E 80420 Middle A Key 75BE – UI Label 75BF 960K 62200 UI PWB 75BG Parts List Initial Issue 08/2012 PL 1.6 5-12 WorkCentre 5021/5019...
Page 216: Pl 2.1 Ros
PL 2.1 ROS Item Parts No Description A.C. 062K 24840 ROS Assembly (REP 2.1.1, 99.1.1)1310 952K 01240 ROS Wire Harness (REP 99.1.1) 13B1 Initial Issue Parts List 08/2012 PL 2.1 WorkCentre 5021/5019 5-13...
Page 217: Pl 3.1 Main Drive Motor
3.1.1, REP 99.1.1)3010 – 127K 66290 Main Drive Motor (Alternate) (REP 3.1.1, REP 99.1.1)3010 007K 18870 Main Drive Housing 3.2) (REP 3.1.2)30B1 049K 17710 Stud Bracket 30B2 807E 39260 Helical Gear 30B3 Parts List Initial Issue 08/2012 PL 3.1 5-14 WorkCentre 5021/5019...
Page 218: Pl 3.2 Main Drive Housing
Main Drive Housing (P/O Item 10) 30CC 848E 84830 Conductor Cover 30CD 130E 16130 BCR Conductor 30CE 130E 16140 Deve. Conductor 30CF 130E 16150 BTR Conductor 30CG 130E 16160 HV Conductor 30CH Initial Issue Parts List 08/2012 PL 3.2 WorkCentre 5021/5019 5-15...
Page 219: Pl 4.1 Nohad
PL 4.1 NOHAD Item Parts No Description A.C. 054E 50270 NOHAD Duct 33B1 127E 86170 NOHAD Fan (REP 4.1.1) 3301 – Fusing Unit Plate 33B2 – Laser Housing 33B3 Parts List Initial Issue 08/2012 PL 4.1 5-16 WorkCentre 5021/5019...
Page 220: Pl 6.1 Transfer
BTR Spring (Front) 41B5 – Float Spring (P/O Item 1) 41B6 – DTS Conductor (P/O Item 1)41B7 – Film Chute (P/O Item 1) 41B8 059K 79560 BTR Roll (REP 6.1.1) 4101 Initial Issue Parts List 08/2012 PL 6.1 WorkCentre 5021/5019 5-17...
Page 221: Pl 7.1 Fusing Unit
– 126K 31730 120V-Fusing Unit (REP 7.1.1, 99.1.1)43AA 848E 83410 Connector Cover 43B5 952K 01220 220V-Fusing Unit Wire Harness (REP 99.1.1)43B6 – 962K 69060 120V-Fusing Unit Wire Harness (REP 99.1.1)43B6 Parts List Initial Issue 08/2012 PL 7.1 5-18 WorkCentre 5021/5019...
Page 222: Pl 8.1 Drum Cartridge,Toner Cartridge
PL 8.1 Drum Cartridge,Toner Cartridge Item Parts No Description A.C. 013R 00670 Drum Cartridge (REP 8.1.1)4510 006R 01573 Toner Cartridge 4011 Initial Issue Parts List 08/2012 PL 8.1 WorkCentre 5021/5019 5-19...
Page 223: Pl 8.2 Toner System
Shutter Guide 45C4 055E 58451 Dispenser Shutter 45C5 – Guide Seal (P/O Item 3) 45C6 127K 66870 Toner Dispense Motor(REP 99.1.1) 45C7 807E 39410 Gear (21/21T) 45C8 – Clamp 45C9 Parts List Initial Issue 08/2012 PL 8.2 5-20 WorkCentre 5021/5019...
Page 224: Pl 8.3 Dispense Drive
45D2 – Gear (45T) 45D3 – Gear (55/19T) 45D4 807E 31531 Gear (54T) 45D5 – Gear (47/17T) 45D6 – Gear (45T) 45D7 – Gear (96/20T) 45D8 809E 79130 Spring 45D9 Initial Issue Parts List 08/2012 PL 8.3 WorkCentre 5021/5019 5-21...
Page 225: Pl 9.1 Tray 1,Tray Drive
Harness Guide 50B8 014E 45350 Spacer 50B9 013E 41230 Bearing 50BB – Tray Support Bracket 50BC – Instruction Label 50BD – Label (No.1) 50BE 003E 60952 Tray Front Stopper 50BF Parts List Initial Issue 08/2012 PL 9.1 5-22 WorkCentre 5021/5019...
Page 226: Pl 9.2 Tray 1 Component
9.2.1)5033 809E 27650 Spring 50CH 849E 24550 Ground Plate 50CJ – Paper Guide 50CK 803E 15701 Stopper 50CL 848E 85990 Inner Cover 50CM – Bearing Cover 50CN – Spacer 50CP Initial Issue Parts List 08/2012 PL 9.2 WorkCentre 5021/5019 5-23...
Page 227: Pl 10.1 Tray 2 ,Feeder
50D7 014E 59990 Slide Lock (Alternate) 50D8 – 014E 56640 Slide Lock (Alternate) 50D8 826E 07210 Docking Screw 50D9 – Cover 50DB – Holder 50DC – Feeder Connector Cover 50DD Parts List Initial Issue 08/2012 PL 10.1 5-24 WorkCentre 5021/5019...
Page 228: Pl 10.2 Tray 2 Component
Lift Up Shaft 50EP – Stopper 50EQ – Seal 50ER – Tray 50ES – Slide Lock (P/O Item 7) 50ET 604K20541 Gear Kit (Contains 1 each of items 18, 19, 20) Initial Issue Parts List 08/2012 PL 10.2 WorkCentre 5021/5019 5-25...
Page 229: Pl 10.3 Tray 2 Feeder
50H6 – Lower Frame 50H7 019E 56680 Holder 50H8 809E 51080 Spring 50H9 – Rail 50HB – Screw 50HC 604K20360 Roll KIt (Contains 3 each of items 20, 28, 32) Parts List Initial Issue 08/2012 PL 10.3 5-26 WorkCentre 5021/5019...
Page 230: Pl 10.4 Left Cover
Shaft (P/O Item 1) 50J9 809E 54590 Spring 50JB 013E 26100 Bearing 50JC 059E 99241 Pinch Roll 5045 110E 12220 STM Left Cover Switch 50JD 030K 75511 Bracket Assembly 50JE Initial Issue Parts List 08/2012 PL 10.4 WorkCentre 5021/5019 5-27...
Page 231: Pl 10.5 Takeaway Roll
Description A.C. – Chute 50K1 802E 54672 Cover 50K2 130K 64121 Feed Out Sensor 2 50K3 952K 08150 Wire Harness 50K4 059K 26251 Takeaway Roll 5045 413W 11860 Bearing 50K5 Parts List Initial Issue 08/2012 PL 10.5 5-28 WorkCentre 5021/5019...
Page 232: Pl 10.6 Electrical
007E 79830 Gear 50L8 007E 79840 Gear 50L9 007E 79850 Gear 50LB 952K 03070 Wire Harness(REP 99.1.1)50LC – Gasket 50LD 413W 11860 Bearing 50LE 252W 29450 Nylon Washer(8) (t1) 50LF Initial Issue Parts List 08/2012 PL 10.6 WorkCentre 5021/5019 5-29...
Page 233: Pl 10.7 Cover
50M2 802E 56601 Rear Cover 50M3 – Foot 50M4 – Foot (Rear Left) 50M5 – Cover 50M6 849E 34880 Docking Bracket 50M7 826E 07210 Docking Screw 50M8 032E 38920 50M9 Parts List Initial Issue 08/2012 PL 10.7 5-30 WorkCentre 5021/5019...
Page 234: Pl 12.1 Stand
Caster (S) 50N5 – Caster 50N6 – Hinge 50N7 – Screw 50N8 – Foot 50N9 – Foot Cover 50NB – Stopper 50NC – Pipe Cover 50ND – Docking Screw 50NE Initial Issue Parts List 08/2012 PL 12.1 WorkCentre 5021/5019 5-31...
Page 235: Msi
(REP 13.1.1)51AA – Instruction Label (P/O Item 6)51B2 – Size Label (P/O Item 6) 51B3 – Max Label (P/O Item 6) 51B4 604K 80730 MSI Label Kit (Item 3-5) 51B5 Parts List Initial Issue 08/2012 PL 13.1 5-32 WorkCentre 5021/5019...
Page 236: Pl 13.2 Msi Component
050K 69580 MSI Tray 5110 801E 22262 MSI Top Cover 51C2 803E 13171 Paper Stopper 51C3 120E 34130 No Paper Actuator 51C4 899E 01350 Spring 51C5 848E 87781 Gear Cover 51C6 Initial Issue Parts List 08/2012 PL 13.2 WorkCentre 5021/5019 5-33...
Page 237: Pl 13.3 Msi Lower Feeder
930W 00123 MSI No Paper Sensor 51DH 962K 68851 MSI Wire Harness(REP 99.1.1) 51DJ 848E 85862 Connector Cover(REP 99.1.1) 51DK 848E 85940 MSI Lower Cover 51DL 815E 77090 Ground Plate 51DM Parts List Initial Issue 08/2012 PL 13.3 5-34 WorkCentre 5021/5019...
Page 238: Pl 14.1 Simplex/Duplex L/H Cover
848E 83270 Hinge Front Cover 52B6 848E 83290 Hinge Rear Cover 52B7 848K 64890 Simplex L/H Cover 14.2) (REP 14.1.1)52AA – 848K 68300 Duplex L/H Cover 14.3, 14.4) (REP 14.1.1)52AA Initial Issue Parts List 08/2012 PL 14.1 WorkCentre 5021/5019 5-35...
Page 239: Pl 14.2 Simplex L/H Cover
99.1.1) 52C5 868E 78150 Front Latch Support 52C6 809E 99540 Spring 52C7 054E 49700 L/H Cover Upper Chute 52C8 868E 77080 L/H Cover Support 52C9 898E 45921 Caution Label 52CB Parts List Initial Issue 08/2012 PL 14.2 5-36 WorkCentre 5021/5019...
Page 240: Pl 14.3 Duplex L/H Cover-Chute,Latch
Front Latch Lever 52D7 011E 26691 Rear Latch Lever(REP 99.1.1) 52D8 815E 75070 Latch Plate 52D9 809E 99540 Spring 52DB 868E 77080 L/H Cover Support 52DC 898E 45921 Caution Label 52DD Initial Issue Parts List 08/2012 PL 14.3 WorkCentre 5021/5019 5-37...
Page 241: Pl 14.4 Duplex L/H Cover-Roll,Gear
Spring 52EH – Helical Gear (24T) 52EJ – Helical Gear (19T) 52EK – Helical Gear (17T) 52EL – Helical Gear (28T) 52EM 413W 11460 Bearing 52EN 809E 75530 Spring 52EP Parts List Initial Issue 08/2012 PL 14.4 5-38 WorkCentre 5021/5019...
Page 242: Registration
Film Chute (P/O Item 1) 53B5 059K 74891 Registration Roll (REP 15.1.2)5313 013E 40990 Bearing 53B6 121K 52340 Registration Clutch (REP 99.1.1) 53B7 807E 40940 Helical Gear 53B8 032E 41320 Harness Guide 53B9 Initial Issue Parts List 08/2012 PL 15.1 WorkCentre 5021/5019 5-39...
Page 243: Pl 17.1 Simplex/Duplex Exit
807E 39130 Helical Gear (43T) 54B6 807E 39140 Helical Gear (41T) 54B7 127K 66210 Inverter Motor (REP 99.1.1)5251 – Bind Head Screw 54B8 952K 01160 Motor Wire Harness(REP 99.1.1) 54B9 Parts List Initial Issue 08/2012 PL 17.1 5-40 WorkCentre 5021/5019...
Page 244: Pl 18.1 Electrical
(REP 99.1.1)72BC – Screw 72BD – Power Cord (220V) 7122 – – Power Cord (120V) 7122 – USB Cable 72BE – IIT Cable Spacer 72BF 101K 66581 Connector Bracket 72BG Initial Issue Parts List 08/2012 PL 18.1 WorkCentre 5021/5019 5-41...
Page 245: Pl 18.2 Wire Harness
PL 18.2 Wire Harness Item Parts No Description A.C. 962K 69090 Wire Harness (REP 99.1.1)71B1 962K 69100 Wire Harness (REP 99.1.1)71B2 Parts List Initial Issue 08/2012 PL 18.2 5-42 WorkCentre 5021/5019...
Page 246: Pl 19.1 Cover-Front,Top,Right
Fusing Unit Cover 32B3 848E 84611 Right Cover 32B4 – Logo Plate (P/O Item 15) 32B5 – Name Plate (WorkCentre 5021) (P/ O Item 16)32B6 – Name Plate (WorkCentre 5019) (P/ O Item 16)32B7 – CRU Instruction Label (P/O Item 15)32B8...
Page 247: Pl 19.2 Cover-Rear,Left Rear
STM Connector Cover 32C3 848E 87321 Left Rear Cover 32C4 868E 69740 Bracket 32C5 – Blind Cover 32C6 – Data Plate 32C7 – Thumbscrew 32C8 – STM Caution Label 32C9 Parts List Initial Issue 08/2012 PL 19.2 5-44 WorkCentre 5021/5019...
Page 248: Pl 56.1 Dadf Accessory
PL 56.1 DADF Accessory Item Parts No Description A.C. 004K 03410 DADF Platen Cushion (REP 56.1.2) 22B1 059K 75711 DADF 56.2) (REP 56.1.1)22AA – Label 22B2 Initial Issue Parts List 08/2012 PL 56.1 WorkCentre 5021/5019 5-45...
Page 249: Pl 56.2 Dadf Component
809E 50792 Spring 22CD 930W 00121 DADF Open Sensor 22CE – Data Plate 22CF – Clamp 22CG 960K 62441 DADF PWB (REP 56.2.3, 99.1.1)22CH 952K 03540 DADF I/F Wire Harness(REP 99.1.1)22CJ Parts List Initial Issue 08/2012 PL 56.2 5-46 WorkCentre 5021/5019...
Page 250: Pl 56.3 Dadf Base Frame
Seal (Chute 5) 22DF 035K 85380 Seal (B1) 22DG 035K 85390 Seal (B2) 22DH 035K 85400 Seal (B3) 22DJ – Shaft 22DK 899E 01591 Spring (Hook:C,O) 22DL 899E 01911 Spring (Hook:C,C) 22DM Initial Issue Parts List 08/2012 PL 56.3 WorkCentre 5021/5019 5-47...
Page 251: Pl 56.4 Upper Feeder
Handle Lever 22E9 120E 34242 Actuator (Document Set) 22EB 120E 34250 Stopper Actuator 22EC 899E 01541 Spring 22ED 012E 18310 Set Link 22EE 413W 85459 Bearing 22EF 899E 01550 Spring 22EG Parts List Initial Issue 08/2012 PL 56.4 5-48 WorkCentre 5021/5019...
Page 252: Pl 56.5 Feed Roll Nudger Roll Assembly
DADF Nudger Roll (P/O Item 14) (REP 56.5.1)22F8 413W 85459 Bearing 22F9 807E 40760 Helical Gear 22FB – Brake 22FC – Brake Holder 22FD – Housing 22FE 604K 80750 DADF Feed/Nudger Roll Kit (Item 7,8)22FG Initial Issue Parts List 08/2012 PL 56.5 WorkCentre 5021/5019 5-49...
Page 253: Pl 56.6 Dadf Feed Motor,Harness Guide
DADF Feed Motor (REP 56.6.2) 22G3 930W 00121 DADF Document Set Sensor 22G4 952K 03531 Wire Harness (Sensor)(REP 99.1.1)22G5 952K 03510 Wire Harness (Motor/Clutch)(REP 99.1.1)22G6 117K 38960 Ground Wire 22G7 Parts List Initial Issue 08/2012 PL 56.6 5-50 WorkCentre 5021/5019...
Page 254: Pl 56.7 Dadf Feeder Rear Frame
22HF 807E 40830 Gear Pulley 22HG 807E 40840 Gear (19T) 22HH 868E 80570 Bracket 22HJ 899E 01573 Washer 22HK 012E 18290 Link 22HL 899E 01581 Spring 22HM – KL-Clip 22HN Initial Issue Parts List 08/2012 PL 56.7 WorkCentre 5021/5019 5-51...
Page 255: Pl 56.8 Dadf Feeder Front Frame
Knob Handle 22J1 807E 41000 Gear 22J2 868E 80540 Bracket 22J3 807E 40780 Gear (27T) 22J4 807E 40840 Gear (19T) 22J5 815E 76320 Ground Plate 22J6 815E 76340 Ground Plate 22J7 Parts List Initial Issue 08/2012 PL 56.8 5-52 WorkCentre 5021/5019...
Page 256: Pl 56.9 Dadf Tray,Chute
050K 69650 Document Tray 56.11) (REP 56.9.1, 99.1.1)2210 054K 48570 Invert Chute 56.12) (REP 56.9.3)22K1 054K 48580 Retard Chute 56.13) (REP 56.9.2)22K2 054K 49150 Floating Chute 22K3 – Spring 22K4 Initial Issue Parts List 08/2012 PL 56.9 WorkCentre 5021/5019 5-53...
Page 257: Pl 56.10 Dadf Roll,Sensor Bracket
059K 75810 DADF Exit Roll 22L4 049K 17820 Sensor Bracket 56.14) (REP 56.10.2)22L5 413W 11660 Bearing 22L6 – DADF Feeder Frame 22L7 – KL-Clip 22L8 930W 00121 DADF Invert Sensor 22L9 Parts List Initial Issue 08/2012 PL 56.10 5-54 WorkCentre 5021/5019...
Page 258: Pl 56.11 Document Tray
Rack Gear (Front) 22MF 807E 40750 Rack Gear (Rear) 22MG 930W 00121 Document Tray Size Sensor 1 22MH 930W 00121 Document Tray Size Sensor 222MJ 952K 03520 Tray Wire Harness(REP 99.1.1) 22MK Initial Issue Parts List 08/2012 PL 56.11 WorkCentre 5021/5019 5-55...
Page 259: Pl 56.12 Invert Chute
Actuator (Pre Regi.) 22N2 809E 50792 Spring 22N3 035K 82730 Seal (Long) 22N4 035K 82740 Seal (Short) 22N5 – 22N6 120E 34230 Actuator (Invert) 22N7 050E 25313 Invert Gate 22N8 Parts List Initial Issue 08/2012 PL 56.12 5-56 WorkCentre 5021/5019...
Page 260: Pl 56.13 Retard Chute
– Shaft 22PB 019E 84131 Rear Holder 22PC 019E 84120 Front Holder 22PD 059E 08661 Pinch Roll 22PE 899E 01531 Spring 22PF 413W 11460 Bearing 22PG 012E 18280 Link 22PH Initial Issue Parts List 08/2012 PL 56.13 WorkCentre 5021/5019 5-57...
Page 261: Pl 56.14 Sensor Bracket
Parts No Description A.C. 032E 40221 Sensor Bracket 22Q1 930W 00121 DADF Regi. Sensor 22Q2 930W 00121 DADF Pre Regi. Sensor 22Q3 120E 34260 Actuator (Regi.) 22Q4 809E 50792 Spring 22Q5 Parts List Initial Issue 08/2012 PL 56.14 5-58 WorkCentre 5021/5019...
Page 262: Screws
354W 24254 KL-Clip (4) 354W 24278 E-Clip (4:White) 354W 26278 E-Clip (5:White) 354W 27254 KL-Clip (6) 354W 27278 E-Clip (6:White) 354W 29278 E-Clip (8:White) 158W 36678 Screw (M4x16:White) 158W 45078 Screw (M5x10:White) Initial Issue Parts List 08/2012 98.1 WorkCentre 5021/5019 5-59...
Page 263: Paper
9083 Plain (XEROX) 5711 Operational Error (beyond User Guide) 9084 Plain (Other makers) 57B4 No Reproduction after Power ON/OFF 9085 Recycled Paper (XEROX) 5712 Interference with Peripheral 9086 Recycled Paper (Other makers) 57B5 Power at Customer Site 9087 Heavyweight 57B6...
Page 264 Download (Reinstall) 77E1 Download (Version UP) 77E2 Other NVM Changes 7760 Other Diag. Adjustment 77BN Auto Gradation Correction 77F1 ATC Sensor Setup 77F3 Tone Up/Down 77F5 Secondary Traansfer Output Adjustment 77F6 Initial Issue Parts List 08/2012 99.3, 99.4 WorkCentre 5021/5019 5-61...
Page 265 Mechanical Adjustment Originals Full/Harf Parallel Adjutment 1050 Photo Originals 572B Printed Originals 572C Maps and Low Contrast Originals 572D Paste-up Originals 572E Dirty/areased Originals 572F Colored Originals 572G Other Originals 572H Parts List Initial Issue 08/2012 99.6, 99.7 5-62 WorkCentre 5021/5019...
Page 266 Problems at Memory Media (Commercial item) 906B Problems at Wireless LAN 906C Network-related Services SW DocuHouseAccouthgService/ApeosWareAccouthgService 9076 CentreWareDeviceService/ApeosWareDeviceService 9077 DocuShare 9078 FreeFlow related (XDOD) 9079 Print/Scan Driver 907B XDOM 907C External Access Kit 906D Initial Issue Parts List 08/2012 99.8 WorkCentre 5021/5019 5-63...
Page 267 Parts List Initial Issue 08/2012 99.8 5-64 WorkCentre 5021/5019...
Page 268 Navi 1.1 Processor + Option Navi 2.1 IOT Figure 1 j0yg50021 Figure 1 j0lj50011 Initial Issue Parts List 08/2012 Navi 1.1, Navi 2.1 WorkCentre 5021/5019 5-65...
Page 269 Navi 2.2 One Tray Module Navi 2.3 DADF Figure 1 j0lj50023 Figure 1 j0lj50022 Parts List Initial Issue 08/2012 Navi 2.2, Navi 2.3 5-66 WorkCentre 5021/5019...
Page 270 6.3.19 NVM ACCOUNT MODE..................6-83 6.3.3 Analog Monitor Code List 6.3.20 NVM Jam Counter Clear & Initialize HFSI 6.3.3 Analog Monitor Code List..................6-35 6.3.20 NVM Jam Counter Clear & Initialize HFSI............6-85 6.3.4 HFSI Counters Initial Issue General Procedures 08/2012 WorkCentre 5021/5019...
Page 271 6-103 6.4.2.14 Test Pattern Print ..................... 6-104 6.4.2.15 Checking and Repairing the Billing Counter (621-400)........6-105 6.4.3 Error Display during Diag ..................6-107 6.6 KO PROGRAM# LIST 6.6 KO PROGRAM# LIST ....................6-109 General Procedures Initial Issue 08/2012 WorkCentre 5021/5019...
Page 272 DMO-E WorkCentre 5019 220V xxxxxx~xxxxxx (TL200536) DMO-W WorkCentre 5019 110V xxxxxx~xxxxxx (TL200537) INDIA WorkCentre 5019 220V xxxxxx~xxxxxx (TL200538) DMO-E WorkCentre 5021 220V xxxxxx~xxxxxx (TL200539) DMO-W WorkCentre 5021 110V xxxxxx~xxxxxx (TL200540) DMO-E WorkCentre 5021 220V xxxxxx~xxxxxx (TL200541) DMO-W WorkCentre 5021 110V...
Page 273 - Paper Output: • Face down tray (250 paper capacity) • Face down tray (250 paper capac- - Duplex: Factory Option ity) - Duplex: Factory Option PANEL - Fixed LCD - Fixed LCD General Procedures Initial Issue 08/2012 6.1.2, 6.1.3 WorkCentre 5021/5019...
Page 274 Stop state Stop state Stop state (Transfer/Develop- ment) ROS Assembly Operating state Stop state Stop state Stop state Stop state ESS/MCU PWB Operating state Standby Standby Ready to Stop state (Reference) receive Initial Issue General Procedures 08/2012 6.1.4, 6.1.5 WorkCentre 5021/5019...
Page 275 Max Floor Weight Capacity (Reference value): = Main Unit (w/Dup + w/DADF) + STM + Stand = 36.0 kg + 10.7 kg + 19 kg = 65.7 kg Figure 2 j0lj60002 Basic Model 2 General Procedures Initial Issue 08/2012 6.1.6 WorkCentre 5021/5019...
Page 276 Figure 4 j0lj60004 Basic Model 3 • Basic Model 3-1 (Main Unit +STM+ Stand + Platen Cover) Machine Size (W x D x H): 639 mm x 685 mm x 998 mm (Figure 5) Initial Issue General Procedures 08/2012 6.1.6 WorkCentre 5021/5019...
Page 277 Main Unit + Platen Cover + STM + 0.65 Stand Main Unit + DADF 0.56 Main Unit + DADF + STM 0.56 Main Unit + DADF + STM + Stand 0.66 Figure 2 j0lj60009 Main Unit (w/DADF) +STM+ Stand General Procedures Initial Issue 08/2012 6.1.7 WorkCentre 5021/5019...
Page 278 The machine shall operate properly when it is placed horizontally and the front-to-back tilt in the surface below the cabinet (casters) is within 5mm and the side-to-side tilt is within 10mm. Figure 3 j0lj60010 Initial Issue General Procedures 08/2012 6.1.7, 6.1.8 WorkCentre 5021/5019...
Page 279 CPS: 3.0 W or less 3.0 W or less (20cpm) (18cpm) Plug-in Off mode 0.5 W of less 6.1.10.3 TEC method Table 3 Configuration TEC (KWh/week) CP 20ppm CP 18ppm General Procedures Initial Issue 08/2012 6.1.9, 6.1.10 6-10 WorkCentre 5021/5019...
Page 280 Plug-in Off Mode *4 Power (BA Std) (W) Power (Catalog) Power (W)*1 *3 Power (ErP Std) Power (W)*3 18PPM CPS Platen/Simp (230V) 20PPM CPS DADF/Dup (230V) 18PPM CPS Platen/Simp (115V) 20PPM CPSDADF/Dup (115V) Initial Issue General Procedures 08/2012 6.1.11 WorkCentre 5021/5019 6-11...
Page 281 *2: Full System Configuaration: DADF + IIT + IOT + Duplex + STM • *3: LwAd: Sound power level at a source. = measured value LwA (1 M/C) + 0.3B • *4: LpAm: Sound pressure level at a bystander position General Procedures Initial Issue 08/2012 6.1.11, 6.1.12 6-12 WorkCentre 5021/5019...
Page 282 1st sheet is efected from Exit. *2: When machine exits Sleep Mode / Low Power Mode after one hour passes from the transi- tion to Sleep Mode / Low Power Mode. Initial Issue General Procedures 08/2012 6.1.13, 6.1.14 WorkCentre 5021/5019 6-13...
Page 283 Tray, and the Tray is inserted again while the Bottom Plate has not dropped, in Reload the remaining paper amount cannot be detected correctly. *: There is no 2 Sided for Plain Reload General Procedures Initial Issue 08/2012 6.1.15, 6.1.16 6-14 WorkCentre 5021/5019...
Page 284 60-63 Plain Normal Paper 64-90 Heavy- Thick Paper 1 91-110 O weight Lightweight Thin Paper 60-63 6.1.17.2 Classifications and Paper Types This is not specified as there is no classification. Initial Issue General Procedures 08/2012 6.1.17, 6.1.18 WorkCentre 5021/5019 6-15...
Page 285 Output Resolution (dpi) 600X600 6.1.19.3 OCT Depth 1bit OCT (Offset Catch Tray) output function not available. IE (Black Text only) None 6.1.19.4 Side Tray Side Tray output function not available. General Procedures Initial Issue 08/2012 6.1.19, 6.1.20 6-16 WorkCentre 5021/5019...
Page 286 If the paper ran out when printing/copying is in progress, this will select another Tray that contains paper with the same size and orientation as the last printed/copied paper and continue with the copying/printing. Initial Issue General Procedures 08/2012 6.1.21, 6.1.22 WorkCentre 5021/5019 6-17...
Page 287 Maximum print guaranteed area: 289.0 mm wide x 423.4 mm long However, this print area is fully applied only when the Copy Job and Print Job uses paper with size A3 SEF in width direction or 11x17’ SEF in length direction. General Procedures Initial Issue 08/2012 6.1.23 6-18 WorkCentre 5021/5019...
Page 288 *1: Specified in the state where the center of the document is set correctly. *2: Specified in the state where the Side Guide is set correctly. *3: The User Adjustment Pitch is 0.254 mm. *4: The User Adjustment Pitch is 0.135 mm. Initial Issue General Procedures 08/2012 6.1.24 WorkCentre 5021/5019 6-19...
Page 289 P17 and P13, or the maximum shift of the intersections of the diagonal line E with the various lines and the straight line connecting P8 and P18, whichever is larger. Parallelism [mm] (P10~P12)-(P15~P16) General Procedures Initial Issue 08/2012 6.1.24, 6.1.25 6-20 WorkCentre 5021/5019...
Page 290 3 kinds of document type ('Text'', ''Photo'', ''Text/Photo'') can be select via PC 6.1.26.9 Density adjustment • Print density can be adjusted by gamma correction and threshold choice of binarization. Initial Issue General Procedures 08/2012 6.1.26, 6.1.27 WorkCentre 5021/5019 6-21...
Page 291 (A4 LEF 1 Sided Copy) Size/Weight Width: 540 mm or shorter x Depth: 492 or shorter x Height: 95 mm or shorter 6.3 kg or lighter (TBD) (Counter Balance included) General Procedures Initial Issue 08/2012 6.1.28, 6.1.29 6-22 WorkCentre 5021/5019...
Page 292 Number of counter increments Normal Mode* Large Size Mode Fixed Paper size over 100mm2 Non- fixed paper size Fixed paper size 100mm2 or less *: Factory default setting: Normal Mode Initial Issue General Procedures 08/2012 6.1.28, 6.1.29 WorkCentre 5021/5019 6-23...
Page 293 General Procedures Initial Issue 08/2012 6.1.28, 6.1.29 6-24 WorkCentre 5021/5019...
Page 294 *: 499T 00353 : STUBBY DRIVER should be used when replacing the ROS ASSEMBLY. 6.2.1.2 Service Consumables There are no Service Consumables unique to this model. Whenever special consumables for the machine are required, it will be notified in a separate technical information. Initial Issue General Procedures 08/2012 6.2.1, 6.2.2 WorkCentre 5021/5019 6-25...
Page 295 General Procedures Initial Issue 08/2012 6.2.1, 6.2.2 6-26 WorkCentre 5021/5019...
Page 296 005-222 DOCUMENT TRAY SIZE SENSOR 2 L: Document detected at DOCUMENT TRAY SIZE SENSOR 2 005-224 SACN START H: SCAN START signal ON detected 005-228 APS EXIST L: APS SENSOR detected Initial Issue General Procedures 08/2012 6.3.1.1 WorkCentre 5021/5019 6-27...
Page 297 Component Name Connecter Level Description 062-201 SHEET ABORT Registers a document 062-212 IIT REGI. SENSOR L: IIT REGI SENSOR deactuated 062-240 DADF EXIST H: DADF not installed 062-272 SCAN START Scanning possible General Procedures Initial Issue 08/2012 6.3.1.2 6-28 WorkCentre 5021/5019...
Page 298 L: SW 5 of TRAY 2 PAPER SIZE SWITCH is ON 071-105 REGI. SENSOR L: Paper detected at REGI SENSOR 071-106 FUSING UNIT EXIT SENSOR L: Paper detected at FUSING UNIT EXIT SENSOR Initial Issue General Procedures 08/2012 6.3.1.3 WorkCentre 5021/5019 6-29...
Page 299 General Procedures Initial Issue 08/2012 6.3.1.3 6-30 WorkCentre 5021/5019...
Page 300 L: Turns ON the DOCUMENT READY signal. 005-088 Image Area ON Turns ON the Image Area signal for 5 s. 005-098 TAKEAWAY CLUTCH Turns ON the TAKEAWAY CLUTCH for 3 s. Initial Issue General Procedures 08/2012 6.3.2.1 WorkCentre 5021/5019 6-31...
Page 301 BCR AC DC Bias On Turns ON the AC and DC BCR Bias. 092-001 TONER DISPENSE MOTOR On L: Drives the TONER DISPENSE MOTOR. 094-001 BTR +Bias On Turns ON the BTR positive bias. General Procedures Initial Issue 08/2012 6.3.2.2 6-32 WorkCentre 5021/5019...
Page 302 Table 1 IOT Output Component Check List Chain-Link Component Name Connector Level Description 094-002 BTR -Bias On Turns ON the BTR negative bias. Initial Issue General Procedures 08/2012 6.3.2.3 WorkCentre 5021/5019 6-33...
Page 303 General Procedures Initial Issue 08/2012 6.3.2.3 6-34 WorkCentre 5021/5019...
Page 304 Normal Environment: 490 (210 degrees C) to 761 (145 degrees C) • High Temperature Failure Determination Level: when 292 and lower [270 degrees C and higher] is detected continuously for the specified time. Initial Issue General Procedures 08/2012 6.3.3 WorkCentre 5021/5019 6-35...
Page 305 General Procedures Initial Issue 08/2012 6.3.3 6-36 WorkCentre 5021/5019...
Page 306 To clear the counter, enter the HFSI Counter Read / Clear Mode and above select [Clear] -> [Start] to clear it to '0'. Counts the no. of times the lamp turns ON (including AGOC, LampCheck). Initial Issue General Procedures 08/2012 6.3.4.1 WorkCentre 5021/5019 6-37...
Page 307 343K Cycle This can count up to the maximum of 8,000,000 and the maximum value is retained (Ref 75K PV) until the counter is cleared. [20PPM] 343K Cycle (Ref 80K PV) General Procedures Initial Issue 08/2012 6.3.4.3 6-38 WorkCentre 5021/5019...
Page 308 2) Adjustment Range (when 711-141 value is Default) : +1.5 mm (105 pulse) / -1.5 mm (135 pulse) 3) Adjustment Range (when 711-141 value is 80 to 230) : +5.5 mm (80 pulse) / -12.5 mm (230 pulse) Initial Issue General Procedures 08/2012 6.3.5 WorkCentre 5021/5019 6-39...
Page 309 NVM 1Count: 0.026112 * 40 = 1.044 mm 711-151 Loop Amount Adjustment (Side 2) (x6 Pulse) 0-14 30 Pulse Exit Roll Step: 0.035904 NVM 1Count: 0.035904 * 30 = 1.077 mm General Procedures Initial Issue 08/2012 6.3.5 6-40 WorkCentre 5021/5019...
Page 310 Default Value: 0 ms, +80 ms/-20 ms, 4 ms increments Value at Side 2 (T1 ms) 711-209 Invert Start Time Adjustment Value (T6 ms) 0-25 4 ms Default Value: 0 ms, +80 ms/-20 ms, 4 ms increments Initial Issue General Procedures 08/2012 6.3.5 WorkCentre 5021/5019 6-41...
Page 311 ADF-IIT Combine Adjustment Value Data 15 0-255 Adjustment Value Data 15 sent to IIT during ADF-IIT Combine 711-297 Communication Fail Bypass 0: Communication Fail Bypass OFF 1: Communication Fail Bypass ON General Procedures Initial Issue 08/2012 6.3.5 6-42 WorkCentre 5021/5019...
Page 312 Switches among 8x10 SEF, 8x10.5 SEF, and 8.5x11 SEF. 0: Default 1: 8.5X11S 2: 8X10S 3: 8X10.5S 710-607 Alternate Size Set 7 Switches among 8x10 LEF, 8x10.5 LEF, and 8.5x11 LEF. 0: Default 1: 8.5X11L 2: 8X10L 3: 8X10.5L Initial Issue General Procedures 08/2012 6.3.6 WorkCentre 5021/5019 6-43...
Page 313 Controls whether to perform Fail bypass for the [Configuration Check]. 0: Fail Bypass OFF 1: Fail Bypass ON 715-022 Lamp Fan Fail Bypass Lamp Fan Fail Detection 0: Detects Lamp Fan Fail. 1: Does not detect Lamp Fan Fail. General Procedures Initial Issue 08/2012 6.3.6 6-44 WorkCentre 5021/5019...
Page 314 CVT FS Offset Side 2-5 (214.9~215.9) 0-240 Fast Scan Regi Correction Value (0.1 mm/step) during CVT 'Factory Settings' 715-066 CVT FS Offset Side 1-6 (254-257) 0-240 Fast Scan Regi Correction Value (0.1 mm/step) during CVT 'Factory Settings' Initial Issue General Procedures 08/2012 6.3.6 WorkCentre 5021/5019 6-45...
Page 315 0-240 Fast Scan Regi Correction Value (0.1 mm/step) during CVT 'Factory Settings' 715-087 CVT FS Offset Side 4-7 (266.7-267) 0-240 Fast Scan Regi Correction Value (0.1 mm/step) during CVT 'Factory Settings' General Procedures Initial Issue 08/2012 6.3.6 6-46 WorkCentre 5021/5019...
Page 316 0-1023 Data obtained when Lamp Check fails (Blank scan data of G compared at checking) 715-418 AOC Flow Abnormal End Count 0-255 No. of times the AOC flow has ended abnormally Initial Issue General Procedures 08/2012 6.3.6 WorkCentre 5021/5019 6-47...
Page 317 General Procedures Initial Issue 08/2012 6.3.6 6-48 WorkCentre 5021/5019...
Page 318 Table 1 NVM DIAG Setting Setting Range Range (Minimum (Maximum Write Initialization Chain-Link NVM Name Value) Value) Default Value Yes/No Yes/No Description 740-001 DIAG_TONE_UP_DOWN_JOB_VOLUME Enable Enable Diagnostic Tone Up/Down job volume (Unit: 1 sheet) Initial Issue General Procedures 08/2012 6.3.7 WorkCentre 5021/5019 6-49...
Page 319 General Procedures Initial Issue 08/2012 6.3.7 6-50 WorkCentre 5021/5019...
Page 320 1: Deodorant Filter available 741-032 NOHAD_FAN_FAIL_START_TIMER Enable Enable The time where Fail Detection is prohibited after the Fan operation. (Unit: 1 s) 741-033 NOHAD_FAN_FAIL_SUMPLE_TIME_THRESHOLD Enable Enable Fan Fail Signal Accumulated Time (Unit: 1 s) Initial Issue General Procedures 08/2012 6.3.8 WorkCentre 5021/5019 6-51...
Page 321 Fail Accumulated Time, it will be judged as a Fail. (Unit: times) 741-035 NOHAD_FAN_FAIL_BYPASS Enable Enable FAN Fail Bypass 0: Bypass OFF 1: Bypass ON General Procedures Initial Issue 08/2012 6.3.8 6-52 WorkCentre 5021/5019...
Page 322 ROS Write Position (All) ALL_TRAY (0.169 mm increments) 742-042 PH_ROS_LASER_SIDE_REGI_ADJUSTMENT_ Enable Enable ROS Write Position (Tray 1) TRAY1 (0.169 mm increments) 742-043 PH_ROS_LASER_SIDE_REGI_ADJUSTMENT_ Enable Enable ROS Write Position (Tray 2) TRAY2 (0.169 mm increments) Initial Issue General Procedures 08/2012 6.3.9 WorkCentre 5021/5019 6-53...
Page 323 ROS Write Position (Dup-Tray 1) DUP_TRAY1 (0.169 mm increments) 742-047 PH_ROS_LASER_SIDE_REGI_ADJUSTMENT_ Enable Enable ROS Write Position (Dup-Tray 2) DUP_TRAY2 (0.169 mm increments) 742-048 PH_ROS_LASER_SIDE_REGI_ADJUSTMENT_ Enable Enable ROS Write Position (Dup-MSI) DUP_MSI (0.169 mm increments) General Procedures Initial Issue 08/2012 6.3.9 6-54 WorkCentre 5021/5019...
Page 324 The Overheat Temp Fail has occurred. 744-056 Fusing_U41_HISTORY Enable Enable Types of Fusing On Time Fail occurence: 0: Has not occurred1: U4-1 Control 12: U4-1 Control 23: U4-1 Con- trol 34: U4-1 Control 4 Initial Issue General Procedures 08/2012 6.3.10 WorkCentre 5021/5019 6-55...
Page 325 General Procedures Initial Issue 08/2012 6.3.10 6-56 WorkCentre 5021/5019...
Page 326 (Unit: %) 745-104 XERO_BTR_NET_OUTPUT_SIDE1_BIAS Enable Enable Stores the BTR Final Output (for Side 1) (Unit: 0.1 MicroAmp) 745-105 XERO_BTR_NET_OUTPUT_SIDE2_BIAS Enable Enable Stores the BTR Final Output (for Side 2) (Unit: 0.1 MicroAmp) Initial Issue General Procedures 08/2012 6.3.11 WorkCentre 5021/5019 6-57...
Page 327 General Procedures Initial Issue 08/2012 6.3.11 6-58 WorkCentre 5021/5019...
Page 328 (Unit: 100 cycle) 750-052 XERO_DRUM_PRE_NEAR_PV_DATA 65535 Enable Enable PV When Pre Near Occurs (Unit: 100 sheet) 750-053 XERO_DRUM_PRE_NEAR_TICK_DATA 5000 Enable Enable Remaining Film Thickness When Pre Near Occurs (Unit: 0.01 Micrometer) Initial Issue General Procedures 08/2012 6.3.12 WorkCentre 5021/5019 6-59...
Page 329 (Unit: 100 cycle) 750-058 XERO_DRUM_LIFE_END_PV_DATA 65535 Enable Enable PV When Life End Occurs (Unit: 100 sheet) 750-059 XERO_DRUM_LIFE_END_TICK_DATA 5000 Enable Enable Remaining Film Thickness When Life End Occurs (Unit: 0.01 Micrometer) General Procedures Initial Issue 08/2012 6.3.12 6-60 WorkCentre 5021/5019...
Page 330 The timeout time during priority start up. This may shorten the lifespan of the ROS. (Unit: 1 s) 749-002 ROS_MOTOR_JOB_END_AUTO_STOP_TIME Enable Enable ROS Motor Stop Delay This may shorten the lifespan of the ROS. (Unit: 1 s) Initial Issue General Procedures 08/2012 6.3.13 WorkCentre 5021/5019 6-61...
Page 331 General Procedures Initial Issue 08/2012 6.3.13 6-62 WorkCentre 5021/5019...
Page 332 752-086 PRC_TEMP_SNR_FAIL Enable Enable Temperature Sensor Fail 0: Normal 1: Fail 752-087 PRC_TEMP_SNR_FAIL_CNT 65535 Enable Enable Temperature Sensor Fail Count 752-094 PRC_MAX_TEMP Enable Enable Maximum temperature value (Unit: 1 degrees C) Initial Issue General Procedures 08/2012 6.3.14 WorkCentre 5021/5019 6-63...
Page 333 1: Empty detection count in progress 2: NearEmpty 3: Empty 752-402 PRC_ATC_EMPTY_CHECK_STATE1_CNT 65535 Enable Enable ATC empty detection state 1 count 752-403 PRC_BUFFER_EMPTY_CHECK_CNT -30000 30000 Enable Enable Buffer empty detection count General Procedures Initial Issue 08/2012 6.3.14 6-64 WorkCentre 5021/5019...
Page 334 The actual temperature 752-557 PRC_RECOERY_RETRY_CNT Enable Enable Recovery retry count 752-750 PRC_DELTA_VH_PR2 -1000 1000 Enable Enable Delta VHpr2 752-765 PRC_DELTA_VB_PR -255 Enable Enable Delta VBpr 752-766 PRC_DELTA_VB -255 Enable Enable Delta VB Initial Issue General Procedures 08/2012 6.3.14 WorkCentre 5021/5019 6-65...
Page 335 General Procedures Initial Issue 08/2012 6.3.14 6-66 WorkCentre 5021/5019...
Page 336 Chain-Link NVM Name Value) Value) Value Yes/No Yes/No Description 767-082 CRUM_MODE Disable Disable Stores the CRUM control status. 767-083 CRUM_MODE_SWITCH Enable Enable Switch for changing 3rd Party Mode to Xerox Mode Initial Issue General Procedures 08/2012 6.3.15 WorkCentre 5021/5019 6-67...
Page 337 General Procedures Initial Issue 08/2012 6.3.15 6-68 WorkCentre 5021/5019...
Page 338 27: UTC +09:00, 28: UTC +09:30, 29: UTC +10:00 30: UTC +11:00, 31: UTC +12:00, 32: UTC +13:00 700-122 DATE_FORMAT 0: YYMMDD 1: MMDDYY 2: DDMMYY 700-123 TIME_FORMAT 0: 12h 1: 24h Initial Issue General Procedures 08/2012 6.3.16 WorkCentre 5021/5019 6-69...
Page 339 1: Count as Large Size (2 counts) 780-009 IOT_TRAY1_PAPER_SIZE 1: 11x17S (For PAPER_CLASS = XC) 2: A3S 5: B4S 6: 8.5x14S 7: 8.5x13S 9: A4S 10: 8.5x11S 14: B5S 16: 8.5x11L 18: A4L 23: B5L General Procedures Initial Issue 08/2012 6.3.16 6-70 WorkCentre 5021/5019...
Page 340 20: 16K(GCO)L 23: B5L 780-009 (For PAPER_CLASS = XE/DMO-E) 1: 11x17S 2: A3S 5: B4S 6: 8.5x14S 7: 8.5x13S 9: A4S 10: 8.5x11S 14: B5S 16: 8.5x11L 18: A4L 23: B5L Initial Issue General Procedures 08/2012 6.3.16 WorkCentre 5021/5019 6-71...
Page 341 (For PAPER_CLASS = AP/GCO) 1: 11x17S 2: A3S 3: 8K(GCO)S 5: B4S 6: 8.5x14S 7: 8.5x13S 9: A4S 10: 8.5x11S 11: 16K(GCO)S 14: B5S 16: 8.5x11L 18: A4L 20: 16K(GCO)L 23: B5L General Procedures Initial Issue 08/2012 6.3.16 6-72 WorkCentre 5021/5019...
Page 342 780-017 (For PAPER_CLASS = DMO-W) 1: 11x17S 2: A3S 5: B4S 6: 8.5x14S 7: 8.5x13S 9: A4S 10: 8.5x11S 14: B5S 16: 8.5x11L 18: A4L 19: A5S 23: B5L 56: 8.5x13.4S Initial Issue General Procedures 08/2012 6.3.16 WorkCentre 5021/5019 6-73...
Page 343 2: Display only when the Auto Reset Timer had timed-out 790-004 UIPANEL_TONER_ALERT 0: Do not display 1: Display only after the power had been turned OFF and ON 2: Display only when the Auto Reset Timer had timed-out General Procedures Initial Issue 08/2012 6.3.16 6-74 WorkCentre 5021/5019...
Page 344 Shadow Suppression Level for Full Color Scan. EVEL 0: Lower -2 1: Lower -1 2: Normal 3: Higher +1 4: Higher +2 680-409 IPS_CL_BALANCE_DEF_K_LOW_DENSITY Default Color Balance Adjustment Level K Color Low Density Initial Issue General Procedures 08/2012 6.3.17 WorkCentre 5021/5019 6-75...
Page 345 The section B negative is specified with 2 complements. 680-422 IPS_FULL_COLOR_SCAN_SATURATION_A Saturation Adjustment for Full Color Scan. DJUSTMENT 0: Pastel +2 1: Pastel +1 2: Normal 3: Vivid +1 4: Vivid +2 General Procedures Initial Issue 08/2012 6.3.17 6-76 WorkCentre 5021/5019...
Page 346 4: More Contrast +2 680-424 IPS_COLOR_SPACE Color Space 0: Standard Color Space 1: Device Color Space 680-425 IPS_IMAGE_ENHANCE_FOR_COPY_ The binarization image processing method at Photo Mode of PHOTO_MODE Copy. 0: Error Diffusion 1: Dither Initial Issue General Procedures 08/2012 6.3.17 WorkCentre 5021/5019 6-77...
Page 347 General Procedures Initial Issue 08/2012 6.3.17 6-78 WorkCentre 5021/5019...
Page 348 COPYJOB_PRESET_MAGNIFICATION 3010 (For PAPER_CLASS = DMO-W) 790-060 COPYJOB_PRESET_MAGNIFICATION 3010 (For PAPER_CLASS = AP/GCO) 790-060 COPYJOB_PRESET_MAGNIFICATION 3010 (For PAPER_CLASS = XE/DMO-E) 790-070 COPYJOB_DEFAULT_TRAY 3000 0: APS 1: Tray1 2: STM 5: MSI Initial Issue General Procedures 08/2012 6.3.18 WorkCentre 5021/5019 6-79...
Page 349 (For PAPER_CLASS = XC) 2: A3S 5: B4S 6: 8.5x14S 7: 8.5x13S 9: A4S 10: 8.5x11S 14: B5S 16: 8.5x11L 17: 5.5x8.5S 18: A4L 19: A5S 23: B5L 134: Deemed Document Size General Procedures Initial Issue 08/2012 6.3.18 6-80 WorkCentre 5021/5019...
Page 350 1: 11x17S (For PAPER_CLASS = XE/DMO-E) 2: A3S 5: B4S 6: 8.5x14S 7: 8.5x13S 9: A4S 10: 8.5x11S 14: B5S 16: 8.5x11L 18: A4L 19: A5S 23: B5L 134: Deemed Document Size Initial Issue General Procedures 08/2012 6.3.18 WorkCentre 5021/5019 6-81...
Page 351 4: Sharpen +2 840-023 SCANJOB_DEFAULT_AE_LEVEL 4002 0: Level 1 1: Level 2 2: Level 3 3: Level 4 4: Level 5 870-200 DIAG_TEST_PRINT_INPUT_TRAY 1: Tray 1 2: STM 5: MSI 870-202 DIAG_TEST_PRINT_JOB_VOLUMN Quantity General Procedures Initial Issue 08/2012 6.3.18 6-82 WorkCentre 5021/5019...
Page 352 Range Tools (Minimum (Maximum Scan Default Value Chain-Link NVM Name Value) Value) Default Value Yes/No Yes/No Description 700-540 COPY_ACCOUNT_MODE 0: Account Free Mode 1: Single Account Mode 2: Multi Account Mode Initial Issue General Procedures 08/2012 6.3.19 WorkCentre 5021/5019 6-83...
Page 353 General Procedures Initial Issue 08/2012 6.3.19 6-84 WorkCentre 5021/5019...
Page 354 999-999 NVM Initialize-All Area Same as above 999-980 Maintenance Report • Refer to [6.4.2.7 Maintenance Report]. 999-970 DATA All Delete Initializes the Job History • Refer to [6.4.2.1.2 Data All Delete]. Initial Issue General Procedures 08/2012 6.3.20 WorkCentre 5021/5019 6-85...
Page 355 General Procedures Initial Issue 08/2012 6.3.20 6-86 WorkCentre 5021/5019...
Page 356 The [Chain-Link Number Entry] screen will appear. 11. DRUM Counter Reset 12. ATC Sensor Read 13. Tone Up/Down • Tone Up • Tone Down 14. Test Pattern Print 15. Checking and Repairing the Billing Counter (621-400) Initial Issue General Procedures 08/2012 6.4.1.1 WorkCentre 5021/5019 6-87...
Page 357 CE Diag Mode. Exiting from the CE Diag Mode will automatically reboot the machine. Figure 2 j0lj64002 Input the Chain-Link Number in the [Chain-Link Number Entry] screen to perform the var- ious Diagnostics. General Procedures Initial Issue 08/2012 6.4.1.3 6-88 WorkCentre 5021/5019...
Page 358 Initial Issue General Procedures 08/2012 6.4.1.3 WorkCentre 5021/5019 6-89...
Page 359 General Procedures Initial Issue 08/2012 6.4.1.3 6-90 WorkCentre 5021/5019...
Page 360 Pressing the [Clear All] button returns you to the [Chain-Link Number Entry] screen. Figure 1 j0lj64003 Pressing the [Start] button starts the initialization of the [Fault History]. • An animation will be displayed to indicate that it is in progress. Initial Issue General Procedures 08/2012 6.4.2.1.1 WorkCentre 5021/5019 6-91...
Page 361 Pressing the [Clear All] button returns you to the [Chain-Link Number Entry] screen. Figure 1 j0lj64003 Pressing the [Start] button starts the initialization of the [DATA All Delete]. • An animation will be displayed to indicate that it is in progress. General Procedures Initial Issue 08/2012 6.4.2.1.2 6-92 WorkCentre 5021/5019...
Page 362 (1) Pressing the [Start] button when an NVM Read value is being displayed causes the currently displayed setting value to disappear and displays the cursor for inputting the setting value that it is to be changed to. Initial Issue General Procedures 08/2012 6.4.2.2 WorkCentre 5021/5019 6-93...
Page 363 Pressing the [Clear All] button returns you to the [Chain-Link Number Entry] screen. Figure 1 j0lj64011 • For the analog value of 1000 to 1099, only the lower 3 digits are displayed. – Example.: 1099 is displayed as '099'. General Procedures Initial Issue 08/2012 6.4.2.3 6-94 WorkCentre 5021/5019...
Page 364 Pressing the [Clear All] button returns you to the [Chain-Link Number Entry] screen. Figure 1 j0lj64003 Pressing the [Start] button starts the initialization of the [NVM]. • An animation will be displayed to indicate that it is in progress. Initial Issue General Procedures 08/2012 6.4.2.4, 6.4.2.5 WorkCentre 5021/5019 6-95...
Page 365 Input the Chain-Link No. and press the [Start] button. • When an Output Component is in operation, an animation will be displayed to indi- cate that it is in progress. General Procedures Initial Issue 08/2012 6.4.2.5, 6.4.2.6 6-96 WorkCentre 5021/5019...
Page 366 Figure 1 j0lj64012 After the last output or when the [Stop] button is pressed, [End] will be displayed. Pressing the [Clear All] button returns you to the [Chain-Link Number Entry] screen. Initial Issue General Procedures 08/2012 6.4.2.6, 6.4.2.7 WorkCentre 5021/5019 6-97...
Page 367 Pressing the [Clear All] button returns you to the [Chain-Link Number Entry] screen. Figure 1 j0lj64003 Pressing the [Start] button starts the clearing of all [HFSI Counter]. • An animation will be displayed to indicate that it is in progress. General Procedures Initial Issue 08/2012 6.4.2.8 6-98 WorkCentre 5021/5019...
Page 368 Pressing the [Clear All] button returns you to the [Chain-Link Number Entry] screen. Figure 1 j0lj64003 Pressing the [Start] button starts the clearing of all [Jam Counter]. • An animation will be displayed to indicate that it is in progress. Initial Issue General Procedures 08/2012 6.4.2.9, 6.4.2.10 WorkCentre 5021/5019 6-99...
Page 369 Figure 1 j0lj64003 Pressing the [Start] button starts the reset of the [Drum Counter]. • An animation will be displayed to indicate that it is in progress. Figure 2 j0lj64004 General Procedures Initial Issue 08/2012 6.4.2.10, 6.4.2.11 6-100 WorkCentre 5021/5019...
Page 370 Pressing the [Start] button computes the TC Correction Target Value and computes the ATC Average Value after the Xero/Deve ERU drive has started. At this time, an animation will be displayed to indicate that it is in progress. Initial Issue General Procedures 08/2012 6.4.2.11, 6.4.2.12 WorkCentre 5021/5019 6-101...
Page 371 Pressing the [Original Size] button will display the ATC Average Value and the ATC Correction Target Value alternately on the UI. – ATC Correction Target Value Figure 3 j0lj64010 – ATC Average Value General Procedures Initial Issue 08/2012 6.4.2.12 6-102 WorkCentre 5021/5019...
Page 372 Pressing the [Start] button displays the animation to indicate that it is in progress. It will count up after each blank paper that is output. The machine will output the specified number of solid black printouts to lighten the toner density. Initial Issue General Procedures 08/2012 6.4.2.13 WorkCentre 5021/5019 6-103...
Page 373 NOTE: The Quantity can be specified up to 2 digits, with the maximum of 99. Pressing the [Start] button outputs the test pattern. An animation will be displayed to indi- cate that it is being output. Figure 1 j0lj64012 General Procedures Initial Issue 08/2012 6.4.2.13, 6.4.2.14 6-104 WorkCentre 5021/5019...
Page 374 Restores the data from the External (Master) EEP ROM to the Mounted (Backup) EEP ROM NVM Restore Restores the data from the Mounted (Backup) EEP ROM to the External (Master) EEP ROM Initial Issue General Procedures 08/2012 6.4.2.14, 6.4.2.15 WorkCentre 5021/5019 6-105...
Page 375 Pressing the [Start] button displays the animation to indicate that it is in progress. Figure 2 j0lj64009 Pressing the [Clear All] button returns you to the [Chain-Link Number Entry] screen. General Procedures Initial Issue 08/2012 6.4.2.15 6-106 WorkCentre 5021/5019...
Page 376 Unable to perform the function as the parts that are the target for the Diag are malfunctioning, etc. READ TEMPERTURE Err E-4 Unable to perform the function as the parts that are the target for the Diag are malfunctioning, etc. Initial Issue General Procedures 08/2012 6.4.3 WorkCentre 5021/5019 6-107...
Page 377 General Procedures Initial Issue 08/2012 6.4.3 6-108 WorkCentre 5021/5019...
Page 378 3: XE/DMO-E (EU) 4: AP/GCO (AP) 5: DMO-W (SA (South America)) Locale Information: Paper Size Group 2: XC (NA (North America)) (WC 5021/5019) 3: XE/DMO-E (EU) 4: AP/GCO (AP) 5: DMO-W (SA (South America)) Initial Issue General Procedures 08/2012 WorkCentre 5021/5019 6-109...
Page 379 0: Plain 2: Heavyweight 5: Lightweight Reset Copy Count for All User in Multi Account Mode 0: Do not do anything 1: Clear the Copy Counter for All User in Multi Account Mode General Procedures Initial Issue 08/2012 6-110 WorkCentre 5021/5019...
Page 380 UI Panel Firmware Version 0.0.0 255.255.255 DADF Firmware Version 0.0.0 255.255.255 3000 Copy Job: UI Default Settings: 0~2, 5 0: APS Default Tray Setting in Copy Mode 1: Tray1 2: STM 5: MSI Initial Issue General Procedures 08/2012 WorkCentre 5021/5019 6-111...
Page 381 (For PAPER_CLASS = XC) 16~19, 23, 5: B4S 6: 8.5x14S 7: 8.5x13S 9: A4S 10: 8.5x11S 14: B5S 16: 8.5x11L 17: 5.5x8.5S 18: A4L 19: A5S 23: B5L 134: Deemed Document Size General Procedures Initial Issue 08/2012 6-112 WorkCentre 5021/5019...
Page 382 14: B5S 16: 8.5x11L 18: A4L 19: A5S 23: B5L 134: Deemed Document Size 3009 Copy Job: UI Default Settings: 0: S/S Duplex Feature Default Setting 1: S/D 2: D/S 3: D/D Initial Issue General Procedures 08/2012 WorkCentre 5021/5019 6-113...
Page 383 Completed Copy Impressions for User 3 in Multi Account Mode 0 10000 7005 Completed Copy Impressions for User 4 in Multi Account Mode 0 10000 7006 Completed Copy Impressions for User 5 in Multi Account Mode 0 10000 General Procedures Initial Issue 08/2012 6-114 WorkCentre 5021/5019...
Page 384 Completed Copy Impressions for User 8 in Multi Account Mode 0 10000 7010 Completed Copy Impressions for User 9 in Multi Account Mode 0 10000 7011 Completed Copy Impressions for User 10 in Multi Account 10000 Mode Initial Issue General Procedures 08/2012 WorkCentre 5021/5019 6-115...
Page 385 Chain 2 Mode Selection CH2.1 Control Panel ...................... 7-39 Chain 3 Machine Run Control CH3.1 PWB Communication (ESS/MCU-IIT and ESS/MCU-DADF) ......7-41 CH3.2 PWB Communication (ESS/MCU-STM and ESS/MCU-NET) ......7-42 CH3.3 Electric Billing...................... 7-43 Initial Issue Wiring Data 08/2012 WorkCentre 5021/5019...
Page 386 ESS/MCU PWB (to Nohad Fan) P/J220C Tray 2 Feed/Lift Up Motor (1TM) P/J400 ESS/MCU PWB P/J401 ESS/MCU PWB P/J402 ESS/MCU PWB P/J403 ESS/MCU PWB P/J405 ESS/MCU PWB P/J406 ESS/MCU PWB P/J407 ESS/MCU PWB Initial Issue Wiring Data 08/2012 7.1.1 WorkCentre 5021/5019...
Page 387 IIT Regi. Sensor P/J721 Carriage Motor P/J740 UI PWB P/J751 DADF PWB P/J752 DADF PWB P/J753 DADF PWB P/J754 DADF PWB P/J756 DADF PWB (to Exit Nip Release Solenoid) P/J758 DADF PWB Wiring Data Initial Issue 08/2012 7.1.1 WorkCentre 5021/5019...
Page 388: Plug/Jack Location
7.1.2 Plug/Jack Location Figure 2 DADF 2 of 2 (j0yg71002) Figure 1 DADF 1 of 2 (j0lj71001) Initial Issue Wiring Data 08/2012 7.1.2 WorkCentre 5021/5019...
Page 389 Figure 3 IIT / UI (j0lj71003) Figure 4 L/H Unit / MSI / Fusing Unit (j0lj71004) Wiring Data Initial Issue 08/2012 7.1.2 WorkCentre 5021/5019...
Page 390 Figure 5 ROS Unit / DRUM Cartridge (j0yg71005) Figure 6 ESS/MCU PWB (j0yg71006) Initial Issue Wiring Data 08/2012 7.1.2 WorkCentre 5021/5019...
Page 391 Figure 7 Rear Location 1 of 2/Net I/F PWB (Option) (j0yg71007) Figure 8 Rear Location 2 of 2 (j0lj71008) Wiring Data Initial Issue 08/2012 7.1.2 WorkCentre 5021/5019...
Page 392 Figure 9 1TM 1 of 2 (j0lj71009) Figure 10 1TM 2 of 2 (j0lj71010) Initial Issue Wiring Data 08/2012 7.1.2 WorkCentre 5021/5019...
Page 393 Wiring Data Initial Issue 08/2012 7.1.2 7-10 WorkCentre 5021/5019...
Page 394: Ach
7.2.1.1 ACH Figure 1 j0yg720101 Initial Issue Wiring Data 08/2012 7.2.1.1 WorkCentre 5021/5019 7-11...
Page 395: Acn
7.2.1.2 ACN Figure 1 j0yg720102 Wiring Data Initial Issue 08/2012 7.2.1.2 7-12 WorkCentre 5021/5019...
Page 396: Vdc/+3.3Vdc
7.2.1.3 +2.5VDC/+3.3VDC Figure 1 j0yg720103 Initial Issue Wiring Data 08/2012 7.2.1.3 WorkCentre 5021/5019 7-13...
Page 397: 5Vdc-1
7.2.1.4 +5VDC-1 Figure 1 j0yg720104 Wiring Data Initial Issue 08/2012 7.2.1.4 7-14 WorkCentre 5021/5019...
Page 398: 5Vdc-2
7.2.1.5 +5VDC-2 Figure 1 j0yg720105 Initial Issue Wiring Data 08/2012 7.2.1.5 WorkCentre 5021/5019 7-15...
Page 399: Rtn-1
7.2.1.6 5V RTN-1 Figure 1 j0yg720106 Wiring Data Initial Issue 08/2012 7.2.1.6 7-16 WorkCentre 5021/5019...
Page 400: Rtn-2
7.2.1.7 5V RTN-2 Figure 1 j0yg720107 Initial Issue Wiring Data 08/2012 7.2.1.7 WorkCentre 5021/5019 7-17...
Page 401: 24Vdc-1
7.2.1.8 +24VDC-1 Figure 1 j0yg720108 Wiring Data Initial Issue 08/2012 7.2.1.8 7-18 WorkCentre 5021/5019...
Page 402: 24Vdc-2
7.2.1.9 +24VDC-2 Figure 1 j0yg720109 Initial Issue Wiring Data 08/2012 7.2.1.9 WorkCentre 5021/5019 7-19...
Page 403: Rtn
7.2.1.10 24V RTN Figure 1 j0yg720110 Wiring Data Initial Issue 08/2012 7.2.1.10 7-20 WorkCentre 5021/5019...
Page 404: Iit +3.3Vdc/+5Vdc/+24Vdc
7.2.1.11 IIT +3.3VDC/+5VDC/+24VDC Figure 1 j0yg720111 Initial Issue Wiring Data 08/2012 7.2.1.11 WorkCentre 5021/5019 7-21...
Page 405: Iit 3.3V/5V/24V Rtn
7.2.1.12 IIT 3.3V/5V/24V RTN Figure 1 j0yg720112 Wiring Data Initial Issue 08/2012 7.2.1.12 7-22 WorkCentre 5021/5019...
Page 406: Dadf +5Vdc
7.2.56.1 DADF +5VDC Figure 1 j0yg725601 Initial Issue Wiring Data 08/2012 7.2.56.1 WorkCentre 5021/5019 7-23...
Page 407: Dadf 5V Rtn
7.2.56.2 DADF 5V RTN Figure 1 j0yg725602 Wiring Data Initial Issue 08/2012 7.2.56.2 7-24 WorkCentre 5021/5019...
Page 408: Dadf +24Vdc
7.2.56.3 DADF +24VDC Figure 1 j0yg725603 Initial Issue Wiring Data 08/2012 7.2.56.3 WorkCentre 5021/5019 7-25...
Page 409: Dadf 24V Rtn
7.2.56.4 DADF 24V RTN Figure 1 j0yg725604 Wiring Data Initial Issue 08/2012 7.2.56.4 7-26 WorkCentre 5021/5019...
Page 410: How To Use Bsds
This symbol is used to show where the input into the functions comes from. This example shows the input comes from the Group Functions in Chain 1-3. Figure 6 9055 Initial Issue Wiring Data 08/2012 1., 2. WorkCentre 5021/5019 7-27...
Page 411 (shown at lower right of the BSD).This example shows direction in which the signal runs. the location the signal line starts from is marked in Zone (H-4) in CH8.5. Figure 13 9046 Figure 20 9038 Wiring Data Initial Issue 08/2012 7-28 WorkCentre 5021/5019...
Page 412 Figure 26 9066 Figure 33 9074 This symbol shows the fasten is used for connection. This symbol shows switch and is also used as Interlock Switch. Figure 27 9028 Figure 34 9075 Initial Issue Wiring Data 08/2012 2., 3. WorkCentre 5021/5019 7-29...
Page 413: Signal Name
Figure 2 9073 The example indicates that when the component is ON, the signal level is (L) and that when it is OFF, the signal level is (H) with the voltage +24VDC. Wiring Data Initial Issue 08/2012 2., 3. 7-30 WorkCentre 5021/5019...
Page 414: Dc Voltage
YELLOW GREEN BLUE VIOLET GRAY WHITE BLACK GN/YL GREEN/YELLOW PINK Figures on the BSDs The grayed-out portion of the figure shows the path from Motoror Solenoid to parts to drive. Initial Issue Wiring Data 08/2012 4., 5. WorkCentre 5021/5019 7-31...
Page 415 Wiring Data Initial Issue 08/2012 4., 5. 7-32 WorkCentre 5021/5019...
Page 416: Ch1.1 Main Power On And M/C Power Control
CH1.1 Main Power On and M/C Power Control Figure 1 j0yg730101 Initial Issue Wiring Data 08/2012 CH1.1 WorkCentre 5021/5019 7-33...
Page 417: Ch1.2 Dc Power Generation (+5Vdc)
CH1.2 DC Power Generation (+5VDC) Figure 1 j0yg730102 Wiring Data Initial Issue 08/2012 CH1.2 7-34 WorkCentre 5021/5019...
Page 418: Ch1.3 Dc Power Generation (+24Vdc)
CH1.3 DC Power Generation (+24VDC) Figure 1 j0yg730103 Initial Issue Wiring Data 08/2012 CH1.3 WorkCentre 5021/5019 7-35...
Page 419: Ch1.4 Iit/Dadf Dc Power Distribution
CH1.4 IIT/DADF DC Power Distribution Figure 1 j0yg730104 Wiring Data Initial Issue 08/2012 CH1.4 7-36 WorkCentre 5021/5019...
Page 420: Ch1.5 Power Interlock Switching (1 Of 2)
CH1.5 Power Interlock Switching (1 of 2) Figure 1 j0yg730105 Initial Issue Wiring Data 08/2012 CH1.5 WorkCentre 5021/5019 7-37...
Page 421: Ch1.6 Power Interlock Switching (2 Of 2)
CH1.6 Power Interlock Switching (2 of 2) Figure 1 j0yg730106 Wiring Data Initial Issue 08/2012 CH1.6 7-38 WorkCentre 5021/5019...
Page 422: Ch2.1 Control Panel
CH2.1 Control Panel Figure 1 j0yg730201 Initial Issue Wiring Data 08/2012 CH2.1 WorkCentre 5021/5019 7-39...
Page 423 Wiring Data Initial Issue 08/2012 CH2.1 7-40 WorkCentre 5021/5019...
Page 424: Ch3.1 Pwb Communication (Ess/Mcu-Iit And Ess/Mcu-Dadf)
CH3.1 PWB Communication (ESS/MCU-IIT and ESS/MCU- DADF) Figure 1 j0yg730301 Initial Issue Wiring Data 08/2012 CH3.1 WorkCentre 5021/5019 7-41...
Page 425: Ch3.2 Pwb Communication (Ess/Mcu-Stm And Ess/Mcu-Net)
CH3.2 PWB Communication (ESS/MCU-STM and ESS/ MCU-NET) Figure 1 j0yg730302 Wiring Data Initial Issue 08/2012 CH3.2 7-42 WorkCentre 5021/5019...
Page 426: Ch3.3 Electric Billing
CH3.3 Electric Billing Figure 1 j0yg730303 Initial Issue Wiring Data 08/2012 CH3.3 WorkCentre 5021/5019 7-43...
Page 427 Wiring Data Initial Issue 08/2012 CH3.3 7-44 WorkCentre 5021/5019...
Page 428: Ch4.1 Main Drive Control
CH4.1 Main Drive Control Figure 1 j0yg730401 Initial Issue Wiring Data 08/2012 CH4.1 WorkCentre 5021/5019 7-45...
Page 429 Wiring Data Initial Issue 08/2012 CH4.1 7-46 WorkCentre 5021/5019...
Page 430: Ch5.1 Dadf Interlock And Document Setting
CH5.1 DADF Interlock and Document Setting Figure 1 j0yg730501 Initial Issue Wiring Data 08/2012 CH5.1 WorkCentre 5021/5019 7-47...
Page 431: Ch5.2 Document Size Sensing (1 Of 2)
CH5.2 Document Size Sensing (1 of 2) Figure 1 j0yg730502 Wiring Data Initial Issue 08/2012 CH5.2 7-48 WorkCentre 5021/5019...
Page 432: Ch5.3 Document Size Sensing (2 Of 2)
CH5.3 Document Size Sensing (2 of 2) Figure 1 j0yg730503 Initial Issue Wiring Data 08/2012 CH5.3 WorkCentre 5021/5019 7-49...
Page 433: Ch5.4 Document Feeding
CH5.4 Document Feeding Figure 1 j0yg730504 Wiring Data Initial Issue 08/2012 CH5.4 7-50 WorkCentre 5021/5019...
Page 434: Ch5.5 Document Scan, Invert And Exit Transportation
CH5.5 Document Scan, Invert and Exit Transportation Figure 1 j0yg730505 Initial Issue Wiring Data 08/2012 CH5.5 WorkCentre 5021/5019 7-51...
Page 435: Ch5.6 Document Path
CH5.6 Document Path Figure 1 j0yg730506 Wiring Data Initial Issue 08/2012 CH5.6 7-52 WorkCentre 5021/5019...
Page 436: Ch5.7 Document Transmission
CH5.7 Document Transmission Figure 1 j0yg730507 Initial Issue Wiring Data 08/2012 CH5.7 WorkCentre 5021/5019 7-53...
Page 437 Wiring Data Initial Issue 08/2012 CH5.7 7-54 WorkCentre 5021/5019...
Page 438: Ch6.1 Document Illumination
CH6.1 Document Illumination Figure 1 j0yg730601 Initial Issue Wiring Data 08/2012 CH6.1 WorkCentre 5021/5019 7-55...
Page 439: Ch6.2 Carriage Control
CH6.2 Carriage Control Figure 1 j0yg730602 Wiring Data Initial Issue 08/2012 CH6.2 7-56 WorkCentre 5021/5019...
Page 440: Ch6.3 Image Input
CH6.3 Image Input Figure 1 j0yg730603 Initial Issue Wiring Data 08/2012 CH6.3 WorkCentre 5021/5019 7-57...
Page 441: Ch6.4 Laser Control
CH6.4 Laser Control Figure 1 j0yg730604 Wiring Data Initial Issue 08/2012 CH6.4 7-58 WorkCentre 5021/5019...
Page 442: Ch7.1 Tray 2 Sensing (1Tm)
CH7.1 Tray 2 Sensing (1TM) Figure 1 j0yg730701 Initial Issue Wiring Data 08/2012 CH7.1 WorkCentre 5021/5019 7-59...
Page 443: Ch7.2 Tray 1 Paper Stacking
CH7.2 Tray 1 Paper Stacking Figure 1 j0yg730702 Wiring Data Initial Issue 08/2012 CH7.2 7-60 WorkCentre 5021/5019...
Page 444: Ch7.3 Tray 2 Paper Stacking (1Tm)
CH7.3 Tray 2 Paper Stacking (1TM) Figure 1 j0yg730703 Initial Issue Wiring Data 08/2012 CH7.3 WorkCentre 5021/5019 7-61...
Page 445: Ch7.4 Msi Paper Stacking
CH7.4 MSI Paper Stacking Figure 1 j0yg730704 Wiring Data Initial Issue 08/2012 CH7.4 7-62 WorkCentre 5021/5019...
Page 446: Ch8.1 Tray 1 And Msi Paper Transportation
CH8.1 Tray 1 and MSI Paper Transportation Figure 1 j0yg730801 Initial Issue Wiring Data 08/2012 CH8.1 WorkCentre 5021/5019 7-63...
Page 447: Ch8.2 Tray Module Paper Transportation (1Tm)
CH8.2 Tray Module Paper Transportation (1TM) Figure 1 j0yg730802 Wiring Data Initial Issue 08/2012 CH8.2 7-64 WorkCentre 5021/5019...
Page 448: Ch8.3 Registration
CH8.3 Registration Figure 1 j0yg730803 Initial Issue Wiring Data 08/2012 CH8.3 WorkCentre 5021/5019 7-65...
Page 449: Ch8.4 Paper Path
CH8.4 Paper Path Figure 1 j0yg730804 Wiring Data Initial Issue 08/2012 CH8.4 7-66 WorkCentre 5021/5019...
Page 450: Ch9.1 Xero Life Control
CH9.1 Xero Life Control Figure 1 j0yg730901 Initial Issue Wiring Data 08/2012 CH9.1 WorkCentre 5021/5019 7-67...
Page 451: Ch9.2 Charging, Exposure And Development
CH9.2 Charging, Exposure and Development Figure 1 j0yg730902 Wiring Data Initial Issue 08/2012 CH9.2 7-68 WorkCentre 5021/5019...
Page 452: Ch9.3 Toner Dispense And Toner Life Control
CH9.3 Toner Dispense and Toner Life Control Figure 1 j0yg730903 Initial Issue Wiring Data 08/2012 CH9.3 WorkCentre 5021/5019 7-69...
Page 453: Ch9.4 Image Transfer And Stripping
CH9.4 Image Transfer and Stripping Figure 1 j0yg730904 Wiring Data Initial Issue 08/2012 CH9.4 7-70 WorkCentre 5021/5019...
Page 454: Ch10.1 Fusing Heat Control (1 Of 2)
CH10.1 Fusing Heat Control (1 of 2) Figure 1 j0yg731001 Initial Issue Wiring Data 08/2012 CH10.1 WorkCentre 5021/5019 7-71...
Page 455: Ch10.2 Fusing Heat Control (2 Of 2)
CH10.2 Fusing Heat Control (2 of 2) Figure 1 j0yg731002 Wiring Data Initial Issue 08/2012 CH10.2 7-72 WorkCentre 5021/5019...
Page 456: Ch10.3 Fusing
CH10.3 Fusing Figure 1 j0yg731003 Initial Issue Wiring Data 08/2012 CH10.3 WorkCentre 5021/5019 7-73...
Page 457: Ch10.4 Exit And Duplex Paper Transportation
CH10.4 Exit and Duplex Paper Transportation Figure 1 j0yg731004 Wiring Data Initial Issue 08/2012 CH10.4 7-74 WorkCentre 5021/5019...

This manual is also suitable for:

Workcentre 5019

Xerox WorkCentre 5021 Service Documentation

2 Status Indicator Raps

3 Image Quality

3.1 Introduction

3.3 Image Defect Sample

4 Repairs and Adjustments

Introduction

Fusing Unit

Repairs and Adjustments

Dadf

5 Parts List

5.1 Introduction

Parts List

1 Iit/Ui

2 Ros

3 Drive

4 Nohad

6 Transfer

7 Fusing Unit

8 Xero./Deve.

9 Feeder;Tray (Tray 1)

10 One Tray Module (Tray 2)

Parts List

Msi

12 Stand

14 L/H Cover

Registration

17 Exit

18 Electrical

19 Cover

56 Dadf

Screws

99 Adjustment/Consumables Area Code List

7 Wiring Data

7.1 Plug/Jack Location List

7.2.1 Iot/Iit

7.2 Wire Network

7.2.2 Dadf

7.3.1 Preface

7.3 Bsd

Chain 1 Standby Power

Chain 2 Mode Selection

Chain 3 Machine Run Control

Chain 5 Document Transportation

Chain 4 Start Print Power

Chain 6 Imaging

Chain 7 Paper Supplying

Chain 8 Paper Transportation

Chain 9 Marking

Chain 10 Fusing & Paper Transportation

Quick Links

Chapters

Troubleshooting

Related Manuals for Xerox WorkCentre 5021

Summary of Contents for Xerox WorkCentre 5021